Construction Materials Project: Lightweight Concrete

Name: Adam Joshua

ID - 2017003232
Submission Date: 04/27/20
ABSTRACT
The planet of today is seeing the development of very complex and difficult structural
engineering systems. Comparison was rendered in this analysis between standard cement
concrete and light weight concrete with varying aggregate and admixture amounts. Expanded
Clay aggregates: 0 percent, 25 percent, 50 percent, 75 percent, and 100 percent of coarse
aggregates, 10 percent silica dust, and 1.6 percent PVA (Poly Vinyl Alcohol) continuous
substitution of cement and soil. This helps raise concrete volume and thus decrease weight. The
usage of fly-ash as a partial substitute of cement in concrete is gaining enormous popularity
today, largely due to the increase of concrete's long-term stability along with ecological benefits.
Owing to its widespread usage of construction, the global use of natural sand is too strong, which
results of insufficient availability.
Lightweight concrete is of extreme importance for the construction sector. Much of today's
concrete work focuses on high-grade concrete, suggesting a cost-effective commodity that
satisfies rigorous grade criteria, like sustainability. Lightweight concrete can be described as a
form of concrete that contains an expanding agent such that it increases the mixture volume
while at the same time providing additional qualities such as reducing the dead weight. It is
thinner than normal concrete. Lightweight concrete was commonly used in countries such as the
USA, the United Kingdom and Sweden.
Light weight concrete has a remarkably long tradition and was licensed for the first time in 1923,
specifically for use as a substitute for insulation. Although there is proof that air entertainers
were used by the Romans to decrease mass, this was not exactly a true concrete of Light weight.
Significant developments in manufacturing machinery and higher quality surfactants (foaming
agents) over the past 20 years have allowed the usage of foamed concrete on a wider scale.
Lightweight and free flowing, it is a substance ideal for a broad variety of uses such as, though
not limited to, the manufacture of panels and columns, floor and roof screeds, wall casting,
whole house casting, sound protection barriers, and other applications.
Table of Contents
ABSTRACT...................................................................................................................................................1
INTRODUCTION...........................................................................................................................................2
BACKGROUND INFORMATION...................................................................................................................3
EXPERIMENTAL WORK................................................................................................................................5
KEY FINDINGS AND CONCLUSIONS.............................................................................................................6
REFERENCES................................................................................................................................................8
INTRODUCTION
Lightweight concrete is a form of concrete that incorporates compressed lightweight aggregates
that raise the mixture volume while at the same time providing additional qualities such as
lowering dead weight. Lightweight concrete can be described as a form of concrete that contains
an expanding agent in that it increases the mixture volume while at the same time providing
additional qualities such as nail ability and decreasing the dead weight. It is thinner than normal
concrete. Lightweight concrete was commonly used in countries such as the USA, the United
Kingdom and Sweden. A low density and thermal conductivity are the core specialties of
lightweight concrete. Its benefits include a drop in dead load, higher building speeds and lower
shipping and storage costs.
Lightweight concrete retains its wide voids and when put on the ground, does not create laitance
layers or cement films. This work was focused on Lightweight concrete aerated results.
Sufficient water cement ratio, however, is essential for creating sufficient consistency between
cement and soil. Insufficient water may create a lack of unity between objects, resulting in a loss
of concrete strength. Likewise, too much water will cause cement to run off aggregate to form
layers of laitance, thereby weakening in power. This is why this fundamental analysis study is
prepared to demonstrate the lightweight concrete practices and development. The emphasis was
on aerated lightweight concrete results such as compressive strength measurements, water
absorption and density, and additional testing and contrasts produced with other forms of
lightweight concrete.
Lightweight concrete retains its wide voids and when put on the ground, does not create laitance
layers or cement films. This work was focused on the application of enlarged clay aggregate to
produce lightweight concrete. Sufficient water cement ratio, however, is essential for creating
sufficient consistency between cement and soil. Lightweight concrete is typically used for
construction purposes, where its usage results in a lower average cost of a building than standard
weight concrete.
Many structural lightweight aggregate suppliers have proposed requirements and mixed the
proportioning details pertaining to their products, and some provide field control and technical
support to insure the usage of the defined concrete standard. Normal structural lightweight
requirements call for minimal compressive power, limited slump, average weight, and maximum
and minimum air content values. However, the contractor may also be concerned with the freshly
mixed concrete property, such as bleeding, workability, and finishing ability. It may also be used
for platforms with buildings, curbs, down canopies, balconies, decks, fishponds, walls, setting
pillars, castings, stairs, or practically any job that can usually be performed for regular weight
concrete. Using it where ease is necessary in lifting and carrying. Lightweight Concrete often
provides higher transition levels of temperature than normal weight concrete, contributing to
better insulation factors.
BACKGROUND INFORMATION
Over the last 2 decades, LWC (Lightweight Concrete) has been implemented all over the world.
But, the use of LWC is not very common in Malaysia; this may be due to large quantities of
gravel aggregate still available on the market. Malaysia imports lightweight aggregates from
France and Germany, and at Nilai, Negeri Sembilan, a lightweight wall panel factory was built in
1983.
Based on the statement, we know there is a problem about the LWC application in the
construction industry in Malaysia. It might not be common to connect high costs, limited skills
and expertise, not having enough capacity worker, machinery and equipment to construct the
LWC is not necessary, or other factors.
Lightweight concrete (LWC) is typically less than 2000 kg / m3 density and more than 20 N /
mm2 of compressive power, classified as structural LWC. The problem in producing LWC is to
reduce density while retaining intensity and without detrimental cost effects. A common method
of reducing the density of a concrete is to add various forms of lighter aggregates into the matrix.
The crushed stone and sand are the components that are typically substituted with Lightweight
Aggregate (LWA) to create LWC.
Lightweight concrete retains its wide voids and when put on the ground, does not create laitance
layers or cement films. This work was focused on Lightweight concrete aerated results.
Sufficient water cement ratio, however, is essential for creating sufficient consistency between
cement and water. Insufficient water may create a lack of unity between objects, resulting in a
loss of concrete strength. Likewise, too much water will cause cement to run off aggregate to
form layers of laitance, thereby weakening in power.
Their low density and thermal conductivity are the core specialties of lightweight concrete. Its
benefits include a drop in dead load, higher building speeds and lower shipping and storage
costs. For around 18 years, the building of 'The Pantheon' of lightweight concrete content
remains eminently standing in Rome until now.
This work was focused on Lightweight Concrete results. Sufficient water cement ratio, however,
is essential for creating sufficient consistency between cement and soil. Insufficient water may
create a lack of cohesion between objects, resulting in a loss of concrete strength. Likewise, too
much water will cause cement to run off aggregate to form laitance layers, thereby weakening in
intensity. This study report is intended to demonstrate the events and results of the concrete
lightweight research project.
 Figure 1: Compressive strength and density of lightweight concrete.
Figure 1 shows the graph of Lightweight concrete compressive power, and density. Lightweight
concrete results such as compressive strength measures, spilt tensile strength measures, and
standard concrete (M1) density tests and contrasts were conducted. The usage of sufficient dose
of fly ash improves longevity by minimizing the alkali silica reaction, avoiding sulfate attacks
and the entrance of potentially hazardous materials such as chloride and water.
Many structural lightweight aggregate suppliers have proposed requirements and mixed the
proportioning details pertaining to their products, and some provide field control and technical
support to insure the usage of the defined concrete standard. Normal structural lightweight
requirements call for minimal compressive power, limited slump, average weight, and maximum
and minimum air content values. However, the contractor may also be concerned with the freshly
mixed concrete property, such as bleeding, workability, and finishing ability.
Lightweight concrete may be primed either by pumping air into its structure, or by omitting or
even combining the smaller sizes of the aggregate with a solid, translucent or porous aggregate.
In fact, lightweight concrete can be divided into three groups:
1. concrete no-fines
2. lightweight concrete aggregate
3. aerated / foamed concrete
Concrete no-fines can be described as a lightweight concrete composed of cement and fine
aggregate. Uniformly spaced voids form all over the space. The key advantages of this style of
lightweight concrete are that it retains the wide voids and when mounted on the ground, it does
not create laitance layers or cement material. No-fines concrete that is commonly used for
exterior walls and partitions for both load bearing and non-load bearing. The intensity of
concrete no-fines decreases with the rise of the cement material. It is therefore prone to the
quality of the atmosphere. Insufficient water may induce a lack of unity between the particles
and therefore a consequent reduction of concrete strength. Similarly, too much water will cause
cement film to run off the aggregate to form layers, making the remainder of the concrete
deficient in cement, thus weakening the strength
Lightweight Aggregate Concrete: Porous lightweight, low specific gravity cement is used
instead of ordinary concrete in this lightweight construction. The lightweight aggregate can be
natural aggregates such as pumice, scoria, and both those of volcanic origin and the
manufactured aggregate such as extended blast-furnace slag, vermiculite, and clinker aggregate.
The key attribute of this lightweight composite is its strong porosity resulting in a low specific
gravity.
Structurally lightweight aggregate concrete is completely compacted, close to that of thick
aggregate regular reinforced concrete. For steel reinforcing it can be seen as providing a strong
connection between the steel and the concrete. The concrete would provide sufficient defense
against steel corrosion. The form and feel of the aggregate pieces, and the fine aggregate's coarse
composition, continue to create rough concrete mixes. Only the denser, lightweight aggregate
varieties are 6 ideals for use in structural concrete.
Aerated concrete has no coarse cement, so may be called aerated mortar. Aerated concrete is
usually created by injecting air or other gas into a slurry of cement and a fine powder. The sand
is substituted in industrial practice by pulverized fuel ash or other silica, and lime can be used
instead of cement. The aerated concrete is shaped in two forms. The first approach is to inject the
gas into the mix by means of a chemical reaction during its porous state.
The second process, using an air-training agent, air is applied either by mixing-in secure foam or
whipping-in air. Typically, the first approach is used in prefabricated concrete factories where
the prefabricated structures are then autoclaved to manufacture concrete with a relatively high
strength and minimal drying shrinkage. The second approach is primarily used for in-situ
construction and is ideal for roof screeds or pipe lagging insulation. Section 4 indicates the
concrete which is aerated.

EXPERIMENTAL WORK
To study the behavior of lightweight concrete, normal concrete testing was performed to
determine the material and structural properties of each type of lightweight concrete, and how
these properties will differ depending on a different type of mixture and its composition. Once
concrete has hardened it will endure a broad variety of testing to show its potential to function as
expected or to determine its characteristics. This typically entails making prototypes from fresh
concrete for new construction, then checking them as the construction matures for specific
assets.
The vector studied in this analysis is a dosage variance of 10% by weight of cement, 20% by
weight of fly ash (M2). We have been utilizing natural sand all over India. The amount of
concrete generated in India, relative to some advanced countries, has not been large. The old
methods of producing ordinary crushed sand have been substituted over the last 4 to 5 years by
new crushers specifically built to make, cubic, fairly smooth textured, well graded sand, strong
enough to substitute natural sand.
Concrete containing quarry dust (QD) as a fine aggregate promises higher strength, lower
permeability and higher density which allows for better resistance to freezing / thawing cycles
and durability in adverse environments. The 100% removal of quarry dust in traditional concrete
is feasible with adequate pre-use preparation of quarry dust. It is necessary to increase the
compressive strength of quarry dust concrete, and even to use super plasticizers to boost the
workability of concrete covered by quarry dust. Concrete generated using quarry fines shows
progress in higher flexural strength, abrasion resistance and unit weight that are very useful in
minimizing corrosion or leaching.

Properties NCA Sand CSA QD

Bulk Density(kg/m3) 1460 1450 1440 1666
Specific gravity 2.65 2.62 1.50 2.65
Fineness Modulus 7.1 7.11 7.12 7.01
Water Absorption (%) 1.0 1.80 2 0.84
Table 1: Physical properties of NCA and CSA
Save for water absorption, there is no need to handle the coconut shell as an aggregate before
usage. Coconut shell is Cement compliant. Coconut shell aggregate concrete's 28-day air-dry
densities are less than 2000 kg / m3, so these are within the spectrum of lightweight structural
concrete. The present findings are partial substitution by coarse aggregate of the coconut shell
(M4) (25 per cent).
Nowadays lightweight concrete extends its applications with the development of technology. For
e.g., in perlite shape with its exceptional insulating characteristics. This is commonly used in
masonry building as loose-fill insulation where it improves fire safety, decreases noise
propagation, does not rot and is immune to termites. It is often used for boats, roof frames, and
other applications

KEY FINDINGS AND CONCLUSIONS

The initial results revealed that the lightweight concrete has the ideal power to be an acceptable
building material for the urban construction method. For lower density mixture the strength of
aerated lightweight concrete is poor. This contributed to the increment of voids created by the
foam in the study. While decrease of the concrete's compressive power.
The foamed lightweight concrete is not ideal for use as a non-load bearing structure, as the
compressive strength is 27 percent lower than suggested. The compressive strength is still
recognized as non-load bearing framework. Lightweight concrete has been used by the Romans
since the 18th century.
The application on the 'The Pantheon' where pumice aggregate is used in the construction of in-
situ cast concrete is the proof of its use. In the late nineteenth century in the USA and England,
clinker was used, for example, in their building of the 'British Museum' and other low-cost
buildings. During the First World War, the lightweight concrete was used in building. U.S.
primarily used for shipbuilding and concrete blocks. In England and Sweden during the 1930s
the foamed blast furnace-slag and pumice aggregate was used for block construction.
For this analysis, concrete density and strength characteristics were examined by volume
replacement of cement by 10%, 20%, 30% fly ash, complete replacement of sand by quarry dust
and 25% replacement of coarse aggregate with coconut shells. This was found that there were
reductions in concrete density with M4 compared to M1, increases with M2, M3 compared to
M1 associated with reductions in concrete compressive strength with M4 associated to M1,
increases with M2, M3 compared to M1 Compared with decreases in concrete spilt tensile
strength with M4 compared to M1, increases with M2, M3 compared to M1
Nowadays, with the development in science, lightweight concrete, for example, extends its uses
in the shape in perlite, with its excellent insulating properties. It is commonly used in masonry
building as loose-fill insulation where it improves fire safety, decreases noise propagation, does
not rot and is immune to termites. It is often used for boats, roof frames, and other applications.

Figure 2: shows flow chart of lightweight concretes.

Lightweight concrete was used by the Romans since the 18th century. The use on the "Pantheon"
where pumice aggregate is used in the production of cast in-situ concrete is evidence of its use.
Throughout the late nineteenth century in the USA and Europe, clinker was used for example the
"London Museum" and other low-cost housing throughout their building. In the First World War
the lightweight concrete was also used in building.
The most significant aspect of the lightweight concrete to be produced was its thermal insulation
property, for which the architectural lightweight concrete eventually obtained a thermal
conductivity value of = 0.15 W/(m·K). This culminated in a cumulative coefficient of heat
transfer (U value) of 0.28 W/(K·m2) for the wall thickness of 50 cm considered here.
The measured U value thus satisfies the criteria of ENEV 2009 regarding the coefficient of heat
transfer of an external portion of the building. A U value of 0.20 W/(K·m2) was obtained using a
mineral foam-core insulation when incorporated in one wall of the experimental structure.
U.S. primarily used for shipbuilding and concrete blocks. The foamed blast furnace-slag and
pumice aggregate for block forming were invented in England and Sweden during the 1930s.
Nowadays lightweight concrete extends its applications with the development in technology.
Through research and results, lightweight aggregate concrete has been shown to act structurally
in almost the same way as standard weight concrete. The variations are mainly the ones in degree
for properties that vary. In addition to the added expense of the lightweight blend, the
manufacturer will recognize the advantages of lighter weight and stronger insulation. The
contractor will consider the several specific shipping, positioning and finishing specifications.
Much helpful knowledge is accessible via their field control and professional assistance from
suppliers of lightweight aggregates.

REFERENCES
1. C.Marthong, T.P. Agrawal. “Effect of Fly ash Additive on Concrete Properties”
Journal of Engineering Research and Application, Vol.2 July- August 2012.
2. Lohani T.K et al., “Optimum utilization of Quarry dust as partial replacement of sand
in concrete” Int. Journal of Applied sciences and Engineering Research, Vol. 1,
No.2012.
3. Gopal Charan Behera, et al., “Effect of coconut shell aggregate On Normal
Strength Concrete” International journal of Engineering Research & technology,
vol.2,June-2013.
4. Vishwas P. et al., “Comparative Study on Coconut Shell Aggregate with Conventional
Concrete” Int. Journal of Engineering and Innovative Technology, Vol. 2 June 2013.
5. M.S. Shetty “Advanced concrete technology”
6. IS 10262- 1984 “ Concrete mix proportioning Guidelines”