ABSTRACT

A Lightweight or a Cellular or a Foamed concrete is a cementitious

material with a minimum of 20% mechanically entrained foam in the mortar
mix where air pores are entrapped in the matrix by means of a suitable foaming
agent. This type of concrete is advanced in various aspects such as Weight ratio,
Lower coefficient of thermal expansion, Acoustic insulation within aerated
concrete. In this study a comparative study is to be done using two different
reagents such as Lithofoam ( Protein based reagent ) and Sodium Lauryl
Sulphate ( Synthetic based Reagent ) with a view to determine it’s potential as a
construction material. Coarse aggregates are not to be used and Fine aggregates
of two different grades are to be used here. Concrete casting is made into cubes
of optimum sizes and compressive strength test will be taken at every 7, 14, 21
and 28 days respectively to obtain a comparative result. The ultimate desire of
the project is to find which of the two reagents have yielded higher compressive
strength after the final test.
 CHAPTER-1
INTRODUCTION

AIM:
To determine comparatively the compressive strength of the lightweight
concrete while it has been mixed with the reagents Lithofoam and Sodium
lauryl sulphate.

OBJECTIVES:

 To obtain the most stable form of lightweight foamed concrete density

with the protein and synthetic reagents.
 To obtain a good strength material with good workability.
 To obtain higher compressive strength with fly ash as partial replacement
for fine aggregates.
 To optimize the foam parameters and to find the optimum level of reagent
concentration and foam generation.

PREFACE:
Lightweight concrete can be defined as a type of concrete which includes
an expanding agent in that it increases the volume of the mixture while giving
additional qualities such as viability and lessened the dead weight.

Lightweight concrete maintains its large voids and not forming laitance
layers or cement films when placed on the wall. This research was based on the
performance of aerated lightweight concrete. However, sufficient water cement
ratio is vital to produce adequate cohesion between cement and water.
Insufficient water can cause lack of cohesion between particles, thus loss in
strength of concrete. Like-wise too much water can cause cement to run off
aggregate to form laitance layers, subsequently weakens in strength.

This research report is prepared to show the activities and progress of the
lightweight concrete research project while it has been mixed with the reagents
Lithofoam and Sodium Lauryl Sulphate. The performance of aerated
lightweight concrete such as compressive strength tests, water absorption and
density and supplementary tests and comparisons made with other types of
lightweight concrete were carried out.

FOAMED LIGHTWEIGHT CONCRETE:

Foamed concrete is a type of lightweight concrete that can be produced

by creating pores in the concrete through the addition of a foaming agent to
the mix that will react with cement to produce air voids. It is also well known
as a cellular concrete. This type of concrete is produced with about 20% or
more air by volume in the concrete. It is produced with only fine aggregates
so that its unit weight is approximately two-third of the unit weight of
conventional concrete. Due to the absence of coarse aggregate and the
introduction of larger pore spaces, cellular concrete has some improved
characteristics; like lighter weight, better insulation properties, good fire-
proof performance, good seismic performance and durability. It has a very
broad application.
The introduction of the pores are generally achieved through mechanical
means either by;
 Pre-formed foaming or
 Mix foaming
PRE-FOAMING METHOD:
The pre-foaming method comprises of producing a base mix and stable
preformed aqueous foam separately and then thoroughly blending the foam
into the base mix. The foam is made using a foam generator. In the foam
generator, the foaming agent is diluted in water to make a pre-foaming
solution and then the pre-foaming solution is expanded with air into foam.
The mix foaming method involves the addition of a quantity of foaming agent
to the slurry & whisking the mixture into a stable mass with the required
density.

FOAMING REAGENTS:
There are generally two types of foaming agents.
 Protein-based foaming agent
 Synthetic-based foaming agent
The protein-based foaming agents can be gotten from natural sources
like animal proteins (horn, blood, bones of cows, pigs & other reminders of
animal carcasses). Synthetic- based foaming agent on have densities of about
40g/litre. They are very stable at concrete densities above 1000kg/m3 and give
good strength.

ADVANTAGES:
 Foamed concrete is light in weight so that the adjacent sub-structure is
not subjected to much vertical stress.
 It has minimal heat conductivity and excellent sound insulation qualities
that regular concrete lacks.
 It is resistant to freezing and thawing.
 It is a free-flowing concrete that does not need to be compacted.
 It adheres to any subgrade contour when used in foundations and
 excavations.
 This concrete can be easily pumped over a long distance with relatively
little pressure.
 It is a substance that does last a long time and will not decay and lasts as
long as a rock.
 It has a low permeability coefficient.

APPLICATIONS:
 Foamed lightweight concrete can be used in various civil and structural
constructions due to it’s unique qualities, such as, density reduction, low
thermal conductivity, high flowability, self-compacting concrete,
simplicity of production and comparatively low cost.
 Low density foamed concrete, for example, is used for cavity filling and
insulation, whereas high density foamed concrete has been employed in
structural applications.
 This concrete is also used to make lightweight blocks and pre-cast
panels, fire insulation, thermal and acoustic insulation, road sub-base,
trench restoration, soil stabilization and shock absorption barriers for
airports and regular traffic.
 It is also an excellent material for voids like old sewers, storage tanks,
basements, ducts and voids under highways caused by a lot of strong
rainfall because of it’s flowability.
 CHAPTER-2
LITERATURE SURVEY

2.1 RESEARCH STUDIES:

INDU SIVA RANJINI AND RAMAMURTHY:

As per the studies done by Indu Siva Ranjini and Ramamurthy, the
properties of the foam depends on the type of foaming agent or surfactant that
is used. The two important characteristics influenced by the type of surfactant
used are the stability of foam and foam density. It was concluded that the
concentration of the foaming agent does not have much effect on the foam
density at different foam generation pressures. The different type of foaming
agents include, protein based foaming agents and synthetic based foaming
agents. There are different foaming agents that come under synthetic foaming
agent such as Sodium lauryl sulphate, Sodium lauryl ether sulphate, Sulfanol,
monoethanolamide. The stability of foam is generally measured by free
drainage test as prescribed in Def Standard 42-40. The optimum concentration
of Sodium lauryl sulphate and foam generation pressure were observed as
1.8% and 115KPa respectively from the studies.

NAMBIAR AND RAMAMURTHY:

As per the studies on characteristics of foam concrete in its fresh state, by

Nambiar and Ramamurthy, it is observed that the consistency of the foam
concrete mainly depends on the volume of foam added and the water to solids
ratio. The consistency of the mix reduces when the foam is added due to the
reduction in self weight of the mix. the moisture movement behavior of foam
concrete becomes more complex as it contains larger volume of air voids.
Sorptivity and water absorption are the most useful parameters which can
explain the moisture movement behavior of concrete. It is concluded that the
water absorption and sorptivity of foam concrete are lower than the
corresponding base mixes and they reduce with increase in foam content.

An investigation on the properties of foam concrete was also done with

fly ash as filler material by Nambiar and K. Ramamurthy. Conclusion from the
study is that the flow behavior of foam concrete is mainly influenced by the
foam volume and filler type. The study also says that for higher flow values,
increased water to solids ratio has to be adopted and also finer filler material
results in higher strength to density ratio.

M. R. JONES AND Mc CARTHY:

As per the studies by M. R. Jones and McCarthy, the use of fine fly ash in
foam concrete as a partial replacement of cement and partial replacement of
fine aggregate with coarse fly ash improves the strength of foam concrete. The
compressive strength of foam concrete is greatly improved with the use of
additives such as silica fume and fly ash.

They also stated that foam concrete with a dry density between 600–1600
kg/m3 has a thermal conductivity that varies between 0.1 and 0.7 W/mK; and
when compared to regular weight concrete, it has a 5 to 30% lower thermal
conductivity.
AMEER ET.AL.

As per the studies by Ameer et.al., describes an experimental study of an

enhancement of pre-formed foamed concrete, 1300-1900 kg/m3, by utilising
two types of additives, silica fume and fly ash, to partially replace Portland
cement and fine sand. They focused on consistency, mechanical and thermal
properties as well as presenting a comparison with normal weight, lightweight
and foamed concretes. In addition to conventional foamed concrete mixes,
foamed concrete mixes with high flowability and strength were also
manufactured in this study. The mixes had 28-day compressive strengths from
6 to 23 MPa and corresponding thermal conductivities in the dry state from
0.475 to 0.951 W/mK, whereas for the same density range, the mixes gave 19-
47 MPa and 0.498-0.962 W/mK. Compared to other studies on foamed
concrete, the results from the mixes investigated in this study showed higher
strengths (for a given density), higher tensile to compressive strength ratios
and higher moduli of elasticity.

ALI ET.AL.

As per the experimental investigations by Ali et.al. (2014), exhibits the

raw materials used in aerated concrete, types of agent, properties and
applications. The production method is classified for each foamed and
autoclaved concrete. The literature review of aerated lightweight properties is
focuses on the porosity, permeability, compressive strength and splitting
strength.
HILAL ET.AL.

As per the experimental investigations by Hilal et al. studied on void

structure and strength of foamed concrete made without/with additives. Study
has been undertaken to investigate the effect of different additives on the
strength foamed concrete by characterizing air-void size and shape parameters
and identifying the influence of these parameters and changes to cement paste
microstructure on strength. Nine different mixes, made using a preformed
foam, were investigated with varying density (nominally 1300, 1600 and 1900
kg/m3) without/ with additives (silica fume, fly ash and super plasticizer) used
either individually or together. Optical microscopy and scanning electron
microscopy were used in this investigation. Compared to the conventional
mixes, inclusion of additives (individually or in combination) helped to
improve both the cement paste microstructure and air-void structure of
foamed concrete. For a given density, although the additives in combination
led to increased void numbers, higher strength was achieved due to reduced
void size and connectivity, by preventing their merging and producing a
narrow void size distribution. Furthermore, super plasticizer has the most
beneficial influence on voids when used alone and it further improves void
structure (smaller and number voids) when used in combination with other
additives. Not only enhancement of void structure but also improved cement
paste microstructure both contribute to the strength of the foamed concrete.

PRAKASH ET.AL.

As per the experimental investigations by Prakash et.al. the feasibility of

using aerated concrete block as an alternative to the conventional masonry
units. The preliminary studies focused estimating physical, strength and
elastic properties of Aerated concrete block units. These included Initial rate
of absorption, density test, water absorption test etc. The compressive
strength, modulus of elasticity and the flexural strength of the units were
obtained. There is scanty information on the physical, strength and elastic
properties of Aerated concrete blocks. The present investigation has
endeavored to study all such properties. Having obtained the results, it would
now be interesting and useful to compare the results with that of conventional
masonry units.

RAMAMURTHY ET.AL.

As per the experimental investigations by Ramamurthy et.al. the

behavior of foam concrete under sulphate environments. This reports the
effects of variation in density, concentration and type of cation associated
with sulphate on the expansion, mass and strength loss of foam concrete
produced with two synthetic surfactants. Comparisons are made between
behavior of foam concrete of different densities and that of corresponding
base mixes of mortar without foam. The investigations indicated that the
expansion in sodium sulphate environment was up to 28% higher than that of
magnesium sulphate environment which can be attributed to greater quantum
of ettringite formation in sodium sulphate environment. The major
deterioration mechanism in magnesium sulphate environment is disintegration
of cementing material and this contributed to loss in mass of 1% and higher
sulphate deterioration factor of 0.4 for specimens under very fiber severe
magnesium sulphate environment. Irrespective of the type of sulphate
environment, the deterioration of foam concrete was lower than that of base
mix.
SATHYA NARAYANAN ET.AL.

As per the investigations done by Sathya Narayanan et.al. he deals with

the identification of suitable set accelerator for foam concrete made using
sodium lauryl sulphate as foaming agent, which is facilitating demolding time
within 2 hours. As conventional accelerators, calcium chloride, calcium
nitrate, Tri ethanol amine were not-effective in foam concrete, alum and
Class-C fly ash were tried. Demolding test was performed to the mixes having
optimum density (1200–1300 kg/m3). From the studies it showed Class-C fly
ash has been identified as the most appropriate accelerator for foam concrete
mix with SLS. Use of Class-C fly ash as complete replacement of sand and
combination mixes provide flexibility in its adoption as an accelerator. Class-
C fly ash was observed as a potential set-accelerator, facilitating demolding at
90 min.

SHI CONG ET.AL.

As per the studies by Shi Cong et.al. the use of high percentages of
recycled aggregates in concrete would usually worsen the concrete properties.
This paper tries to address the deficiency of the use of recycled aggregates by
systematically presenting results on the influence of incorporating Class F fly
ash on concrete properties. In this study, two series of concrete mixtures were
prepared with water-to-binder W/B ratios of 0.45 and 0.55. The recycled
aggregate was used as 0, 20, 50, and 100% by weight replacements of natural
aggregate. In addition, fly ash was used as 0, 25 and 35% by weight
replacements of cement. The results showed that the compressive strengths,
tensile strengths, and static modulus of elasticity values of the concrete at all
ages decreased as the recycled aggregate and the fly ash contents increased.
Further, an increase in the recycled aggregate content decreased the resistance
to chloride ion penetration and increased the drying shrinkage and creep of
concrete. Nevertheless, the use of fly ash as a substitute for cement improved
the resistance to chloride ion penetration and decreased the drying shrinkage
and creep of the recycled aggregate concrete. The results showed that one of
the practical ways to utilizes high percentage of recycled aggregate in
structural concrete is by incorporating 25–35% of fly ash as some of the
drawbacks induced by the use of recycled aggregates in concrete could be
minimized.

Y.H. MUHAMED AMRAN ET.AL.

As per the investigations by Y.H. Muhamed Amran et.al. the

properties and applications of foamed concrete, which included a review of
foamed concrete constituents, fabrication techniques, and properties of
foamed concrete. Foamed concrete consists of basic and supplementary
components. This paper provided a review of foamed concrete constituents,
fabrication techniques, and properties of foamed concrete. It also aimed in
providing a comprehensive insight into possible applications of foamed
concrete in the construction industry today. The compressive strength is
considered as the primary function of the desirable density design, as a main
consideration for this lightweight concrete, which can finally be used to
fabricate structural, non or semi-structural components. Meanwhile, durability
is another property of foamed concrete that needs to be at a level which can
effectively allow it to resist the aggressive environments. This can be
achieved by selecting the most suitable type of foam agent added. Foam
agents produce a uniformed distribution of pores, where they decrease the
segregation problem in an early state, prevent the ingression of chloride,
prohibit sulphate attack and increase the time range during fire while
enhancing its fire resistance. Stable foamed concrete production depends on
many factors such as type of foaming agent, method of preparation of
foaming agent to initiate a uniform or homogeneous distribution of air voids
(bubbles), design calculation accuracy of the mixture, and foamed concrete
production, hence the enhancement of performance in fresh and hardened
states are significantly elaborated. order to produce foamed concrete with high
consistency and stability, it is recommended to reduce the volume of foaming
agent, using partial replacement of cement by either fly ash or silica fume
which reduces the process of heat of hydration.

ZHANG ET.AL.

As per the investigations by Zhang et.al. on geopolymer foam concrete as

the development of sustainable construction and building materials with
reduced environmental footprint in both manufacturing and operational phases
of the material lifecycle is attracting increased interest in the housing and
construction industry worldwide. Recent innovations have led to the
development of geopolymer foam concrete, which combines the performance
benefits and operational energy savings achievable through the use of
lightweight foam concrete, with the cradle-to-gate emission reductions obtained
through the use of a geopolymer binder derived from fly ash. To bring a better
understanding of the properties and potential large-scale benefits associated
with the use of geopolymer foam concretes, this paper addresses some of the
sustainability questions currently facing the cement and concrete industry, in the
context of the utilization of foam concretes based either on Ordinary Portland
Cement (OPC) or on geopolymer binders. The potential of geopolymer binders
to provide enhanced fire resistance is also significant, and the aluminosilicate
basis of the geopolymer binding phases is important in bringing high
temperature stability.

M. SIVA ET.AL.

As per the work done by M. Siva et.al. foam with maximum stability is
obtained when Sodium Hydroxide is added along with Sodium Lauryl Sulphate
and water.

WEIGLER AND KARL:

As per the work done by Weigler and Karl the lightweight aggregate foam
concrete that is used in structural component production experiences a decrease
in thermal conductivity as its dry density decreases, for every 100 kg/m3
reduction in dry density, its thermal conductivity drops 0.004 W/mK.

DEMIR ET.AL.

As per the work done by Demir et.al. where the rheological features of
foam concrete were examined experimentally, the viscosity features of foam
concrete were examined using viscometer and Marsh cone. It is stated that the
Marsh cone provides practical advantage when determining the viscosity, and
that the mixture has high viscosity if the flow duration exceeds 1 minute,
thereby negatively impacting the mechanical properties.

KLINCARSLAN AND TUZLAK:

As per the work done by Klincarslan and Tuzlak in a study where fly as
was used in foam concrete, it was found that fly ash has a positive impact on
compressive strength.

PAN ET.AL.

As per the work done by Pan et.al. the researchers have found that the
density of foam concrete was reduced by 150 kg/m3 and its thermal
conductivity coefficient at 0.005 W/mK.

NAMSONEA ET.AL.

As per the experimental investigation by Namsonea et.al discussed low

density, excellent thermal characteristics, and moderate strength. Another type
of cellular concrete is FC. Depending on the application, a variety of densities
can be achieved by aerating cement mortar with foaming agents and controlling
the ratios of cement, sand, water, and foaming agent. FC is created with cement
mortar, a foaming agent, and no additional heat processing. It is crucial to take
FC durability into consideration, particularly in cold and damp environment
conditions. Mechanical strength, water absorption, and frost resistance are key
factors in durability. Additionally, shrinkage (including shrinkage from
carbonation) needs to be taken into account. Carbonation processes are sped up
by a material's low density and high open porosity.

HABSYA ET.AL.

As per the experimental investigations by Habsya et.al. the purpose

othis research is to determine how the fly ash content affects the density,
thermal conductivity, compressive strength, and water absorption in
lightweight foamed concrete (LFC) Cement, water, sand, fly ash (FA), and
foam make up this LFC. A 1:1 water-to-cement ratio and a 1:4 cement-to-
aggregate ratio are used to create LFC. Sand and FA made up the aggregates,
which varied in weight by 0%, 10%, 20%, and 30%. Foam made up between
30 and 40 percent of the volume of the mortar. The density, thermal
conductivity, and compressive strength of LFC all drop as foam content rises.
That, however, makes it absorb more water. Along with decreasing water
absorption, FA content also affects density, thermal conductivity, and
compressive strength.
HASHIM ET.AL.

As per the work done by Hashim et.al. the effects of various foaming
agents, such as protein-based versus synthetic-based foaming agents, on the
characteristics of foamed concrete are empirically investigated by the author
in this work. Experimental research and analysis were done on the foam
stability, compressive strength, and drying shrinkage of the foamed concrete
specimen. In this work, the microstructure, or the size and distribution of the
pores, has also been characterized in order to better understand how the
foaming agent affects the characteristics of foam concrete. Both foamed
concrete's compressive strength increased as density increased, however the
protein-based foamed concrete performed better, having a 13% greater
strength than the synthetic foamed concrete at a density of 1200 kg/m3. At a
density of 1200 kg/m3, protein-based foamed concrete was shown to shrink
29% less throughout the drying process than synthetic foamed concrete.
Thus, this study shows that the features of foamed concrete would be
improved by the application of protein-based foaming agents. enhanced
qualities of foamed concrete.

MOHD ET.AL.

As per the work done by mohd et.al. Foamed concrete with densities
between 400 kg/m3 and 1600 kg/m3 and an improvement in the workability
and bond adhesion will also increase the flexural and tensile strength. The
 strengths of foamed concrete foamed concrete is developed is between the
100kg/m3 to 15000 kg/m3 and also used in the housing applications,
prefabrications and cast-in place wall, either load bearing or non-load bearing
structures.

HAMEED ET.AL.

As per the experimental investigations by studied the effect of

mechanical properties of foamed concrete by the replacement of cement with
0%, 10% and 20% of fly ash and also by the addition of fibers at dosages of
1%, 1.5%. It was observed that the compressive strength of foamed concrete
is about 5N/mm2 when cement is replaced with fly ash at 10% dosage and by
the addition of fibers the split tensile strength was increased when compared
to conventional mix.

FALLIAN ET.AL.

As per the work done by Fallian et.al. effect of curing conditions, cement
type, foaming agent and dry density the initial findings of an ongoing
experiment involving foamed concrete are presented in this study. Here, it is
explored how cement type, dry density, water content, curing conditions, and,
most crucially, the foaming agents used in the cement paste affect compressive
strength. This experimental study includes more than 100 foamed concrete
specimens with a fixed water/cement ratio, dry densities ranging from roughly
350 to 850 kg/m3, two types of cement, three foaming agents of either a protein
or synthetic nature, and curing conditions in water at 30 C, in air, as well as
inside a cellophane sheet at environmental temperature. When protein foaming
agents are used in the mix design, it is discovered that the increase in
compressive strength with density is more or less represented by a linear trend.

JOHNPAUL ET.AL.

As per the work done by Johnpaul et.al This study aims to create foam
concrete with high strength and low weight. The primary goal of the study is to
use readily accessible resources to strengthen foam concrete. For practical
construction in civil engineering applications, foam concrete is a creatively
applied science. Only trial mixtures are used to carry out the complete ratio. For
7, 14, and 28 days, the cube has been prepared. The cube should not be
submerged in water because there is foam present; only dry curing has been
done. According to the compressive strength results, the ratio with the
maximum compressive strength can be used to make (Cellular Light Weight
Concrete) CLC Blocks as well as fill concrete.

MOHAMMAD ET.AL.
 As per the work done by Mohammad et.al. the investigation of the
compressive and flexural strengths of LFC in combination with polypropylene
fibers is described. This study used a 3:1 cement to sand ratio. All samples were
examined with the desired density of 1500. LFC design now includes
polypropylene fiber with volume fractions of 0.25% and 0.40%. mixtures. the
purpose of the foamed concrete was to get the desired effect from volume
proportion of Different polypropylene fibers that have cure times of 7, 28, and
60 days are employed.

KHAWAJA ET.AL.

As per the work done by Khawaja et.al. In comparison to control foam

concrete, the microstructural, thermal, fresh, physico mechanical, and bagasse
ash incorporation capabilities of foam concrete are presented in this study.
10% of sugarcane bagasse ash is seen to have been added to the foam
concrete mix. highest increase in compressive strength (14.50%) and
minimum decrease in thermal conductivity (10.76%) as compared to control
mix. Sugarcane bagasse ash replaces sand in foam concrete in an
environmentally responsible manner without compromising its mechanical
characteristics.