INVESTIGATION ON SANDWICHED WALL PANEL

WITH LIGHTWEIGHT CONCRETE USING BLOATED

CLAY

A PROJECT REPORT

Submitted by

BERSIL TONY. K.W (RA2112001020012)

in partial fulfillment for the award of the degree

of

MASTER OF TECHNOLOGY

in

STRUCTURAL ENGINEERING

SRM INSTITUTE OF SCIENCE AND TECHNOLOGY

RAMAPURAM, CHENNAI 600 089

NOVEMBER 2022

i
 SRM INSTITUTE OF SCIENCE AND TECHNOLOGY
RAMAPURAM, CHENNAI 600 089

BONAFIDE CERTIFICATE

Certified that this project report titled “INVESTIGATION ON

SANDWICHED WALL PANEL WITH LIGHTWEIGHT
CONCRETE USING BLOATED CLAY” is the bonafide work of Mr.
K.W. BERSIL TONY (Reg.No.:RA2112001020012) who carried out the
project work under my supervision.

Submitted for the University Examination held on ____________

SIGNATURE OF HOD SIGNATURE OF GUIDE

Mr. D.SENTHILVELAN
Head of the Department
Department of Civil Engineering
SRM Institute of Science
and Technology
Ramapuram, Chennai 600 089
Mr. D.SENTHILVELAN
Head of the Department
Department of Civil Engineering
SRM Institute of Science
and Technology
Ramapuram, Chennai 600 089

INTERNAL EXAMINER-I INTERNAL EXAMINER-II

ii
 ABSTRACT

The heavy dead weights of concrete structures are posing a head ache for

the structural engineers to design the various members much complicated to take

its own weight. The present investigations are carried out to develop a simple,

lightweight and cost effective technology for replacing the existing wall systems.

So that here going to use Bloated Clay in this producing the lightweight concrete.

Bloated Clay are used as a replacement to the coarse aggregates.

The Bloated Clay were partially replaced in place of coarse aggregates by

0, 30%, 35%, 40% and 45%. M25 grade of concrete was designed and tested for

various sandwich panel. The mix design for different types of mixes were prepared

by replacing the coarse aggregates at different percentages of Bloated Clay

aggregate.

Experimental investigations like workability, Compressive strength test,

split tensile strength test, Flexural strength test for Cube, Panel, cylinder & prism

different concrete mixes with different percentages of Bloated Clay aggregate

after 7, 14 and 28-days curing period has done. It has been observed that the

workability increases with increase in the percentage of replacement of Bloated

Clay aggregate increases. The strength of concrete also increases with the Bloated

Clay aggregate up to 35% percentage.

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 ACKNOWLEDGEMENT

We would like to thank the people in the field of engineering for their

guidance throughout this program Mr. D. SENTHILVELAN, for his

continuous encouragement and valuable suggestion to bring this work in a

complete form

We deem it great pride in expressing our heartfelt gratitude to our head

of the department Mr. D. SENTHILVELAN Head Of Department, for his

inspiring encouragement and moral support.

We express our sincere thanks to our TOP MANAGEMENT for helping

us by providing all facilities for successful completion of our project

We also bring immense thanks to all our staff members of civil

engineering department for their guidance and encouragement.

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 TABLE OF CONTENTS

Title

CHAPTER PAGE
NO. NO.
Abstract iii
Acknowledgement iv
Table of contents v
List of table vi
List of figures viii
1 INTRODUCTION 1
1.1 General 1
1.2 Objective of the project 1
1.3 Scope of the project 2
1.4 Historical Background 3
1.5 Properties of Concrete 4
1.6 Light Weight Concrete 5
Lightweight pre-fabricated sandwich
1.7 6
structural elements
1.8 LECA 7
1.9 ADVANTAGES O Bloated Clay 8
1.10 ADVANTAGE Of lightweight concrete 8
1.11 DIADVANTAGE Of lightweight concrete 9
1.12 Application of lightweight concrete 9

v
 Environmental and Economic Benefits of
1.10 10
Tile Aggregate Concrete
2 LITERATURE REVIEW 11
2.1 General 11
2.2 Literature Review 11
3 MATERIALS & METHODOLOGY 28
3.1 General 28
3.2 Cement 28
3.3 Aggregates 29
3.3.1 Coarse Aggregate 30
3.3.2 Fine Aggregates 31
3.4 Water 32
3.5 Bloated Clay 33
3.6 Objectives 34
3.7 Scope 34
3.8 Methodology 35
3.9 Flow Chart 37
4 CONCRETE MIX DESIGN
4.1 Mixing Procedure 38
4.2 Mix Calculation 41
5 EXPERINMENTAL INVESTIGATION
5.1 General 44
5.2 Preparation and Testing of Specimen 44
5.3 Cube Compressive Strength Test 46
5.4 Split tensile strength test 47
5.5 Flexural strength test 48

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 5.6 Flexural strength of sandwich wall panel 48
6 Result and Discussion 51
6.1 Slump cone test 51
6.2 Compressive strength 52
6.3 Split tensile strength 55
6.4 Flexural strength 58
6.5 Sandwich panel test 63
6.6 Load deflection behaviour 65
7 Conclusion 66
8 Reference 67
9 Certificate 71

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 LIST OF TABLE
Figure. Page.
Description
No No
3.1 Properties of cement 29

3.2 Properties of Coarse Aggregate 31

3.3 Properties of Fine Aggregate 31

3.4 Properties of Bloated Clay 34

4.1 Fineness Modulus and Gradation 39

4.2 Proportions 42

6.1 Slump value 51

6.2 7th day compressive strength 52

6.3 14th day compressive strength 53

6.4 28th day compressive strength 53

6.5 Cube compressive strength value 54
6.6 7th day split tensile strength 55

6.7 14th day split tensile strength 56

6.8 28th day split tensile strength 57

6.9 Split tensile strength 57

6.10 7th day flexural strength 59
6.11 14th day flexural strength 59
6.12 28th day flexural strength 60
6.13 flexural strength 60
6.14 Percentage increase over conventional 60
6.15 RC Panel result 63

viii
 LIST OF FIGURES

S.No Description Page

3.1 Cement 29

3.2 Coarse aggregate 30

3.3 Fine aggregate 32

3.4 Bloated clay sample 33

5.1 Slump test 45

5.2 Specimen casting 45

5.3 Split tensile strength test 47

5.4 Flexural strength test 48

5.5 Panel reinforcement detail 49

5.6 Casting and curing of trail mix specimen 50

5.7 Formwork and casting of wall panel 50

5.8 Reinforcement and casted wall panel 50

6.1 Comparison of cube compressive strength 54

6.2 Comparison of split tensile strength 58

6.3 Comparison of flexural strength 61

6.4 Comparison of first crack and ultimate loads 64

6.5 Load vs deflection curve for all panels 65

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 CHAPATER 1
INTRODUCTION

1.1 General

Concrete is a composite material consist of mainly

water, aggregate, and cement. The physical properties
desired for the finished material can be attained by adding
additives and reinforcements to the concrete mixture. A solid
mass that can be easily moulded into desired shape can be
formed by mixing these ingredients in certain proportions.
Over the time, a hard matrix formed by cement binds the rest
of the ingredients together into a single hard (rigid) durable
material with many uses such as buildings, pavements etc.,
The technology of using concrete was adopted earlier on
large-scale by the ancient Romans, and the major part of
concrete technology was highly used in the Roman Empire.
The colosseum in Rome was built largely of concrete and the
dome of the pantheon is the World’s largest unreinforced
concrete structure. After the collapse of Roman Empire in
the mid-18th century, the technology was re-pioneered as the
usage of concrete has become rare. Today, the widely used
man made material is concrete in terms of tonnage.

1.2 Objective of the project

The objective of this study is to find out the behavior

of sandwiched wall panel with partial replacement of

1
coarse aggregate concrete using lightweight bloated clay.
However, it is expected that the use of bloated clay in
concrete improve the strength properties of concrete.
1. Effect of lightweight bloated clay concrete on
workability.
2. Effect on Cube & Panel Compressive strength of
concrete.
3.Effect on Tensile strength of concrete.
4. Comparison of result of different tests with varying
proportion of light weight bloated clay concrete panel with
normal concrete.

1.3 Scope of the project

Following parameters influences behavior of the light

weight bloated clay concrete, so these parameters are kept
constant for the experimental work.
Thus, the scope of the project can be summarized as:
1. To obtain Mix proportions of Control concrete by IS
method.
2. To perform the specific gravity test, sieve analysis and
slump test under Indian Standard methods.
3. To conduct compressive strength, split tensile test using
with and without bloated clay as per Indian Standard
methods.

2
1.4 Historical Background

Although high strength concrete is considered as

relatively a new material, its development has been gradually
increasing over years. In 1950s, USA considered the
concrete with a compressive strength of 34mpa as high
strength. In 1960’s, the concrete with compressive strength
41mpa to 52mpa was used commercially. In the early
1970’s, 62mpa concrete has been made. Within the world
state of affairs, however, within the last fifteen years,
concrete of terribly high strength entered into the
construction sector of high-rise buildings and long span
bridges. The compressive strength over 110mpa has been
thought-about by IS 456-2000 for the applications in pre-
stressed concrete members and cast-in-place buildings.

However, recently reactive concrete could be the one

that having a compressive strength of nearly 250mpa. It is
fully supported by pozzolanic materials. The first distinction
between high-strength concrete and nominal-strength
concrete refers to the relation of utmost resistance offered by
compressive strength of the concrete sample for the
application of any type of load. Though there is no correct
separation between high-strength concrete and normal-
strength concrete, the Yankee Concrete Institute defined the
compressive strength greater than 42mpa as high strength
concrete.

3
1.5 Properties of Concrete

Generally the Concrete is a material having high

compressive strength than to tensile strength. As it has lower
tensile stress it is generally reinforced with some materials
that are strong in tension like steel. The elastic behavior of
concrete at low stress levels is relatively constant but at
higher stress levels start decreasing as matrix cracking
develops. Concrete has a low coefficient of thermal
expansion and its maturity leads to shrinkage.
Due to the shrinkage and tension, all concrete
structures crack to some extent. Concrete prone to creep
when it is subjected to long-duration forces. For the
applications various tests be performed to ensure the
properties of concrete correspond to the specifications.
Different strengths of concrete are attained by different
mixes of concrete ingredients, which are measured in psi or
Mpa. Different strengths of concrete are used for different
purposes of constructions.
If the concrete must be light weight a very low-
strength concrete may be used. The Lightweight concrete is
achieved by the addition of lightweight aggregates, air or
foam, the side effect is that the strength of concrete will get
reduced. The concrete with 3000-psi to 4000-psi is often
used for routine works. Although the concrete with 5000-psi
is more expensive option is commercially available as a
more durable one. For larger civil projects the concrete with

4
5000-psi is oftenly used. The concrete strength above 5000
psi was often used for specific building elements. For
example, the high-rise concrete buildings composed of the
lower floor columns may use 12,000 psi or more strength
concrete, to keep the columns sizes small.
Bridges may use concrete of strength 10,000 psi in
long beams to minimize the number of spans required. The
other structural needs may occasionally require high-
strength concrete. The concrete of very high strength may be
specified if the structure must be very rigid, even much
stronger than required to bear the service loads. For these
commercial reasons the concrete of strength as high as
19000-psi has been used.

1.6 Light Weight Concrete

One of the disadvantages of concrete is its high self-

weight. Density of normal concrete will be in the range of
order of 2200 to 2600 kg/m3. This heavy self-weight will
make the concrete to some extent as an uneconomical
structural material. Attempts have been done in the past to
reduce the self-weight of concrete to increase its efficiency
of concrete as a structural material. The lightweight concrete
density varies from 300 to 1850 kg/m3 using various
ingredients.
Basically there is only one method for making
lightweight concrete, by inclusion of air in concrete. This is

5
 achieved in actual practice by three different ways.
i. By replacing the usual mineral aggregate by
cellular porous or lightweight aggregate.
ii. Introducing the gas or air bubbles in mortar,
known as aerated concrete.
iii. Omitting the sand from the aggregates, called
as No-fines concrete.
Lightweight concrete has become more popular in
recent years and have more advantages over the conventional
concrete.

1.7 Lightweight pre-fabricated sandwich structural elements

Lightweight pre-fabricated sandwich structural

elements in building construction is a growing trend in
construction all over the world due to its high strength-to
weight ratio, reduced weight and good thermal insulation
characteristics. Sandwich construction element consists of
encasement of high performance material and a thick
lightweight and low strength material as core. Ferro cement
is regarded as highly versatile thin material possessing
superior properties. Sandwich composite structure possesses
excellent flexural and shear properties. Their inherent
lightweight characteristics make them ideal structural
components where weight reduction is desirable. Thus
structural sandwich blocks are becoming important elements

6
in modern lightweight construction. In concrete
construction, self-weight of structure it represents a very
large proportion of the total load on the structures thus,
reduction in the self-weight of the structures by adopting an
appropriate approach results in the reduction of element
cross-section, size of foundation and supporting elements
there by reduced overall cost of the project. The lightweight
structural elements can be applied for construction of the
buildings on soils with lower load-bearing capacity. Reduced
self-weight of the structures using lightweight concrete
reduces the risk of earthquake damages to the structures
because the earth quake forces that will influence the civil
engineering structures and buildings are proportional to the
mass of the structures and building. Thus reducing the mass
of the structure or building is of utmost importance to reduce
their risk due to earthquake acceleration. Among the other
advantages, its good thermal insulation due to the cellular
thick core makes it an ideal external construction
component. Some recent investigations suggest their
excellent energy-absorbing characteristics under high
velocity impact loading conditions.

1.8 LECA

LECA means Light Expanded Clay Aggregate. LECA

consists of small, lightweight, bloated particles of burnt clay.
The thousands of small, air-filled cavities give LECA its
strength and thermal insulation properties. The base material

7
is plastic clay which is extensively pre-treated and then
heated and expanded in a rotary kiln.

1.9 ADVANTAGES OF Bloated Clay

• Light in weight (380 to 710 Kg/m3)

• Sound protection
• Water absorption(40% of volume in the immersed
state amid 48Hrs)
• Fire opposition
• Lightening up to 30% of the dead burden
• Appropriate conduct in seismic tremor
• Low moduli of the flexibility of LECA concrete

1.10 ADVANTAGE of Lightweight concrete

• Lightweight concrete is often particularly sensitive

to the amount of water in the mix.
• Because of the porosity and angularlity of the
aggregate, placement and finishing are difficult,
necessitating the use of experienced labor.
• In Rare situations, cement mortar may separate the
aggregate and cause them to floaty on the surface.
• To ensure the correct mixing of concrete, the mixing
period is longer than that of standard concrete.
Lightweight concrete is porous and has a low
resistance

8
1.11 DISADVANTAGE of lightweight concrete
• It minimizes the dead load of the building.
• It is simple to handle, which decreases the cost of
transportation and handling.
• Enhances workability.
• Thermal conductivity is decreased with lightweight
concrete.
• The use of lightweight concrete in the rooms where
air conditioning is to be installe during the buildings
construction would result in good thermal comfort
and decreased power usage.
• Storages and more durable in comparison.
• When compared to regular concrete, it has high
resilience to freezing and thawing.
• The use of lightweight concrete provides an outlet
for industrial wastes such as fly ash, clinkers, slag,
and so on, which cause problems in landfills

1.12 Application of Lightweight Concrete

• Because of LWC has a low strength, it is utilized in

the building of roof slabs, tiny houses with load
bearing walls, and so on.
• It is also employed in the construction of staircases,
window, and garden walls, among other things.
• This is utilized in the construction of partition walls

9
 in large buildings.
• These are formed into slabs and utilized as thermal
insulators throughout the buildings

1.13 Environmental and Economic Benefits of

Bloated Clay Concrete:
The usage of Bloated Clay as replacement to coarse
aggregate in concrete has the benefits in the aspects of cost
and reduction of pollution from construction industry. The
cost of concrete manufacturing will reduce considerably
over conventional concrete by including Bloated Clay since
it is readily available at very low cost and there-by reducing
the construction pollution or effective usage of construction
materials.

10
 CHAPTER 2
LITERATURE REVIEW

2.1 General:

Being the major component of structure, many

researches have been done on concrete to improve its
properties in every possible manner to develop a sustainable
concrete mass. The concrete can be strengthened only by the
replacement of its ingredients by better ones. Not only
replacing by some material but using an alternate material
makes the environment friendly at the same time more
suitable to construction. In this aspect lot of researches have
been done on using the Bloated Clay aggregate in concrete.
The present study is focused only on the literature related to
usage of Bloated Clay in Sandwich panel in concrete as a
replacement to coarse aggregate. The details of literature
review are given below.

2.2 Literature Review:

X. Frank Xu et.al, [2001]: done an analytical approach

with a two-scale asymptotic homogenization technique is
developed for evaluation of effective transverse shear stiffness
of thin-walled honeycomb core structures with general
configurations, and the governing 3D partial differential
equations are solved with the assumptions of free warping

11
constraints and constant variables through the core wall
thickness. A detailed study is given for three typical honeycomb
cores consisting of sinusoidal, tubular, and hexagonal
configurations, and their solutions are validated with existing
equations and numerical analyses. The developed approach
with certain modifications can be extended to other sandwich
structures, and a summary of explicit solutions for the
transverse shear stiffness of common honeycomb core
configurations is provided.

Guido Camata et.al, [2005]: presented a study on the

evaluation of the static performance of a glass fiber-reinforced
polymer (GFRP) honeycomb bridge deck that was installed in
O’Fallon Park over Bear Creek west of the City of Denver. The
configuration of core and face sheet of panel is shown in fig.
2.1. The crushing capacity of the panel was also examined by
subjecting four 330×305×190 mm (13×12×7.5 in.) specimens
to compression tests. The experimental data were analyzed and
compared to results obtained from analytical and finite element
models, which have been used to enhance the understanding of
the experimental observations. The failure of all four beams was
caused by the delamination of the top faces. Failure of panel is
shown in fig. 2.1. Results indicated that increasing the face
thickness increases the flexural stiffness of a beam.

Prakash Kumar et.al, [2004]: conduct Fatigue and

failure tests on a 9.144 m long by 609.6 mm wide prototype

12
deck sample, equivalent to a quarter portion of the bridge
deck. The loads for these tests were computed so as to meet
American Association of State Highway and Transportation
Officials (AASHTO) H-20 truckload requirements based on
strength and maximum deflection. Stiffness changes were
monitored by periodically interrupting the run to perform a
quasi-static test to service load. Results from these tests
indicated no loss in stiffness up to 2 million cycles. Following
the fatigue testing, the test sample was tested to failure and no
loss in strength was observed. The study also discussed the
design of the bridge deck in detail.

Wahyu Lestari et.al, [2006]: conducted a combined

analytical and experimental study of dynamic characteristics
of honeycomb composite sandwich structures in bridge
systems. The composite sandwich beams are made of E-glass
fiber and polyester resins, and the core consists of the
corrugated cells in a sinusoidal configuration. Based on the
modeling of equivalent properties for the face laminates and
core elements, analytical predictions of effective flexural and
transverse shear stiffness properties of sandwich beams along
the longitudinal and transverse to the sinusoidal core wave
directions are first obtained. This study can be used as an
effective tool to assess the bending and transverse shear
stiffness properties of composite honeycomb sandwich
structures with relatively thick face sheets, and the evaluated
mechanical properties can be adopted in highway design and
structural health assessment.

13
 Gaetano G. Galletti et.al, [2007]: discusses the
theoretical and quantitative design and analysis of a
honeycomb panel sandwich structure. The initial design is
based on specific requirements that the panel must achieve
prior to failure under load. Materials to be used for the facing
and core are selected based on the given requirements. With
the materials chosen, the facing sheets and core are analyzed
for failure. Failure occurs when the stresses in the panel
exceed the properties of the materials by any mode.

Paul et.al, [2008]: The mechanical characteristics of light

weight Geopolymer concrete generated by substituting
regular coarse aggregate with light weight expanded clay
aggregates are investigated in this research (LECA).
However, structural application of LECA with a density of
1700kg/m3 was restricted to 60% replacement of coarse
aggregate. Both split tensile strength and flexural strength
reduced by roughly 35 percent when coarse aggregate was
replaced with LECA by 40 percent, although they were still
well within structural limitation.

Ke-peng Qiu, et.al, [2009]: study the bending and

dynamic responses of sandwich panels with the size variation
of different sandwich cores and the homogenized cores are
analyzed numerically, including the hexagonal and
rectangular cores, the square and rhombic cores and the
circle and X-shape corrugated cores. In dependence on the

14
 ratio of the span dimensions to thickness, the laminate plate
theory is also adopted for the static and dynamic analysis of
sandwich panels with the homogenized cores. Study shows
that the size effect of cores is very obvious and important for
the structural response of sandwich panels.

Nahro Radi Husein et.al, [2013]: investigated the

strength capability of lightweight web sandwich panel
(LWSP) in terms of first crack load, load deflection
curve for flexural load with (one point loading and
third point loading), module of rupture, ultimate
flexural load, axial load- deformation curve and the failure
mode. The unit weight of the LWSP’s which have aerated
concrete as a core is (1850-1950) Kg/m3 and the unit weight
of the LWSP’s which have thermocol as a core (1250
1300) Kg/m3.

Abhijit Mandlik et.al, [2013]: Experimental

investigation of engineering properties such as compressive
strength, modulus of elasticity, drying shrinkage and creep, of
expanded polystyrene (EPS)aggregate concrete varying in
density. Cost of EPS is less compared to that of normal
concrete. Increase in the EPS beads content in concrete mixes
reduces the compressive and tensile strength of concrete. All the
EPS concrete without any special bonding agent show good
workability and could easily be compacted and finished.

15
 Salini Theres N. Kurian et.al, [2013]: conducted an
analytical study on the fatigue behavior of GFRP bridge deck
panels. Finite element software ANSYS is used for modeling
and analyzing multi-cellular GFRP bridge deck panels. Result
show that GFRP deck panel is a suitable alternative for RC
panels.

Abhijit Mandlikce et.al, [2015]: following

conclusions were drawn from this study.

Hereby, they have observed that cost of EPS is less

compared to that of normal concrete. Increase in the EPS beads
content in concrete mixes reduces the compressive and tensile
strength of concrete. All the EPS concrete without any special
bonding agent show good workability and could easily be
compacted and finished. The replacement by using EPS has
shown a positive application as an alternate material in building
nonstructural members, and it also serves as a solution for EPS
disposal. Obtained results suggest that expanded polystyrene
concrete has scope for nonstructural applications, like wall
panels, partition walls, etc.

Nagasankar P. et.al. [2015]: investigates the effect of

different orientations of fiber in the skins and different
thicknesses of the skins and polypropylene honeycomb core
(PPHC) on the transverse shear damping of the sandwich using
experimental and theoretical studies. In order to study the effect

16
of fiber orientation of the skin on the natural frequency and loss
factors, five different orientations (all 0o, ±30o, ±45o, ±60o and
all 90o) were considered. An impulse technique was used to
calculate the natural frequency and loss factor of the
composites. The natural frequency and loss factor were also
computed theoretically and compared. The transverse shear
effect and damping loss factor increases with the increase in the
thicknesses of the skins and core of the sandwich.

Bagon.C, et.al, (2016): The performance of concrete

containing expanded polystyrene beads was studied in the
context of marine floating structures. It was found that, for an
equal density of about 80 % that of sea water, polystyrene
concrete has a compressive strength that is 50 % higher, a
modulus of elasticity 100 % higher, and a modulus of rupture 25
% higher than those of perlite concrete. Furthermore,
polystyrene concrete is much more resistant to sulphate
solutions than perlite concrete even though it is less resistant
than normal-weight concrete.

Dr. A.S. Kanagalakshmi, et.al, (2016), deals with the

development of lightweight concrete. This also shows the
importance of water/cement ratio as in first type of concrete
it produce lightweight structural concrete with the unit weight
varying from 1200 to 2000 kg/m³.. The isomer of all the

17
phenyl groups on same side called polystyrene. Now a day’s
number of researches have been done on lightweight concrete
but in this research have tried to make a concrete having
possible lesser density and higher compressive strength. The
Aerated concrete is a much lighter concrete and can float on
water. It does not contain coarse aggregates. It is composed
of cement, sand, high water cement ratio. Just as we mix the
cement-sand slurry with EPS, the expansion in the volume
can be observed. Within 5 minutes it expands by 30%. It
consists of many pores and thus is not structurally strong. It
is a good insulator of heat and sound and thus can be used in
place of conventional bricks or at the places which does not
bear any load.

Gowthamaprasanth.U, et.al, (2016), deals with

floating concrete precast slab with addition of vermiculite
and pumice. Buoyancy plays major role on floating objects.
In order to design a floating concrete slab Light Weight
Concrete (LWC) plays a prominent role in reducing the
density and to increase the thermal insulation. Light weight
concrete (LWC) is formed by Natural aggregate, synthetic
light weight aggregate. Vermiculite is a light weight and
cheap product because of its thermal resistance has become
a valuable insulating material. The density of these concrete
varies from 750 Kg/m³ to 2050 Kg/m³. Pumice is a natural
graded light weight coarse aggregate which has a dry density
of 1200 Kg/m³ to 1450 Kg/m. The light Weight Concrete

18
(LWC) M20 using the light weight coarse aggregate as
Pumice stone as a full replacement to 100%, light weight fine
aggregate as Vermiculite as a replacement of fine aggregate
to 75 %. The Cement (Ordinary Portland cement) is partially
replaced by Fly Ash up to 50 % and some other mineral
admixture are added which are Steel Fibre and Super
plasticizer (SP 430) are added.

S. Ananda Selvan et.al, [2016]: have an experimental

study on the lightweight polystyrene sandwich blocks for
replacement of bricks. An experimental study was conducted
to investigate the compressive strength of lightweight
sandwich blocks since the weight of common building bricks
is more or less weight concrete blocks. Specimen block of
size 400x200x100 mm were prepared using combination of
cement, sand, wire mesh and thermocole with and without
different shear connector. In order to make use of this
building material more efficiently and make people aware of
its benefits, an organized technique is required to promote
them. The test result are compared with each other and found
that the light weight polystyrene sandwich concrete block
offered higher compressive strength of 1.12Mpa at 28 days.
The density is found 1200Kg/m3. Hence there is a reduction
of dead load, faster building rates in construction and lower
haulage and handling cost.

19
 P. Rajalakshmi et.al, [2016]: Use of ceramic waste
will ensure an effective measure in maintaining environment
and improving properties of concrete. The replacement of
aggregates in concrete by ceramic wastes will have major
environmental benefits. In ceramic industry about 30%
production goes as waste. The ceramic waste aggregate is
hard and durable material than the conventional coarse
aggregate. It has good thermal resistance. The durability
properties of ceramic waste aggregate are also good. This
research studied the fine aggregate replacement by ceramic
tiles fine aggregate accordingly in the range of 10% and
coarse aggregate accordingly in the range of 30%,
60%,100% by weight of M-30 grade concrete. This paper
recommends that waste ceramic tiles can be used as an
alternate construction material to coarse and fine aggregate
in concrete irrespective of the conventional concrete, it has
good strength properties i.e., 10% CFA and 60% CCA being
the maximum strength.

Arunkumar M.P. et.al, [2016] presents the study of

influence of core geometry on vibration and acoustic
response characteristics of sandwich panels which are used
as aerospace structures. Commercial finite element software
ANSYS has been used to carry out the vibration response
analyses while code built-in-house using MATLAB for the
Rayleigh integral has been used to obtain the sound radiation
characteristics. In honeycomb core sandwich panel the effect

20
 of face sheet thickness on vibration and sound radiation
characteristics are significant. One can select cell size as the
parameter to reduce the weight without affecting the sound
and vibration characteristics.

Mehdi Tehrani1 et.al, [2016] investigate the effect of

geometric parameters including thickness of core and face
sheets, panel height, spot weld distance, and spot weld radius
on the mechanical behavior (deflection and shear force) of a
corrugated-core steel sandwich panel. To reduce the complexity
of geometry in the finite-element modeling simulation, the size
of the model is reduced to a quarter model by applying
symmetry planes. Based on the application of the sandwich
panels, core geometries for the panels can be designed in
different forms and shapes. The obtained results from full
factorial analysis with five geometric parameters revealed that
core and face sheet thicknesses are the most important factors
because they have significant contributions (41% for each) to
the panel maximum deflection response.

Pradeepa S et.al, [2016]: has study on use of

reinforced thermocole panels as an alternate building
material. Thermocole or polystyrene has already found
extensive use as filler material in structural members.
Various studies have also shown that thermocole panels offer
high bending stiffness at low densities due to minimal
compressive and flexural strength. To determine the

21
suitability of using reinforced thermocole technology in
construction. Hence technology offers a way of meeting the
housing demand at a total lower cost. Thus we aim to prove
that by using reinforced thermocole as an alternate building
material we can achieve an easy, fast and cheap method of
construction.

Bagon. C, et al. (2016), The performance of concrete

containing expanded polystyrene beads was studied in the
context of marine floating structures. It was found that, for
an equal density of about 80 % that of sea water, polystyrene
concrete has a compressive strength that is 50 % higher, a
modulus of elasticity 100 % higher, and a modulus of rupture
25 % higher than those of perlite concrete. Furthermore,
polystyrene concrete is much more resistant to sulphate
solutions than perlite concrete even though it is less resistant
than normal-weight concrete.

Surya Man Koju et.al, [2017]: They concluded that

Thermal conductivity of EPS based lightweigroom
temperature is found to be 0.14 W/(m.K) which is nearly
three times less than that of common building brick. Thermal
conductivity varies, however, according to the significant
change in source temperature. At extreme temperature it may
reach up to 0.65 W/(m.K). Thermal resistance of 90 mm
panel is found nearly 1 m2.K/W at room temperature, which

22
quite desires insulation property in building materials in
many situations. It can be said that from thermal insulation
point of view, EPS based lightweight concrete sandwich
panel is much better than common brick for building
partition walls.

Alaa M. Rashad et.al, [2018]: Lightweight expanded

clay aggregate as a building material – An overview In spite
of the mechanical behavior of lightweight concrete mortar
strongly depends on the type of lightweight aggregate and
mixture composition, the incorporation of LECA in the
matrix decreased mechanical strength. The mechanical
strength decreased as LECA content increased. The
incorporation of LECA in the mixture increased water
absorption, decreased its resistance to chloride penetration,
decreased its shrinkage and decreased its freeze/thaw
resistance. The main findings of this review are the
incorporation of LECA in the matrix increased its
workability, decreased density, decreased mechanical
strength, decreased freeze/thaw resistance, increased water
absorption, decreased chloride penetration resistance, but
increased thermal insulation and fire resistance.

Swathi Arivalagan et.al, [2018]: normal weight

aggregates, aims to investigate on concrete mix M25 by the
effect of partially and fully replacement of the coarse

23
aggregate by LECA with various percentage such as 20%,
40%, 60%, 80% and 100%. The Structural light weight
concrete as we call is a concrete whose density varies from
1400 to 2000 kg/m3.

The density of concrete is found to decrease with the increase

in percentage replacement of normal aggregate by Light
Expanded Clay Aggregate. 34.60 to 21.77 MPa and 3.20 to
1.5 MPa respectively with increase in LECA content from
0% to 100%. Concrete blocks can be used in spite of bricks
in building structure.

R. Ayswarya et.al, [2018]: experimented on M40 grade

concrete with varying percentage of replacement of
conventional coarse aggregates with expanded clay
aggregates. Five different mix proportions were made with
percentage of replacement of coarse aggregates as 0%, 20%,
40%, 60% and 80%. The addition of LECA reduced the
density of concrete and also enhanced the workability of the
concrete. The compresive strength of each mix was
determined after 3rd and 7th day of curing. With increasing
percentage of replacement of LECA, decrease in
compressive strength was observed. The workability of
lightweight concrete was reported to be decreasing with
increase in expanded clay aggregate which is contradictory
to the previous works. The density of concrete reduced with
increased expanded clay aggregate content.

24
 S. Keerthipriya et.al, [2020]: This report presents
experimental study on effect of partial replacement of fine
aggregate (Jelly) by Light weight coarse aggregate (LECA).
cube compressive strength, split tensile strength cylinders
and flexural strength of light weight concrete against
conventional concrete by partially replacing natural
aggregates by LECA by 20%, 40%, 60%, 80% and 100%.
Lightweight aggregate has been effectively utilized for well
more than two millennia. By replacing the usual mineral
aggregate by light weight aggregate. Later the compressive
strength at 7 days and 28 days decreased to 22.222
N/mm2and 26.667 N/mm2 respectively for LWSCC 10.

Beyond 15 % of LECA content in fine aggregate

Ming Kun Yew et.al, [2020]: experimented on the

partial replacement of coarse aggregates with light expanded
clay aggregates. Five mixes were made with replacement
percentages as 50%, 60%,70%, 80% and 90%. The fresh and
hardened properties of concrete was studied. As the
percentage of replacement increased, the density of concrete
decreased but the workability of concrete increased.
Compressive strength, split tensile strength and flexural
strength was decreasing with increasing proportion of light
expanded clay aggregates. It was concluded that, 70%

25
 replacement of conventional aggregates with expanded clay
aggregates provided optimum results.

Trilok Gupta et.al, [2021]: The Lightweight

aggregate concrete is an innovative building material used to
reduce the selfweight of a high-rise building.Recently, the use
of lightweight aggregate in construction is increasing
immensely due to its performance during an
earthquake.lightweight aggregate and waste materials of less
density can be used for structural applications with a strength
equivalent to that of normal weight concrete.The paper’s overall
finding reveals that LWAC can be used in sustainable
construction growth and reduce waste by using it as natural
aggregate in concrete to maintain environmental sustainability.
The use of lightweight aggregate in structural concrete will help
in productivity and in improving the initial and long-term
performance of concrete and service life of the structure with
environmental sustainability

Abhishek Kumar Singh et.al, [2022]: Mechanical

Properties of Light Weight Concrete using Lightweight
Expanded Clay Aggregate Because self-weight accounts for a
major amount of the total load applied to the structure, LECA is
utilized in concrete to lower the need for coarse aggregate and
in the design of concrete buildings. This is crucial in
circumstances like poor soils and tall constructions. It also

26
offers significant advantages in terms of lowering concrete
density, which improves labour efficiency. The main purpose
of this study is to examine the weight and strength
characteristics of concrete, such as cube compressive strength,
split tensile strength cylinders, and flexural strength of light
weight concrete versus conventional concrete by substituting
LECA for natural aggregates by 25%, 50%, 75%, and 100%,
respectively.

Mohammed Riyadh Al-Dikheeli et.al, [2022]: This

work intends to make structural lightweight aggregate concrete
by using artificial expanded clay aggregate with different
replacement levels from normal coarse aggregate and improve
it with a high-performance superplasticizer to increase its
strength. The mechanical characteristics covered in the present
work were compressive strength, flexural strength, and splitting
tensile strength in addition to freezing and thawing resistance.
Different densities were found for all mixes ranging between
normal and lightweight concrete and that depends on the
replacement of normal aggregate with lightweight aggregates.
Mixes with replacement exceeding 25% give compressive
strength less than 17 MPa and cannot be regarded as structural
lightweight concrete. Lightweight mixes give high durability
against freeze-thaw cycles where the reduction in compressive
strength was 6.2, 4.6, and 5.5% for 10% rep, 15% rep, and 20%
rep mixes, respectively, compared with 32.2% reduction for
reference mix.

27
 CHAPTER 3
MATERIALS & METHODOLOGY

3.1 General

The modern civil engineering needs to deal with

traditional construction materials as well as advanced
materials. Traditional construction materials, such as
timber, steel, asphalt and Portland cement concrete are
often used in many construction projects. Modern materials
such as polymers and composites are making headway into
the construction industry. Significant research on these
materials has ledto better understanding of these materials
and improved their strength and durability performance.
The traditional material used today are far superior to those
of the past, and new materials are being specially developed
to satisfy the needs of civil engineering applicationsTo a
civil engineering performance of materials of materials in
structures and their ability to resist various stress are of
prime importance. This laboratory experimental work is
intended to help of engineering to understand the physical
and structural properties of common construction materials

3.2 Cement

Cement has different properties and characteristics

which depend upon their chemical compositions. By
changing in fineness of grinding, oxide compositions cement

28
 has exhibit different properties and different kind of cement.
The use of additives, changing chemical composition, and
use of different raw materials have resulted the availability
of many types of cements. Cement used in the experimental
work is 0rdinary portland cement of 53 grades conforming
to IS: 8112/1989.

Table-3.1 Properties of cement

SL. Properties Test results IS: 169-1989

NO
1. Normal consistency 0.32
2. Initial setting time 50min Minimum of 30min
3. Final setting time 320min Maximum of 600min
4. Specific gravity 2.7
5. Compressive strength 56.6 Mpa Minimum of 53Mpa

Figure 3.1: Cement

3.3 Aggregates

Aggregates are the important constituents in concrete.

They give body to the concrete, reduce shrinkage and effect

29
economy. The fact that the aggregates occupy 70-80 present
of volume of concrete, it has some impact on various
characteristics and properties of concrete. Earlier, aggregates
were considered as chemically inert material but now it has
been recognized that some of the aggregate are chemical
active and also certain aggregates ere exhibit chemical bond
at the interface of aggregate and paste.

Figure 3.2: Coarse Aggregates

3.3.1 Coarse Aggregates

Crushed granite of 10mm & 20mm size are used as coarse
aggregate.

30
 Table 3.2: Properties of Coarse Aggregate

S.No Description Test Results

1 Nominal size used 20mm
2 Specific gravity 2.7
3 Impact value 10.5
4 Water absorption 0.15%
5 Sieve analysis 20mm
6 Aggregate crushing value 20.19%
Bulk density of coarse aggregate (Poured
1687.31kg/m3
7 density) Bulk density of coarse aggregate 1935.3 kg/m3
(Tapped density)

3.3.2 Fine Aggregates

Fine aggregate which satisfied the required
properties for experimental work and conforms to zone as
per the specification of IS: 383-1970.

Table 3.3: Properties of Fine Aggregate

S.No Description Test Result

1 Sand zone Zone- III
2 Specific gravity 2.6
3 Free Moisture 1%
4 Bulk density of fine aggregate (poured density) 1385.16 kg/m3

Bulk density of fine aggregate (tapped density) 1606.23 kg/m3

31
 Figure 3.3: Fine Aggregate

3.4 Water
Water plays a vital role in achieving the strength of
concrete. For complete hydration it requires about 3/10th of
its weight of water. It is practically proved that minimum
water-cement ratio 0.35 is required for conventional
concrete. Water participates in chemical reaction with
cement and cement paste is formed and binds with coarse
aggregate and fine aggregates. If more water is used,
segregation and bleeding takes place, so that the concrete
becomes weak, but most of the water will absorb by the
fibers. Hence it may avoid bleeding. If water content
exceeds permissible limits it may cause bleeding. If less
water is used, the required workability is not achieved.
Potable water fit for drinking is required to be used in the
concrete and it should have pH value ranges between 6 to 9.

32
3.5 Bloated clay
Bloated clay by its commercial name LECA
(Lightweight Expanded Clay Aggregate) is an aggregate
made by expanding clay at average temperature of 1200 C°
in rotary kiln. LECA is usually produced from 0.1 mm up
to 25 mm and supplied in various range sizes. Some of the
important advantages of LECA aggregate are: lightness,
thermal insulation by low conductivity coefficient,
soundproofing by high acoustic resistance, moisture
impermeable, incompressible under permanent pressure and
gravity loads, non– decomposition against severe condition,
fire resistant.

Figure 3.4: Bloated Clay Sample

33
 Table 3.4: Properties of Bloated Clay

S.N Description Test

o Results
1 Origin Rock Feldspar
2 Impact value 49.5%
3 Specific gravity 0.56
5 Water absorption 18%

3.6 Objectives
The objective of this study is to find out the behavior
of sandwiched wall panel with partial replacement of coarse
aggregate concrete using lightweight bloated clay. However,
it is expected that the use of bloated clay in concrete improve
the strength properties of concrete.
1. Effect of lightweight bloated clay concrete on
workability.
2. Effect on Cube & Panel Compressive strength of
concrete.
3.Effect on Tensile strength of concrete.
4. Comparison of result of different tests with varying
proportion of light weight bloated clay concrete panel with
normal concrete.

3.7 Scope
Following parameters influences behavior of the light
weight bloated clay concrete, so these parameters are kept
constant for the experimental work.

34
Thus, the scope of the project can be summarized as:
1. To obtain Mix proportions of Control concrete by IS
method.
2. To perform the specific gravity test, sieve analysis and
slump test under Indian Standard methods.
3. To conduct compressive strength, split tensile test using
with and without bloated clay as per Indian Standard
methods.

3.8 Methodology

A preliminary study on compressive strength, tensile

strength and flexural using different proportions of light
weight concrete resulted in a varying ratio of bloated clay of
0, 30, 35 and 45 percent by volume of coarse aggregate. In
the present study, experimental concrete cubes of size
150mm x 150mm, in thickness of 150mm and cylinder of
diameter 150mm and height of 300mm, both with PCC
(plain concrete) and lightweight concrete with experimental
bloated clay were cast and tested for compression, tensile for
7 ,14 and 28 days of curing. A concrete beam of size 150mm
x 150mm x 500 mm were casted and tested for flexural
strength after 7 ,14 and 28 days. And Concrete Sandwich
Panel Size is 1000mm x 800mm x 150mm.
Partial replacement of coarse aggregate with bloated
clay concrete can, in general, be produced using
conventional concrete practice, though there are obviously
some important differences. The basic problem is to

35
introduce a sufficient volume of uniformly dispersed to
achieve the desired improvements in mechanical behaviour,
while retaining sufficient workability in the fresh mix to
permit proper mixing, placing and finishing. The
performance of the hardened concrete is enhanced more by
bloated clay with a proper shape, since this improves the
good matrix bond. On the other hand, a proper shape of
bloated clay adversely affects the workability of the fresh
mix. In general, the problems of both workability and
uniform distribution increase with increasing bloated clay
shape. Partial replacement of coarse aggregate with light
weight concrete can be placed adequately using normal
concrete equipment. It appears to be very stiff because the
bloated clay tend to inhibit flow; however, when vibrated,
the material will flow readily into the forms. It should be
noted that water should be added to light weight concrete
mixes to improve the workability only with great care, since
above a w/c ratio of about 0.5, additional water may increase
the slump of the light weight concrete without increasing its
workability and place ability under vibration. The finishing
operations with bloated clay concrete are essentially the same
as for ordinary concrete, though perhaps more care must be
taken regarding workmanship.

36
3.9 Flow Chart

Collecting of Materials

Testing & Preparation of Materials

Ratio of Materials and Proportioning of Concrete

Mixing of Material

Testing (Slump Test)

Casting of concrete

Curing of specimen (7days,14days,28days)

Testing of Specimen & Collecting of Data

Analysis of Result

Finalization of Documents

Conclusions

37
 CHAPATER 4

CONCRETE MIX DESIGN

4.1. Mixing Procedure

Uniform mixing of concrete should be ensured to get
correct test results of the specimen. For ordinary concrete,
initially the coarse aggregate is weighed for required
quantity per mix proportioning and poured in mixer; then
Sand is weighed and poured into the mixer, which is
completely dry. Cement is weighed and uniformly spread on
the surface of sand and uniform mixing is ensured. Dry
mixing is carried out, later water mixed with the dry mix,
mixing is ensured up to a minimum of 5 minutes until
uniform color of concrete is seen. Then concrete is placed in
moulds as per procedure.

For light weight bloated clay aggregate, the above-

explained procedure is followed except that before adding
water to cement, sand and coarse aggregate. Bloated clay is
thoroughly mixed with cement, sand and coarse aggregate,
then the mixture of bloated clay aggregate, sand and Cement
is mixed with water and further procedure is followed to
achieve the different types of Bloated Clay aggregate
concrete with 0, 30%, 35%, 40% and 45% by addition of
bloated clay aggregate over volume of coarse aggregate.

38
 Stipulation for Proportion:
i. Grade designation = M30
ii. Type of cement = Ordinary Portland Cement 53 grade
iii. Max nominal size of the aggregate = 20mm
iv. Min Cement content = 300 kg/cum
v. Max W/C ratio = 0.5
vi. Exposure condition = Moderate
vii. Type of aggregate = Crushed angular

Test Data:
a) Cement-Portland Cement 43 grade

b) Specific Gravity of cement = 2.7

c) Specific Gravity of coarse aggregates =2.7

d) specific Gravity of fine aggregate = 2.6

e) Sand confirming to zone-III

From Sieve Analysis of 1000g of sand:

Table 4.1: Fineness Modulus and Gradation

Cum.
Wt. Percentage Wt. Percentage
Size Percentage
retained retained Passing
Wt. retained
10 0.00 0.00 0.00 100
4.75 0.00 0.00 0.00 100
2.36 110.5 11.05 11.05 88.95
1.18 129.3 12.93 23.98 76.02
0.6 149.4 14.94 38.92 61.08
0.3 411.2 41.12 80.04 19.96
0.15 199.6 19.96 100 0.00

39
Fineness Modulus= Cumulative % Wt. Retained/100= 253.99/100=
2.53
When FM is matched with limits of FM for Fine
Aggregates, we come to know it is a fine sand. And
when Percentage Passing is matched with the data
given in IS: 383 for gradation of fine aggregate, we
come to know it is of Zone III.

Target mean strength for mix proportion is given by

fck = fck+1.65*S
= 30+1.65*6.5 (value is according to IS 10262:2019)
= 40.8 N/mm2

From Table 2 of IS 10262:2009, to determine the

maximum water content. Nominal size of aggregate is
20mm so water content corresponding to it is 186 liters.
Estimated water content for 100mm slump is 1.06 * 186 =
197.16 liter i.e. 197L.

Cement content will be 197/0.5= 394 Kg/m3.

From Table 5 of IS 456 minimum cement content for
moderate exposure condition is 300 Kg/m3 < 394 Kg/m3.
HENCE OK.

From Table 3 of IS 10262:2019,

Nominal maximum size of aggregate=20 mm
Zone of fine aggregate= Zone III

40
So,

Volume of Coarse Aggregate per Unit Volume of Total

Aggregate= 0.64A Volume of Coarse Aggregate per Unit
Volume of Total Aggregate= 0.36A

4.2 Mix Calculation

a) Volume of concrete
b) Volume of cement
Gravity x1/1000
cu.m
c) Volume of water
x1/1000
= 1m3
= Mass of cement /Specific
= 394/2.7x1/1000=0.146
= Mass of water /Specific Gravity
= 197/1x1/1000=0.197 cu.m

d) Volume of aggregates = a-(b+c) = 1-(0.146+197) = 0.657

cu. m
e) Mass of coarse aggregate= d x Volume of coarse
aggregate x Specific
gravity of coarse
aggregate x 1000
= 0.657 x 0.64 x 2.7 x 1000=
1135.3 Kg

f) Mass of fine aggregate = d x Volume of fine

aggregate x Specific

gravity of
fine aggregate x 1000

41
 = 0.657 x 0.36 x 2.6 x
1000= 615 Kg

Table 4.2: Proportions

Cement= 394 Kg/m3

Water= 197 Kg/m3 Fine

Aggregate= 615 Kg

Coarse Aggregate= 1135.3 Kg

W/C ratio= 0.5

i) For 0% Bloated clay Aggregates (BCA):

Mix Proportions:

C : FA : CA : BCA : WATER
394 : 615 : 1135.3: 0 : 197
1 : 1.6 : 2.9 : 0 : 0.5

ii) For 30% Bloated clay Aggregates (BCA):

Mix Proportions:

C : FA : CA : BCA : WATER
394 : 615 : 794.71 : 340.6 : 197
1 : 1.6 : 2.0 : 0.9 : 0.5

iii) For 35% Bloated clay Aggregates (BCA):

Mix Proportions:

42
 C : FA : CA : BCA : WATER
394 : 615 : 738 : 398 : 197
1 : 1.6 : 1.8 : 1.0 : 0.5

iv) For 40% Bloated clay Aggregates (BCA):

Mix Proportions:

C : FA : CA : BCA : WATER
394 : 615 : 681.2 : 454 : 197
1 : 1.6 : 1.7 : 1.1 : 0.5

v) For 45% Bloated clay Aggregates (BCA):

Mix Proportions:

C : FA : CA : BCA : WATER
394 : 615 : 625 : 511 : 197
1 : 1.6 : 1.6 : 1.3 : 0.5

In this project the concrete grades M30 is designed with a suitable water-

cement ratio at which the desired concrete strength attained and also

forvarious mix replacements of coarse aggregate.

43
 CHAPTER 5

EXPERINMENTAL INVESTIGATION

5.1 General

This chapter presents the details of experimental investigations carried

out on the test specimens to study the strength characteristics of light weight
bloated clay aggregate in different combinations. The experiment is conducted
on light weight bloated clay aggregate test specimens to ascertain the
workability and strength related properties such as cube compressive strength,
cylinder split tensile strength and prism flexural strength of various mixes.
Three specimens are tested, and the average is reported for each mix for each
test. All the tests are conducted as per Indian standards. Based on the strength
test results of cube and cylinders the optimum percentage is arrived. Then the
specimens are casted. After 7,14&28 days curing, the specimens are tested for
compressive, Tensile and flexural strength.

5.2 PREPARATION AND TESTING OF SPECIMEN

The concrete slump test Slump Test (ASTM C 143M-00) is an

empirical test that measures the workability of fresh concrete. More
specifically, it measures the consistency of the concrete in that specific batch.
This test is performed to check the consistency of freshly made concrete.
Consistency is a term very closely related to workability. It is a term which
describes the state of fresh concrete. It refers to the ease with which the concrete
flows. It is used to indicate the degree of wetness. Workability of concrete is
mainly affected by consistency i.e. wetter mixes will be more workable than
drier mixes, but concrete of the same consistency may vary in workability. It is
also used to determine consistency between individual batches.

44
 Concrete is prepared as per mix design. The freshly prepared concrete is
filled in a clean slump cone in four successive layers. 25 tamping is given for
each layer properly before adding another layer. Excessive concrete is strike of
with trowel from the top of the mould after the final layer has been tamped. The
cone is removed immediately by raising it slowly and carefully in the vertical
direction. The settlement or subsidence (slump) (i.e. difference between the
height of the slump mould and the highest point of the subsidized concrete
cone.) in cone measured as soon as it comes to stop.

Figure.5.1. Slump Test

Figure.5.2. Specimen Casting

45
 5.3. CUBE COMPRESSIVE STRENGTH TEST

The cube compressive strength test is carried out on cube specimens of size 150mm x
150mm x 150mm and on Panel specimens of size 300mm x 300mm x 75mm. All
specimens are tested in saturated surface dry condition, after wiping out the surface
moisture. For each mix combination, three identical specimens are tested at the age of
7,14&28 days using compression testing machine. Loading was continued till the
specimen had failed. The reading at that instant of reversal gives the ultimate load. The
test setup is shown in fig. 5.3

5.4. CYLINDER SPLIT TENSILE STRENGTH TEST

This is an indirect test to determine the tensile strength of

cylindrical specimens. Splitting tensile strength test is carried out at the
age of 28 days for the concrete cylinder specimen of size 150mm
diameter and 300mm length using universal testing machine. The load
is applied gradually till the specimen split and the readings are noted.
The test setup is show in fig. 5.4. The splitting tensile strength has been
estimated using the relationship

f = 2P/πdl

Where, f = Splitting tensile strength of concrete in MPa.

P = Load at failure in Newton

d = Diameter of cylinder = 150mm

46
 l = Length of cylinder = 300mm

Figure.5.3: Splitting tensile strength test.

5.5 FLEXURAL STRENGTH TEST FOR PRISM

In order to determine the lateral load resistance of prism, the prisms are
tested for flexure. As illustrated in Fig. 5.5. the prism (100mm x 100mm
x500mm) were placed horizontally and tested for flexural strength according to
third point loading. The initial failure location was observed and found that the
failure location of all prism was within the middle third. The third point loading
was used to determine the stress at failure.

47
 Figure.5.4: Flexural Strength Test - Prism

R= Pl/bd2

Where,

R – Bending stress

P – Maximum applied load in N

l – Span length in mm

b – Average width of the specimen in mm

d – Average thickness of the specimen in mm

5.5 FLEXURAL STRENGTH TEST OF SANDWICH WALL PANEL

In order to determine the lateral load resistance of sandwich panels, the

sandwich panels are tested for flexure. As illustrated in Fig. 5.6. The sandwich
panels (1250mm x 1250mm x150mm) were placed horizontally and tested for
flexural strength according to two point loading.

48
 Fig.5.5 Panel Reinforcement Details

The specimens were placed on the loading fame with two ends fixed. The
load was applied at a constant rate without shocks and increased continuously.
For testing of wall panels, hydraulic jack of 500T capacity was used. The wall
panel was supported at both ends by a 30cm steel plate such that the strut formed
due to failure will not move outwards the panel. Load was applied till the wall
panel fails. Load applied was measured using a dial gauge. Figure.5.7 shows
the test set up as per ACI 318 – 08.The loading area will be 15cm towards both
sides from center. Figure.5.7 shows the wall panel placed on loading frame for
testing. All the panels displayed brittle failure.

49
 Fig 5.6 casting and curing of trail mix specimens

Fig 5.7 formwork and casting of wall panel

Fig.5.8 reinforceement and casted wall panel

50
 6. RESULT AND DISCUSSION

This chapter deals with the presentation of test result, and discussion on
compressive strength, tensile strength and flexural strength development of
lightweight concrete using bloated clay aggregate concrete over ordinary
concrete at different percentage (0%, 30%, 35%, 40% and 45%) and different
curing period.

6.1 Slump Cone Test Result

Specimen Slump Result

0% 62 mm

30% 73 mm

35% 75 mm

40% 78 mm

45% 79 mm

Table 6.1 Slump Value

The test was conducted for fresh concrete prepared before the moulding
process. A total of 5 concrete mixes are prepared at different times. Workability
Results obtained from slump cone test for M30 grade of concrete is shown in
table 6.1. The workability from the slump cone test is in increasing manner as
the mix proportion replacement increasing. The workability range of concrete
increasing as mentioned while being in medium range overall.

51
6.2 Compressive strength
The compressive strength is the main criterion for the purpose of structural
design. The strength development in Bloated clay aggregate concrete studied at
7, 14 & 28 days. The variation of compressive strength with different percentage
(0%, 30%, 35%, 40% and 45%) of lightweight concrete using bloated clay
aggregate concrete over normal concrete. Result of all concrete specimens
exhibited increase in compressive strength with increase of curing age.

% Load in COMPRESSIVE
STRENGTH in
BCA KN
N/mm2

0% 474.6 21.093

30% 510.8 22.702

35% 541.4 24.062

40% 528.1 23.471

45% 502.7 22.342

Table 6.2: 7 Day Compressive Strength

7 Day Compressive Strength = Load/Area

= 474.6*1000/ (150*150)
= 21.093 N/mm2

52
 % Load in COMPRESSIVE
STRENGTH in
BCA KN
N/mm2

0% 572.43 25.441

30% 664.97 29.56

35% 710.72 31.58

40% 628.96 27.95

45% 594.40 26.46

Table 6.3: 14 Day Compressive Strength

% Load in COMPRESSIVE
STRENGTH in
BCA KN N/mm2

0% 715.54 31.80

30% 831.22 36.94

35% 888.40 39.48

40% 786.20 34.94

45% 744.26 32.07

Table 6.4: 28 Day Compressive Strength

53
 % 7 Days
14 Days N/mm2 28 Days N/mm2
BCA N/mm2

0% 21.09 25.44 31.80

30% 22.70 29.55 36.94

35% 24.06 31.59 39.48

40% 23.47 27.95 34.94

45% 22.34 26.46 33.08

Table 6.5: 7,14&28 days Cube Compressive Strength

Figure 6.1: Comparison of Cube compressive strength

54
 Lightweight concrete using bloated clay aggregate do enhance the static compressive
strength of concrete, with increases in strength ranging from essentially nil to perhaps 24%.
Even in members which contain conventional aggregate in addition to the bloated clay
aggregate, the bloated clay aggregate has little effect on compressive strength. However, the
Bloated clay aggregate does substantially increase the post-cracking ductility, or energy
absorption of the material.

6.3 Split Tensile Strength

The splitting tensile strength was determined at ages of 7 ,14 & 28 days
for moist cured concrete specimens. The test result of the splitting tensile
strength is indicated that in general, all types of concrete specimens exhibited
continued increase in splitting strength with development of curing ages.

From graphs it is observed that the splitting tensile strength of bloated

clay aggregate concrete increases at all ages of curing compared with the
ordinary concrete. This increase maybe ascribed to the significant reduction in
capillary porosity of the cement matrix as well as a proper dispersion of the
cement grains throughout the mix, thereby increasing bond strength leading to a
significant increase in splitting tensile strength.

TENSILE
% Load in
STRENGTH
BCA KN
IN N/mm2
224.
0% 3.17
5
30% 241.2 3.41

35% 269.5 3.81

40% 298.6 4.22

45% 311.4 4.40

Table 6.7: 7 Day Split Tensile Strength

7 Day Tensile Strength = 2P/πDL

55
 = 2*224.5*1000/π*150*300
= 3.176 N/mm2

TENSILE
% Load in
STRENGTH
BCA KN
IN N/mm2
0% 237.7 3.36

30% 245.0 3.46

35% 279.5 3.95

40% 319.23 4.51

45% 348.48 4.93

Table 6.8: 14 Day Split Tensile Strength

56
 TENSILE
% Load in
STRENGTH
BCA KN
IN N/mm2
0% 297.2 4.21

30% 306.3 4.34

35% 328.6 4.65

40% 361.2 5.11

45% 381.2 5.39

Table 6.9: 28th Day Split Tensile Strength

% 7 Days
14 Days N/mm2 28 Days N/mm2
BCA N/mm2

0% 3.177 3.36 4.21

30% 3.414 3.46 4.34

35% 3.814 3.95 4.65

40% 4.226 4.51 5.11

45% 4.407 4.93 5.39

Table 6.10 :7,14&28 days Split Tensile Strength

57
 Figure 6.3. 7,14&28Day Split Tensile Strength

Bloated clay aggregate aligned in the direction of the tensile stress may
bring about very large increases in direct tensile strength, as high as 28% for
bloated clay aggregate. However, for randomly distributed bloated clay
aggregate, the increase in strength is much smaller, ranging from as little as no
increase in some instances to perhaps 40%, with many investigations indicating
intermediate values. Splitting-tension test of Bloated clay aggregate concrete
show similar result. However, as in compression, bloated clay aggregate does
lead to major increases in the post-cracking behavior or toughness of the
concrete.
6.4 Flexural Strength
It is seen that strength of concrete in compression and tension in both
direction (i.e. direct tension and flexural tension) are closely related, but the
relationship is not of direct proportionality. The ratio of two strengths depends
on general level of strength of concrete. In other words, for higher compressive

58
strength of concrete shows higher tensile strength, but the rate of increase of
tensile strength is increasing order.

FLEXURAL
% Load in
STRENGTH
BCA KN
IN N/mm2
0% 14.5 5.80

30% 15.2 6.08

35% 16.4 6.56

40% 16.9 6.76

45% 19.5 7.8

Table 6.11: 7 Day Flexural Strength

7 Day Flexural Strength = PL/BD2

= 14.5*400*1000/100*1002
= 5.8 N/mm2
FLEXURAL
% Load in
STRENGTH
BCA KN
IN N/mm2
0% 16.02 6.40

30% 16.65 6.66

35% 17.55 7.02

40% 17.91 7.16

45% .15 8.46

Table 6.12: 14 Day Flexural Strength

59
 FLEXURAL
% Load in
STRENGTH
BCA KN
IN N/mm2
0% 17.8 7.12

30% 18.5 7.40

35% 19.5 7.82

40% 19.9 7.95

45% 23.5 9.48

Table 6.13: 28th Day Flexural Strength

% 7 Days
14 Days N/mm2 28 Days N/mm2
BCA N/mm2

0% 5.80 6.0 7.12

30% 6.08 6.66 7.40

35% 6.56 7.02 7.82

40% 6.76 7.16 7.95

45% 7.8 8.46 9.48

Table 6.14 :7,14&28 days Flexural Strength

60
 Figure 6.4: 7,14&28 Day Flexural Strength

Bloated clay aggregate is generally found to have aggregate much greater

effect on the flexural strength of bloated clay aggregate concrete than on either
the compressive or tensile strength, with increases of more than 33.14% having
been reported. The increases in flexural strength are particularly sensitive, not
only to the bloated clay aggregate volume, but also to the shape of the bloated
clay aggregate, with in proper shape leading to strength increases. For all the
empirical measures of toughness, bloated clay aggregate with lower bond
characteristics gives lower toughness values than do smooth, proper shape
bloated clay aggregate at the same volume concentrations.

61
 Sl. Gain Over Normal
Properties
No Concrete
Compressive
1. +24.15%
Strength
Split Tensile
2. +28.02%
Strength
Flexural
3. +33.14%
Strength

Table 6.15: Percentage Increase in Strength over conventional mix

62
6.5 Sandwich Panel Test Result:
The panel was subjected to two-point loading after 28
days of curing. Three LVDTs were placed below the two-
point loading supports and mid-point. For every 4 kN, three
deflection values were noted.
The first crack load for the 40% was 19 kN which was
greater than the first crack load for the Conventional beam
was observed to be 12kN.
This was due to the 35% panel bridges the hair cracks
and it delays the first crack load, for the same 40% panel
ultimate load was more than the conventional beam.

% BCA First Crack Load Ultimate Load

0% 12 30
30% 15 39
35% 18 42
40% 19 45
45% 16 36

Table 6.16: RC Beam Results

63
Figure 6.5 Comparisons of First Crack Load and Ultimate
Load

This clearly shows that the adding 45% beam to the

concrete does not much contribute in the strength
development. As the loading increased, hair cracks were
appeared at the bottom of the beam and transverse towards
the top of the beam. The 40% is the load carrying capacity
more. The comparison of first crack load and ultimate load
for the panel was shown in figure 6.6.

6.6 LOAD-DEFLECTION BEHAVIOUR:

64
 Fig. 6.6 Load Vs Deflection Curve for all Beams
Figure 6.6 shows the comparison of the load –
deflection curves obtained using experimental results for
various mixing of fibers.
For 40% the first crack appeared at a load of 19 kN
with a mid-span deflection of 3.2 mm. With the increase in
loading, the crack propagated further and the failure of the
beam occurred at 45 kN with a maximum deflection of 4.9
mm. The beam failure by flexural cracks in the middle one-
third span.

CONCLUSION

The usage of bloated clay aggregate can be studied and

65
 also it is quite hard compared to the conventional
concrete using in conventional concrete.
A combination of different aggregate (based on their
usage) in different proportions in concrete and their
effects on concrete properties like strength, workability
etc., can be determined.
By the use of bloated clay aggregate in concrete, the
physical properties like durability, permeability etc., can
be analyzed to prepare a concrete with more
advantageous than conventional concrete. The addition
of bloated clay aggregate effect on the compressive
strength has increasing by 24.15% with (35%) of
bloated clay aggregate than start increasing and then
decreases by with increase the bloated clay aggregate
quantities. Based on the experimental test result there
will be a improvement in Flexural strength of the 2.5%
mix is higher at age of 7,14 &28 days respectively
compared to all other mixes.

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