1

CELLULAR
LIGHTWEIGHT
CONCRETE
Guided by: ANJANA NP
RISHITHA RAMACHANDRAN
Lecturer S5 CIVIL ENGINEERING
Dept. of Civil Engineering REG.NO 17012227
CONTENTS 2

 Introduction
 General

 Density Range
 Manufacturing Process
 Use of glass in CLC
 Advantages of CLC
 Strength

 Applications
 Conclusion
 Reference
INTRODUCTION 3

 It is a version of lightweight concrete that is produced like normal concrete under ambient conditions. It is produced by
initially making a slurry of Cement +Sand + Fly Ash (constituting 26% - 34 % content) + water.

 A CLC is a lightweight product consisting of Portland cement, cement-silica, cement-pozzolan, lime-pozzolan, lime-
silica pastes or pastes containing blends of these gradients and having homogeneous void or cell structure, attained
with gas-forming chemicals of foaming agents.

 CLC is an air-cured lightweight concrete with fly ash as a major ingredient that can be produced at large project sites
just like traditional concrete, utilising equipment and moulds normally used for traditional concreting.

 It is especially suitable in India for low-rise load bearing constructions and for partitioning work in multistorey blocks.
 Fly Ash as a new additional constituent in its manufacture.
 This CLC can be produced in a density range of 400 kg/m3 to 1,800 kg/m3, with high insulation value and a 28-day
cube crushing strength of up-to 275 kg/cm2.
 GENERAL 4

 Cellular lightweight concrete also known as foamed concrete.

 It is a lightweight cement based material containing gas bubbles evenly distributed in volume.

 CLC is a mixture of cement, flyash, sand, water and forming agent.

 Mostly no course aggregate is used in the production of CLC.

 CLC is a building material combining good mechanical strength with low thermal conductivity and ease of

working.

 It is a low density hardened Portland cement paste or mortar, containing a large number of small bubbles of air

which gives it a fine cellular structure.

DENSITY RANGE 5

 CLC can be produced in a wide range of densities from 400 kg/m3 to 1,800 kg/m3.

 The lower densities of 400 –600 kg/m3 are ideal for thermal insulation applications. CLC’s fire,
termite, water-proof-ness, termite-resistance, very low water absorption and environment friendly. This
range is also used in laying sound insulating layer over structural slabs of intermediate floors in high-
class hotels and institution buildings to minimize transmission of noise between lower and upper
floors.

 The medium density range 800-1000 kg/m3 is utilized for making pre- cast blocks for non-load-
bearing walling masonry in framed structures.

 The high density range from 1200kg/m3 (Crushing strength 65 kg/cm2) to 1800 kg/m3.
DENSITY COMPARED NORMAL 6

CONCRETE TO CLC
 The density of concrete differs from concrete to concrete, it is vastly depends upon the mix

design and other characteristics like specific gravity of aggregates etc.

 The density of normal concrete is taken as 2400 kg per cubic meter.

 the density of cellular lightweight concrete (800-1000 kg/m3).

 high density is (1200 kg/m3 to 1800 kg/m3) and density of the foamed concrete ranges from 400

kg/m3 to 800 kg/m3.

MANUFACTURING PROCESS 7

 Providing a mixture of slurry of Cement, Sand, Fly Ash and water.

 Pouring the mixture into a foam or mould of the intended concrete product.
 Curing the poured mixture.
 Demolding the concrete product and utilizing the concrete product.
• In this process, first the wet mix slurry consists of fly ash, cement, sand and water is either poured or
pumped into assembled moulds of blocks or formwork of reinforced structural elements or poured
onto flat roofs for thermal insulation or for filling of voids.
• The second way is to introduce gas or foam to the concrete mix to produce cellular lightweight
concrete.
• The foam produced using Foam Generator is stable for a time duration far beyond the final setting
time of Cement, thereby creating permanent voids in the finally hardened mass thus imparting
lightness.
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• The entrapped air bubbles are very fine in size and segregated from each other, because of which the
water absorption of the material is less.

• The foam imparts free flowing characteristics to this slurry due to ball bearing effect of foam bubbles,
enabling it to easily flow into all corners. It levels and compacts in the moulds/forms by itself, without
requiring any kind of external vibration or compaction.
9
USE OF GLASS IN CLC 10

 It is a method of manufacturing cellular lightweight concrete using ground glass as a partial

replacement for Portland cement in the mixtures.

 This method also incorporates a method of making cellular lightweight concrete including mixing
these materials in a mixer to form a thick, viscous slurry which will be foamed and cured at room
or elevated temperatures.

 The mixture of CLC using ground glass comprises cement, ground glass, cement substitute, lime,
fiber, foaming agent and water.

 The ground glass may include ground mixed waste glass, flat glass, window glass.
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Specifications of the ingredients:

• The impurities in mixed waste glass, such as metals, plastics, paper, and wood should be separated. Waste
glass should be ground to a particle size passing through a number 30 sieve.
• Lime may include hydrated lime, quicklime or lime kiln dust. The lime kiln dust should contain free CaO
not less than 50%. The lime concentration in the form of CaO should be up to 15% by weight of the
mixture.
• Cement substitutes can be divided into two categories:
i. Reactive materials have cementitious or pozzolanic properties and can also be supplementary
cementing materials including ground blast furnace slag, coal fly ash, natural pozzolans, ground
steel slag and silica fume.
ii. Non-reactive materials do not have any cementitious or pozzolanic properties and usually act as
inert fillers in hardened cement pastes or concrete. Typical examples include: silica flour, crushed
stone dust, saw dust.
 ADVANTAGES OF CLC 12

 Lightweight: Cellular lightweight concrete is low on weight and thus it has a positive impact on weight
management of building material and craning work. Normal concrete on the other hand is very dense and
it’s difficult to work on it especially once it sets into a form.
 Fire resistance: In CLC, the air pockets in its structure are responsible for high resistance to fire breakout.
Irrespective of density range CLC walls are noncombustible and can endure fire breakout for hours.
 Thermal insulation: At reduced density foamed concrete acts as a perfect thermal insulator. Although at this
density it has absolutely no structural reliability in terms of strength.
 Environmental Friendly: Fly ash based cellular lightweight concrete is suitable for surrounding because
fly-ash is one of the by-products of industrial waste.
 Cost-efficient: Apart from fruitful application of industrial waste addition of fly ash also saves considerable
amount of investment on cement products. Hence it substantially diminishes cost of construction.
 STRENGTH 13

 The 28 day compressive strength of cellular light weight concrete varies from 18 Mpa to 20 Mpa

depending upon the density of the mix.

 The flexural strength is in between 1/5 and 1/3 of the compressive strength.

 CLC can be produced in a density range of 400 kg/m3 to 1,800 kg/m3, with high insulation value and a

28-day cube crushing strength of up-to 275 kg/cm2.

 APPLICATIONS OF CLC 14

 Production of heat-insulated light wall panel.

 For soil water drainage process.
 Thermal Insulation of building roofs and walls & roofs of cold storage.
 Filling of depressions in Toilets, floors etc.
 Application in the bridge to prevent freezing.
 Manufacture cement and plaster-based light plate.
 For soil water drainage purposes.
 Utilized for tunnel and shaft filling and lightweight concrete manufacturing.
 Production of Perlite plaster and Perlite lightweight concrete.
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CONCLUSION 16

The deliberations above conclusively establish, that air cured fly-ash based Cellular light-weight
concrete to be a far superior alternative to factory made aerated concrete or manmade light-weight
aggregate blocks. This CLC is even a better alternative to ordinary clay bricks for walling masonry. The
long term stability at low temperatures and potential corrosive effects on cellular light weight concrete
must be completely understood. The influence of admixtures and aggregates on strength of CLC is of
particular interest and is currently being investigated. Moreover, CLC has other diverse applications and
properties, some of which cannot be offered by the conventional alternatives Above all, it is an
environment friendly and energy efficient material, which is the need of the day. It is therefore, no surprise
that more and more builders are progressively opting for this material in their constructions.
 REFERENCE 17

• www.wikipedia.com
• Cellular Lightweight Concrete (Rotating Tower)-Dr. Arch. David Fisher
• www.theconstructor.org
• https://edama.de/lightweight-concrete
• https://happho.com/cellular-lightweight-concrete-clc-blocks/
• http://www.sakshichemsciences.com
• https://gharpedia.com/foamed-cellular-light-weight-concrete/