DISSERATATION PHASE – 1

Experimental investigation of concrete with

expanded clay lightweight aggregate as a fine
aggregate

GUIDED BY: PRESENTED BY :

Prof.Y.V.AKBARI VAGHELA JIGNESH B
CIVIL ENGINEERING DEPARTMENT M.E (STUCTURAL ENGG.)
D.I.E.T. , RAJKOT. 160540720021
 Content
•Introduction
•Aim
•Objective
•Scope of work
•Literature Review
•Material and its properties
•Mix design
 Introduction
• Expanded clay lightweight aggregate is artificial light weight
which is first introduced during world war -1 as a construction
material .
• Stephen J. Hayde is recognized as the founder of Expanded
clay light weight aggregate. And structure made by this
technology is Southwestern Bell telephone company office in
Kansas city , Missouri.
• Expansive clay lightweight aggregate is generally
made of mining clay.
• Due to high temperature and chemical reaction it’s
internal structure is modified.
• Research work is improved in this field mainly after
invention cement earlier it is not use full for structural
member.
• After second world war, there is revolutionary
development in this field.
Manufacturing process

At
tem.1050
Cen.
• Expanded clay is a high quality, durable lightweight aggregate,
that has been used for over half a century.
• Expanded clay can reduce the weight of concrete by almost
50% without compromising strength
• ECA is manufacture from mining clay at temperature around
1000 to 1050 0C in rotary kiln
• The chemical compositions of ECLA is (mass%) SiO2:66.05,
Al2O3: 16.57, Fe2O3: 7.10, K2O: 2.69, Na2O: 0.69, P2O5: 0.21,
MnO: 0.09, AND SO3: 0.03, Ph: 7.2.
 CURRENT APPLICATIONS OF ECLA
• Lightweight concrete
• Structural Concrete
• acoustic insulation and sound absorption
• Precast/ prestressed lightweight Concrete
• Thin Shell Construction
• Resistance to Nuclear Blast
• Geotechnical use foundation filling
• Special Concrete
• Miscellaneous
 Aim
Aim of this research work is to achieve various
parameters such as Strength , workability and
durability against low density using expanded clay
light weight aggregate as replacement of natural fine
aggregate in the nominal concrete.
 Objective
• The main objective is to explore possibilities of
utilizing expanded clay lightweight aggregate
as replacement of natural fine aggregate in
normal concrete
 Scope of work
• Replacing natural fine aggregate by using
expanded clay aggregate at 40% to 100% of
volume.

Casting
of 0% 40% 60% 80% 100%

Cubes 18 18 18 18 18
Beams 9 9 9 9 9
Cylinders 3 3 3 3 3
Disc 3 3 3 3 3
 Conduction of experiments.

• Compressive Strength
• Flexural Strength
• Shear strength
• Bond strength
• Split tensile Strength
• Acid attack
• Fire resistivity test
• Soraptivity and permeability
• Durability study
11
 LITERATURE REVIEW
Sr.no Name of Author Year Title Publisher/Journal

1 Murat Emre Dilli, 2015 A comparison of strength ELSEVIER/

Hakan Nuri and elastic properties BUILDING AND
Atahan, Cengiz between conventional and CONSTRUCTION
Sengul lightweight structural MATERIALS
concretes with ECLA

• In this research paper there is comparison between strength and elastic property of conventional concrete
and concrete with using expanded clay aggregate and for that they select three w/c ratio 0.34, 0.42 and 0.50
for three models LWAC-1 , LWAC-2 and CC. Here yet to low w/s ratio strength is increase in LWAC because
of internal curing property of ECLA.

•In this research work for same poisson’s ratio LWAC shows remarkable reduction in modules of elasticity
and more brittle behavior compare with CC . In this as compressive strength increase ultimate strain value is
increase but as compare with CC , LWAC shows higher ultimate strain value.

•Here compressive strength of LWAC various from 20MPa to 70Mpa with density in range of 1640 kg/m3 to
2050 kg/m3. here test carried out after 28 days and 120 days.

12
Sr.no Name of Author Year Title Publisher/
Journal
2 Alireza Ardakani, 2014 The relation between ELSEVIER/
Muhmoud particle density and static APPLIED CLAY
Yazdani elastic moduli of SCIENCE
lightweight expanded clay
aggregates

• The purpose of this study is to determine relation between the partial density
and elastic modulus of expanded clay lightweight aggregate.
• Here as particle size increase elastic modulus decrease but as particle dry
density increase elastic modulus increases.
• Here for ecla used of particle size varies from 4 to 14 mm and for particle dry
density varies from 480 to 1100 kg/m3 and achieve modulus of elasticity varies
from 0.6 to 6.3 gpa . And according to result equation is derived for modulus of
elasticity is E(Gpa) =8.96p(tonf/m3) -3.78.

13
Sr.no Name of Author Year Title Publisher/
Journal
3 Payam Shafigh, 2014 A comparison study of the ELSEVIER/
Hafez Ghafari, mechanical properties and Materials and
Hilmi Bin drying shrinkage of oil palm Design
Mahmud, Mohd shell and expanded clay
Zamin Jumaat lightweight aggregate
concretes

• In this research work comparison between two light weight concrete , artificial
lightweight aggregate concrete and natural lightweight concrete for low cost
construction work. Here for natural LWA oil palm shell and for artificial LWA
expanded clay lightweight aggregate is selected.
• Here both concrete were made with low w/c ratio along with good workability
and no segregation. In this for curing five condition continuous moist curing,
Air drying and 3,5 and 7 days partial early curing.
• As per result of this paper OPS has 5% more dry density than ECLA but it
achieve higher compressive , flexural and splitting tensile strength about 44%,
30% and 16% .here ECLA achieve ceiling strength early than OPS
14
Sr.no Name of Author Year Title Publisher/
Journal
4 A. Ozguven, 2012 Examination of effective ELSEVIER/
B. L. Gunduz parameters for the CEMENT AND
production of expanded CONCRETE
clay aggregate COMPOSITES

• In this paper , expansion tests were carried out by using samples from three
separate fields to determine different parameters that affect manufacturing.
• As per the result of this paper decreasing size of clay has positive effect on
expansion while decreasing in pallet size has negative effect on it.
• Temperature in furnace and time period has critical values for quality of
aggregates. As temp. increase up to melting point increase expansion. The
effective time period is varies according to types of clay.
• In this paper conditions for optimum manufacturing were explained in detail

15
Sr.no Name of Author Year Title Publisher/
Journal

5 L.H. Nguyen, 2017 Experimental study on the ELSEVIER/

A.-L. Beaucour, thermal properties of BUILDING AND
S. Ortola, lightweight aggregate CONSTRUCTIO
A. Noumove concrete at different N MATERIALS
moisture content and
ambient temperatures

• In this paper test were performed on concrete at three different moisture dry,
partial and saturated state. At dry state four temperature 5 0C, 20 0C, 35 0C and
50 0C are taken to measure.
• As per the result thermal conductivity increase with the temperature between 5
to 35 0C and then stabilizes between 35 to 50 0C. Whereas thermal diffusivity is
not influenced bt the moisture state.

16
Sr.no Name of Author Year Title Publisher/
Journal
6 J.Alexandrebogas, 2014 Long-term behaviour of ELSEVIER/
J. de Brito, concrete produced with CONSTRUCTIO
J. Cabaco recycled lightweight N AND
expanded clay aggregate BUILDING
concrete MATERIALS

• As we know ECLA can be recycled so this paper gives idea of durability of

concrete by using recycled ECLA. In this paper concrete was produced with
20%, 50% and 100% replace with Recycled lightweight aggregate concrete.
• As per study recycle aggregate from non structural member are cost
effective and dose not affect durability of concrete.

17
Sr.no Name of Author Year Title Publisher/
Journal
7 Alessandro P. 2016 Ecological and mechanical ELSEVIER/
Fantilli, assessment of lightweight BUILDING AND
Bernardino fibre-reinforced concrete CONSTRUCTIO
Chiaia, made with rubber or N MATERIALS
Andre Gorino expanded clay aggregates

• In this research work , there were comparisons between rubber lightweight

concrete and traditional lightweight concrete.
• As per the results of this paper tradition concrete was better than rubber
concrete when strength is concerned. So to overcome this problem they use
fibre-reinforced concrete to achieve desire properties.
• Here in this paper Uniaxial and three point bending test were performed. Here
as per paper rubber concrete along with fibre is more sutable for ecological
criteria.

18
Sr.no Name of Author Year Title Publisher/
Journal
8 Michala 2013 Durability of lightweight ELSEVIER/
Hubertova, Expanded clay Aggregate PROCEDIA
Rudolf Hela Concrete ENGINEERING

• The objective of this paper was to learn effect of lightweight concrete in

chemically aggressive liquid and gaseous environments such as high
concentrations of sulphate, chloride ions, automotive gas, oil and gaseous CO2
and SO2 environment .
• Based on the result it can be state that using coal fly ash is positive response as
far as resistance and durability of lightweight concrete in corrosive
environment.

19
 SUMMARY OF LITERATURE REVIEW

 Expanded clay aggregate eco friendly material produce less co2

 ECA can be produce 5 m3 from only 1m3 clay

 Expanded clay aggregate are light in weight and high moisture
content capacity which is more use full in internal curing work
which ultimately gain strength at low density.

 ECA gives good thermal & fire resistance at a design strength.

 ECA saves about 20% cost of overall construction work in precast
work and lightweight concrete work.
 To not face any water absorption problem on fresh concrete it is
advisable to soaked aggregate in water before 48 hours of it use.
in 48 hours it will absorb maximum capacity of water on it. And it
will helpful in internal curing work.
 MATERIAL AND IT’S PROPERTY

• Cement : Ordinary Portland Cement of grade 53 of ultratech

company
• Fine Aggregate : River sand is used as fine aggregate whose
specific gravity is 2.62 as locally available material
• Coarse aggregate : coarse aggregate of 10mm and 20mm of
local source is used whose specific gravity is 2.04 as locally
available material
• Expanded clay aggregate: it is used as replacement of natural
fine aggregate
 PHYSICAL PROPERTIES
Sr. no Physical property of ECLA Test result Concern IS Codes

1 Type Rounded palette structure -

2 Specific gravity 1.26 IS 2386 1963 part-3

3 Water Absorption 38.98 IS 2386 1963 part-3

Impact value test

4 44.44% IS 5640 1970
(for soft coarse aggregate)

5 Crushing value test 59.13 IS 2386 1963 part-4

 REFERANCE CUBE TESTING DETAILS
SR. No. % ECA 7 Days 28 Days

1 0 23.60 34.97
% ECA
2 07 Days 24.89 35.55
28 Days
3 0 21.38 33.00
4 10 23.47 28
5 10 25.64 36.44
2 3 4 5 6 7 8 9
6 10 22.84 36.62
7 40 28.17 42.13
8 40 26.31 40.0
5 9 40 25.34 42.22
4
3
2 Series 1
1 Series 2
Series 3 Series 3
0
 PLAN OF WORK

Final Report

Report
Writing
Result &
Conclusion
Experimental
work

Material
Collection
Literature
Review
Title
Selection
WORK/ JUL AUG SEP OCT NOV DEC JAN FEB MAR APR MAY2
MONTH 2017 2017 2017 2017 2017 2017 2018 2018 2018 2018 018
Thank you