2.

1 Introduction

Concrete is one of the most popular construction materials used since hundred years ago.
Because of its flexibility in usage it becomes more important and is preferred compared to timber
or steel. The combination of cement, coarse aggregate, fine aggregate and water makes up a
concrete. It is an acceptable fact now that not only the strength of concrete which plays a main
role, in deciding the quality of concrete but what matters most is the durability at services stage.
This technological advancement forms a challenge to mankind to look into various ways and
means to improve concrete.

The use of LWC (Lightweight concrete) has been a feature in the construction industry
for centuries, but like other material the expectations of the performance have raised and now we
are expecting a consistent, reliable material and predictable characteristics.

Commonly the concrete with densities lower than 2000 Kg/m³ are defined as lightweight
concrete. Aerated concrete is a lightweight concrete, in which air-voids are entrapped by means
of a suitable aerating agent [1].

Absence of coarse and addition of air bubbles inside this type of concrete reduces the
weight and the strength and meanwhile increases the shrinkage, thermal and acoustic insulating
properties of foam concrete. 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 nailbility and lessened the dead weight[2]. There are several type of
lightweight concrete that commonly using in construction. They are no fines-concrete,
lightweight aggregate concrete, and aerated foam concrete. This research project I want do study
more about aerated concrete.

Aerated concrete does not contain coarse aggregate, and can be regarded as an aerated
mortar. Typically, aerated concrete is made by introducing air or other gas into a cement slurry
and fine sand. In commercial practice, the sand is replaced by pulverizedfuel ash or other
siliceous material, and lime maybe used instead of cement [3].
 It is also can be classified as a high workability concrete or self compacting concrete due
to it’s highly workability [4]. The high air contents in foam concrete result in lower densities,
higher porosities and lower strengths [5]. Foam concrete is generally self-leveling, self-
compacting and can be pumped. It’s ideal for filling redundant voids such as disused fuel tanks,
sewer systems, pipelines, culverts, also it is recommended for reinforcement of temporary road
trenches.

It is this true that the application of LWC (Lightweight concrete) is limited to certain purposes
compared to normal concrete, but the introduction of LWC gives more alternative to construction
industry, which currently focuses on natural resources. Some of the lightweight aggregate are
manufactured from waste material such as Lytag, whereby it was produced from pulverized fuel
ash (PFA). Study shows that in Malaysia the use of LWC is gaining popularity whereby in the
1994, more than 100,000m² of LWC panel have been produced and it can be said that the
demand for the coming year will increase. Some of the major project where LWC panels had
been used and proved beneficial areas follows:-

1. Taman Rasah Jaya Single-storey link houses, Seremban. In this project, M-PANELS
(LWC panel) is used as a wall element. The standard MPANELSis 100mm wide with
length available from 150mm, in 100mm increments.

2. Terrace houses of Taman Puteri, Kulai, Johor.

3. Housing project Desa May, Pulau Pinang.

4. Venice Hill’s Condomonium, Cheras, Selangor.

The LWC panels produced for the above mentioned projects are able to withstand the industrial
environment. This is evident of the capability of LWC in the construction industry. It is of
paramount importance that research on LWC be extended and intensified to incorporate other
durability test that normally done on normal concrete. By so doing the effectiveness of LWC can
be compared to normal concrete.
2.2 TYPES OF LIGHTWEIGHT CONCRETE

Lightweight concrete can be prepared either by injecting air in its composition or it can be
achieved by omitting the finer sizes of the aggregate or even replacing them by a hollow, cellular
or porous aggregate. Particularly, lightweight concrete can be categorized into three groups:
1. No-fines concrete
2. Lightweight aggregate concrete
3. Aerated/Foamed concrete

2.2.1 NO-FINES CONCRETE

No-fines concrete can be defined as a lightweight concrete composed of cement and fine
aggregate. Uniformly distributed voids are formed throughout its mass. The main characteristics
of this type of lightweight concrete is it maintains its large voids and not forming laitance layers
or cement film when placed on the wall. Figure 1 shows one example of No-fines concrete.

FIGURE 1: No-fines Concrete

No-fines concrete usually used for both load bearing and non-load bearing for external walls and
partitions. The strength of no-fines concrete increases as the cement content is increased.
However, it is sensitive to the water composition. Insufficient water can cause lack of cohesion
between the particles and therefore, subsequent loss in strength of the concrete. Likewise too
much water can cause cement film to run off the aggregate to form laitance layers, leaving the
bulk of the concrete deficient in cement and thus weakens the strength.
2.2.2 LIGHTWEIGHT AGGREGATE CONCRETE

Porous lightweight aggregate of low specific gravity is used in this lightweight concrete
instead of ordinary concrete. The lightweight aggregate can be natural aggregate such as pumice,
scoria and all of those of volcanic origin and the artificial aggregate such as expanded blast-
furnace slag, vermiculite and clinker aggregate. The main characteristic of this lightweight
aggregate is its high porosity which results in a low specific gravity. The lightweight aggregate
concrete can be divided into two types according to its application. One is partially compacted
lightweight aggregate concrete and the other is the structural lightweight aggregate concrete. The
partially compacted lightweight aggregate concrete is mainly used for two purposes that is for
precast concrete blocks or panels and cast in-situ roofs and walls. The main requirement for this
type of concrete is that it should have adequate strength and a low density to obtain the best
thermal insulation and a low drying shrinkage to avoid cracking.
Structurally lightweight aggregate concrete is fully compacted similar to that of the
normal reinforced concrete of dense aggregate. It can be used with steel reinforcement as to have
a good bond between the steel and the concrete. The concrete should provide adequate protection
against the corrosion of the steel. The shape and the texture of the aggregate particles and the
coarse nature of the fine aggregate tend to produce harsh concrete mixes. Only the denser
varieties of lightweight aggregate are suitable for use in structural concrete. Figure 2 shows the
feature of lightweight aggregate concrete.
 FIGURE 2: Lightweight Aggregate Concrete

2.2.3 AERATED CONCRETE

Aerated concrete does not contain coarse aggregate, and can be regarded as an aerated
mortar. Typically, aerated concrete is made by introducing air or other gas into a cement slurry
and fine sand. In commercial practice, the sand is replaced by pulverizedfuel ash or other
siliceous material, and lime maybe used instead of cement.
There are two methods to prepare the aerated concrete. The first method is to inject the
gas into the mixing during its plastic condition by means of a chemical reaction. The second
method, air is introduced either by mixing-in stable foam or by whipping-in air, using an air-
entraining agent. The first method is usually used in precast concrete factories where the precast
units are subsequently autoclaved in order to produce concrete with a reasonable high strength
and low drying shrinkage. The second method is mainly used for in-situ concrete, suitable for
insulation roof screeds or pipe lagging. Figure 3 shows the aerated concrete.

FIGURE 4: Aerated Concrete

The differences between the types of lightweight concrete are very much related to its aggregate
grading used in the mixes. Table 1 shows the types and grading of aggregate suitable for the
different types of lightweight concrete.
Table 1: Types and Grading of Lightweight Concrete
2.3 ADVANTAGES AND DISADVANTAGES OF LIGHTWEIGHT CONCRETE
Advantages of lightweight concrete :
a. Loadings on foam concrete sections not deflected into adjoining ground / structures
b. Will not break down when attacked by hydrocarbons, bacteria or fungi
c. Highly fluid material, suitable for pumping over long distances\
d. Self-levelling, no vibration or compaction is required
e. Highly resistant to damage by freeze / thaw cycle
f. Rapid, settlement-free construction
g. Good thermal insulation properties
h. Good energy absorbing properties
i. Insect and rodent-proof
j. Excellent fire-resistance
k. Environmentally sound

Disadvantage of lightweight concrete :

a. Concrete has low tensile strength and hence cracks easily.
b. Fresh concrete shrinks on drying and hardened concrete expands on wetting. Provision
for contraction joints has to be made to avoid the development of cracks due to drying
shrinkage and moisture movement
c. Concrete expands and contracts with the changes in temperature. Hence expansion joints
have to be provided to avoid the formation of cracks due to thermal movement.
d. Concrete under sustained loading undergoes creep resulting in the reduction of prestress
in the prestressed concrete construction.
e. Concrete is not entirely impervious to moisture and contain soluble salts which may
cause efflorescence.
f. Concrete is liable to disintegrate by alkali and sulphate attack.
g. The lack of ductility inherent in concrete as a material is disadvantageous with respect to
earthquake resistant design.

2.4 APPLICATION OF LIGHTWEIGHT CONCRETE

Lightweight concrete has been used since the eighteen centuries by the Romans. The application
on the ‘The Pantheon’ where it uses pumice aggregate in the construction of cast in-situ concrete
is the proof of its usage. In USA and England in the late nineteenth century, clinker was used in
their construction for example the ‘British Museum’ and other low cost housing. The lightweight
concrete was also used in construction during the First World War. The United States used
mainly for shipbuilding and concrete blocks. The foamed blast furnace-slag and pumice
aggregate for block making were introduced in England and Sweden around 1930s. Nowadays
with the advancement of technology, lightweight concrete expands its uses. For example, in the
form of perlite with its outstanding insulating characteristics. It is widely used as loose-fill
insulation in masonry construction where it enhances fire ratings, reduces noise transmission,
does not rot and termite resistant. It is also used for vessels, roof decks and other applications.
Methodology

Foam Concrete mixture

The ratio of Cement:Sand:Water for all these mixes were 1:1.9:0.45. During the experimental

works only one source of foaming agent, cement and sand was used. Foamed concrete was

produced under controlled conditions from cement, water and a liquid chemical that is diluted

with water and aerated to form the foaming agent. The foaming agent used was “Portafoam”

consisting of proteins and manufactured in Pulau Pinang Malaysia.

For every 10 litters of water 330 millilitres of ‘Portafoam’ foaming chemical added and then

aerated to a density of about 80 kg/m3. After mixing foam concrete, the material placed in

moulds as soon as possible to prevent breaking down of the air bubbles before the foam concrete

set. Normal foam concrete is usually compacted using vibrator to expel entrapped air and to

maximize the density to achieve better strength and less permeability. But for foam concrete

where low density is required compaction is avoided. Compaction in foam concrete may result in

breaking down of air entrained bubbles and the required properties will not achieved.

Using Portafoam

Portafoam is fairly easy to use and can even be handled by non-technical personnel. They are

usually several steps the need to be followed when using the foam generator :
A. Preparation of the premix solution - A certain volume of foam concentrate (Noraite PA-

1) is mixed with water according the specified dilution rate to give the premix solution.

This solution is normally stored in a drum of suitable capacity (200 Liters). The quantity

of premix solution made is usually enough for the days.

Figure 1 ; Foam Generator Used to produce the foam.

B. Connecting main unit to the holding tank – The premix solution is delivered to the MSD
unit by suction and therefore will require a hose line to be immersed in the solution or
connected at the bottom of the elevated open tank. Another optional from the MSD is a
by-pass line which acts to regulate the pressure within the MSD unit. This hose line is
normally placed above the highest level of liquid in the holding tank.

C. Connecting the lance unit(nozzle) to the main unit – A hose is normally provided to
connect the lance unit to the main unit. This hose is normally preconnected to the lance
behind the shut off valve at the lance.
Foam Generation and Timing

The amount of foam added to the mortar slurry to produce foam concrete is based on the
mix design calculations. It is important that the correct amount is added in order to obtain the
desired density. The flow rate (liters/min), Q of foam from the generator is normally measured
prior to mixing or when setting up Portafoam. If F liters of foam is required in the mix, then the
time of pumping is F/Q min.

How this time is measured depends on the model of Portafoam used. If a control timer is
present (as in the Portafoam Advan PM-2) then it is just a matter of adjusting the timer to the
required time( in minutes or seconds). If foam output is manually measured (using stop watch),
then it is normal to ensure that this is made to the nearest 1 second and there must at least 2
persons at the mixer ( one pumping and the other measuring time).The rate of foam being
pumped will heavily depend on the air supply from a compressor.

Additional foam is normally required on top of what is calculated due to losses during
mixing and also because of addition of water to maintain slump.

Mixing the concrete

Mixing the concrete for too long (over mixing) can cause the foam bubbles to be destroyed and
resulting density to increase. The best type of mixers to use are the horizontal pan type mixer.
Pan mixer do not normally cause the concrete to drop/ settle as in tilting or rotating drums.
However, if the rotating drum is used, the drum should not be tilted to its maximum in the initial
stages of mixing as this will have the effect of destroying the foam bubbles.

Placing foam concrete

When desired density is reached, transfer the contents of the mixer ( foamed concrete as quickly
as possible to the intended destination). Minimize handling of the foam concrete to ensure that
the mixed density is same as the placed density. This includes avoiding pouring foam concrete
from than 1.5 m height and also mixing previously poured foamed concrete with fresh ones.
Foamed concrete can also be placed using pumps but several factors such as density losses must
be taken into account.

Curing foam concrete

Foam concrete takes about 24 hrs to harden before removing them from the moulds. The strength
at 24 hrs depends on various factor such as the mix design and density of concrete that is
produced. Foam concrete is normally air cured for its gain strength. It is known that foam
concrete does not require immersion in water for its curing. Its strength development is much
better if water is sprayed on it from to time to keep it moist and covered by plastic or wet.

Experimental works

In the first part the prepare design mix done by two different density which are 850 kg/m3 and

950 kg/m3. The details of these foam concretes mix are shown in tables 2 to 3.Mix design sheet

for foamed concrete.

Table 1 shown mix design with dry density is 850 kg/m3

Volume 0.025 m³
Dry Density 850 Kg/m³

Density Difference 100 Kg/m³

Wet Density 950 Kg/m³ B+B7
Solids Mass 23.75 Kg AxC
QxUx
Estimated Foam Mass 1.14 Kg A
Actual Mix Mass(c+s+w) 22.61 Kg D-E
Mix Cement Ratio
Cement 1
Sand 1.9
water 0.45

Total Ratio 3.35 G1+G2+G3

Cement 6.75 Kg G1/I x F
Sand 12.83 Kg G2/I x F
Water 3.04 Kg H/I x F
Add Water 0.950 Kg actual

Total Mortar Weigth 23.57 Kg J+K+L+L1+L2

Mortar Density 2200 Kg/m³ AS MEASURED
Mortar Volume 0.0108 m³ M/N
Estimated Foamed
Volume 0.0142 m³ A-O
Estimated Foamed Ox
Volume 14.2 Liters 1000
Foam Density 80 g/Liter
Foam Weight in Mix 0 Kg Q x 266/1000
New Total Mass 0 Kg M+R
New Density 0 Kg/m³ R1/A
Actual Density Obtained 0 Kg/m³ AS MEASURED

Foam Flow Rate lps

Time of Foaming sec
Note : In order to achieve wet density = 950 kg/m3 foam need to added more as much as 3 liters

so the total of foam added in the mix is 17.2 liters.

Table 2 shown mix design with dry density is 950 kg/m3

Volume 0.025 m³
Dry Density 950 Kg/m³

Density Difference 100 Kg/m³

Wet Density 1050 Kg/m³ B+B7
Solids Mass 26.25 Kg AxC
QxUx
Estimated Foam Mass 1.05 Kg A
Actual Mix Mass(c+s+w) 25.20 Kg D-E
Mix Cement Ratio
Cement 1
Sand 1.9
water 0.45

Total Ratio 3.35 G1+G2+G3

Cement 7.49 Kg G1/I x F
Sand 14.25 Kg G2/I x F
Water 3.37 Kg H/I x F
Add Water 1.200 Kg actual

Total Mortar Weigth 26.11 Kg J+K+L+L1+L2

Mortar Density 2200 Kg/m³ AS MEASURED
Mortar Volume 0.0118 m³ M/N
Estimated Foamed
Volume 0.0132 m³ A-O
Estimated Foamed 13.2 Liters Ox
Volume 1000
Foam Density 80 g/Liter
Foam Weight in Mix 0 Kg Q x 266/1000
New Total Mass 0 Kg M+R
New Density 0 Kg/m³ R1/A
Actual Density Obtained 0 Kg/m³ AS MEASURED

Foam Flow Rate lps

Time of Foaming sec
Note : In order to achieve wet density = 1050 kg/m3 foam need to added more as much as 4 liters

so the total of foam added in the mix is 17.2 liters.