FOAM CONCRETE STUDY AND TESTING

DETAILED STUDY OF FOAM CONCRETE
1- MATERIALS USED
2- MACHINE USED( HAND MAKING WORKABLE EQUIPMENT FOR MIXING)
3-TESTING PROCEDURE
4- YOU GUYZ CAN ALSO LEARN THROUGH THE PHOTOGRAPHS

1. MANUFACTURING AND ANALYSIS OF FOAM CONCRETE BY: TUSHAR KULSHRESTHA SHIVAM KUMAR LOKESH SHARMA DEEPAK KUMAR SAHIL SINGHAL UNDER GUIDANCE OF: Er. RAHUL SHARMA

2. CONTENTS HISTORY OBJECTIVE EQUIPMENTS USED MATERIAL USED METHODOLOGY MAKING OF SLURRY MAKING OF FOAM MIX PROPORTIONS BLENDING OF FOAM AND SLURRY FILLING OF CUBES DEMOULDING CURING TESTING OF COMPRESSIVE STRENGTH CONCLUSION

3. HISTORY Foamed concrete is not a particularly new material, its first patent and recorded use dates back to the early 1920s. According to Sach and Seifert (1999), limited scale production began in 1923 and, according to Arasteh (1988), in 1924 Linde described its production, properties and applications. The application of foamed concrete for construction works was not recognized until the late 1970s, when it began to be used in the Netherlands for filling voids and for ground engineering applications.

4. OBJECTIVE To compare the density and compressive strength of foamed concrete with conventional concrete. To make lightweight concrete having specified strength so that it can wear the load of building structure . To understand the actual behaviour of concrete when foaming agent and superplasticizers is added to ascertain strength of concrete which is one of the most important criteria of the concrete. To reduce the cost of structure

5. EQUIPMENTS USED FOR FAST MIXING OF SLURRY AND TO MAKE FOAMING AGENT WE MAKE A SIMPLE WORKABLE MACHINE INSTEAD OF BYING FOAM GENERATOR AND MIXER BEACAUSE IT COSTS TOO HIGH. OTHER EQUIPMENTS 150mm CUBE MOULDS ELECTRONIC WEIGHING MACHINE TROWEL , GLOVES, WRENCH.

6. MATERIAL USED

7. CEMENT: - Ordinary Portland cement is commonly used, but rapid hardening cement can also be used if necessary. We used ordinary Portland cement of having density 384 g/cm 3 SAND: - The maximum size of sand used can be 5mm. Use of finer sands up to 2mm with amount passing through 600-micron sieve range from 60 to 95%. Sand used of density 422.5 g/cm 3 WATER: - Mixing water for concrete should be clean and free from injurious amounts of oils, acids, alkalis, salts, organic matter, or other potentially deleterious substances. When water is used to produce foam, it has to be potable and for best performance, it should not exceed 25°C

8. Foaming agent The quality of foam is critical to the stability of foamed concrete and will affect the strength and stiffness of the final product; therefore, good quality foam was produced by blending the foaming agent. Foaming agent we had used is CLC (cellular lightweight concrete) foaming agent. It is prepared with raw material in presence of Ca(OH)₂ and a small portion of NaHSO3. For improving the stability it is modified with the addition of several kinds of gel and surfactants.

9. ADDITIVES(SUPERPLASTICIZERS) This admixtures can be used as water reducers, maintaining a fixed workability. Polycarboxylate ether superplasticizer was used as a water-reducing agent to maintain sufficient workability of the unfoamed mixture (without foam) and to produce a high strength foamed concrete with low water/binder ratio. Superplasticizers used in the amount of .3% weight of cement.

10. METHODOLOGY The first step is to make a cement slurry or a sand cement slurry that is appropriate for the mix design. We’ll make sand cement slurry to achieve foam concrete of specific density. The second step is to make suitable foam . The foam is made separately from the slurry. Once the foam has been made it is blended in to the slurry to make foamed concrete.

11. MAKING OF SLURRY The cement we used for the slurry is Ordinary Portland Cement . Sand is specified in the mix design ideally it should be fine with 2mm-5mm maximum size and 60 to 90% passing through a 600 micron sieve . First we dry mix the sand and cement after which water is added into it. The water: cement ratio of the slurry is usually between 0.5 and 0.6 . To increase the compressive strength we add superplasticizer of low dosage (.3% by weight of cement) .

12. BEFORE DRYMIX AFTER DRYMIX WHEN WATER IS ADDED ADDITION OF SUPERPLASTICI-ZER DRY MIXING WET MIXING

13. MAKING OF FOAM (water + foaming agent ) (mixing) (stable foam) water used to produce foam is potable and for best performance, it should not exceed 25°C. We used 50ml foam agent per litre of water. Of course the recipe can be changed, but we are happy with what came out for our proportions.

14. MIX PROPORTIONS TYPE CEMENT SAND WATER CEMENT RATIO FOAM AGENT WEIGHT(GRAMS) CEMENT SAND WATER(ml) A 1 2 .5 25% 2000 4000 1200 B 1 1 .5 25% 2500 2500 1000 C 2 1 .5 25% 4000 2000 1200

15. BLENDING OF FOAM AND SLURRY ADDING FOAM TO SLURRY MIXING OF FOAM AND SLURRY

16. FILLING OF CUBES

17. DEMOULDING Initial setting time of lightweight concrete is 12 hours and can be demould after 24 hours But in case of low density lightweight concrete the timing will be Initial time: 24 hours Final setting time: 3 days

18. CURING For 24 hours we let the concrete block cure in water. After which we used gunny bags that is kept wet.

19. RESULT

20. COMPRESSION TEST The cubes were crushed on a more sensitive press (on compression testing machine) the usually used for normal concrete. two cubes from the same mixture of foamed. Compressive strength of foamed concrete was recorded for 7 and 28 days. Compressive strength (N/mm²) = LOAD/ AREA

21. COMPRESSION TEST VALUES Type Age(days) Load(KN) Area(mm)² Compressive strength( N/mm²) A 7 450 150*150 20 B 7 400 150*150 17.77 C 7 500 150*150 22.22

22. COMPRESSION TEST VALUES Type Age(days) Load(KN) Area(mm)² Compressive strength( N/mm²) A 28 675 150*150 30 B 28 600 150*150 26.65 C 28 750 150*150 33.33

23. COMPARISON OF CONVENTIONAL CONCRETE WITH LIGHTWEIGHT CONCRETE

24. S.NO PARAMETERS CONVENTIONAL CONCRETE LIGHTWEIGHT CONCRETE 1- BASIC RAW MATERIAL SAND, CEMENT, AGGREGATE, WATER SAND, CEMENT, WATER 2- APPLICATION LOAD BEARING THERMAL INSULATION, PARTITION WALL, NON LOAD BEARING EXTERNAL WALL 3- DRY DENSITY(K g/cm³) GENERALLY OF 2400 400-1800 4- AGING NO GAINS STRENGTH WITH AGE 5- THERMAL INSULATION NORMAL VERY GOOD 6- SOUND INSULATION NORMAL VERY GOOD 7- EASE IN WORKING NORMAL VERY GOOD

25. ADVANTAGES Weight reduction of superstructure using foam concrete walls: less steel Suitable for buildings in hurricane, cyclone, earthquake. Cost reduction for transport and storage Environment friendly Low investment- just one machine required Easy to use/produce/handle Increase compressive strength with the time

26. DISADVANTAGES Very sensitive with water content in the mixtures Mixing time is longer than conventional concrete to assure proper mixing Compressive strength of foamed concrete reduce with its density

27. CONCLUSIONS The Compressive Strength of Foamed Concrete increases with increase in the Density. Fine aggregate had a beneficial effect on significantly increase in Compressive Strength of Foamed Concrete. De-moulding of higher density foamed concrete panels is possible after 24 hours but it requires minimum 3 days for lower density foamed concrete panels which is a limitation. The starting of Strength gain for foamed concrete is on higher side than that of normal weight concrete. Improved structural efficiency in terms of strength to density ratio resulting load reduction on the structure and substructure.

28. Th e initial findings have shown that the foam concrete has a desirable strength to be an alternative construction material for the industrialized building system. The strength of foam concrete is low for lower density mixture. Significant reduction of overall weight results in saving structural frames, footing or piles and rapid and relatively simple construction. The mixed proportion for foamed concrete used in this research report can be used for structural purpose because there 28 days Compressive Strength is more than 17 MPa. The ratio developed in our project can be used for various works like precast blocks, false ceilings, precast wall elements/panels.

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