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You are here: Home Perlite Concrete

Concrete
LIGHT WEIGHT INSULATING CONCRETE

Click image to download Perlite Brochure

Perlite concrete aggregate combined with portland cement and water produces a lightweight insulating
concrete used for lightweight roof decks, floor fills, lightweight structural decks, insulation for steam and
coolant lines, bases of cryogenic storage tanks, oven insulation, interstitial spaces in reconditioned water
and sewer lines, interstitial floors in hospitals, lightweight pre-cast forms and blocks, statuary, basic fills,
and many other applications where a lightweight permanent concrete is desired.
Although many uses could be described in greater detail, the most common and well-established use has
been for insulating flat roof decks.
Physical properties of perlite concrete vary according to mix designs. Perlite concrete can be made with a
dry density of 320 kg/m3 or with the addition of sand or other aggregates up to 1440 kg/m3.
The lower the density, the higher the insulating value.
For most uses to maintain a proper balance between insulation value
and compressive strength, a 1:6 (one part Portland cement by
volume to 6 parts perlite by volume) mix is chosen with a density
between 384 and 480 kg/m3. This provides a k factor range of 0.085
to 0.095 W/m-k and a compressive strength of 125 to 200 psi (986 to
1378 Pa).
ADVANTAGES OF PERLITE CONCRETE

Extremely light weight

K
CLASS

AGGREGATE

WEIGHT (KG/M3)
(W/M/C)

Light weight
Medium

Perlite
Slag, shale, clay,
pumice

Heavy

Sand & gravel

320-640

0.07-012

960-1520

0.24-0.75

2240-2400

1.30-1.73

Superior thermal & acoustic insulation When mixed with Portland cement, perlite produces a
concrete that offers up to 20 times more thermal insulation than ordinary concrete.The necessity of air
conditioning, rising fuel costs and the need to conserve energy make it obvious that a small investment
in proper insulation at the time of design and construction can save countless dollars in heating and
cooling costs during the life of the building.

AdaptablePerlite concrete can be easily placed on flat, uneven or curved surfaces. It is ideally used
in drainage slopes. Densities can be easily altered to meet requirements.

Fire retardantPerlite concrete is non-combustible and can be used to establish up to four hour fire
ratings.

Reduced construction costsThe use of perlite concrete reduces the demand for structural steel,
reduces cartage costs and improves energy efficiency.

PERLITE GRADE TO BE SUPPLIED = P400

STANDARD SPECIFICATION FOR LIGHTWEIGHT AGGREGATES

FOR INSULATING CONCRETE
(SIGNIFICANT PARTS OF ASTM C-332, GROUP I)

Sieve AnalysisWeight
Basic Specifications

Density

( Percent Passing Each

Sieve)

9.5mm

..

4.75mm

100%

2.36mm

1.18mm
PERLITE

85 to
100%
40 to
85%

120 to 196 kg/m 3

600

20 to

microns

60%

300

5 to

microns

25%

150

0 to

microns

10%

MIXING PERLITE CONCRETE

While perlite insulating concrete is mixed in the same equipment and by similar methods as sand-gravel
concrete, there are some considerations that must be given to the order of addition of materials and to the
time of mixing to assure correct concrete properties and adequate yield. The following mixing information
for transit mixing is presented as a guide to the manufacturer to eliminate some of the questions that may
arise in the field and to ensure successful construction with perlite concrete.
Transit Mixing
When transit mixing perlite concrete for the first time, it is suggested that INPRO be consulted for
suggestions as to the correct mixing time and procedure. These may vary with the type and age of locally
available equipment.
The mixing procedure used by many transit operations is as follows:
1.

Determine the load of the mixer.

2.

Add to the mixer the correct amount of water for the load.

3.

Add the correct amount of air entraining agent and cement to the mixer and mix until a slurry is
formed.

4.

Add the required number of bags of perlite concrete aggregate.

5.

Do not rotate the drum during transit.

6.

Upon arriving at the job site, mix at top speed for not less than 3 nor more than 5 minutes.

7.

Discharge in normal manner after checking wet density for conformance to specification range.

8.

Rotate the drum at idle speed when discharging last of load to assure complete discharge of
concrete.

9.

Do not wash out drum between loads; use the same trucks throughout a job.

10.

NOTE: When mixing perlite concrete it is generally suggested that 100-150 revolutions of the transit
mixer drum will give good perlite concrete. This varies with the age and effectiveness of equipment.

If possible, the drum should be charged with water, air entraining agent and cement at the batching plant,
and the perlite aggregate should be added at the job site, mixing at high speed until the desired density and
consistency is reached.
Care must be taken to ensure proper mixing time for the perlite insulating concrete. Using the correct
amount of water as specified, the perlite concrete should have a slump of approximately 7-18 cm when
properly mixed and may appear too wet by normal concrete practices. However, if the mix appears too dry
or too stiff, the mixing time has probably been too short. Continue mixing until the desired plasticity is
reached. Extra water and under mixing may reduce the yield.
The first truck load of perlite concrete will usually discharge about 1/4m3 short since this quantity will coat
the inner walls of the truck drum. However, this will not occur in subsequent loads because the walls will be
coated sufficiently. After discharging the last load, 26-38 litres of water may be added to the revolving drum
to wash out this coating and this mixture may be dumped and blended with concrete from the previous load.
This will not impair the perlite concrete properties because the excess water bleeds out without loss of
cement.
Wet Density
The wet density of perlite insulating concrete as poured is important in the control of the physical properties
of the dry concrete and the yield achieved. The strength and the insulating value depend on the wet density.
Heavier weight means greater strength and less insulation. Therefore, the architect or engineer usually
specifies the wet density of the perlite concrete with a plus or minus 32 kg/m3 range.
Field Control
The wet density can be checked for conformance to the architects specifications beginning with the first
truckload delivered. Adjustments to the mixing procedure should be made at that time and additional checks
made periodically during pouring.
The simplest method of field checking wet density is as follows:
1.

Determine the exact volume of a cylindrical container such as a rigid 10 litre container. This can be
done by first weighing the empty container, then filling it completely full with water and weighing it

again and subtracting the two weights. This provides the net weight of the volume of water, and, if
divided by the density of the water, the result is the exact volume of the container.Example:

Weight of Empty Container

3.

kg

Weight of Container Filled

10.4

with Water

5 kg

Net Weight of Water

2.

.91

9.54
kg

Volume = Net Weight of Water Density of Water = 9.54 kg 1000kg/m3 = 0.00954 m3

Fill the container with wet perlite concrete as it leaves the mixer and weigh again. Subtract the
weight of the empty container and divide the remainder by the volume as determined in Step 1. The
result is the wet density of the perlite concrete in kgs per cubic metre which should be within 32
kg/m3 of the specified value.Example: (Based on a 1:6 mix)

Weight of Container Filled

with Concrete

Weight of Empty Container

Weight of Perlite Concrete

.
7.05
kg
.91
kg
6.14
kg

4.

Wet Density = Weight of Perlite Concrete Volume = 6.14 0.00954 = 643.6 kg/m3

5.

Therefore, the field test wet density is within the 648 32 kg/m 3 specification range.

AIR ENTRAINING AGENT

The use of the correct amount of air entraining agent of the proper concentration is of extreme importance
in successful perlite concrete construction. The air-entraining agent produces countless tiny air bubbles in
the concrete which reduces the density, increase the yield and contributes to the insulation value of the dry
concrete. Air entrained concrete is also more resistant to water absorption.
Care should be taken in mixing perlite concrete to ensure that the proper amount of agent is used. Excess
air entraining reduces the strength of the concrete. An even distribution of agent is also essential to produce
the desired concrete characteristics.
PLACEMENT OF PERLITE CONCRETE

Perlite concrete may be placed through the use of crane and bucket or by pumping. The preferred method is
by pumping. A progressive cavity pump is recommended, as this type of pump will not place undo pressure
on the perlite. In addition, pump hose should be a minimum of 3 inches in diameter. Hose kinking should be
avoided. Hoses should be tied off at each joint.
YIELD
Yield is defined as the ratio between the volume of the wet perlite concrete as discharged from the mixer
and the volume of perlite concrete aggregate used in the mix. The mix proportions included in the
specifications are based on extensive field and laboratory tests and are established for 100% yield. If the
correct quantities of material and mixing procedure are used, a 100% yield should result. Yield may vary
however as it is effected by job site conditions included mixing time, fineness of aggregate, pumping
equipment, height to be pumped, length of hose, etc.
Field Check for Yield:
The first step necessary in making a field check for yield is to determine the wet density of the perlite
concrete as previously outlined.
The wet density and the weight of total ingredients for the mix being used are then substituted in the
following formula:
a. Weight of Total Ingredients Wet Weight per Volume of Concrete = Yield
b. Yield Weight of Total Volume of Perlite Aggregate X 100 = % Yield
Example:
Consider a mix of 42.73 kg of Portland cement to 6 ft 3 of perlite (0.17 m3 of perlite)
The wet density as determined in the Example is 643 kg/m 3.
The weight of total ingredients is as follows:

Portland Cement

42.73
kg

Perlite0.17 m3 @ 128.0

21.17

kg/m3

kg

Water45.42 liters

Air Entraining Agent

Total

45.42
kg
negligibl
e
109.32

kg

Substituting in formula (a): 109.32 643.6 = 0.17 = Yield

Substituting this value in formula (b): 0.17 0.17 X 100 = 100%
Loss of Yield:
If the yield as checked by the wet density is less than 100%, a loss of yield is evident. A loss of yield may be
attributed to a number of factors as previously noted. However, one or more of the following factors should
be checked:

Air entraining Agent: Be sure that the proper amount is being added to each batch. Check
concentration.

Mixing Procedure and Time: Be certain that materials are added in the proper sequence. Under
mixing will usually result in loss of yield while overtaxing can adversely affect the air entrainment.

Water: Check the amount of water being added. After about one minute of mixing, properly
proportioned perlite concrete often looks too dry. If extra water is added, yield can be reduced. Hard
water will often offset the effect of the air-entraining agent and may require adjustment of the quantity
of air entraining agent.

MIX DESIGN DATA

The proper proportions of materials for various perlite concrete mixes are shown in the following table. The
importance of properly designing and specifying the mix and the proper use of the air entraining agent
cannot be overemphasized.
The following may be used as an example. Further mix designs are available upon request including designs
to achieve perlite to normal sand-cement mixes to produce structural lightweight concretes of 11201600kg/m3 with strength of 7000-14000kPa.
MATERIALS PER CUBIC METRE BASED ON 100% YIELD
WET

OVEN
MIX RATIO
(CEMENT/P

DRY

DEN

DENS

SITY

ITY

ERLITE

AIR
CEM

PER

WA

ENTRAI

ENT

LITE

TER

NING

KG

M3

M3

AGENT

RAN
GE

AGGREGAT

(TYPI

CAL)

BY

KG/M

KG/

VOLUME)

M3

1:4

1:5

1:6

1:8

576

488

432

352

376
kgs

301
kgs

252
kgs

188
kgs

808.0
1.0

.30

+/48.0
728.0

1.0

.29

+/48.0
648.0

1.0

.27

+/48.0
584.0

1.0

.27

+/48.0

THE ABOVE DATE IS FROM TESTING & EXPERIENCE AND IS GIVEN TO INFORM ABOUT PERLITE CONCRETE.
SINCE THERE IS NO CONTROL OVER MATERIALS OTHER THAN PERLITE, NOR OVER MIXING AND
EMPLACEMENT TECNIQUES, NO WARRANTY IS EXPRESSED OR IMPLIED.

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Transit Mix Perlite Concrete

Insulating Underground Pipe and Ducting with Perlite Insulating Concrete

Perlite Insulating Concrete Pool Base for In-Ground Vinyl Pools

(for specifications on Aggregates for Perlite Concrete refer to ASTM C332)

Concrete Roof Decks

Perlite Insulating Concrete Roofdeck

Perlite Insulating Concrete Roofdeck (Specs)

Nail Holding Power of Perlite Concrete

Further information is available from NZ Perlite: info@perlite.co.nz