“LIGHT WEIGHT CONCRETE”

A TECHNICAL SEMINAR REPORT

JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY ANANTAPUR

ANANTAPUR – 515002, A.P INDIA

In partial fulfilment of the requirements for the award of the degree of

BACHELOR OF TECHNOLOGY
IN
CIVIL ENGINEERING
Submitted by
VELUVARTHI TIRUMALA REDDY
(173R1A0148)

DEPARTMENT OF CIVIL ENGINEERING

RAMIREDDY SUBBARAMI REDDY ENGINEERING
COLLEGE
(Approved by A.I.C.T.E, New Delhi; Affiliated to JNTU ANANTAPURAM) NH-16,
KADANUTHALA, KAVALI, SPSR NELLORE Dist

(2020-2021)

CERTIFICATE
This is to certify that the Technical seminar presentation entitle “LIGHT
WEIGHT CONCRETE ” is submitted by VELUVARTHI TIRUMALA
REDDY (173R1A0148) during the year 2020-2021 in partial fulfilment of
the requirements for the award of degree of Bachelor of Technology in
CIVIL ENGINEERING in JAWAHARLAL NEHRU
TECHNOLOGICAL UNIVERSITY, ANANTAPUR.

Seminar Supervisor. HOD

 CONTENTS
1. INTRODUCTION

2. SUMMARY OF THE INVENTION

3. DESCRIPTION OF THE PREFERRED EMBONIMENTS

4. WHAT IS CLAIMED

5. CONCLUSION

6. REFERENCE
 Abstract
Structural lightweight concrete has an in-place density (unit/weight) on the order of 90 to
115lb/ft3 (1440 to 1840 kg/m3) compared to normal weight concrete with a density in the
range of 140 to 150 lb/ft3 (2240 to 2400 kg/m3). For structural applications, the concrete
strength should be greater than 2500 psi (17.0 MPa). The concrete mixture is made with a
lightweight coarse aggregate. In this matter, in some real cases, a portion or the entire fine
aggregate may be a lightweight product. Lightweight aggregate used in the structural
lightweight concrete are typically expanded shale, clay, or slate materials that have been fired
in a rotary kiln to develop a porous structure. Other products such as air-cooled blast furnace
slag are also utilized. There are other classes of non-structural lightweight concrete with lower
density made with other aggregate materials and higher are voids in the cement paste matrix,
such as in cellular concrete. These are typically used for their insulation properties. This paper
aims to describe and generate the structural lightweight concrete.

Keywords: Lightweight; weight ratio; lightweight fillers; bulk densitie

1. Introduction and other load bearing elements. Structural lightweight concrete

Lightweight concrete having a filler/cement weight ratio of mixtures can be designed to
about (350i-l00):(650:300) and a achieve similar strengths as normalweight concrete. The same is
water/cement weight ratio of about 0.65 $0.25, the true for other mechanical and
improvement comprising lightweight durability performance requirements. Structural lightweight
fillers comprising: concrete provides a more
(a) strongly absorbent, foamed alkali metal silicate glass, efficient strength-to-weight ratio in structural elements. In most
concrete compatible products of a cases, the marginally higher
smooth unbroken surface, of an approximately spherical or cost of the lightweight concrete is offset by size reduction
ellipsoidal shape in grain sizes of of structural elements, less
0.1-6 mm., preferably 0.1-4.0 mm., and bulk densities of reinforcing steel and reduced volume of concrete, resulting in
0.15 :010 kilograms per cubic lower overall cost. In buildings,
decimeter; and structural lightweight concrete provides a higher fire-rated
(b) very hard, low absorbent, foamed or bloated or concrete structure. Structural
otherwise made porous inorganic lightweight concrete also benefits from energy conservation
lightweight additives in grain sizes of 4-25 mm. and bulk considerations as it provides
densities of 0.6:02 kilograms per higher R-values of wall elements for improved insulation
cubic decimeter, wherein the volume ratio of (a) to (b) is about properties. The porosity of
1:9 to 9:1. lightweight aggregate provides a source of water for internal
curing of the concrete that
provides continued enhancement of concrete strength and
1.1. Why the Structural Lightweight Concrete is used?
durability. This does not preclude
The primary use of structural lightweight concrete is to reduce
the need for external curing.
the dead load of a concrete
structure, which then allows the structural designer to reduce
the size of columns, footings
 Air content of structural lightweight concrete must be closely
monitored and controlled to
ensure that the density requirements are being achieved.
Testing for air content must be
according to the volumetric method, ASTM C 173, or
calculated using the gravimetric
Fig. 1. Sprinkling Aggregate in a Stockpile method described in ASTM C 138. Virtually all lightweight
concrete is air- entrained [3].
Finishing lightweight concrete requires proper attention to
The structural lightweight concrete has been used for bridge
detail. Excessive amounts of water
decks as shown in Fig.1., piers
or excessive slump will cause the lightweight aggregate to
and beams, slabs and wall elements in steel and concrete frame
segregate from the mortar. Bull
buildings, parking structures,
floating will generally provide an adequate finish [3]. If the
tilt-up walls, topping slabs and composite slabs on metal deck
surface for an interior floor is to
[1].
receive a hard toweled finish, use precautions to minimize
the formation of blisters or
1.2. How the Structural Lightweight Concrete is used? delimitations. See CIPs 13 and 20 for discussions on blisters and
Lightweight concrete can be manufactured with a combination delimitations, respectively.
of fine and coarse lightweight Due to the inherent higher total moisture content of lightweight
aggregate or coarse light- weight aggregate and normal weight concrete it typically takes a
fine aggregate. Com- plete longer time than normal weight concrete to dry to levels that
replacement of normal weight fine aggregate with a light- might be considered adequate
weight aggregate will decrease the for application of floor covering materials. The splitting
concrete density by proximately 10 lb/ft3 (160 kg/m3) [2]. tensile strength of lightweight
Designers recognize that structural concrete is used in structural design criteria. The design
lightweight concrete will not typically serve in an oven-dry engineer may request the information
environment. Therefore, structural for a particular source of lightweight aggregate prior to the
design generally relies on an equilibrium density (sometimes design. The splitting tensile
referred to as air-dry density); strength corresponding to the specified compressive strength
the condition in which some moisture is retained within the is determined in laboratory
lightweight concrete. Equilibrium evaluations. Splitting tensile strength testing is not used as a
density is a standardized value intended to represent the basis for field acceptance of
approximate density of the in- place concrete. Ensure that the requirements of the designer relative to
concrete when it is in service. Project specifications should fire resistance or insulation
indicate the required equilibrium properties of lightweight concrete building elements are in
density of the lightweight concrete. Equilibrium density is conformance with applicable
defined in ASTM C 567, and can industry standards. For a successful project, information is
be calculated from the concrete mixture proportions [2]. available from the supplier of
Field acceptance is based on lightweight aggregate and the ready mixed concrete
measured density of fresh concrete in accordance with ASTM C producer. With proper planning,
138. Equilibrium density will structural lightweight concrete can provide an economical
be approximately 3 to 8 lb/ ft3 (50 to 130 kg/m3) less than the solution to many engineering
fresh density and a correlation applications [4].
should be agreed upon prior to delivery of concrete. The
tolerance for acceptance on fresh
density is typically ±3 lb/ ft3 (±50 kg/m3) from the target value.
Lightweight aggregates must
comply with the requirements of ASTM Specification C 330.
Due to the cellular nature of
lightweight aggregate particles absorption typically is in the
range of 5% to 20% by weight of
dry aggregate. Lightweight aggregates generally require wetting
prior to use to achieve a high 2. Innovation description
degree of saturation. The field of the invention is coating or plastic compositions of
inorganic settable ingredients
of Portland cement containing silica aggregates.
The state of the art of the raw material as used in the present
invention may be ascertained by
reference to the Kirk-Othmer Encyclopedia of Chemical
Technology, 2nd Ed., (1964), Vol. 4,
Some concrete producers may not have the capability of pages 684-710 under the section Cement, and by reference to
pre-wetting lightweight US. Pats. 3,184,371 of Seidl;
aggregates in cold weather if temperature controlled storage 3,261,894 of Seidl; and 3,652,310 of Kraemer et al., which
is not available. Some issued May 18, 1965; July 19,
lightweight aggregate suppliers furnish vacuum saturated 1966; and Mar. 28, 1972 respectively. These disclosures are
aggregate. With the exception of incorporated herein.
bridges and marine structures, specifications for structural It is known to the art to produce an inherently dense structural
lightweight concrete do not lightweight concrete which can
typically have a requirement for maximum water-to- be reinforced by binding with a cement paste bloated o r foamed
cementations materials (w/cm) ratio. The mineral products having a
w/cm ratio of structural lightweight concrete cannot be precisely suitable screening characteristic. These mineral products are
determined because of the of a silicate, clay, and/or
difficulty in determining the absorption of lightweight carbonate character, such as bloated shale, bloated clay,
aggregate. etc., or granules from waste
p'rb'ducts, such as flue ash, slag pumice, etc., and they may ellipsoidal shape with grain sizes of 0.1-6 mm., preferably
also be sintered d" or steam 0.1-4.0 mm., and with bulk
hardened. In the case of lightweight concrete, the additives of densities of 0.15:0.10 kg./dm. combined with very hard,
gravel and sand usual in high low-absorbent, porous (foamed,
density concrete are replaced entirely or partially by the bloated or otherwise) inorganic lightweights additives in grain
above-mentioned lightweight sizes of 4- 25 mm. afid "bfilk'
substances and, otherwise, the procedures used in concrete densities of 0.6102 kg./dm. and by processing this combination,
technology are retained according to the state of the
unchanged. art of concrete technology, with a sufficient amount of cement
The bulk densities of the lightweight additives are all above 0.4 and water at a water-cement
kg./dm. (kilograms per cubic ratio of 0.65:0.25
decimeter), generally between 0.6-0.8 kg./dm. with a portion and within the standard, in most cases steadily rising screening
above 0.8 kg./dm. The grain characteristic curve for
apparent densities are approximately twice these values. additives. The shaping by means of concrete forms by shaking,
With the decreasing bulk densities of the additives, not with and without a top load,
only the concrete densities are and the setting take place in a conventional manner.
reduced, but also the compressive strengths, especially in the
case of the coarse additives. The
3. DESCRIPTION OF THE PREFERRED EMBODIMENTS
decreased grain density of the fine additives, however, has only
In spite of the great differences in density between the finer,
a minor effect or hardly any
extremely lightweight
effect at all, on the strength of the lightweight concrete
additives and the coarser, hard and heavier. additives, no
when these fine additives are
separation of the mix occurs during
combined with hard coarse additives. However, when heavier,
the manufacture of the concrete and during casting, when the
coarser additives are combined
additives mentioned above have
with lighter, finer lag gtygjgh Ladditiues -segregation of the
a strong absorbability with respect to water. Consequently, in a
concrete m'a's's takes place. This
preferred embodiment of this
segregation becomes the more pronounced, the greater the
density 3,814,614 Patented June 4,
1974 difference of the additives and the lower the concrete
consistency. Thus, it is impossible
in the case of wide density disparity of the additives and poor
consistency, to be sure that the
requirements for homogeneity of a structural lightweight
invention, the foamed, inorganic, concrete-compatible products
concrete can be satisfied.
absorb, after saturation under
For a great variety of reasons, the interest in lightweight
water for one hour and drip-drying for one-half hour, more than
concrete having density as low as
15 percent by weight.
possible and a compressive strength as high as possible, is
For reasons of space filling, the shape of the lightweight
great, primarily because the
additives of small granular size
of 0.1-6 mm., preferably 0.1-4 mm., is of utmost importance in
order to obtain the structural
lightweight concrete of this invention with a low density.
Absorbent inorganic products with a density of 0.15 10.1
ltg./dm. as required for the
small grain additive, but a non-smooth surface, e.g. prelates,
thermal insulating characteristics increase with decreasing
vermiculites etc., are, due to their
density and because of the load
uneven shape and an insufficient space-filling, not suitable for
reduction obtained in buildings. It has not been possible to
the production of the structural
produce, by the methods known
lightweight concrete of this invention. On the other hand,
heretofore, a dense structural lightweight concrete of a high
concrete-compatible, inorganic,
compressive strength with
foamed, granular products having a smooth or slightly
densities of below 1200 kg./m. (kilograms/cubic meter). This
rough surface, of a spherical or
can be ascertained from the fact
ellipsoidal configuration with a space filling of more than 45
that the Preliminary Guidelines for the Manufacture and Testing
percent and a high absorbency,
of Reinforced Lightweight
wherein the absorbency of the individual grain can be somewhat
Concrete, published in August of 1967, by the German
different, may be used.
Committee for Reinforced Concrete
The lightweight granulated foamed materials produced
permit only the following apparent density classifications for
according to US. Pats. 3,184,371
structural lightweight concrete:
and 3,261,894 of Alois Seidl, which issued May 18, 1965 and
Apparent density classification Test results (nominal apparent
July 19, 1966 respectively, and
density): kg./dm. 1.30 1.20-
German Pat. 1,671,266 (corresponding to US. Patent application
1.40 1.50 1.41-1.60
Ser. No. 724,634 and now
abandoned) have proved to be most advantageous. According
2. SUMMARY OF THE INVENTION to US. Pats. 3,184,371 and
Having in mind the limitations of the prior art, it is therefore an 3,261,894, granular fillers are produced by:
object of the present (a) Dissolving a fibrous inorganic silicate in aqueous alkali
invention to prepare a lightweight structural concrete metal silicate solution in the
wherein this density threshold is proportion of 0.02-0.7 or 0.02-0.8 parts by weight fibrous
substantially depressed below 1.20 kg./dm. without endangering inorganic silicate to one part of the
the density of the concrete aqueous alkali metal silicate;
and without appreciably reducing the compressive strength. (b) Drying the solution;
This is accomplished by the (c) Granulating the product; and
combination, as additives, of strongly absorbent, foamed, alkali (d) Heating the granules to 700-900 C.
metal silicate glass, concrete German Pat. 1,671,243 (corresponding to US. patent
compatible products of a smooth unbroken surface, having an application Ser. No. 56,075)
approximately spherical or disclose in place of step (d) above;
(d) Coating the granules with a refractory substance,
such as lime; and
(e) Heating the coated product between about 600- It is
also possible to employ
especially lightweight alkali silicate particles prepared as
EXAMPLE A The strongly absorbent, foamed, inorganic,
disclosed in German unexamined
concrete compatible products
published application 1,804,137. In order to avoid shrinking
of a smooth unbroken surface having an approximately spherical
in the preparation of these
or ellipsoidal shape in grain
particles, blowing agents were added when the particles were in
sizes of 0.1-6 mm., preferably 0.1-4.0 mm., with bulk densities
the plastic condition. These
of 0.15:0.10 kg./dm. as used
in the examples reported in Tables I and II as follows are
prepared by dissolving fibrous or
powdered silicate or oxide materials in aqueous alkali metal
silicate solution in the proportion
of 0.02 to 07:1 parts by weight, drying the solution,
granulating the product, coating the
blowing agents split off gases at 400-700? C. or vaporize or
granules with a refractory substance, such as lime, and heating
are subject to gas-liberating
the coated product between
reactions. Subsequent to a predrying step, the substance was
about 600-1000 C.
foamed at 500-700 C.
EXAMPLE B The very hard, low-absorbent, foamed or
Furthermore suitable are the lightweight granulated materials
bloated or otherwise made
prepared as disclosed in
porous, inorganic lightweight additives in grain sizes of 4-25
U.S. Pat. 3,652,310 of Kraemer et al., which issued Mar. 28,
mm. and bulk densities of
1972. According to Kraemer et
0.6102 kg./dm. as used in the examples reported in Tables I and
al., foamed glass particles are prepared by:
II as follows are prepared by
(a) Dissolving about 0.02-0.7 parts by weight of fibrous
treating well refined red mud with an organic blowing agent
inorganic silicate in one part by
such as sugar, molasses or
weight of an aqueous alkali metal silicate solution;
powdered carbon, pressing the treated mud through a perforated
(b) Evaporating the mixture to a water content of about 5-20
screen by a worm gear press,
percent by heating;
cutting the pressed strands into short pieces, drying the small
(c) Granulating the dried material to a particle size between
cylinders to a water content of
about 0.5- mm.;
about 5 to 10 percent and expanding the granules in an oven at a
(d) coating the granulated material with a dispersion of a
temperature of about 1000 to
high melting inorganic
1400 C. and cooling to room temperature. In the compositions
compound having a melting point between about 1200 and 2500
reported in the Tables I and II,
C.; and
the weight ratios of the components vary as follows:
(e) Heating the coated material between about 600 to 1000 C. to
produce the foamed
glass particles.
The glass particles are mixed with lime and water, molded to
form a shaped body and
conditioned in a saturated water vapor atmosphere to
produce a calcium hydro-silicate
element.
These lightweight additives, due to their small grain size, Table I, foamed glass granules
light weight, controllable
absorbency, concrete compatibility, and smooth,
predominantly round granular shape, are
easily combined with the substantially heavier, hard, little Tables II: prepared by treating well refined red mud with an
absorbable larger granulated organic blowing agent such as sugar,
materials based on bloated clay, bloated shale, flue ash, slag, molasses or powdered carbon, pressing the treated mud
etc., and thereby a structural
lightweight concrete is attained having substantially
improved properties as compared to
those concretes known heretofore. Since the surface of these
small granules is hardened by
melting the sequestrates, due to the manner in which the
granules are manufactured, the
customary abrasion during the mixing periods is avoided.
The gap in the screening characteristic of the additives for the
structural lightweight
concrete according to this invention, of 0.06-0.1 mm. is closed
water/cement ratio=0.65:0.35
by minor percentages of quartz
electrostatic filler ash/cement ratio= (0-0.4): 1 kg.
powder Or concrete-compatible flue ash.
sand/cement ratio=(0-0.7): 1 kg.
As examples of the lightweight structural concrete of this
filler (a) bulk density 0.15:0.10 kgJdmF/cement ratio filler
invention, the concrete
(b) bulk density 0,610.3
compositions are set forth, as compiled in the following
kgJdmfi/eement ratio One cubic meter of the lightweight
examples, wherein the procedure is
concrete contains about 250-320
that disclosed in accordance with the Preliminary Guidelines
liters of water and cement and about 750- 680 liters of filler.
and the Preliminary Pamphlet I
According to the examples shown in Table I, foamed glass
of the German Committee for Reinforced Concrete (in the
granules of the indicated
editions of August 1967 and July
grain size and bulk density with an absorbency of 70
1968):
percent by weight are mixed with
granulated bloated clay of the indicated grain size and bulk
density with an absorbency of 7
percent by weight, and moistened with water. To this prepared by:
mixture is added a cement glue, (a) Dissolving about 0.02 to 0.7 parts by weight of fibrous
consisting of cement P2 450, precipitate from an electrostatic inorganic silicate in one part
filter, and water. The mixture of by weight of an aqueous alkali metal silicate solution;
consistency K2 is poured into concrete forms under constant (b) Evaporating the mixture to a water content of References
agitation. After 28 days, this Cited by weight; UNITED
structural lightweight concrete exhibits the values for density, STATES
compressive strength, and A-
value as set forth in Table I.
By replacing the foamed glass granules in Examples 14 as
tabulated in Table I by a
conventional lightweight additive within the same granular
spectrum, for example bloated
shale, Examples 1a-3a are obtained as tabulated in Table II.
(Water 0.56, cement 0.92.-300) the improvement comprising
PATENTS I (e) granulating the dried material to a particle size
said lightweight filler
between about mm;
comprising:
3,652,310 3/ 1972 Kraemer et al 106120 (d) coating the
(a) strongly absorbent, foamed, alkali metal silicate glass,
granulated material with a dispersion
concrete-compatible products
5 FOREIGN PATENTS of a high-melting inorganic compound
having a smooth unbroken surface of an approximately spherical
having a melt- 1,219,948 1
or Table III
/1971 Great B i i ing point between about 1200 to 2500 C.; and
(e) heating the coated material
Nominal value 1. 500 1, 500 1, 00 Thermal conductivity between about 600 to DELBERT GANTZ, 'y Examiner
X (calculated) thermal 1000 C. producing foamed glass
conductivity (measured) plus 20% 0. 00 a a as In Table III particles. 10 BERGER, Assistant Examine- 5. Lightweight
which follows, the characteristic structural concrete prepared from
data of ellipsoidal shape in grain sizes of about 0.1-6 mm. th n r the composition of claim 1, having a density less than 1.20 US.
t s are compared: 55 and a Cl. X.I. (kilograms per cubic
bulk density of about 0.15:0.10 kilograms per With an decimeter)
increasing proportion of foamed glass
granules cubic decimeter; and in the fine-grained range, the dry
5. Conclusion
density of the concrete (b)
Structural lightweight concrete had an in-place density
very h d, 1 b b t, porous, inorganic lights reduced to below 1000
(unit/weight) on the order of 90 to
kg./m. whereas replacing the
weight additives i grain sizes of about 5 m fqamed 8 0 y bIOated 115lb/ft3 (1440 to 1840 kg/m3) compared to normal weight
shale fsesults m mcreasmgly concrete with a density in the
and bulk densities of about 06:02 kilograms per higher densities range of 140 to 150 lb/ft3 (2240 to 2400 kg/m3). For
111,10 1600 kg/m- 0 cubic
structural applications, the concrete
strength should be greater than 2500 psi (17.0 MPa). The
concrete mixture was made with a
lightweight coarse aggregate. In this matter, in some real cases,
a portion or the entire fine
aggregate might be a lightweight product. Lightweight
aggregate used in the structural
decimeter and wherein the volume ratio of The values for
lightweight concrete are typically expanded shale, clay, or slate
the thermal conductivity are
materials that have been fired
impaired in the same manner.
in a rotary kiln to develop a porous structure. Other products
such as air-cooled blast furnace
slag are also utilized. There were other classes of non-structural
lightweight concrete with
Table III: The characteristic data of ellipsoidal shape
lower density made with other aggregate materials and higher
are voids in the cement paste
matrix, such as in cellular concrete. These were typically used
for their insulation properties.
This paper aimed to describe and generate the structural
lightweight concrete.
4. What is claimed is:
1. In a lightweight structural concrete composition having a
water/ cement weight ratio
of 0.65 $0.25 and lightweight filler/cement weight ratio of
(350x100) (650 (a)/(b) is about 1:9
to 9:1.
2. The lightweight structural concrete composition according to
claim 1, characterized
in that the absorbency of the foamed, alkali metal silicate glass,
concrete-compatible products,
after being fully saturated with water for one hour and being
drip-dried for one-half hour,
amounts to more than 15 percent by weight.
3. The lightweight structural concrete composition of claim 1,
wherein the grain size of
(a) is about 0.1-4.0 mm.
4. The lightweight structural concrete composition of claim 3,
wherein component (a) is
References
1. Guide for Structural Lightweight
Aggregate Concrete BCI 213R,
American
Concrete Institute, Farmington Hills, MI, www.concrete.org.
2. Guide for Determining the Fire Endurance of Concrete Ele-
ments, ACI 216R,
American Concrete Institute, Farmington Hills, MI
3. ASTM C 94, C 138, C 173, C 330 and C 567, Annual Book
of ASTM Standards,
Volume 04.02, ASTM International, West Conshohocken, PA,
www.astm.org.
4. Lightweight Concrete and Aggregates, Tom Holm, ASTM
169C, Chapter 48,
ASTM International, West Conshohocken, PA
5. Pumping Structural Lightweight Concrete, Info Sheet
#4770.1, Expanded Shale
Clay and Slate Institute, Salt Lake City, Utah, www.escsi.org