Experimental Studies on Cellular Light Weight Concrete Based On Foam, Fly Ash, and Silica Fume

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 09 Issue: 09 | Sep 2022 www.irjet.net p-ISSN: 2395-0072
© 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 816
Experimental Studies on Cellular Light Weight Concrete Based On
Foam, Fly Ash, and Silica Fume
Abbas Joun1, Mr Rajneesh Kumar2
1Master of Technology in Civil Engineering, Lucknow Institute of Technology, Lucknow, India
2Assistant Professor, Civil Engineering, Lucknow Institute of Technology, Lucknow, India
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Abstract - Foam is unambiguously entrained in the
significant based slurry or mortarthatisproducedatadensity
of 400 kg/m3 to 1950 kg/m to create Cell Light Weight
Concrete (CLWC), a design material exhibiting features of
cement. CLWC is appropriate material, despite its strength
being exceptionally less when diverged from the conventional
concrete however can be used intheplanswhicharepresented
to non-load bearing, as there has beenawidespread needfora
construction material that transports successfully in the
future. The packaging wall and its heat-shielding properties
make it useful even if they are not central to the product itself;
this is so since the product is less heavy than average. Because
of its weakness, materials such as fly flotsam and jetsam, silica
fume, etc. are added to the CLWC during construction.
Inadequate knowledge of CLWC's features and security has
severely restricted its applications. Concrete, fine amounts,
coarse aggregates, silica seethe, flyrubbishasadmixtures, and
aluminum powder as an air entraining expert are all required
to develop lightweight concrete. Silica haze and fly rubbish
completely change the mix's explicit qualities. Lightweight
concrete has compressive and flexural strengths that are on
par with those of regular concrete. The primary benefits
include a lesser need for dead weight, which may lead to
increased production rates and lower costs in handling and
transport. In the grand scheme of things, it will be seen as a
crucial and flexible material in development right now. The
uses include, but are not limited to, multi-story homes and
floors, prestressed ranges, section walls, building tops, and a
great many other components. Compressive strength, water
absorption, the thickness of valuable materials, and using
water content to provide necessary cohesiveness between
water and cement are among the most notable features of
lightweight concrete. It maintains consciousness despite
exposure to massive gaps and dramatic changes in scenery.
Excessive water use may cause significant run-off from
aggregates toward the film layer, which can weaken the
structure.
Key Words: Foam, Fly ash, Silica, Cellular Lightweight
Concrete, Cement.
1. INTRODUCTION
The production of concrete entails combining sand, water,
and concrete following a predetermined ratio, with the
assistance of hardening the mixture unpredictably. These
three components will always be combined in this exact
proportion. Concrete may be useful in ensuring the effective
completion of large-scale construction projects. To be more
specific, when a greater portion of these substances are
mixed to form a mass that could be poured to incline
towards design or workspace work, this takesplacewiththe
assistance of utilizing the reaction of concreteand waterand
various components within side the all to form solidified
concrete. This takes place to form a solidified concretemass.
To put it another way, when a bigger fraction of these
ingredients are mixed to produce a mass that might be
poured to slant toward design or workstation labor, this is
referred to as "pouring." Totals and water have thepotential
to exert some control over the significance by modifying or
solidifying it with the appropriate components or
admixtures, respectively. This would have the addedbenefit
of bringing the excellent andvarious connectedpropertiesof
the significant back up to date. Totals and water would also
have the potential to exert some control over the signs
themselves. Cement-based housing requires the use of the
component that must be kept in mind for mixing. This
component is highly vital for the building of dwellings.
Additionally, the Cellular Lightweight cement (LWC) itself
implies "fragile in weight," which may be normally in a
general sense less in added weight and is consistently 20%
to 40% lighter than the regular weight concrete. This is
because the LWC is made of a different type of material. This
is because the LWC is constructed using a unique kind of
material, which accounts for the difference. This is a
significant advantage that should not be ignored. The usage
of lightweight cement, which is exhibited asa majorkind but
is sensitive in weight, minimizes theamountofweightthatis
considered to be sluggish. Although lightweight cement is
displayed as a significant kind, it is sensitive in weight. This
is because lightweight cement is delicate in terms of weight
yet is considered to be an important kind. The particular
components that are used to make lightweight cement may
vary based on the area or location and the sources that are
available in that place. This may be the case because the
precise components used to make lightweight cement may
vary. Because the sources that are accessible in that area are
subject to change, this can be the case. The three most
essential head substances for increasing the usage of
lightweight concrete are lightweight coarse total, air
entraining informed authority, and admixtures. The term
"lightweight coarse total" refers to the kind of lightweight
aggregate that will be discussed here.

2. AGGREGATES
It is a common misunderstanding that these components
become inert or dormant after they have been combined
with appropriate development concrete;however,thisisnot
the case. Materials like as crushed shakes, rock,andsandare
examples of this category; they are often employed instead
of totals that exist naturally in the environment throughout
the building process. Cement is normally made up of
anywhere between seventy-five and eighty-five percent of a
component which is known as a full component. In addition
to its form and size, the presence of toxins, its capacity to
survive being pounded, and the quantity that is assessed
may all play a role in determining the qualities of cement.
Figure-01: Aggregate
3. CONCRETE
Concrete is by a significant margin the most important
component of cement; in the sense that it moves toward the
function of the enclosing vehicle for the various ornamental
aspects. Concrete is the most essential componentofcement.
Concrete will be made up of concrete in addition to other
solid components that are geared up to takeonthechallenge
of fusing particles of robust matter to produce a somewhat
weighty mass. Their primary function is to bind the fine
(sand) and coarse (corn meal) material particles together;
consequently, their constituents are calcareous concretes
that include mixtures of lime as their primary component.
Because their primary function is to bind the fine andcoarse
material particles together, theirconstituentsarecalcareous
concretes. The vast bulk of the importancemaybeattributed
to regular Portlandcement(OPC).OrdinaryPortlandCement
may be found in the following grades: 33 Grade
(IS269:1989), 43 Grade (IS8112:1989), and 53 Grade
(IS12669-1987). The 43-Grade concretes are, for the most
part, the types of things that almost anybody who keeps a
look out for them may reasonably anticipate discovering.
The Ultra Tech Cement of the 43 grade OPC is used in the
preparation of the cast areas of strength for the sample.
Concretes that is driven by water and concretes that are not
driven by water are the two unique categories that may be
used to classify cement materials. These classifications are
based on the distinct coagulation and crystallization
mechanisms that are inherent to each kind of concrete.
Concretes that are being pushed by pressure and are now
setting and hardening are said to concentrate hydration
responses, which means that they want water. On the other
hand, non-water-driven concretes essentially react withgas
and may simply set when exposed to air. This kind of
concrete is not driven by water.
4. ADMIXTURES
In the process of mixing concrete, key mixtures may have
admixtures added to them. Admixturesarea typeofmaterial
that may be added to key mixtures. This addition is only a
small percentage of the total mass of concrete. When mixed
with the customary huge combinations,thisisdonetocreate
a genuinely astounding difference. Even though the method
of developing admixtures may be inorganic and
conventional, the attributes that are produced for them are
in no way comparable to those that are developed for
minerals. It is both the beginning and the conclusion of the
procedure, as well as a critical component for the large still
addition of integrating responsibilities to raise the cement's
multiple qualities. Additionally, it is a significant component
of the process. Because of the substances that they are
associated with, the additives are frequently referred to by
names such as water-reducing, water-preventing, speeding
up, water-preventing and speeding up, water-diminishing
and speeding up, and superplasticizer. These names are all
derived from the features that the additions confer to the
material.
5. FLY ASH
The garbage that is collected electrostatically or directly
from the exhaust gases of coal-finished power plantsisoften
referred to as crushed fuel debris. This waste also goes by
the name of crushed fuel debris. The fake pozzolana that is
seen most commonly is made up of crushed fuel waste. The
particles of fly trash are spherical and have an
extraordinarily high fineness: the majority of the particles
have an evaluation between 1 micrometer and 100
micrometers, and the specific surface area of flyjunk isoften
stated in the region of 250 to 600 m2/kg. Fly debris that has
been given the classification of Class C is considered to be a
high-lime waste. This trash comes from lignite coal and may
have a lime percentage that is as high as 24 percent.
Depending on the amount of time that has passed, the
compressive strength of fly ash may vary anywherefrom 7.1
MPa to 47.5 MPa. This can happen anywherefromonedayto
three hundred sixty-five days.

Figure-02: Fly Ash used in admixture
6. SILICA FUME
In many instances, it is the delayed appearance of large
materials that have already begun to harden.Inother words,
it is a delayed appearance. Pozzolana was the name thatwas
first given to this substance whenitwasoriginallydescribed.
In addition to this, it is advised as being more moderatethan
regular silica smoke or cemented silica smoke, and it is the
ultimate result of the development of siliconandferrosilicon
compounds from high-moderate quartz and coal in lower-
curve electric heaters. In addition to this, it is advised as
being more moderate than regular silica smokeorcemented
silica smoke, and it is the ultimate result. In addition to this,
it is recommended since it is considered to be milder in
comparison to regular silica smoke or cemented silica
smoke. The following amounts of silica concentration are, in
general, reflective of normal silica levels: silicon metal
includes 94–98% silica, while ferrosilicon has 90% silica.13
In the majority of instances, the specific gravity of silica
seethe is somewhere in the neighborhood of around 2.20;
nevertheless, it is possible for the specific gravity to be
significantly increased if there is a much smaller quantity of
silica present.
7. RESULT AND ANALYSIS
After all of the necessary production, and audits have been
carried out, a person may get a high-quality and reasonably
priced basic component that is light inweightandisreferred
to as lightweight cement by adding admixtures suchassilica
smoke and fly ash, for example. If all other possibilities have
been investigated and ruled out, a correct proportioning
blending of concrete, sand, silica smoke, aggregates, and Fly
garbage bin may be used to produce high compressive
mettle. It will have a smaller dead storeinthecenterportion,
higher resilience to fire and strength, and a cheaper total
cost when compared to normal cement. Additionally, it will
be stronger. The severe nature of concrete is a result of
several factors,includingthecorrectvolumes,proportioning,
and mixing of the elements, as well as the collection,
transporting, and setting of those ingredients. It has been
found that the water-significant level plays key parts in the
essential combination, strength, setting time,andusefulness
of the large. [Citation needed] [Citation needed] The less
water and temperature that is utilized during the setup
process, the more advantageous and expedient it will be
from the very beginning. The water-significant degrees that
fall between the range of 0.45 and 0.5 are the ones that are
used the most often.
7.1. Compressive strength Vs Day
For the block test, two distinct sorts of modelsareused, each
of which has considerable areas of strength for either 150 x
150 x 150 mm or 100 x 100 x 100 mm, depending on the
dimensions of the whole object. For this evaluation, solid
forms with dimensions of 100 millimeters on each of the
three axes are employed. After seven days of lightning,
twenty-eight days of restoring,andfifty-sixdaysofrestoring,
the models are put through a pressure testing machine so
that they can be examined more thoroughly. The bearing
surfaces of the testing machinewill becleaned,andanyloose
sand or other debris will be removed from the surfaces of
the model that are going to be in contact with the pressure
plates. In addition, the bearing surfaces of the testing
machine will be cleaned. The model must be organized in
such a way that the heap is applied on the chat sides of the
significant regions of strength for the as cast.
19.08
22.23
25.5
19.99 21.25
30.4
16.75
20.75
27.5
0
5
10
15
20
25
30
35
7 14 28
Compressive
strength
Nmm2
Days
Compressive strength vs
days
Mix 1 Mix2(10%) Mix 3(20%)
Figure-03: Compressive Strength Vs Day

7.2. Flexural Strength
The test should be based on the model that wascreatedafter
the mitigating condition was eliminated. This will prevent
surface drying, which can lead to a reduction in flexural
strength. Place the model on the stacking focuses. The hand-
completed surface of the model ought not tobeintouch with
stacking focuses. This will assure good contact between the
model and stacking points. Centre the stacking framework
like the applied force. Bring the block exerting force in
contact with the model surface at the stacking places. Using
loads that are between 2 and 6 percent of the insane load
that was calculated. Using leaf-type sensor gauges with a
length of at least 25 mm, determine whether or not any gap
between the model and the store applying or supportblocks
is more important or not for each of the gauges. These
gauges have a diameter of 0.10 mm and a thickness of 0.38
mm.
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
7 14 28
Flexure
Strength
Nm2
Days
Flexure strength chart
Normal (Mix 1) Mix 2 Mix 3
Figure-04: Flexural Strength
7.3. Percentage of Weight Reduction
One of the key criteria that helps to identify cellular
lightweight concrete is the additional weight, which is also
referred to as the self-weight of the material. Because foam
was present, there were fewer important forms to begin
with, which in turn led to a decrease in the quantity of
concrete that was necessary to produce those forms. In
addition to this, the use of a decreased lightweight complete
has a sizeable impact on the quantity of concrete that is
essential for the production of those forms.
The weightdifferencebetweenordinaryweightconcreteand
cell lightweight concrete, also known as LWC, generally
ranges anywhere from 20 to 40 percent lighter. This
property often accounts for the bulk ofthedecreaseinadded
weight, which is why the word "lightweight" relates to the
material's intrinsic qualityof being"lowin weight."Theterm
"lightweight concrete" refers to an essential kind of building
material that is light in weight and gets rid of excess weight
in this manner.
Table-01: Weight Reduction
It has been suggested that because blends 2 and 3 each have
20% of foam added to them, the process of adding the foam
should be done in two differentsteps. Whencomparedtothe
regular or standard significant mix, it was shown that
lightweight concrete had a reduction in self-weight that
varied from 30.9% to 33.92% and 29.79%.
8. CONCLUSION
The goals of this endeavor are to reduce the quantity of
unused extra material, minimize the pressure that is
imposed on an arrangement, make it easier to set up and
maintain, make progress more swiftly toward new
development, and attain a high compressive strength. When
the appropriate quantities of concrete, sand, silica smoke,
aggregates, and flying debris are combined in the
appropriate proportions, they can impart high compressive
stress to the essential. It will strengthentheresistancetofire
and strength while minimizing the dead heap of the critical
area, and when compared to regular cement, it will be more
cost-effective than regular cement. Concrete's zones of
strength are produced by utilizing suitable aggregates,
following the proper proportioning and mixing procedures,
bringing theconstituent partstogether,andtransporting and
setting them. It has been found that the ratio of water to
cement plays a significant part in the process of formulating
the critical mix, in addition to having a significant impact on

the value, setting time, and strength of the concrete. In most
circumstances, cell lightweight concrete is an alternative to
normal cement that is lighter in weight. Foam is requiredfor
the manufacturing process, and between 10 and 20 percent
of silica smoke and fly, trash is incorporated into the
material throughout the process. Mix 2 has a total of 10% of
the significant weight contributed by admixtures, whereas
Mix 3 has a total of 20% of the significant weightcontributed
by admixtures. This is because silica smoke and fly litter
each contribute 10% and 20% of significant weight,
respectively. In this approach, Mix 2 results in a low starting
setting time, quick acquisitionofcompressivestrength,more
noticeable weakness, and amazing comfort when compared
to Mix 3. In addition, the beginning setting time of Mix 2 is
much shorter. This is because Mix 2 has a greater quantityof
admixtures that are significantly contributing to the
substantial, and silica smoke and fly trash are both
accelerating admixtures.
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41.2417

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