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ABSTRACT
Lightweight foamed concrete is a concrete made by cement slurry mixed with prefoamed
foams so that foam concrete is lighter than conventional concrete. The objectives of this
study is to develop optimal prefoamed lightweight foamed concrete possessing improved
lightness, flowability and strength by using polymer foam agent, admixtures and industrial
by-products such as styrofoam, silica-fume and fly-ash. In this paper, extensive test data
on lightweight foamed concrete are presented. This paper also presents the mechanical
characteristics of developed lightweight foamed concrete including long-term behaviors and
their improvement. It is expected that this study provides an important guide to manufacture
structural lightweight foamed concrete using polymer foam agent.
1. INTRODUCTION
Lightweight foamed concrete is a kind of lightweight concrete, which is lighter than
normal concrete by mixing foams into cement slurry [1]. According to foaming type,
lightweight foamed concrete is classified as pre-foaming type foamed concrete which is
mixed by prefoamed foams in cement slurry, after-foaming type foamed concrete which
is mixed with foaming agents such as aluminum powder and zinc powder, and
mixed-foaming type foamed concrete which is mixed with surface active agent into cement
slurry during mixing [2]. In this study, lightweight foamed concrete is manufactured by
the pre-foaming type because of its advantages for controlling the quantity of the foam
and easiness of placing during construction. The foam agent is the most important factor
for the foamed concrete and foam agents are classified as polymer foam agent, protein
foam agent and surface active agent. Protein foam agent compounded of animal blood and
gelatin is made of several kinds of amino acid and makes about 0.20.8mm size of a
pore in the cream at the time of foaming. Surface active agent is made of alkyl benzene
sulfonate and is hard to obtain stable foams in cement slurry at the time of foaming. In
this study, polymer
------------------------------------------------------------------------* Correspondence to : H.-W.Song, Dept. of Civil Eng., Yonsei Univ., Seoul 120-749, Korea
song@bubble.yonsei.ac.kr
foam agent is used since the polymer foam agent does not have the defect due to corrosion
and bad smells due to chloride and zinc, and also the polymer foam agent develops stable
pores films surrounding the foam. As a polymer compounded of water repelling hydrocarbon
and water attaching hydrocarbon, the polymer foam agent has neutral PH and makes about
0.10.4mm size of a pore in the state of white cream at the time of foaming. In order
to use industrial by-product for the partial substitution of the foam, expanded polystyrene
bead (so-called styrofoams) is also used. Styrofoams, which is used to have brown color
and round shape, are normally manufactured by expanding petroleum, coal-tar and
polystyrene in heat. Styrofoams do not absorb water because it is consist of about million
closed cellulars. In manufacturing processes of the foamed concrete as shown in Fig.1,
the foams are made by compressed air in pre-foaming method. Dilute water and foam
agent with ratio of 50:1 are used to make foams at foaming instrument. Omnimixer which
has 250l capacity is used for mixing, and only vibrated compaction is performed to minimize
antifoaming. Curing is performed in curing room at the normal temperature for at least
48 hours and then continued in curing tank at 202 for 28 days. In this study, we
define the optimal lightweight foamed concrete as a foamed concrete which has more than
180mm flow value, more than 30kg/cm2 compressive strength, and about 0.5t/m3 unit volume
weight.
cement
admixtures
styrofoam
Compressed
air
foaming
instrument
foam agent,
dilute water
water (3/4)
foam
water (1/4)
foamed concrete
Fig.3 shows compressive strength normalized by compressive strength without pore ( 0) for
different pore ratios P which can be expressed as eq.1 and eq.2 by regression analysis. These equations
are similar with those by Balshin and Ryshkewitch [3][4].
= 0(1-P)4
(1)
= 0e-6P
(2)
The pore ratio has also direct relationship with unit volume weight of the foamed
concrete. The relationship between pore ratio and unit volume weight con [t/m3] by
regression analysis is obtained as eq.3.
con = 2.1 - 2.3P
(3)
Flowability is estimated from flow values. The flow value 180 is regulated as standard
value to acquire sufficient flowability because it enables 500m pumping without material
segregation [5]. Foamed concrete with styrofoam is verified to have more than 180 flow
value when water-cement ratio is more than 0.5.
/0 10
Eq. 1
Eq. 2
120
120
100
100
N o .1 : W /C 0 .2 5
S F 0%
N o .2 : W /C 0 .3 0
S F 15%
N o .3 : W /C 0 .3 5
S F 20 %
N o .4 : W /C 0 .3 5
S F 2 5%
N o .5 : W /C 0 .3 0
S F 3 0%
N o .6 : W /C 0 .2 0
S F 30%
80
80
60
60
40
40
20
00
No.1
No.2
No.3
No.4
No.5
conventional one.
No.6
-20
0.2
-40
0.4
-60
0.6
-80
0.8
-100
1.0
1.2
-120
80
60
40
20
0
1 OS
J EW
2 M AL
3
N OR
COPPER
FOAM CO N C. CO M
5
EN T
M O N O4CRETE IM PR OVEM
STR EN G TH
Flash-setting agent 0%
Flash-setting agent 6%
Flash-setting agent 8%
Flash-setting agent 10%
14
12
14
12
10
10
100
200
300
400
500
600
700
MIN.
16
FLOW (cm)
FLOW (cm)
16
18
800
18
100
200
300
400
500
600
700
12
800
MIN.
16
10
15
20
25
30
AGE (day)
194
278
192
326
174
365
0.13
0.097
0.055
0.032
natural frequency ()
damping time (10-3sec)
impact coefficient (i)
Damping effect decreases as pore ratio decreases due to increase of the damping time. And
impact coefficient which is obtained by static amplitude to dynamic amplitude ratio at the time
of impact decreases as pore ratio decreases. Thus it is founded that more pore ratio of foamed
concrete decrease, more resistance of impact increase and absortion of impact decrease. Fig.14 and
Fig.15 compare transmission function of acceleration and acceleration element for specimen 1 and
4.
2.5
104
ACCELERATION ()
ACCELERATION ()
No.4 specimen
No.1 specimen
No.4 specimen
2.0
1.5
1.0
0.5
82
60
No.1 specimen
22
00
0.0
0
100
200
300
0.50
400
0.55
FREQUENCY (Hz)
no.
note
1-1
1-2
2-1
2-2
3-1
3-2
4-1
4-2
B:F=3:7
B:F=3:7
FA=10%
B:F=1:9
B:F=2:8
89.30
92.75
87.64
96.29
95.44
85.91
96.38
81.85
16.07
22.06
21.03
23.11
5.09
4.58
5.14
20.06
5.4 Permeability
From permeability test, permeability coefficients are obtained as 9.510-87.210-4
cm/sec, the range is similar to that of coarse-grained silt and coarse-grained clay, and it
is more than 50 times larger than that of normal concrete. Fig. 17 shows that the permeability
coefficient of lightweight foamed concrete is proportional to unit weight and inversely
proportional to pore ratio.
SHRINKAGE STRAIN ( )
1500
1000
500
Styrofoam
Styrofoam
Styrofoam + fly ash
Styrofoam + fly ash
O n ly foam
O n ly foam
-500
10
20
30
40
50
60
AG E (day)
10 -3
2000
10 -4
10 -5
10 -6
10 -7
0.60
0.65
0.70
0.75
PO R E R ATE
6. CONCLUSIONS
By using the polymer foam agent, we develop a lightweight foamed concrete which has
more than 180 flow value and increased compressive strength than conventional one.
Compressive strength of the developed lightweight foamed concrete is 36.6/ when unit
volume weight is 0.55t/ and 86/ for 0.86t/. From the experiments for different
mixing factors, optimum mix proportion of lightweight foamed concrete is presented and
the mechanical characteristics including long term behavior and the durability of developed
foamed concrete with different mix proportions are also presented.
REFERENCES
[1] Watson, K. L., Eden, N. B. and Farrant, J. R., "The Effect of Admixture on the
Relationship between Compressive Strength and Density of Autoclaved Aerated Concrete
made from Slate Powder and Portland Cement", Silicates Industrials, Vol. 43, 1978, pp.
57-64.
[2] Short, A. and Kinniburgh, W., "Lightweight Concrete", 3rd Ed., Applied Science
Publishers Ltd., London, 1978, pp. 1-14.
[3] Watson, K. L., "Autoclaved Aerated Concrete from Slate Waste, Part 2 : Some