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INTRODUCTION
The first known use of lightweight concrete (LWC) dates
back over 2000 years. There are several LWC structures in
the Mediterranean region, but the three most notable structures were built during the early Roman Empire and include
the Port of Cosa, the Pantheon Dome, and the Coliseum.1
The use of LWC is usually predicated on the reduction of
project cost, improved functionality, or a combination of
both. Estimating the total cost of a project is necessary
when considering LWC because the cost per cubic yard
(cubic meter) is usually higher than a comparable unit of
ordinary concrete.
Recently, with the challenge of the development of
concrete constructions, high-rise buildings, and long-span
concrete, LWC has been a promising modern construction
technology. In comparison with ordinary concrete structures, lighter weights, the ability to reduce the dead load
of structures, reduced footings sizes, smaller dimensions,
higher specific strength, and better thermal insulation can be
obtained by replacing normalweight aggregates (NWA) with
or partially by lightweight aggregate (LWA).2,3 LWA are
broadly classified into two types: natural (pumice, diatomite,
volcanic cinders), and artificial (perlite, clay, sintered fly
ash, expanded shale).
Structural lightweight aggregate concrete (SLWAC) has
been viewed differently since the early 1990s. The technological development of high-performance concrete, the
advances in manufacturing LWA, the new durability and
applicability requirements of concrete and the oil industrys interest in using these materials for offshore rigs
have all contributed to a new generation of SLWAC. This
ACI Materials Journal/May-June 2015
365
a gray system, some information is known and some information is unknown. In a white system, the relationships
among factors in the system are certain; in a gray system,
the relationships among factors in the system are uncertain.
GRA is an impacting measurement method in gray system
theory that analyzes uncertain relations between one main
factor and all the other factors in a given system. In the case
when experiments are ambiguous or when the experimental
method cannot be carried out exactly, gray analysis helps
to compensate for the shortcomings in statistical regression.
GRA is actually a measurement of the absolute value of the
data difference between sequences, and it could be used to
measure the approximate correlation between sequences.
This study investigated the multi-response optimization
using Taguchi method coupled with GRG to achieve favorable compressive strength and density of LWC simultaneously. Finally, necessary confirmation tests were conducted
to validate the experimental results.
RESEARCH SIGNIFICANCE
This study investigated the multi-response optimization using Taguchi method coupled with GRG to achieve
favorable compressive strength and density of LWC simultaneously. It will be helpful to the engineers in deciding
the levels of the LWC parameters for desired performance
characteristics.
EXPERIMENTAL PROCEDURE
Materials, mixture proportions and experimental plan
MaterialsThe constituent materials used in this study
were locally available materials specified by the following:
1. Cement: Grade 6250 psi (42.5 N) ordinary portland
cement was used in this investigation. Cement is conforms
to the EN 196-1:2005 standard specification.
2. Silica fume: Silica fume of mineral admixtures was
used as 10% addition of cement weight. It had 75,000 cm2/g
specific surface area, as given by the manufacturer.
3. Normalweight aggregates (NWA):
Fine aggregates: Medium well-graded natural siliceous
sand with a fineness modulus of 2.76 was used. Measurements of unit weight and specific weight were 99.88 lb/ft3
(1600 kg/m3) and 2.5, respectively.
Coarse aggregates: Natural well-graded crushed bazalt
with angular particles of a maximum nominal size of
0.492in. (12.5 mm) was used. The surface of the particles
was rougher. Measurements of unit weight and specific
weight were 96.75 lb/ft3 (1550 kg/m3) and 2.55, respectively.
4. Lightweight aggregates (LWA):
Coarse aggregates LWACA: crushed shale bricks (Csh)
was used with 0, 10, 20, and 30% replacement of bazalt by
volume. Csh were crushed to size of approximately 0.492 in.
(12.5 mm) by using crushing hummer and then grinded for
determined by experiments aiming at the percentage passing
as used bazalt, as shown in Fig. 1. Measurements of unit
weight and specific weight were 68.66 lb/ft3 (1100 kg/m3)
and 1.9, respectively.
Fine aggregates LWAFA: four types of LWAFA: 1) polystyrene foam (F); 2) perlite (P); 3) crushed lightweight lime
bricks (aerated concrete) (CL); 4) and mixture of crushed
ACI Materials Journal/May-June 2015
Mixture
no.
Fine aggregate
replacement, %
F, 10
F, 20
Cement
Silica
fume
Water
Sand
LWAFA
Bazalt
LWACA
HRWRA
LCr
160
500
50
165
430.1
0.75
887.5
10
10
160
500
50
165
382.3
1.53
798.7
66.1
10
F, 30
20
1.5
160
500
50
165
303.52
2.1
644.2
120
10
7.5
F, 40
30
1.5
160
500
50
165
260.2
2.8
563.6
180
10
7.5
P, 10
30
1.5
160
500
50
165
390.2
11.44
563.6
180
10
7.5
P, 20
20
1.5
160
500
50
165
346.8
22.9
644.2
120
10
7.5
P, 30
10
160
500
50
165
334.5
37.8
798.7
66.1
10
P, 40
160
500
50
165
286.7
50.5
887.5
10
CL, 10
20
160
500
50
165
430.1
22.9
710
132.3
10
10
CL, 20
30
160
500
50
165
382.3
45.9
621.3
198.4
10
11
CL, 30
1.5
160
500
50
165
303.5
62.4
805.2
10
7.5
12
CL, 40
10
1.5
160
500
50
165
260.2
83.3
724.7
60
10
7.5
13
CSL, 10
10
1.5
160
500
50
165
390.2
29.5
724.7
60
10
7.5
14
CSL, 20
1.5
160
500
50
165
346.8
59
805.2
10
7.5
15
CSL, 30
30
160
500
50
165
334.5
97.5
621.3
198.4
10
CSL, 40
20
160
500
50
165
286.7
130
710
132.3
10
16
Control
factors
LWAFA
Levels
Unit
Type
CL
CSL
Experiment no.
Density,
lb/ft3 (kg/m3)
1.25
(20)
6.87
(110)
41.2
(660)
68.66
(1100)
0.1
0.1
0.2
0.1
0.1
LWAFA
10
20
30
40
0.3
0.2
0.15
Csh*
(LWACA)
10
20
30
0.4
0.3
0.15
Foam agent
(LCr)
0.1
0.3
0.15
1.5
0.2
0.2
0.15
0.3
0.1
0.1
0.4
0.1
CL
0.1
0.2
0.1
10
CL
0.2
0.3
0.1
11
CL
0.3
0.15
12
CL
0.4
0.1
0.15
13
CSL
0.1
0.1
0.15
14
CSL
0.2
0.15
15
CSL
0.3
0.3
0.1
16
CSL
0.4
0.2
0.1
CSL: crushed shale bricks and lightweight lime bricks (1:1); and Csh: crushed shale
bricks.
MSD =
1 n 2
yi (1)
n i =1
368
MSD =
1 n 1
n i =1 yi2
(2)
Experiment No.
R1, lb/ft3
R2, psi
65.31
65.80
65.74
65.57
121.7
3676.5
65.80
27.96
65.44
65.55
65.57
65.52
115.5
2647.1
65.34
25.11
65.63
65.47
65.49
113
2573.5
65.15
24.86
65.79
65.35
65.36
110.5
2500
64.96
24.61
Delta
0.47
0.45
0.38
0.05
118.6
2794.1
65.58
25.58
Rank
114.2
3676.5
-65.25
27.96
Contribution
34.81
33.33
28.15
3.70
118.6
4117.6
65.58
28.94
115.5
2794.1
65.34
25.58
121.7
4044.1
65.80
28.79
10
118.6
3970.6
65.58
28.63
Level
11
121.72
3676.5
65.80
27.96
25.63
27.88
27.27
27.06
12
115.5
3382.4
65.34
27.23
27.01
27.32
27.62
26.87
28.15
26.59
27.11
13
124.9
4235.3
66.02
29.19
14
124.9
3529.4
66.02
27.60
27.06
26.07
25.86
15
115.5
2500
65.34
24.61
Delta
2.52
1.81
1.76
0.18
16
121.1
3235.3
65.76
26.85
Notes: R1: density; R2: compressive strength; 1 lb/ft3 = 16.02 kg/m3; 1 psi = 0.0068 MPa.
i = (S/N) = 10log(MSDi)
(3)
Rank
Contribution
40.19
28.87
28.07
2.87
i = 1,2...n; k = 1,2...m
xi (k ) =
yi (k ) min yi (k )
(4)
max yi (k ) min yi (k )
xi (k ) =
max yi (k ) yi (k )
(5)
max yi (k ) min yi (k )
0i (k ) = x0 (k ) xi (k )
(7)
i ( x0 (k ), xi (k )) =
min + y max
(8)
i (k ) + y max
i =
1 m
i (k ) (9)
m k =1
R1
R2
Reference sequence
Experiment No. 1
0.22
0.68
0.65
0.08
0.83
0.04
1.00
0.00
0.43
0.17
0.74
0.68
0.43
0.93
0.65
0.17
CONFIRMATION TESTS
Because the optimal combination of process parameters
is selected from the response tables according to Taguchi
analysis, the confirmation tests are processed. It is a good idea
to plan on running an additional few samples at the optimum
condition. The confirmation tests serve two purposes. First,
they establish the new performance at the improvement
achieved. Second, they allow the experimenter to determine
how close the estimate is to the results observed. The result
expected is considered to be confirmed when the mean of
a number of samples tested at the optimum condition falls
close to it.
The results of confirmation experiment are compared
with the initial conditions of design operating parameters.
It is obvious from Table 8, that Experiment No. 5 has the
lowest GRG value (0.423) compared to the other experiments. Therefore, it can be concluded that Experiment No.5
possesses initial setting parameters. Table 10 shows the
compared results of the optimal and initial design of process
parameters. For the single performance characteristic, the
density of LWC is greatly reduced from 118.6 to 110.5 lb/ft3
(1900 to 1770 kg/m3). Similarly, the effect of improvement
for the compressive strength has anticipated that it is accel-
Compatibility sequence
0.22
0.89
10
0.43
0.85
11
0.22
0.68
12
0.65
0.51
13
0.00
1.00
14
0.00
0.59
15
0.65
0.00
16
0.26
0.42
i(k)
Experiment No.
R1
R2
R1
R2
S/N of i, db
0.78
0.32
0.39
0.61
0.499
6.04
0.35
0.92
0.59
0.35
0.472
6.53
0.17
0.96
0.74
0.34
0.542
5.31
0.33
0.667
3.52
0.47
0.38
0.423
7.48
0.26
0.32
0.66
0.61
0.633
3.98
0.57
0.47
0.88
0.675
3.41
0.35
0.83
0.59
0.38
0.483
6.33
0.78
0.11
0.39
0.82
0.605
4.37
10
0.57
0.15
0.47
0.77
0.618
4.18
11
0.78
0.32
0.39
0.61
0.499
6.04
12
0.35
0.49
0.59
0.50
0.547
5.24
13
1.00
0.00
0.33
1.00
0.667
3.52
14
1.00
0.41
0.33
0.55
0.442
7.08
15
0.35
1.00
0.59
0.33
0.462
6.72
16
0.74
0.58
0.40
0.46
0.434
7.25
371
pred = m + ( i m ) (10)
i =1
CONCLUSIONS
In this paper, the optimal LWC parameters were determined for multi-performance characteristics (density and
5.35
5.37
6.371
5.603
5.299
5.443
4.676
5.272
4.958
5.353
5.227
6.143
5.584
5.476
Delta
1.185
0.231
1.695
0.331
Rank
Contribution
34.43
6.71
49.24
9.62
Fig. 3Percentage
parameters.
contribution
of
different
LWC
Taguchi method
GRA-based
Taguchi
Experimental value
Predicted value
Optimum combination
of LWC parameters
R1
R2
R1
R2
Errors, %
R1 min
A1B4C4D2
110.5 (1770)
109.9 (1760)
0.565
R2 max
A3B1C2D1
4567.6 (31.06)
4420.6 (30.06)
3.22
R1 and R2 optimum in
the minimax sense
A3B3C2D2
116.7 (1870)
4020.6 (27.34)
118.5 (1897.5)
3873.5 (26.34)
1.47, 3.66
A2B1C4D2
118.6 (1900)
2794.1 (19)
117.5 (1882.5)
3266.2 (22.21)
0.921, 16.89
Notes: R1: density, lb/ft3 (kg/m3); R2: compressive strength, psi (MPa).
372
Mariam Farouk Ghazy is an Associate Professor in the Faculty of Engineering in the Department of Structural Engineering at Tanta University,
Tanta, Egypt. Her research interests include concrete technology, fiber-reinforced concrete, inspection and quality control of reinforced concrete, green
and sustainable concrete, and composites.
Mohamed Fattouh Abd El Hameed is a Professor in the Faculty of
Engineering in the Department of Production Engineering and Mechanical Design at Minufiya University, Shibin Al Kawm, Al Minufiya, Egypt.
He received his PhD in production engineering from Dresden University,
Dresden, Germany, in 1981. His research interests include various areas of
design and analysis of experiments.
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373
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