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COMPARATIVE STUDY AND PERFORMANCE OF CELLULAR LIGHT WEIGHT

CONCRETE

Conference Paper · December 2016

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 Proceedings of International Interdisciplinary Conference On Engineering Science & Management Held
on 17th - 18th December 2016, in Goa, India. ISBN: 9788193137383

COMPARATIVE STUDY AND PERFORMANCE OF

CELLULAR LIGHT WEIGHT CONCRETE
Anik Gupta Mukul Rathore
Research Scholar, Academy of Scientific and Research Scholar, Academy of Scientific and
Innovative ResearchCRRI Staff Quarters, Innovative ResearchCRRI Staff Quarters,
New Delhi 110025, India. New Delhi 110025, India.

Abstract- Cellular Lightweight Concrete has been permeability, wear resistance, and economy. CLC
successfully used and it has gained popularity due to technology has been used in over 45 countries of the
its lower density and comparative strength than world over the past 30 years to construct over a hundred
conventional brick. It is created by uniform thousand houses, apartments, schools, hospitals,
distribution of air bubbles throughout the mass of industrial, commercial buildings etc. The introduction
concrete. The foam contains isolated air bubbles, in India of a modified version using over 25% fly ash
which creates million of unconnected tiny voids/cells has made it an even more eco-friendly and cost
in the mix resulting in lighter weight of concrete. effective version of CLC. In the process, the product
CLC can be produced in wide range of controlled brings quality housing closer to the masses at a faster
3 3
densities from 400 kg/m to 1,800 kg/m . So, this and at a lower cost. CLC, is the first of its kind with a
report presents a comparative study of CLC with very simple method of production, which can easily be
equal strength of brick having lower density as adopted in pre-cast plants or even at the project-site
compared to bricks. Further we have analyzed the itself under ambient conditions. It requires only a
economical savings in structural design nominal investment. The CLC version with fly ash as
requirements as per the deduction in dead load of one of its major constituents, is still cheaper and more
the whole structure, so this also includes an overall environment friendly. CLC has moderate embodied
capital reduction. In was observed in the study that energy content and performs very well as thermal
savings in steel due to use of CLC blocks in terms of insulation. Blocks are made to very exacting
weight of beam member were found to be 8.635kg dimensions and are usually laid in thin-bed mortar that
Keywords- Cellular light weight concrete, CLC, is applied with a toothed trowel, although more
brick masonry, conventional thick-bed mortar can be used. CLC has a
I. INTRODUCTION long life and does not produce toxic gases after it has
Concrete is known as a common material which is been put in place. It offers a substantial material savings
widely used in the construction industry, from basic as little cement and no gravel is used. Cellular
work to multi-storey building and mega structure. Lightweight Concrete (CLC) is produced by the mixing
Concrete is a material where mixture by cement, water, of sand, fly-ash cement foam and water in requisite
and aggregate (fine) which must be workable, proportion in ready mix plant or ordinary concrete
resistance to freezing, chemicals resistance, low mixer. The mixed slurry is then poured into moulds of

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 Proceedings of International Interdisciplinary Conference On Engineering Science & Management Held
on 17th - 18th December 2016, in Goa, India. ISBN: 9788193137383

pre-cast blocks / structural components / assembled or hard to obtain or is very costly. In multi storey
form-work of building elements. It is essentially air- constructions, partitions, floor, and other non-load
cured, thus can be produced at project site, utilizing bearing building elements are recommended to be made
equipment and moulds normally in use for conventional in cellular cement concrete, thereby substantially
concrete. The foam is produced with the help of a Foam reducing the dead-load of the structure therefore
Generator by using a foaming agent. The foam contains consequently saving reinforcing steel required for
isolated air bubbles, which creates million of foundations and main structural elements.
unconnected tiny voids/cells in the mix resulting in C. SAVING IN TRANSPORTATION COSTS
lighter weight of concrete. CLC has a long life and does Reduced weight of materials and zero transportation of
not produce toxic gases after it has been put in place. It CLC produced at project site imply less/nil
offers a substantial material savings as little cement and transportation expenses.
no gravel is used. It is easier to handle and place one D. EASE OF HANDLNG
CLC block as compared to equal volume of bricks. (1 Building elements of CLC can be handled manually in
Block=14 Bricks approx.). CLC, like conventional larger dimensions (double sized) in comparison with
concrete ages well, increasing its strength by as much those of dense concrete.
as 50% (!) between 28 and 90 days after pouring, As E. HILLY AREA
long as CLC draws humidity from the atmosphere it Construction in hilly areas is easier with CLC as
will keep on increasing its mechanical properties. expensive transportation of bricks is dispensed with.
Curing takes place within the same period as F. ECO-FRIENDLY
conventional concrete. If casting is done in the evening, CLC is remarkably eco friendly. It saves depletion of
the concrete could be demoulded the next morning. the top soil, while at the same time it can actually use
Curing can be speeded up by heat, steam or chemical fly ash as industrial waste as one of its major
(accelerators). CLC is an excellent and competitive constituents. The production process of CLC or its use
material for low-rise, load-bearing construction and does not release any harmful effluents to ground, water
outside walls as well as partitioning work in multi– or air (unlike smoke of brick kilns and ruining of top
storied building soil in production of bricks). CLC due to its low weight
II. ADVANTAGES OF CLC is ideal for making partition walls. The use of CLC for
A. REDUCTION OF DEAD LOAD this purpose will reduce the need for plywood
Unstable ground conditions or desire to add extra floors partitions. This consequently will result in reduction in
on to existing structures often limits application of deforestation and will benefit environment.
normal dense concrete. Lightest possible dead load is G. THERMAL INSULATION
also highly appreciated for economy in structural Air is known to be the best insulation material
design in high earthquake prone areas. available. Air voids, if smaller than 2mm in size
B. MATERIAL SAVING consequently increase thermal insulation subsequently.
CLC uses no gravel-only sand, cement, water, fly ash, Normal aggregate concrete has a specific thermal
and foam. The use of cellular cement concrete yields conductivity of 2.1W/m.k compared to 0.404 only for
substantial savings where gravel is not readily available 1200 kg/cum cellular concrete. To offer identical

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 Proceedings of International Interdisciplinary Conference On Engineering Science & Management Held
on 17th - 18th December 2016, in Goa, India. ISBN: 9788193137383

thermal insulation as a 100 mm thick wall, the The maximum variation in the length of the unit shall
equivalent thickness of dense concrete wall would have not be more than ±5mm and the maximum variation in
to be more than five times thicker (i.e. 500mm) and ten the height and width of the unit shall not be more than
times heavier. ±3mm (see Fig .1 for mode of measurement) .The
H. FIRE PROTECTION overall dimensions of the unit, when measured as given
Fire rating of cellular light weight block is far superior in Annex B shall be in accordance with 4.2.1 and
to that of brickwork or dense concrete. Just a 100mm subject to tolerances mentioned in 4.2.3 of IS 2185.
thick wall of 1200kg/cum CLC offers fire endurance
(heat transmission) of 3 hours. Moreover, there are no B L
dangerous fumes or spread of fire as experienced with
plywood partitions having rigid (styro, urethane)
insulation material often the reason for loss of life of
individuals due to toxic fumes during fires.
I. ISOLATION:
CLC blocks can be used as an isolated wall as it cannot Fig. 1 Faces of CLC Block
trespass of heat and cold from the wall made from CLC A concrete masonry unit, anyone of external
blocks. dimensions of which is greater than the corresponding
J. MISCELLANOUS dimension of a brick as specified in IS 3952 and of such
Speedy construction, universal applicability, easy to size and mass as to permit it to be handled by one man
handle, uniformity and good quality. is called a block. Gross Area is the total area occupied
III. TEST PERFORMED by the block on its bedding face, including areas of
A. DIMENSIONS cavities and end recesses. Overall dimensions shall be
Concrete masonry units shall be made in sizes and measured with a steel scale graduated in 1 mm
shapes to fit different construction needs. They include divisions.
stretcher, comer, double comer or pier, jamb, header, B. DENSITY
bull nose and partition block and floor units. The density calculated by dividing the mass of an oven
CLC block shall be referred to by its nominal dry block by the overall volume, including the holes or
dimensions. The term 'nominal' means that the cavities and end recesses. The average block density,
dimension includes the thickness of the mortar joint. when determined as given shall not vary by more than ±
Actual dimensions (length and height) shall be 10 mm 5 percent of the density specified in Table I of IS 2185.
short of the nominal dimension (or 6 mm short in Three blocks taken at random from the samples selected
special cases where finer jointing is specified). in accordance with 11, shall be dried to a constant mass
The nominal dimensions of the concrete blocks shall be in a suitable oven heated to approximately 100°C. After
as follows: cooling the blocks to room temperature, the dimensions
Length 400, 500 or 600 mm of each block shall be measured in centimeters (to the
Height 250 or 300 mm nearest millimeters) and the overall volume computed
Width 100, 150, 200 or 250 mm in cubic centimeters.

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 Proceedings of International Interdisciplinary Conference On Engineering Science & Management Held
on 17th - 18th December 2016, in Goa, India. ISBN: 9788193137383

The blocks shall then be weighted in kilograms (to the divided by the gross cross-sectional area of the unit, in
nearest 10g) and the density of each block calculated- square millimeters. The gross area of a unit is the total

Density= area of a section perpendicular to the direction of the

load, including areas within cells and within re-entrant
The average of the densities for the three blocks shall
spaces unless these spaces are to be occupied in the
be taken as the average density.
masonry by portions of adjacent masonry. The term
C. WATER ABSORPTION
„characteristic compressive strength‟ means that value
The average water absorption, when determined in the
of the strength of the material below which not more
manner prescribed as here shall not exceed the values
than 5 percent of the test results are expected to fall.
prescribed in Table I. Three full-size units shall be
The average and the minimum individual compressive
used. The test specimens shall be completely immersed
strength when determined in the manner described here
in water at room temperature for 24h. The specimens
and shall be not less than that prescribed. The testing
shall then be weighed, while suspended by a metal wire
machine shall be equipped with two steel bearing
and completely submerged in water. They shall be
blocks one of which is a spherically seated block that
removed from the water and allowed to drain for 1min
will transmit load to the upper surface of the masonry
by placing them on a 10mm or coarser wire mesh,
specimen, and the other a plane rigid block on which
visible surface water being removed with a damp cloth,
the specimen will rest. When the bearing area of the
and immediately weighed. All specimens shall be dried
steel blocks is not sufficient to cover the bearing area of
in a ventilated oven at 100°C to 115°C for not less than
the masonry specimen, steel bearing plates should be
24h and until two successive weighing at intervals of 2h
used.
show an increments of loss not greater than 0.2 percent
Specimens shall be tested with the centroid of their
of the last previously determined mass of the specimen.
bearing surfaces aligned vertically with the centre of
Calculate the water absorption as follows:
thrust of the spherically seated block of the testing
Water Absorption (%) =
machine and as per code IS 456-1957.
A = Wet Mass of Unit in kg; Gypsum Plaster Capping neat paste of special high-
B = Dry Mass of Unit in kg. strength plaster and water shall be spread evenly on a
TABLE I non-absorbent surface that has been lightly coated with
PERMISSIBLE VALUE OF WATER ABSORPTION oil. Such gypsum plaster, when gauged with water at
AS PER IS:2185-2008 the capping consistency shall have a compressive
Block Density in Oven Water Absorption (%) strength at a 2h age of not less than 25 N/mm2, when
800
Dry 12.5
Oven Dry Density tested on 50mm cubes.
1000 3 12.5
(kg/m ) The load up to one-half of the expected maximum load
1200 10.0
1400 10.0 may be applied at any convenient rate, after which the
1600 7.5 control of the machine shall be adjusted as required to
1800 7.5 give a uniform rate of travel of the moving head such
D. COMPRESSIVE STRENGTH
that the remaining load is applied in not less than one
The compressive strength of a concrete masonry unit
nor more than two minutes.
shall be taken as the maximum load, in Newton,

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 Proceedings of International Interdisciplinary Conference On Engineering Science & Management Held
on 17th - 18th December 2016, in Goa, India. ISBN: 9788193137383

Report be results to the nearest 0.1 N/mm2 separately purpose, which is advantageous in terms of general
for each unit and is the average for the 8 units. construction properties as well as eco-friendliness.
Block Density in Compressive Strength in V. REFERENCES
Oven Dry N/mm 2 [1] The Construction Journal of India, “Cellular Light
(kg/m ) 3 Weight Concrete”, Oct. 1998 Vol. 1 Issue 4
Average Individual
[2] K. Krishna Bhavani Siram, International Journal of
Min. Min.
Engineering and Advanced Technology (IJEAT) ISSN:
800 2.5 2.0
2249 – 8958, “Cellular Light-Weight Concrete Blocks
1000 3.5 2.8
as a Replacement of Burnt Clay Bricks”, December
1200 6.5 5.2 2012 Volume-2, Issue-2.
1400 12.0 9.0 [3] IS 2185 (Part 1): 2005, “Concrete Masonry Units –
Specification” Part 1- Concrete masonry unit hollow
1600 17.5 14.5
and solids blocks, 2005.
180 25 22
[4] IS 2185 (Part 2): 1983, “Concrete Masonry Units –
TABLE II Specification‟‟ Part 2- Concrete masonry unit light
PERMISSIBLE VALUE OF COMPRESSIVE weight hollow and solid blocks, 1983.
STRENGTH AS PER IS:2185-2008. [5] IS 2185 (Part 3): 1984, “Concrete Masonry Units –
IV. RESULT AND DISCUSSIONS Specification” Part 3- Concrete masonry unit
The specimen for various tests has been discussed in autoclaved blocks, 1984.
above mentioned tests. In this chapter, discussion will [6] IS 2185 (Part 4): 2008, “Concrete Masonry Units –
be focused on the performance of Cellular lightweight Specification” Part 4- Preformed foam cellular concrete
concrete. All the tests method adopted were described blocks.
in the previous chapter. The results presented in this
chapter are regarding the compressive strength test,
density and water absorption for different mixes of the
Cellular lightweight concrete.
The amount of steel reinforcement used in the CLC
block was found to be 1513.53 mm2 whereas the
amount of steel reinforcement required for brick
masonry was 1681.64 mm2. Therefore savings obtained
using CLC blocks is approximately 168.1 mm2 i.e.
8.635 Kg. Also this study has shown that the use of fly
ash in foamed concrete, can greatly improve its
properties. Most of the cleaner production effort is
required in India and hence CLC blocks may be used as
a replacement of burnt clay bricks, for construction

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