Project report

on
Cellular light weight
concrete
A PROJECT REPORT

Submitted in partial fulfilment of the requirements for the

Award of the degree of

BACHELOR OF TECHNOLOGY

SUBMITTED TO SUBMITTED BY

Mr. Kapil karadia Vishal kumar singh

Head of department (Civil) 15EAYCE122
ACERC, Jaipur B. Tech IV Year

DEPARTMENT OF CIVIL ENGINEERING

ARYA COLLEGE OF ENGINEERING & RESEARCH
CENTRE
SP-40, RIICO INDUSTRIAL AREA, KUKAS, JAIPUR,
 CANDIDATE’S DECLARATION

I hereby declare that the work, which is being presented in the

project report, entitled “Cellular light weight concrete " in partial
fulfillment for the award of Degree of “Bachelor of Technology”
in Civil Engineering submitted to the Department of civil
Engineering, Arya College of Engineering &Research Centre,
Rajasthan Technical University is a record of my own work
carried under the Guidance of Mr. Kapil Karadia (Head of
Department-CE).
I have not submitted the matter presented in this Report anywhere
for the award of any other Degree.

Vishal kumar Singh

Roll No.: 15EAYCE122
 ACKNOWLEDGEMENT

I would like warmest thanks to the management, This seminar

wouldn’t have been possible without their continuous support
and motivation.

We would like to first of all express our thanks to Dr. Pooja

Agarwal, Director of Arya Main Campus, for providing us such a
great infrastructure and environment for our overall development.
We express sincere thanks to Prof. Himanshu Arora, Principal of
ACERC, for his kind cooperation and extendible support.
I would also like to thank Mr. Kapil Karadia, H.O.D of CE
Department, for their contribution in preparing my Minor project
report and to guide me for delivering the seminar. And for his
painstaking efforts and enthusiastic cooperation to make seminar
possible.

Vishal kumar Singh

15EAYCE122
ABSTRACT:

Now-a-days there are so many technologies involved in the recent development of

concrete. Of these, Cellular Lightweight Concrete (CLC) is one of the recent emerging
technology in making concrete. By using this type of concrete, we have found so many
advantages when compared to the normal conventional concrete. This paper mainly
focused on making cellular light weight concrete based on flyash. Fly ash is considered
as one of the waste industrial product that cannot be easily disposed. It solves the
problem of disposal of flyash and at the same time it reduces the cost of the construction.
Therefore, flyash based CLC is considered as environment friendly sustainable material
produced with least energy demand. This paper also focused on the innovative idea of
using glass as a partial replacement of cement in fly ash based cellular light weight
concrete.

The density is considerably reduced by using fly ash based cellular lightweight
concrete than normal concrete and at the same time, the strength is not affected by
appropriate design mix. When we use this type of concrete we achieve large volume by
less amount of concrete. The manufacturing process of this type of concrete does not
involve any high cost techniques. Manufacturing process of CLC is similar to normal
concrete and in this additionally foam generating machine is used. We are committed
to expanding and sharing the knowledge, experience and techniques of cellular light
weight concrete, and to promoting its ever wider use.
INTRODUCTION

CELLULAR LIGHT WEIGHT CONCRETE

CLC (Cellular Lightweight Concrete):

It is a version of lightweight concrete that is produced like normal concrete under
ambient conditions. It is produced by initially making a slurry of Cement +Sand + Fly Ash
(constituting 26% - 34 % content) + water, which is further mixed with the addition of
preformed
stable foam in an ordinary concrete mixer under ambient conditions. The mixture
is either poured or pumped into assembled moulds of blocks or formwork of reinforced
structural elements or poured onto flat roofs or voids for thermal insulation or filling. The
foam imparts free flowing characteristics to this slurry due to ball bearing effect of foam
bubbles enabling it to easily flow into all corners and compact by itself in the
moulds/forms without requiring any kind of vibration or compaction


It is a version of lightweight concrete that is produced like normal concrete under
ambient conditions. It is produced by initially making a slurry of Cement +Sand + Fly
Ash (constituting 26% - 34 % content) + water,

A cellular concrete is a lightweight product consisting of Portland cement, cement-
silica, cement-pozzolan, lime-pozzolan, lime-silica pastes or pastes containing blends
of these gradients and having homogeneous void or cell structure, attained with gas-
forming chemicals of foaming agents.


In cellular lightweight concrete, the density can be controlled by the introduction of gas
or foam by foam generator.


CLC is an air-cured lightweight concrete with fly ash as a major ingredient that can be
produced at large project sites just like traditional concrete, utilising equipment and
moulds normally used for traditional concreting.


It is especially suitable in India for low-rise load bearing constructions and for
partitioning work in multistorey blocks.
 FOAM GENERATOR CLC BLOCK FLOATS
IN WATER


Fly Ash as a new additional constituent in its manufacture. Fly ash can constitutes more
than 25% (ranging between 26% to 33%) of the solid material constituents of CLC
mixes for different density outputs.

Fly-ash- a nuisance waste product from thermal power plants - as an over 25 %
constituent material. This CLC can be produced in a density range of 400 kg/m 3 to
1,800 kg/m3, with high insulation value and a 28-day cube crushing strength of up-to
275 kg/cm2.


It is not only found a productive use of a waste industrial product, but incorporation of
fly ash also saves nearly 40% on cement content, otherwise needed for the
corresponding Cement and Sand only mixes, thereby also leading to substantial
reduction in the cost of manufacture.


Normally the density of the cellular light weight concrete ranges from 400 kg/m3 to
1,800 kg/m3


Cellular Light Weight Concrete based housing is fire proof, termite proof,
thermally insulated, sound proof, environment friendly.
 Cellular light weight concrete block Magnified view

MARKET

Construction industry boom can be seen in almost all the developing countries.
The demand for supplies is high; supply of raw material like bricks, cement, sand, iron
and steel, builder hardware, paints, manpower and everything else regarding
construction.
The construction industry is also very vital because anybody who is concerned
with economic development these days highlights the need for infrastructure
development. The infrastructure is in the form of roads, ports, buildings, factories and so
on, and all of them involve construction.
Bricks remain one of the most important building materials in the country. Brick
making is a traditional industry in India, generally confined to rural areas. Notably, the
Indian brick industry, with more than 1 Lakh production units producing about 100 billion
tons a brick annually, is the second largest brick producer in the world after that of
China. The industry has an annual turnover of more than Rs. 10,000 Crores and, very
importantly, it is one of the largest employment generating industries, employing millions
of workers. However, brick making is an energy intensive process as fuel costs account
for almost 30% of the production cost.
The country consumes about 180 billion tons bricks, exhausting approximately
340 billion tons of clay every year and about 5000 acres of top soil land is made unfertile
for a long period. The demand supply gap for bricks is estimated to be 80 billion tons for
the year 2006 thus leaving a scope for establishment of more brick units across India.
Despite all initiatives to introduce alternative walling materials like cellular light
weight concrete, sand lime bricks, compressed earth blocks, concrete / stonecrete
blocks, and fly ash bricks, it is envisaged that sand lime bricks and cellular light weight
concrete bricks would still occupy the dominant position in the foreseeable decade.
The excellent mechanical properties and durability of CLC and fly ash brick
enlarges its scope for application in building construction and development of
infrastructure, construction of pavements, dams, tanks, under water works, canal lining
and irrigation work etc. Enormous quantities of CLC and fly ash are available in and
around thermal power stations in all the states. The demand of bricks could be met by
establishing small units near thermal power stations and to meet the local demand with

less transportation costs.

Cellular light weight concrete – Density range:

This Cellular Lightweight Concrete (CLC) can be produced in a wide range of

densities from 400 kg/m3 to 1,800 kg/m3 to suit different applications: -

 The lower densities of 400 –600 kg/m3 are ideal for thermal insulation
applications. CLC’s fire, termite, water-proof-ness, termite-resistance, very low
water absorption and environment friendliness. This range is also used in laying
sound insulating layer over structural slabs of intermediate floors in high-class
hotels and institution buildings to minimise transmission of noise between lower
and upper floors. It can also be used as a filling in depressions in bathrooms or
other floors due to up-stand beams etc. It make a far superior alternative to the
commonly used Thermocole, glasswool, woodwool etc.

 The medium density range 800-1000 kg/m3 is utilized for making pre-
cast blocks for non-load-bearing walling masonry in framed structures. The size
of blocks for the party/external walls may be 500x250x200 mm and the internal
partition blocks may be 500x250x100 mm nominal size, although any desired size
as per requirements, may be produced.

 The high density range from 1200kg/m3 (Crushing strength 65 kg/cm2) to 1800
kg/m3 (Crushing strength 250 kg/cm2) is structural grade material utilized for:-

(a) In-situ casting of structural (load-bearing) walls and roofs of

low rise individual or group housing schemes.
 (b) Manufacture of reinforced structural cladding or partitioning
panels.

(c) Making pre-cast blocks (500x250x200/100 mm) for load-

bearing walling masonry for low rise buildings.

MANUFACTURING PROCESS:
TECHNOLOGY AND PROCESS
Production Procedure of CLC
Sand:
Optimum properties are achieved when selecting the most suitable raw material.
The sand is mostly preferred from river, which is washed and should be with minimum
20% fines. Dust in sand increases the demand for water and cement, without adding to
the properties. It also increases shrinkage. A certain, small amount of fines contributes
towards strength. As in conventional concrete (CC), the sand should be free of organic
material or other impurities. Crushed sand, due to sharp edges may destroy the foam
mechanically.
Cement:
Portland cement is preferred over other cements, such as pozzolan. For early
stripping and optimum mechanical properties, high-grade (early strength) cement is
recommended. Thick walls and when using battery-moulds, excess heat is developing
within and might therefore ask for a lesser grade of cement. The slower, the hardening,
the better the final quality of concrete. Where economical, fly ash may be added to the
mix to substitute some of the cement. Fly ash normally will retard hardening though.
Water:
When used to produce foam, it has to be potable and for best performance, it
should not exceed 25°C. Under no circumstances must the foaming agent be brought in
contact with any oil, fat, chemical or other material that might harm its function (Oil has
an influence on the surface-tension of water). The oil/wax used in moulds will not harm,
since the foam by then will embedded in mortar. Water to prepare the mix has to
conform to general requirements for concrete.
Foaming Agent:
The containments holding foaming agent must be kept airtight and under
temperatures not exceeding 25°C. This way the shelf life is guaranteed for 24 months
PROJECT PROFILE FOR CLC & SAND LIME BRICKS
5
from date of Invoice. Once diluted in 40 parts of potable water, the emulsion must be
used soonest.

CONTENTS IN KILOGRAM IN LITRES

Portland Cement 190 61

Sand 430 164

Fly-Ash 309 100(approx.)

Water 250 250

Foam - 423
Density of Foam:
The weight of the foam should be minimum 80 g/l/ the containment should be as
close as possible to 10 Liters in volume, to check the weight (density) of the foam.
Preparation of moulds:
For smooth surfaces clean moulds completely of remaining concrete, the steel/or
wood surface must be oiled, mostly vegetable oil is preferred. Trials with different
materials will have to show best results. Oil will not destroy the mix, once the foam has
been mixed in the mortar.
Steel reinforcement will be placed in the moulds as usual. No coating of the steel
is necessary. In panels of more than 12-15 cm thickness, the use of double mesh is
recommended. The steel connected to the lifting anchors should reach more than half of
the width of the panel and should possibly not be connected to the mesh. Ordinary steel
is used as in CC when casting densities of 1200 or higher. The high ratio of cement to
material in CLC ensures proper protection of the steel against corrosion.
Charging, Mixing and Pouring:
Before charging the mixer with material, it must be rinsed, in particular if the
concrete produced before, used any additive, which might have adverse reaction on the
foam. Where possible, start the mixer before charging it with material. If the sand
contains excessive amount of water, the weight has to be adjusted, adding that much
more sand as it contains water by weight, reducing at the same time amount of water to
be added to the mix. To obtain optimum performance, sand is first fed into the mixer,
first absorbing water left after rinsing of form the previous CLC mix.
Once set correctly, the foam generator will keep the consistency stable, as long as
airand
water supply remains constant as well. We still recommend to check the weight of
the foam once in a week or if the density/consistency of the mix varies.
PROJECT PROFILE FOR CLC & SAND LIME BRICKS
6
Gravity mixers (e.g. Ready Mix) take the foam under almost instantly and
distribute it homogenously in the mix. It takes more time to achieve a proper distribution
when using pan-mixers or similar. In between pours, the mixer should be kept in motion
until it is completely discharged.
CLC always should be poured in the shortest possible time. If buckets are used
to fill moulds, they should hold as much CLC as possible, possibly even pouring one
complete panel in one step. Extended time between pours of one building member might
result in the creation of dry-joints as happening in the case with regular concrete as well.
Although CLC does not require vibration - at least not to density the mix - which
is liquid anyhow, vibration of horizontally produced panels will show an even better
surface, drawing cement slurry to the mould side. Preference is given to High-Frequency
vibrators. Length of vibration 15-20 sec. or until bubbles on the surface appears in large
numbers. Use aluminum or other straight and sharp-edged screed slats immediately
after pouring the concrete. Delayed screeding might “smear” the surface. If moulds have
to be moved after screeding, this might have to be repeated. Any disturbance of the
freshly poured CLC during the setting process, might be harmful and cause part of it to
collapse, in particular when the concrete is not hard enough yet to carry the weight and
the foam has been weakened by loss of water, drawn by the cement already for setting.
The poured building member should be covered, if possible, with a canvass or
plastic sheet to keep the evaporating water on the surface. As with CC, hardening may
be accelerated either by heating the moulds, steam or chemical (ask for details). Using
most standard types of cement, panels may be lifted the day after casting. Due to the
reduced strength in CLC, moulds should be tilted before lifting the panels. For the same
reason panels of CLC should be handled with utmost care to avoid damage.
Curing / Transport / Assembly
Panels should be positioned upwards on the curing yard, resting on a soft
underground - best on a rake or wooden beams. All possible efforts should be taken, in
PROJECT PROFILE FOR CLC & SAND LIME BRICKS
7
particular in dry and hot climate or more even when windy, to keep the panels damp for
at least three, bettor for more days. A sprinkler will be helpful or canvas that is kept wet.
Curing compound would be the costly alternative. Standards call for a 24 day curing
period for cement-based building members.
Due to reduced weight, more volume of CLC building elements can be
transported at the same (increased pay-load) then of CC. Panels should be kept upright
during transport and also on a soft/wooden underground. Unload only in tilted position.
Assembly
Assembly of panels in CLC happens usually the same way as with CC. Special
care has to be taken not to apply any mechanical force to avoid damage. If necessary,
panels of CLC may be sawn (no gravel), definitely nailed (without the use of dowels as
in AAC), drilled or profiled. In densities of 1200 kg/m³ and higher, where reinforcement is
used, CLC requires no special coating/plaster on the outside. Water-repellent paint
(dispersion-paint) will be suitable.
Vertical casting
The high fluidity of CLC allows full height walls or complete houses (floor by
floor) to be cast in one pour, inclusive the slab. Frames for voids for windows, doors and
other opening, or penings therefore are cast in place, together with empty tubes and
pipes for power and sanitary. No voids, no sagging (beneath frames). Walls/ partitions
may be as slender as 50 mm thick only (!) as no vibration is necessary. With a coarse
sand paper stuck to a piece of board, rub the walls immediately after stripping, in circular
motion, to eliminate possibly honey-web or “noses” caused by possible irregularities in
the mould or by joints. Perhaps a day after stripping it is recommended to saw imitation
joints from both sides of the walls on neuralgic positions to allow possible shrinkage to
“accumulate” in the joints and not show on the walls, as also done in CC when casting in
situ.
As with all lightweight concretes (lesser with CC), hair-cracks might appear but
have no adverse effect on the reinforcement, and usually disappear when painted. This
PROJECT PROFILE FOR CLC & SAND LIME BRICKS
8
way one complete house is cast each day with every set of vertical mould. Where
applicable even the gable can be cast at the same time with appropriate modification to
the mould.
Production Procedure of Sand Lime Bricks:
The process of manufacture of sand lime bricks involves the preparation of the
raw material viz., the sand and the quick lime, mixing them in the right proportion with
specified quality of water and allowing the mixture to react for a specified period. The
reacted material is once again taken and the moisture content suitably readjusted and
thoroughly missed again before it is passed on to the press hopper. This properly
prepared mixture is compressed under high hydraulic pressure to form the required size
of bricks/ blocks. These green bricks are autoclaved for a specified time at specified
temperature and pressure to harden the green bricks. This process of hardening gives
the required strength to the green brick. After this process of hardening, the brick is
ready for use immediately. If coloured bricks are to be manufactured suitable pigments
will be added at the time of remixing after reaction.
1.4 INVESTMENT
The project calls for an investment of Rs. 120.00 Lakhs to set up a unit to
manufacture 130 TPD of CLC Bricks and 120 TPD of sand lime bricks with 300 days of
operations. The plant and machinery required for the project are indigenously available.
Table 1: Project Cost (Rs. Lakhs)
Description Amount
1. Land & Land Development 6.20
2. Buildings & Civil works 6.00
3. Plant & Machinery 50.00
4. Misc. Fixed Assets 9.00
6. Contingencies 2.80
8. Preliminary & Pre-operative Expenses 17.00
9. Margin Money for Working capital 29.00
Total 120.00
PROJECT PROFILE FOR CLC & SAND LIME BRICKS
9
Suggested means of finance is tabulated below.
Table 2: Means of finance (Rs. Lakhs)
Description Amount
1. Equity from Promoters 40.00
2. Term Loan 80.00
Total 120.00
The debt equity is considered as 2.00 with 15% as interest on term loan.
The product mix and the sales prices are as follows
CLC Bricks 130 TPD Rs. 6 per Kg

SL Bricks 120 TPD Rs. 2 per Kg

Wet density = 1.179 kg/m3

Total volume (submerged in water) 1.000 liters (= 1 m³)

Content of air in concrete approx. = 43%

Content of Fly-Ash = 33%

 In this process, first the wet mix slurry consists of fly ash, cement, sand and water
is either poured or pumped into assembled moulds of blocks or formwork of
reinforced structural elements or poured onto flat roofs for thermal insulation or
for filling of voids.
 The second way is to introduce gas or foam to the concrete mix to produce
cellular lightweight concrete.

 The foam produced using Foam Generator is stable for a time duration far beyond
the final setting time of Cement, thereby creating permanent voids in the finally
hardened mass thus imparting lightness.

 The entrapped air bubbles are very fine in size and segregated from each other,
because of which the water absorption of the material is less.

 The foam imparts free flowing characteristics to this slurry due to ball bearing
effect of foam bubbles, enabling it to easily flow into all corners. It levels and
 compacts in the moulds/forms by itself, without requiring any kind of external
vibration or compaction.

Mixing process CLC Mix being poured into block moulds

INNOVATIVE IDEA: (USE OF GLASS IN CLC)

  It is a method of manufacturing cellular lightweight concrete using ground glass
as a partial replacement for Portland cement in the mixtures.
 This method also incorporates a method of making cellular lightweight concrete
including mixing these materials in a mixer to form a thick, viscous slurry which
will be foamed and cured at room or elevated temperatures.

 The mixture of CLC using ground glass comprises cement, ground glass, cement
substitute, lime, fiber, foaming agent and water.

 The ground glass may include ground mixed waste glass, flat glass, window glass
and mixtures thereof.

Specifications of the ingredients:

 The impurities in mixed waste glass, such as metals, plastics, paper, and wood
should be separated. Waste glass should be ground to a particle size passing
through a number 30 sieve.
 Lime may include hydrated lime, quicklime or lime kiln dust. The lime kiln dust
should contain free CaO not less than 50%. The lime concentration in the form of
CaO should be up to 15% by weight of the mixture.
 Cement substitutes can be divided into two categories:
(i) reactive materials
(ii) non-reactive materials
(i) Reactive materials have cementitious or pozzolanic properties and can also be
supplementary cementing materials including ground blast furnace slag, coal
fly ash, natural pozzolans, ground steel slag and silica fume.
(ii) Non-reactive materials do not have any cementitious or pozzolanic
properties and usually act as inert fillers in hardened cement pastes or
concrete. Typical examples include: silica flour, crushed stone dust, saw dust
and/or pulverized ceramics.
OBJECTIVES OF USING GLASS IN CLC:

 able to produce very stable cellular lightweight concrete mixtures

during the foaming or aeration process.
 able to produce light color cellular lightweight concrete mixtures
that can be easily tinted by adding proper pigments.
 able to provide applications which can use inexpensive recycled
materials.

ADVANTAGES OF CLC:

 CLC being the typical concrete, it keeps gaining strength with time, so long as
some moisture is available in the surroundings. It is therefore as weatherproof,
termite resistant, fireproof and durable as any other concrete.
 Cellular Lightweight Concrete is an environment friendly sustainable material
produced with least energy demand.
 Moreover CLC consumes a waste industrial product - Fly Ash - as one of its
basic constituent materials thereby helping to reduce environmental pollution.

 It substitutes use of burnt clay bricks, which are wasting precious agricultural
soil and need energy for baking and kiln smoke vitiate the atmosphere.

 Thinner walls in the case of CLC result in higher Carpet/Plinth area ratio
(106% to 107%) in comparison to brick alternative.

 CLC produced at project site saves energy expended in baking bricks, as

also energy spent in transporting bricks/ dense concrete blocks to site of work.
CLC blocks being lighter than bricks or Dense Concrete blocks save on labour
deployed for on-site handling, masoning, cutting and filling chases etc.

 The capital investment in production of CLC is far far less (in fact less than
0.05%) than the investment needed for producing Aerated Autoclaved
 Concrete. Only one low investment Foam Generator needs to be added to
Concrete making establishment.

 Being integrally cast as a lightweight reinforced shell, these cellular light weight
concrete structures are highly resistant to earthquake shocks or storms in coastal
areas.
 Cellular light weight concrete, even in the structural grade densities, is nearly
three times thermally more efficient than brick or mud walls. Therefore even
thinner walls of CLC are better thermal comfort than single bricks/ dense concrete
block walls.
 Being industrialized system the speed of construction is very fast and the work
can be executed mostly with the help of unskilled labour.
 Production of CLC is cheaper than normal concrete since fly ash, available free
constitutes over 25% of its raw material contents.
 Better strength to weight ratio .
 Reduction of dead load resulting in saving of steel & cement and reduction in
foundation size.
 Better Acoustics and thermal insulation (Air conditioning requirement is
considerably reduced).
 Saving in consumption of mortar and Higher Fire Rating.
 Resistance to fungus, vermin and rot .

 Strength:

 The 28 day compressive strength of cellular light weight concrete varies from 18
Mpa to 20 Mpa depending upon the density of the mix.

 The flexural strength of is, in general, between 1/5 and 1/3 of the compressive
strength .

 CLC can be produced in a density range of 400 kg/m3 to 1,800 kg/m3, with high
insulation value and a 28-day cube crushing strength of up-to 275 kg/cm2.
 The wide range in densities and consequently their different thermal and
structural properties, make CLC equally suitable for use: -

 As reinforced load-bearing in-situ walls and roofs in Low Rise Buildings.

 Even block-work (made from pre-cast blocks produced at the project site
or obtained from a pre-casting plant) can also be used for load-bearing low
rise constructions.

 Non load-bearing internal or external walls in High Rise Buildings.

 Thermal Insulation of building roofs and walls & roofs of cold storage.

 Filling of depressions in Toilets, floors etc.

CONCLUSION:

The deliberations above conclusively establish, that air cured fly-ash based
Cellular light-weight concrete to be a far superior alternative to factory made aerated
concrete or manmade light-weight aggregate blocks. This CLC is even a better
alternative to ordinary clay bricks for walling masonry. The long term stability at low
temperatures and potential corrosive effects on cellular light weight concrete must be
completely understood. The influence of admixtures and aggregates on strength of CLC
is of particular interest and is currently being investigated. Moreover, CLC has other
diverse applications and properties, some of which cannot be offered by the conventional
alternatives
 Above all, it is an environment friendly and energy efficient material, which is the
need of the day. It is therefore, no surprise that more and more builders are progressively
opting for this material in their constructions.