DETAILED STUDY OF FOAM CONCRETE 1- MATERIALS USED 2- MACHINE USED( HAND MAKING WORKABLE EQUIPMENT FOR MIXING) 3-TESTING PROCEDURE 4- YOU GUYZ CAN ALSO LEARN THROUGH THE PHOTOGRAPHS

1. MANUFACTURING AND
ANALYSIS OF FOAM
CONCRETE
BY:
TUSHAR KULSHRESTHA
SHIVAM KUMAR
LOKESH SHARMA
DEEPAK KUMAR
SAHIL SINGHAL
UNDER GUIDANCE OF:
Er. RAHUL SHARMA

2. CONTENTS
• HISTORY
• OBJECTIVE
• EQUIPMENTS USED
• MATERIAL USED
• METHODOLOGY
 MAKING OF SLURRY
 MAKING OF FOAM
 MIX PROPORTIONS
 BLENDING OF FOAM AND SLURRY
 FILLING OF CUBES
 DEMOULDING
 CURING
• TESTING OF COMPRESSIVE STRENGTH
• CONCLUSION

3. HISTORY
Foamed concrete is not a particularly new material, its first patent
and recorded use dates back to the early 1920s. According to Sach
and Seifert (1999), limited scale production began in 1923 and,
according to Arasteh (1988), in 1924 Linde described its production,
properties and applications. The application of foamed concrete for
construction works was not recognized until the late 1970s, when it
began to be used in the Netherlands for filling voids and for ground
engineering applications.

4. OBJECTIVE
• To compare the density and compressive strength of foamed concrete with
conventional concrete.
• To make lightweight concrete having specified strength so that it can wear
the load of building structure .
• To understand the actual behaviour of concrete when foaming agent and
superplasticizers is added to ascertain strength of concrete which is one of
the most important criteria of the concrete.
• To reduce the cost of structure

5. EQUIPMENTS USED
• FOR FAST MIXING OF SLURRY
AND TO MAKE FOAMING AGENT
WE MAKE A SIMPLE WORKABLE
MACHINE INSTEAD OF BYING
FOAM GENERATOR AND MIXER
BEACAUSE IT COSTS TOO HIGH.
• OTHER EQUIPMENTS
• 150mm CUBE MOULDS
• ELECTRONIC WEIGHING
MACHINE
• TROWEL , GLOVES, WRENCH.

6. MATERIAL USED

7. CEMENT: -
Ordinary Portland cement is commonly used, but rapid hardening cement can also be
used if necessary. We used ordinary Portland cement of having density 384g/cm3
SAND: -
The maximum size of sand used can be 5mm. Use of finer sands up to 2mm with
amount passing through 600-micron sieve range from 60 to 95%. Sand used of density
422.5 g/cm3
WATER: -
Mixing water for concrete should be clean and free from injurious amounts of oils,
acids, alkalis, salts, organic matter, or other potentially deleterious substances. When
water is used to produce foam, it has to be potable and for best performance, it should
not exceed 25°C

8. Foaming agent
The quality of foam is critical to the
stability of foamed concrete and will affect
the strength and stiffness of the final
product; therefore, good quality foam was
produced by blending the foaming agent.
Foaming agent we had used is CLC
(cellular lightweight concrete) foaming
agent. It is prepared with raw material in
presence of Ca(OH)₂ and a small portion
of NaHSO3. For improving the stability it
is modified with the addition of several
kinds of gel and surfactants.

9. ADDITIVES(SUPERPLASTICIZERS)
• This admixtures can be used as water
reducers, maintaining a fixed
workability. Polycarboxylate ether
superplasticizer was used as a water-
reducing agent to maintain sufficient
workability of the unfoamed mixture
(without foam) and to produce a high
strength foamed concrete with low
water/binder ratio.
• Superplasticizers used in the amount of
.3% weight of cement.

10. METHODOLOGY
The first step is to make a cement slurry or a sand cement
slurry that is appropriate for the mix design. We’ll make
sand cement slurry to achieve foam concrete of specific
density. The second step is to make suitable foam. The
foam is made separately from the slurry. Once the foam has
been made it is blended in to the slurry to make foamed
concrete.

11. MAKING OF SLURRY
The cement we used for the slurry is Ordinary Portland
Cement. Sand is specified in the mix design ideally it should
be fine with 2mm-5mm maximum size and 60 to 90%
passing through a 600 micron sieve . First we dry mix the
sand and cement after which water is added into it. The
water: cement ratio of the slurry is usually between 0.5 and
0.6. To increase the compressive strength we add
superplasticizer of low dosage (.3% by weight of cement) .

12. BEFORE DRYMIX AFTER DRYMIX
WHEN WATER
IS ADDED
ADDITION OF
SUPERPLASTICI-
ZER
DRY MIXING WET MIXING

13. MAKING OF FOAM
(water + foaming agent) (mixing) (stable foam)
• water used to produce foam
is potable and for best
performance, it should not
exceed 25°C.
• We used 50ml foam agent
per litre of water.
• Of course the recipe can be
changed, but we are happy
with what came out for our
proportions.

14. MIX PROPORTIONS
TYPE CEMENT SAND
WATER
CEMENT
RATIO
FOAM
AGENT
WEIGHT(GRAMS)
CEMENT SAND WATER(ml)
A 1 2 .5 25% 2000 4000 1200
B 1 1 .5 25% 2500 2500 1000
C 2 1 .5 25% 4000 2000 1200

15. BLENDING OF FOAM AND
SLURRY
ADDING FOAM TO
SLURRY
MIXING OF FOAM
AND SLURRY

16. FILLING OF
CUBES

17. DEMOULDING
• Initial setting time of lightweight
concrete is 12 hours and can be
demould after 24 hours
• But in case of low density
lightweight concrete the timing
will be
Initial time: 24 hours
Final setting time: 3 days

18. CURING
• For 24 hours we let the
concrete block cure in
water.
• After which we used
gunny bags that is kept
wet.

19. RESULT

20. COMPRESSION TEST
• The cubes were crushed on a more sensitive press (on compression testing
machine) the usually used for normal concrete. two cubes from the same
mixture of foamed.
• Compressive strength of foamed concrete was recorded for 7 and 28 days.
• Compressive strength (N/mm²) = LOAD/ AREA

21. COMPRESSION TEST VALUES
Type Age(days) Load(KN) Area(mm)² Compressive strength( N/mm²)
A 7 450 150*150 20
B 7 400 150*150 17.77
C 7 500 150*150 22.22

22. COMPRESSION TEST VALUES
Type Age(days) Load(KN) Area(mm)² Compressive strength( N/mm²)
A 28 675 150*150 30
B 28 600 150*150 26.65
C 28 750 150*150 33.33

23. COMPARISON OF
CONVENTIONAL CONCRETE
WITH LIGHTWEIGHT
CONCRETE

24. S.NO PARAMETERS CONVENTIONAL
CONCRETE
LIGHTWEIGHT CONCRETE
1- BASIC RAW MATERIAL SAND, CEMENT,
AGGREGATE, WATER
SAND, CEMENT, WATER
2- APPLICATION LOAD BEARING THERMAL INSULATION,
PARTITION WALL, NON
LOAD BEARING EXTERNAL
WALL
3- DRY DENSITY(Kg/cm³) GENERALLY OF 2400 400-1800
4- AGING NO GAINS STRENGTH WITH AGE
5- THERMAL INSULATION NORMAL VERY GOOD
6- SOUND INSULATION NORMAL VERY GOOD
7- EASE IN WORKING NORMAL VERY GOOD

25. ADVANTAGES
• Weight reduction of superstructure using foam concrete walls: less steel
• Suitable for buildings in hurricane, cyclone, earthquake.
• Cost reduction for transport and storage
• Environment friendly
• Low investment- just one machine required
• Easy to use/produce/handle
• Increase compressive strength with the time

26. DISADVANTAGES
• Very sensitive with water content in the mixtures
• Mixing time is longer than conventional concrete to
assure proper mixing
• Compressive strength of foamed concrete reduce with its
density

27. CONCLUSIONS
• The Compressive Strength of Foamed Concrete increases with increase in the Density.
• Fine aggregate had a beneficial effect on significantly increase in Compressive Strength of
Foamed Concrete.
• De-moulding of higher density foamed concrete panels is possible after 24 hours but it
requires minimum 3 days for lower density foamed concrete panels which is a limitation.
• The starting of Strength gain for foamed concrete is on higher side than that of normal
weight concrete.
• Improved structural efficiency in terms of strength to density ratio resulting load reduction
on the structure and substructure.

28. • The initial findings have shown that the foam concrete has a desirable strength to be an
alternative construction material for the industrialized building system. The strength of foam
concrete is low for lower density mixture. Significant reduction of overall weight results in
saving structural frames, footing or piles and rapid and relatively simple construction.
• The mixed proportion for foamed concrete used in this research report can be used for
structural purpose because there 28 days Compressive Strength is more than 17 MPa.
• The ratio developed in our project can be used for various works like precast blocks, false
ceilings, precast wall elements/panels.