DURABILITY CONSIDERATION OF EXPANDED POLYSTYRENE (EPS)

CONCRETE

KENNETH SU SWEE KWANG

This project is submitted in partial fulfillment of the requirements for the degree of

Bachclor cif' I: nginccring with I lonours

(('ivil Engineering)

Faculty of I: nginccring

t'ti(ý'I: RSFI'I MALAYSIA SARAWAK

2(H)9

Dedicated to my beloved family

ACKNOWLEDGEMENTS

First and foremost, the author would like to express sincere gratitude to his

supervisor, Assoc. Prof. I)r. Ahmed Lehhe Mohamed Mauroof; who has given a lot

of supervision, numerous advice, guidance and ideas and encouragement thus

completing this final year project. Not forgetting also, thank you to all the

hardworking technicians of Civil Engineering Laboratory especially to Mr. Nur Adha

Abdul Wahab, without their hardworking and point of idea this final year project will

not he as good as no%%". A separate word of thank is also expressed to the author's

family especially my twin brother fir his endless supports and love, in giving the

courage and strength to the author at all time. Thanks are also due to his friends, who

shared their concern, views and advices with the author in making success of this

project. Last but not least, the author express his cordial thanks to all there who

contributed intellectually, materially and morally, in words and in deeds, to

successful of this project.

i

ABSTRACT

The results of the study on the appropriate mix proportions of Expanded

Polystyrene (EPS) concrete is presented. The study mainly to investigate the mix

proportions of EPS concrete with various percentages of EPS aggregate replaced

with normal weight aggregates to obtain the lowest water absorption. The

experimental study was focused on the normal weight concrete (NWC) and FPS

concrete mixtures having water binder ratio of 0.49 with a total hinder of 466 kg/m`.

The results of the experimental investigation show that the EPS concrete water

absorption increases with an increase in the percent replacement of ITS aggregate

with normal weight aggregates.

ii

ABSTRAK

Hasil pengajian yang srsuai prapc)rsi campuran konkrit Expanded

1'o4vstyrc"nc" (EPS) dipamcrkan. Tujuan utama pengajian ini adalah untuk

mcmpclajari proporsi campuran konkrit EPS dengan hcrbagai peratus aggregate ITS

diganti dengan aggregate berat hiasa untuk mcmpcrolch pcnycrapan air tcrcndah.

Pengajian ekspcrimental ini difokuskan pada konkrit berat hiasa (NWC) dan

campuran konkrit EPS merniliki nishah air kcpada simcn 0.49 dcngan jumlah simcn

466 kg m`. Hasil penyclidikan pcrcuhaan mcnunjukkan hahawa pcnycrapan air

konkrit EPS mcningkat dcngan pcningkatan pcratus pcnggantian aggregate HIS

dengan aggregate berat hiasa.

III

TABLE OF CONTENTS

Contents

ACKNOWLEDGEMENT

ABSTRACT

ABSTRAK

TABLE OF CONTENTS

LIST OF TABLES

LIST OF FIGURES

CHAPTER 1: INTRODUCTION

1.1 INTRODUCTION

1.2 BACKGROUND

1.3 S('OPI-. 01: STUDY

1.4 OUTLINE OF PROJECT RE: PORT

CHAPTER 2: LITERATURE REVIEW

?. l GENERAL

1 1) AGGREGATES

2.2.1 Týpcs of'aggrcgatcs

>>i I: PS aggregatc

Page No.

i

il

iii

1%,

vii

viii

I

ý

3

3

S

6

IU

IV

2.2.3 Effect of EPS aggregate size and volume on physical II

properties of EPS concrete.

2.3 EPS LIGHTWEIGHT CONCRETE

2.3.1 General

2.3.2 Mix proportions

2.3.3 Water absorption

19

20

21

CHAPTER 3: METHODOLOGY

3.1 GENERAL. 22

3.2 MATERIALS 22

3.2.1 Cement

3.2.2 Normal weight aggregate

3.2.3 Expanded PolystýTene (EPS) aggregate

3.2.4 Water

23

23

23

24

. 1.3 MIX PROPORTIONS 25

3.4 TI: S"I PROGRAMS

3.4.1 Test Program I Compressive strength test

3.4.2 Test Program 2- Water absorption test

CHAPTER 4: RESULT AND DISCUSSION

4.1 GE-'NE-. RAI.

4.2 ('()'WPRE: SSI\'E: S'1'RE: NGT'EE

4.3 \VA'1'E: R ABSORPTION

26

27

21)

2O

32

V

CHAPTER 5: CONCLUSIONS AND RECOMMENDATIONS

5.1 CONCLUSIONS 35

5.1.1 Compressive strength test

5.1.2 Water absorption test

35

36

5.2 RECOMMENDATIONS 36

REFERENCES 37

APPENDIX 41

Vi

LIST OF TABLES

Tables Page No.

Table 2.1 Typical test results on sample of stone aggregates from ('MS 9

Quarries Sdn. Bhd (Malaysian Institute of Architects, 2(x)6).

Table 2.2 BS and ASTM sieve sizes for grading of fine aggregate I0

(Neville and Brooks. 1990).

Table 2.3 Mixing properties of various samples (EfTendi, 2004). 12

Table 2.4 Compressive strength and unit weight of various concrete 12

mixtures (EfTendi. 2004).

Table 2.5 Characteristics of polystyrene aggregates (D. S. Eiahu et al., 14

2OO6).

Table 2.6 FPS heads characteristics (Ilaghi and Arahani, 2006). 16

Table 2.7 Details of FPS concrete mixes containing silica fume (6anesh Ix

and Saradhi. 2(X)3).

Table 2.5 Relationship between water-cement ratio and compressive 21

strength of' concrete using Type I Portland cement (ACI

Committee 211.2-91,1997).

Table 3.1 Mix proportions of E PS concrete and normal weight concrete 25

(NWC).

Table 4.1 Compressive strength test results. 30

Table 4.2 Water absorption test results. 32

vii

LIST OF FIGURES

Figures Page No.

Figure 2.1 Water absorption for various type of mix (Effendi, 2004). 13

Figure 2.2 Variation of compressive strength with age for different 14

densities (D. S. Babu et al., 2006).

Figure 2.3 Variation of water absorption with time (D. S. Bahu et al.. 15

2006).

Figure 2.4 Variation of strength with density (Haghi and Arabani. 2006). 16

Figure 2.5 Effects of EPS %volume on compressive strength (Haghi and 17

Arabani, 2(x)6).

Figure 2.6 Variation of strength with density and ITS volume (Ganesh 18

and Saradhi. 2003).

Figure 2.7 Variation of the 30-min and the final absorption value 19

(Ganesh and Saradhi. 2003).

Figure 3.1 Sieve machine. 24

Figure 3.2 Concrete mixer. 26

Figure 3.3 ('ompressive strength test machine. 27

Figure 3.4 Oven fir preparing samples to oven dry state. 2`4

Figure 4.1 Variation of compressive strength with density of concrete. 31

Figure 4.2 EPS concrete cube sample aflcr testing. 31

Figure 4.3 Variation of water absorption with density of concrete. 34

viii

CHAPTER 1

INTRODUCTION

1.1 INTRODUCTION

Lightweight aggregate concrete, had been increasingly used by the

construction industry, was reported to have a significant durability in severe

exposure conditions (Zhang and Gjor v, 1991). Among the problems related to the

use of conventional lightweight aggregates produced from clay, slate and shale in

concrete, a major one is that these porous aggregates absorb a very large quantity of

the ºnixing water. The performance of the concrete will then he affected, apart from

the fact that it is difficult to maintain specific water content during the casting. To

maintain acceptable slump levels, additional water will also he needed since the

aggregate absorb significant amount of water. Also, the durability of any concrete is

primarily controlled by the permeability and a better understanding of moisture

transfer can therefore reduce or prevent the damage in building materials (Goual et

al., 20M). Concrete is also affected by the aggressive action of' deleterious

substances presents in industrial liquids and gases or in marine environment through

chemical attack. This deterioration of concrete also leads to the corrosion of the

reinforcement resulting in the spalling ofconcrete.

i

Taking into consideration the above, it is vital to improve the matrix

characteristics to ensure that the absorption is limited to acceptable limits. Non-

absorbent, hydrophobic and closed cellular aggregates like expanded polystyrene

(EPS) beads do not suffer with this disadvantage (Sussman, 1975, Cook, 1983,

Ravindrarajah and Tuck. 1994).

The main purpose of this study was to investigate the durability of the

Expanded Polystyrene (EPS) lightweight concrete. The type of EPS aggregates used

in this study was polystyrene board from shops and used polystyrene protective

casing as found in the packaging of electrical appliances. The main concern of the

study was to determine the lowest water absorption of' EPS concrete with different

percentages of EPS aggregate in the EPS concrete.

1.2 BACKGROUND

Lightweight concrete has been widely used especially in the construction of

long span bridges, high rise building and offshore structures, which produce

structural member with smaller cross-section and this will significantly reduce the

size of the foundation (A('I Committee 2138-0.3,2(K)3). Expanded Polystyrene

(EPS) lightweight concrete is produced by introducing ITS beads as aggregate.

According to Sussman (1975), lightweight concrete made with ITS aggregates show

significantly lower water absorption compared with normal weight concrete due to

the non-absorbent nature of the ITS aggregates.

I

1.3 SCOPE OF STUDY

The objective of this study is to determine the appropriate EPS mix

proportion to get a very low water absorption property in concrete. The main

objectives are as follow:

" To conduct laboratory test on the water absorption on different mix

proportions of normal weight concrete and EPS concrete.

" To perform compressive strength tests on different mix proportions of normal

weight concrete and EPS concrete.

1.4 OUTLINE OF PROJECT REPORT

Chapter 2 provides the literature and studies on the aggregates used in the

FPS concrete mixture. Factors that affecting the water absorption and compressive

strength were also discussed. The contents of this chapter also represents the source

references used to execute the project.

Chapter 3 describes the program and methodology of' laboratory works such

as preparation of materials, mixing proportions of' concrete samples and testing

programs.

Chapter 4 illustrates the results gathered from the experimental works and

analysis of the data obtained fro in the tests results which consist of water absorption

and compressive strength of concrete samples.

3

Finally, Chapter 5 contains a conclusions based on the discussion of results in

the preceding chapter and the recommendations for future study.

4

CHAPTER 2

LITERATURE REVIEW

2.1 GENERAL

The purpose of this chapter is to present the infbn ation gathered which are

related to the present study. The first part presents the infiormation on Expanded

Polystyrene (FPS) aggregates and its effect on the physical properties of FPS

lightweight concrete. This chapter also consists of the characteristics of l": l'S

aggregates.

The tollowing part of' this chapter presents the studies conducted and

intonation related ITS concrete. The infimnation gathered based on research done

includes the mix proportions of' ITS concrete, materials and properties to produce

FPS concrete.

S

2.2 AGGREGATES

2.2.1 Types of aggregates

According to Derucher ct al. (1998), aggregate is a combination of sand.

gravel, crushed stone, slag, or other material of mineral composition, used in

combination with a binding medium to form such materials as bituminous and

Portland cement concrete, macadam. mastic, mortar, plaster, as in railroad ballast,

filter beds and various manufacturing processes. Derucher also classified ag,, rega1e

as natural or manufacturer. Natural aggregates are taken from natural deposits

without change in their nature during production, with the exception of crushing.

sizing. grading or washing. In this group. crushed stone, gravel, sand (the most

common), pumice. shells, iron ore and limcrock may include. A/anafaeturrc/

aggregates include blast furnace slag, clay, shale and lightweight aggregates.

The aggregates can he divided into two types fine and coarse aggregate.

According to ASTM ('125 (Concrete and Concrete Aggregate), tine uýýýýregatc is

defined as aggregate passing a in. (9.5 mm) sieve and almost entirely passing a

No. 4 (4.75 mm) sieve and predominantly retained on the No. 200 (75 µm) sieve or

that portion of an aggregate passing the No. 4 (4.75 mm) sieve and retained on the

No. 200 (75 µm) sieve. Coarse a ggrvgate is defined as aggregate predominantly

retained on the No. 4 (4.75 mm) sieve and retained on the No. 2(N) (75 µm) sieve"

(Derucher et al.. 199S).

6

According to Portland Cement Association (PCA) quoted from American

Concrete Institute (ACI), 1994 stated that the aggregates are inert granular materials

such as sand, gravel or crushed stone and combined with water and Portland cement,

are an essential ingredient in concrete. For a good concrete mix, aggregates need to

be clean, hard. strong particles free of absorbed chemicals or coatings of clay and

other fine materials that could cause the deterioration of concrete. Aggregates report

for (() to 75 percent of' the total volume of concrete and can he divided into two

distinct categories-tines and coarse.

Lightweight aggregate is defined as aggregate with particle density less than

20(H)kg m' or a dry loose bulk density of less than 120( kg ni . Lightweight

aggregates are light due to the inclusion of air voids and it follows that they are

absorbent, except for the very fcwy with scaled cells. This absorbency plays an

important part in the way the concrete pertk nns in its wet state. Most lightweight

aggregates are manufactured and hence are. by careful production control, unifinrnm

and consistent, which is important to mixing, placing and compaction. Lightweight

aggregates are weaker than natural aggregates and hence put some limitation on

strength achieved by the concrete. This is, however, less significant because they are

more compatible with the matrix allowing the whole to pert nn better in

compression. Lightweight aggregates often are made of waste materials occurring as

by-products tom other industries. and hence their use is ecologically desirable

(Clarke, 1993).

(trading retirs to the determination of the particle-sirr distribution tier

aggregate. (irading limits and maximum aggregate sirr arc speciticd hccausc grading

7

and size affect the amount of aggregate used together with cement and water

requirements, workability. pumpahility. and durability of concrete. In general. if the

water-cement ratio is chosen correctly. a wide range in grading can he used without a

major effect on strength. When gap-graded aggregate are specified. certain particle

sizes of aggregate are omitted from the size continuum. Gap-graded aggregate are

used to obtain uniform textures in exposed aggregate concrete. Close control of mix

proportions is necessary to avoid segregation. (A('I. 1994).

Particle shape and surface texture influence the properties of freshly mixed

concrete more than the properties of hardened concrete. Rough-textured, angular, and

elongated particles require more water to produce workable concrete than smooth,

rounded compact aggregate. Consequently, the cement content must also he

increased to maintain the water-cement ratio. Generally, flat and elongated particles

are avoided or are limited to about 15 percent by weight of the total aggregate. I Init-

weight measures the volume that graded aggregate and the voids between them will

occupy in concrete. The void content between particles aflccts the amount of cement

paste required fir the mix. Angular aggregate will increase the void content. Larger

sires of well-graded aggregate and improved grading decrease the void content.

Absorption and surface moisture of aggregate are measured when selecting aggregate

because the internal structure of aggregate is made up of solid material and voids that

may or may not contain water. The amount of water in the concrete mixture must be

adjusted to include the moisture conditions of' the aggregate. Abrasion and skid

resistance of an aggregate are essential when the aggregate is to he used in concrete

constantlý subject to abrasion as in heavy-duty flcors or pavements. I)iflcrrnt

minerals in the aggregate wear and polish at dil1crent rates. Ilarder aggregate can he

S

sclectcci in highly abrasive conditions to minimize wear. (('emcnt& Concrete liasics.

P('A. A('1.1 994).

According to CMS Quarries Sdn 13hd, the stone aggregated produced and

supplied comply to the Malaysian Standard (M. S 21) and M. S 30) set by the Jahatan

Kerja Rava (Public Works Department). Typical test results on sample of stone

aggregates taken from the ('MS Quarries Sdn 13hd are given in Table 2.1. The

various sizes of stone aggregates also presented in their wwwebsite. The microtonalite

stone aggregates produced at from Stahar Quarry and PPES Pcnkuari Sdn l3hd. The

microtonalitc are igneous rock and belong to the same classification igneous rock

type as granite. In term ot'yuality and hardness. microtonalite are classified under the

granite rock (Malaysian Institute of Architects, 2006).

Table 2.1: Typical test results on sample of' stone aggregates from ('MS Quarries

Scan. Bhd (Malaysian Institute of Architects, 200(.

Test Parameter

Aggrqgatc ('rushing Valuc Aij,,. rcgatc Impact V. 11LIC Los Ani! clcs Abrasion Valuc Spccifv(iravitv Watcr Absorption

Stahar Quarry PIT'S l'cnkuan

Still lihci (1licrutunulitc)

13 Iý 16 2.64

2.1 "ýý

f; ukit Akud Quarry

(Limestone)

25 °°

? ll °u

26 2.71

0.3 °n

tichuyiu Ou; irry

* ('Onclurtccl by: JKlt ('cntral Materials Laboratory. Kuching

27 °, o

?. hh

l). z? ",.

According to Neville and Brooks (199O), the fine aggregate and coal-se

aggregate are separated according to a size of S rani 14S sieve (3 16 in. ) or No. 4

ASTN1 sieve (4.75 nom), which is main division to obtain the two dil, fcrent type of

()

aggregate in term of size. The separation of Loth aggregate is always used to produce

good quality of concrete. Table 2.2 shows the 13S and AST M typical sieve sizes used

for grading of aggregate.

Table 2.2: BS and ASTM sieve sizes für grading of* fine aggregate (Neville and

Brooks. 1990).

Aperture Mm or LIfl

5.0 rnni 2.36 min 1.1xmm

BS I ASTM

lll.

0.196 0.0937 0.0469

600 Fun 0.02 34 300 Fun 0.01 17 180 pill 0.0059

2.2.2 EPS aggregates

lýine aTcgatr Previous Aperture

DCSI, s; natl()n Mm or µm in. 3 16 in. 4.75 mni 0.1,87 No. 7- .. 2.36 min 0.0937

No. 14 1.1 ti mttt 0.0469 No. 25 600 µm

}

0.0234 No. 52 iOOltm 0.0117

No. 100 180 lmi 0,0059

Previous I)rsignatiom

No. 4 No. S

No. 16 No. : i() No. 5()

No. 100

: I'S, or expanded polvstýTene, is a rigid cellular plastic originally invented in

Germany by I3ASF in 1950. It has been used in packaging solutions since 1955. It is

98° air but the rest is made from tiny, spherical HIS heads (A('I Committee 2I 3R-

0.3,2003) - themselves made only of* carbon and hydrogen. FTS structures are

produced through a3 part process called steam moulding that expands these tiny

heads to more than 40 times their original size. This expanding process is precisely

timed to determine the size the heads will finally reach. It is this final density of the

expanded heads that determines the strength of the structure. Aller the first stage the

heads are left to absorb air fir between 24 and 4S hours. In the final stage the freshly

I t1

expanded heads are poured into individually manufactured moulds where steam and

pressure are applied to compress and bond the heads into a final structure of the

required strength and density (Simplipac Ltd. ).

Polystyrene aggregate can he used to produce low density concretes required

ftrr building applications (Cook. 1983) and it can he used firr other specialised

applications like the sub-base material fir pavement and railway track bed, as

construction material tor floating marine structures, sea beds and sea fiances. as an

energy absorbing material for the protection of' buried military structures and as

fenders in offshore oil platforms (Short and Kinnihurgh. 1978). Moreover, firr equal

concrete densities, EPS aggregate concrete have exhibited 70 270"/%, higher

compressive strength than vermiculite or perlitc aggregate concrete (Sussman and

Baumann, 1972) and these were found to he fire-resistant and hence used as a good

thermal insulation material in building construction (Sussman, 1975, Sussman and

Baumann. 1972).

2.2.3 Effect of EPS aggregate size and volume on physical properties of EPS

concrete.

I: fl'endi (2004) investigated the physical properties on four samples of' ITS

concrete with cicnsity ranging from I ti00kg m' to 2000kg'mý. : ach sample was

replaced by FPS aggregate by percent Volume with its fine and or coarse aggregate.

The mixing properties of various samples are shown in Table 2.3. Eftcndii (2004)

mentioned that the compressive strength of ITS concrete is lower than that of the

II

nonnal weight concrete due to the replacement of the tine and course aggregates with

EPS aggregates. As shown in Table 2.4, with similar mix proportion. samples 132

and 133 showed an increase in compressive strength with a decrease in FPS aggregate

volume. Effendi (2(X)4) also stated that EIS concrete with density higher than

18OOkg, 'm3 showed lower water absorption compared to nonnal weight concrete.

From Figure 2.1, with similar mix proportion, samples 132 and 133 showed an

increase in water absorption with an increase in ITS aggregate volume. Also from

Figure 2.1. it is shown that sample B3 with a density of I 85Okg'm' has the lowest

water absorption compared with other EPS concrete samples.

Table 2.3: Mixing properties of various samples (l: f1cndi, 2004).

-__-T---__ _ CO` Mix Type rePlarrn

A BI B2 B3 B4

rse aggregate Irnt (°0) With 1: 1'ti

O 50

25

5O O

1-inr aggregate replacement (°O)

with I'11'ti O

--- - ý

15

50

50

l ahlc 2.4: ('omhressivc strength and unit weight of various concrete mixtures

(Effendi, 2004).

Mix 'I, ýTr Unit %%-right (kg 111 ')

A 131 13? B1 13.3

ýýllO

? (1()() 1 900

1850 1 800

2ti days comhressivc strcngth (MI'a)

52.6221 25.11)2'

29.9244 ---

25.9111 24.04ti, 1%

12

Figure 2.1: Water absorption for various type of mix (l: ficncli, 2004).

Experimental work has been carried out by D. S. I3abu ct al. (2OO6) on six

EPS concrete with the density ranging from 1 OOOkg'm' to 2000kgim`. 'there are

three sets of density which are 1 O5Okg'mI, I43Okg/m' and I S20kg m'. 'Fahle 2.5

shows the characteristics of poIystNTene aggregates. Individual sample in each set of

the density has two sizes of EPS aggregate which is shown in 'Fahle 2.5. As shown

in Figure 2.2, all three sets of the densities show that the compressive strength of'the

concrete increases with a decrease in EIS aggregate size and with a decrease in

volume of'EPS aggregate. Whereas shown in Figure 2.3. the water absorption of* the

concrete increases with an increase in ITS aggregate size and with an increase in

volume of EPS aggregate.

13

Table 2.5: Characteristics of polystyrene aggregates (l). S. Balm et al., 200 6).

Sieve size (mm)

8 6.3 4.75 2.36 1.1x

25 ý

1 (x) 1(X) 1 (X) 0

Bulk density (kg m3) 23.6 Specific gravity 0.029 0.014 *Types P and Q arc FPS: t' is t'FPS.

40

35 ý

30 - a ý t Q1 C m w 20

> ý 15 a E 0 U 10

Graclin8 ot'polystyrcnc q4. grc8atc I'ypc 1' Type U

100 100

.! --

35` fly ash concrete

A

c -4-}----------- I

-ýý. . -- -- ý_-

l OO O O l)

rumulati\"r lrisýiný C' O. ) s

Tyjlr l1 100 100 100 100

-

(º (ý(,. S

I . 02 -

  . 1750

U

10% silica fume concrete

0 10 20 30 40 50 60 70 80

Age (days)

fý 1820

1430

f 1050

ý- P10b

  P143

-l4- P187

-"-Q105 -{l- Q 143

f 0187

-*-Ur 175

-(3-US1/,

90 100 110 120

Figure 2.2: Variation of compressive strength with agc 1,0r cliffcrcnt densities (I). ti.

l3ahu cl al.. ? UUh).

14