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PRODUCTION OF FOAMED CONCRETE WITH A METHOD OF MIXING
Norasyikin ht. Md. Yusof
Bachelor of Engineering with Honours (Civil Engineering)
2009
UNIVERSITI MALAYSIA SARA WAK
BORANGPENGESAHAN
JUDUL: PRODUCTION OF FOAMED CONCRETE WITH A METHOD OF MIXING
SESI PENGAJIAN: 2009-2010
Saya NORASYIKIN BT. MD YUSOF (HURUF BESAR)
mengaku membenarkan tesis * ini elisimpan di Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dengan syarat-syarat kegunaan seperti berikut:
1. Tesis adalah hakmilik Universiti Malaysia Sarawak. 2. Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dibenarkan membuat
salinan untuk tujuan pengajian sahaja. 3. Membuat pendigitan untuk membangunkan Pangkalan Data Kandungan Tempatan. 4. Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dibenarkan membuat
salinan tesis ini sebagai bahan pertukaran antara institusi pengajian tinggi. 5. ** Sila tandakan ( ...j ) eli kotak yang berkenaan
D SULIT (Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia seperti yang termaktub di dalam AKTA RAHSIA RASMI 1972).
TERHAD (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan).
TIDAK TERHAD
Disahkan oleh
(TANDATANGAN PENULIS) (TANDATANGAN PENYELIA)
Alamat Tetap: Pos l14A Bt 5 1f4 JIn Muar, Mukim 2 Bagan,
DR MOHAMMAD IBRAHIM SAF A WI (Nama Penyelia)
Tarikh:
Catatan:
83000 Batu Pahat, Johor.
Tarikh: ---------------- ----------------
* Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah, Sarjana dan Sarjana Muda. ** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasaJorganisasi berkenaan dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULIT atau TERHAD.
This project report attached here to, entitle "PRODUCTION OF FOAMED
CONCRETE WITH A METHOD OF MIXING" prepared and submitted by
NORASYIKIN BT. MD YUSOF (13431) as a partial fulfillment of the requirement
for degree of Bachelor of Engineering with Honors in Civil Engineering is hereby
read and approve by:
(Dr Mohammad Ibrahim Safawi)
Project Supervisor
Faculty of Engineering
Universiti Malaysia Sarawak
Date:
PRODUCTION OF FOAMED CONCRETE WITH A METHOD OF MIXING
NORASYIKIN BT. MD. YUSOF
This project is submitted to Faculty of Engineering,
University Malaysia Sarawak in partial fulfilment of the requirement for the
Degree of Bachelor of Engineering with Honours (Civil Engineering) 2009
For my beloved father and mother,
Sister, Brother in law, younger brother and fiance
Thanks for everything.
ACKNOWLEDGEMENTS
Alhamdulillah, first and foremost, thank you to Allah S.W.T with His
companion, guidance, and wishes this project complete successfully. Thanks to my
supervisor, Dr. Mohd Ibrahim Safawi B.Mohd Zain for his help, guidance and
attention in accomplishing this thesis successfully.
Special thanks also for UNIMAS Civil Engineering Laboratory technicians
En Nur Adha b. Hj Abdul Wahab for their help and cooperation during laboratory
work. Their willingness to share their knowledge and time with me during the
research is a valuable experience.
I would like to express my utmost thanks and gratitude to my beloved family,
my mother, father, sister, brother in law, younger brother and my fiance. I would
never have been able to complete this thesis without your continuous love and
support.
Lastly, not forgetting to all my coursemates and friends, who give me support
and help whenever I needed them.
ABSTRACT
In the history of the construction industry, lightweight concrete or foamed
concrete is a special concrete which can very useful in the construction sector
because it is very lightweight and it can compact by itself at each angle of foamwork.
Many researchers have been done in overseas, and show that foamed concrete is free
flowing material which is ideal for wide range of application. Moreover, material
used to produce concrete is cheap to normal concrete. The objective of this thesis is
to determine strength of concrete by using different material such as superplasticizer
and without using superplasticizer follow by mixing by using water and without
using water. The addition of chemical admixture such as superplasticizer (in the
form of liquid) can help achieve as it can produce mortar of normal workability but
with an extremely high strength owing to a very substantial reduction in the
water/cement ratio. There are three test that been through at concrete laboratory such
as Flow Table Test, Curing Test and Strength test in order to understand and look out
character of the concrete. An inspection from this project can show the nature of
foamed concrete when strength test will be done.
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ABSTRAK
Dalam sejarah industri pembinaan, konkrit ringan atau konkrit busa adalah
konkrit khas yang amat berguna dalam industry pembinaan kerana sifatnya yang
ringan dan boleh mampat dengan sendiri di dalam setiap ruang acuan. Banyak kajian
yang telah dijalankan di luar Negara, menunjukkan bahawa konkrit busa mempunyai
sifat yang mengalir dengan sendiri di mana ianya digunakan secara meluas.
Tambahan lagi, bahan yang digunakan untuk menghasilkan konkrit ini murah dan
dapat mengurangkan kos pembinaan. Tujuan kajian ini dijalankan adalah untuk
menentukan kekuatan konkrit dengan mengunakan bahan yang berbeza seperti bahan
menggunkan superpemplastikan dan tidak mengunakan bahan superpemplastikan
diikuti dengan campuran yang mengandungi air dan campuran yang tidak
menggunkan air. Penambahan bahan tambah kimia seperti superpemplastikan
(dalam bentuk cecair) dapat membantu untuk menghasilkan ciri yang lebih baik
dengan menghasilkan mortar dengan kebolehkerjaan biasa bagi mempunyai kekuatan
yang tinggi apabila nisbah airlsimen dikurangkan. Terdapat tiga jenis ujian yang
dijalankan seperti ujian kebolehkerjaan, ujian rendaman dan ujian kekuatan untuk
mengetahui dan melihat sifat-sifat concrete tersebut. Pemerhatian daripada kajian ini
menunjukkan sifat konkrit buih apabila ujian kekuatan dilaksanakan.
111
TABLE OF CONTENTS
CONTENT Page
ACKNOWLEDGEMENT
ABSTRACT II
ABSTRAK III
TABLE OF CONTENT IV
LIST OF TABLE VIll
LIST OF FIGURE IX
CHAPTER 1 INTRODUCTION
1.1 Background 1
1.2 Objectives of Study 2
1.3 Limitation of Study 2
1.4 Outline of the Thesis 3
CHAPTER 2 LITERATURE REVIEW
2.1 Introduction 6
2.2 Foam Concrete 6
2.3 Type of Foamed concrete
2.3.1 Wet Foam 8
2.3.2 Dry Foam 8
2.4 Method of mixing 9
IV
2.4.1 Inline System (Wet Method)
2.4.2 Inline System (Dry Method)
2.4.3 Pre-foamed Method
2.5 Water Cement Ratio
2.6 Strength Criteria
2.7 Material Properties
2.8 Characteristic of Foamed Concrete
2.9 Typical Application
2.10 Mixer
2.10.1 Drum Mixer
2.10.2 Rotating Drum Mixer
2.11 Superplasticizer
2.11.1 Nature of Superplasticizer
2.11.2 Advantages of Superplasticizer
2.11.3 Characteristic of mortar using Superplasticizer
2.12 Pozzolan
2.13 Pulverised Fuel Ash
2.12.1 Benefit of Fly Ash
2.14 Properties of Mortar
CHAPTER 3 METHODOLOGY
3.1
3.2
3.3
General
Preparation of Foamed Concrete
Mixing Procedure
v
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10
10
11
12
13
13
14
16
17
17
17
18
19
20
22
25
26
29
32
32
33
3.3.1 Mixing with Super plasticizer 33
3.3.2 Mixing without Super plasticizer 34
3.4 Equipment 35
3.4.1 Flow Table Test 35
3.4.2 Drum Mixer 36
3.4.3 Mortar Mixer 36
3.4.4 Foam Generator 37
3.4.5 Air Compressor 38
3.4.6 Cylinder 38
3.4.7 Formwork 39
3.5 Material use in Experiment 40
3.5.1 Cement 40
3.5.2 Water 41
3.5.3 Sand 41
3.5.4 Forming agent 42
3.5.5 Super Plasticizer 42
3.5.6 Pozzolan 43
3.6 Experimental Program 43
3.6.1 Casting 45
3.6.2 Curing 46
3.7 Production of Foamed Concrete 46
3.7.1 Flow Table Test 47
3.7.2 Strength Test 48
3.7 Summary 48
VI
CHAPTER 4 RESULT AND ANALYSIS
4.1 Introduction
4.2 Compressive Strength Test
4.3 Mortar Flow Test
4.4 Summary
CHAPTER 5 CONCLUSION AND RECOMMENDATION
5.1 General
5.2 Conclusion
5.3 Recommendation
REFERENCES
APPENDIX
Vll
49
50
58
62
63
63
65
66
68
LIST OF TABLE
Tables Page
Table 2.1 Typical Properties of Foamed Concrete 13
Table 2.2 Main Features and Characteristic of Foamed Concrete 16
Table 2.3 Classification, Composition and Particle characteristic
ofPozzolan for Concrete 22
Table 2.4 Typical Properties ofPF A 25
Table 3.1 Sample of mix 42
Table 3.2 Fine Aggregates Grading 44
Table 3.3 Sample without Water 44
Table 3.4 Sample with Water 44
Table 3.5 Sample Without Superplasticizer 44
Table 3.6 Sample with Superplasticizer 44
Table 3.7 Material used for Sample 45
Table 4.1 Mortar Flow Table Test Result without Water 58
Table 4.2 Mortar Flow Table Test Result with Water 59
Table 4.3 Mortar Flow Table Test Result without Superplasticizer 60
Table 4.4 Mortar Flow Table Test Result with Superplasticizer 61
V111
LIST OF FIGURES
Figures Page
Figure 2.1 Micrograph ofPF A 25
Figure 3.1 Flow Table Test 35
Figure 3.2 Drum Mixer 36
Figure 3.3 Concrete / Mortar mixer 37
Figure 3.4 Foam Generator 37
Figure 3.5 Air Compressor 38
Figure 3.6 Cylinder 39
Figure 3.7 Polystyrene mould 39
Figure 3.8 Cement 40
Figure 3.9 Sand 41
Figure 3.10 Pulverized Fly Ash 43
Figure 3.11 Flow Table Test 47
Figure 3.12 Strength Test 48
Figure 4.1 Result Average Compressive Strength 50
Figure 4.2 Result Average Compressive Strength 52
IX
Figure 4.3 Result Average Compressive Strength 53
Figure 4.4 Result Average Compressive Strength 54
Figure 4.5 Result Average Compressive Strength 55
Figure 4.6 Cube D5 56
Figure 4.7 Cube D1 57
Figure 4.8 Flow Table Test without water 58
Figure 4.9 Flow Table Test with Water 59
Figure 4.10 Flow Table Test using Superplasticizer 60
Figure 4.11 Flow Table Test without using Superplasticizer 61
x
CHAPTERl
INTRODUCTION
1.1 Background
Foam concrete is a type of porous concrete. According to its features and uses
it is similar to aerated concrete. The synonyms are aerated concrete, lightweight
concrete or porous concrete. The term foam concrete is containing no aggregates
only sand, cement, water and stable foam to perform the concrete. This action
incorporates small enclosed air bubbles within the mortar there by making the
concrete lighter.
Basically, there are two method of producing foamed concrete such as pre
foam method and inline method. The inline method can divided into wet method and
dry method. To produces foamed concrete, there are two type of foam will be used
by wet foam and dry foam. A foamed concrete is described as having an air content
of more than 25% which distinguishes it from highly air entrained materials.
Foamed concrete may have density from as low 500kg/m3 to 1600kg/m3 and strength
from less than IN/mm2 to 25N/mm2.
1
The strength of foamed concrete will be affected by the cement content of the
mix, the water/cement ratio, the proportion of cement to sand and the properties of
the sand. High compressive strength is generally achieved by using high cement
content, a low water/cement ratio and a sand.
Basically, the workability test and strength test will be tested to investigate
properties of foamed concrete. To measure of workability test and strength test will
be tested in the experiment such as slump test. This concrete will be tested before
concrete is casting into mould, therefore the fresh concrete will be used to determine
the workability of concrete mix, and after the concrete harden, strength test will be
measure on 7 days and 28 days.
1.2 Objectives of Study
The aims of this project were to investigate and to improving of workability of
foamed concrete. There are two main objectives of the project are:
1. To produce foamed concrete in laboratory.
11. To determine the effectiveness of using super plasticizer in mortar.
111. To determine and compared strength of foamed concrete, first using super
plasticizer and secondly without using super plasticizer.
2
1.3 Limitation of Study
Foamed concrete is one field that is too wide to discuss. To achieve the
objective of this project, the study is just to focus on the related foamed concrete.
The following are the main limitation of study:
1. This study also by using target density lOOOkg/m3
11. These theses also look out by using water and without water followed by
using super plasticizer and without using super plasticizer.
1.4 Outline of the Thesis
This thesis contains five chapters starting with the introduction in chapter 1,
followed by literature review in chapter 2 and methodology in chapter 3. Chapter 4
also contains result and analysis and the end of the thesis is providing conclusion and
recommendation in chapter 5.
• Chapter 1: Introduction
This chapter discusses about background of foamed concrete and the
objectives and followed by limitation of study.
3
• Chapter 2: Literature Review
This chapter discussed the detail about foamed concrete and properties of
foamed concrete and the application. The properties are strength, water
cement ratio, density and cement content. The application is using a foam
concrete that depend to the density of foam concrete. In this chapter also
discussed about the production of the foamed concrete.
• Chapter 3: Methodology
This chapter discussed about equipment used to produce foam concrete, the
material and mix proportion. In this chapter also contain the test uses to
achieved the objectives this project. The test is checking the strength and
workability of the foamed concrete.
• Chapter 4: Analysis and Discussion
This chapter analyzed and discussed about the data obtained from
experiments.
4
• Chapter 5: Conclusion and Recommendation
This chapter discussed the conclusion base on data and the recommendation
for the further work.
5
CHAPTER 2
LITERATURE REVIEW
2.1 Introduction
This thesis is to produce the foam concrete and test the foamed concrete at
laboratory to identify the suitable density and the mix proportion to use for produce
the foam concrete for structure. All properties of foamed concrete like dry density,
compressive strength, thermal conductivity, and drying shrinkage are describe in this
chapter. Also describe in this chapter is the typical application and the production of
foam concrete.
2.2 Foam Concrete
The term foam concrete is containing no aggregates only sand, cement, water and
stable foam to perform the concrete. This action incorporates small enclosed air
bubbles within the mortar there by making the concrete lighter. A foamed concrete
is described as having an air content of more than 25% which distinguishes it from
highly air entrained materials. Foamed concrete may have density from as low
500kg/m3 to 1600kg/m3 and strength from less than IN/mm2 to 25N/mm2.
6
The stable foam is the most important gradient in the production of foamed
concrete. The foaming generator made foam, where is blend of sand, cement, and
water (the base mix) and foaming agent either protein or synthetic are mixed and
produced stable foam is foamed.
According to a study by (Norizal, 2002) state that foams from protein foaming
agent comes from natural sources and has a weight of around 80g/litre and expansion
of about 12.5 x using portaform foam generator. They generally are more stable then
synthetic foams but have a shorter shelf life of about 12 month in open conditions.
They also give a higher strength of concrete compared to synthetic foams. This is
suitable for densities from 400kg/m3 to 1600kg/m3.
According to a study by (Norizal, 2002) state that synthetic foams have density
of about 40g/litre with an expansion of about 25 x using portafoam. They are very
stable at concrete densities above 1000kg/m3 and give good strength. Their shelf life
is about 16month under sealed condition. This is suitable for densities of 1000kg/m3
and above.
7
2.3 Type of foam concrete
2.3.1 Wet foam
Wet foam is produced by spraymg a solution of foaming agent (usually
synthetic) and water over a fine mesh. This action causes a drop in pressure across
the mesh allowing air to be sucked from atmosphere to equal the pressure. This
equalization of pressure causes the solution to expand into what can best be
described as a foamed similar in appearance to bubble bath foam. With the bubble
size ranging 2-Smm. The foam has a large "loose" bubble structure and although
relatively stable it is not recommended for the production of low density (below
1100kg/m3) foamed materials. It is also not suitable for pumping long distance or
pouring to any great depth.
When tends to happen is that as pressure on the materials increases (this pressure
increase can be as simple as pouring the material over a certain depth), the bubble
basically burst causing a decrease in yield along with an increase in density.
2.3.2 Dry foam
Dry foam is produced by forcing a similar solution of foaming agent and water
through a series of high density restrictions whilst at the same time forcing
compressed air into a mixing chamber. The action of forcing this pressurized air into
the solution expands the solution into thick, tight foam, similar in appearance to
8
shaving foam. The bubble size is typically less than lmm in diameter and of an even
size. The type of foam is extremely stable and these stable properties are passed onto
the foamed materials when the foam is blended with the base materials.
As detailed previously this stability is particularly important when the ratio of
foam to base materials is greater than 50:50. When the foam becomes the dominant
partner within the mix it has to retain its stability to avoid collapse during, pumping,
curing, and pouring. Foamed concrete produced using dry foam can be pumped
further, poured deeper and exhibits better flow characteristics than a like for like mix
produced with a wet foam system.
2.4 Method of Mixing
There are two method of producing foamed concrete such as pre-foamed method
and the inline method:-
2.4.1 Inline system (Wet method)
This system has been driven in the main part by the need for both higher product
quality control and the commercial requirement for lower density material. These
systems incorporate the same type of foam generator and foaming chemicals as used
in the pre-foam method, but differ in that it except wet base materials into an abroad
hopper and add the foam through a completely separate process together.
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