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CELLULAR LIGHT WEIGHT CONCRETE

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CELLULAR LIGHT WEIGHT CONCRETE Powered By Docstoc
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CONTENTS
   Introduction
   What is concrete?
   What is cellular light weight concrete?
   Neopor foam
   Production process
   Placing of CLC
   Tests on CLC
   Properties
   Uniqueness
   Advantages
   Comparison chart
   Applications
    Conclusions
    References

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INTRODUCTION
 CLC is a version of light weight concrete .
 Provides an effort of improving environment by
  conversion of waste into useful building product.
 CLC=Cement slurry +Sand +fly ash +water
  +Preformed stable foam.
 Density range 400kg/m3 – 1800kg/m3.
 Helps in reduction of dead weight of structures.




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WHAT IS CONCRETE?
 Widely used building material.
 Concrete= Cement +Sand +Aggregate +Water.
 Can be moulded into durable structural items of
  various sizes and shapes.
 Quantity of ingredients control the properties of
  concrete in wet and dry state.




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WHAT IS CELLULAR LIGHT WEIGHT
CONCRETE(CLC)?
CLC= Cement
slurry+Sand+Flyash+Water+Preformed
stable foam.
Foam creates millions of tiny voids in the
material.
Foam flows easily into all corners – so
vibrations for compaction not required.
CLC is poured or pumped into assembled
moulds or formwork of RCC elements.
Accelerates pace of construction.

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NEOPOR FOAM
 Neopor foam causes no chemical reaction in the
  concrete but serves as a wrapping material for air
  entrapped.
 The foaming agent warrants high stability for the foam
  and withstands the forces occurring when mixing ,
  conveying, casting, and hydration process.
 1 kg of foaming agent diluted in 4o liters of water
  yields approximately 540 liters of foam.
 foaming agent is bio degradable, non-toxic, non-
  inflammable.
                                                           6
                 FOAM
FOAM GENERATOR          7
MOBILE NEOPOR UNIT
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PRODUCTION PROCESS
 Required quantity of cement,sand,and water are fed into
  the concrete mixer at project site and mixed well.
 Fly ash of specified quality is added next. Fly ash content is
  between 1/3rd to 1/4th of total raw materials depending on
  the target density of the final product.
 Neopor foam produced at site is fed into the concrete mixer
  and mixed well.
 Foam produced is stable for a time duration far beyond the
  final setting time of cement thereby creating permanent
  voids in the final hardened mass.
 This mix can be used for making precast blocks or for
  insitu casting.
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PLACING OF CLC
CLC used in multistory
buildings is pumped or
transported to the job site.
   Then the concrete is spread
to proper thickness usually
between 1.5 to 1.6 inches .
 Darby and trowel is used
to produce a flat surface.


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PLACING OF CLC
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TESTS ON CLC
 Specimen is placed in 3x6 inch cylinders for testing.
 Protect the test cylinders from weather and
  disturbance after casting.
 After 24 hours, cure the specimen with moisture for 7
  days and then dry cure them for another 21 days.
 The cylinder is then tested in the same manner as for
  ordinary concrete cylinders.
 The crushing strength is obtained finally.



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PROPERTIES OF CLC
 More versatile material than other versions of light weight
  concrete.
 Can be produced in wider density range.
 Can be precast or cast in-situ.
 Lower water absorption.
 Easy to produce.
 Cost competitiveness.
 Light weight with superior thermal and sound insulation.
 Ease of working with CLC.
 Resistance to corrosion.
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MOULD   PRECAST CLC BLOCKS   15
UNIQUE FEATURES OF CLC
 Very simple method of production.
 Easily adopted in pre cast plants or even at the project
  site.
 Requires nominal investment only.
 Cheaper and environment friendly.
 Only normal concrete mixers required.
 Ordinary moulds can be used.
 Unskilled laborers only.
 Can be made into pre cast elements whether
  reinforced or unreinforced.

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ADVANTAGES
 Reduction of dead load.
 Material savings.
 Saving in transportation cost.
 Ease of handling.
 Ease of construction in hilly areas.
 Eco friendly.
 Insect resistant.
 Fire protection.
 Speedier construction
 Saves energy and reduces pollution.
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 COMPARISON CHART

Sl no   Parameters    CLC         Burnt        Concrete
                                  clay         hollow
                                  brick        block
1.      Basic raw     Cement,     Top          Cement,
        materials     sand,       agricultur   sand,
                      flyash,     al soil,     aggregate
                      foaming     energy
                      compoun
                      d
2       Production    Ordinary    Specially    Mobile/St
        process       concrete    erected or   ationary
                      mixer ,     central      plant
                      foaming     brick
                      generator   kilns
3       Dry density   400-600     1900         1700
        (kg/m3)       800-1000
                      1200-1800
                                                           18
Sl no   Parameters      CLC         Burnt         Concrete
                                    clay          hollow
                                    brick         brick
4       Compressive     5-10        40-125        30-150
        strength        25-35
        (kg/cm2)        125-250
5       Precast block   500 x 250   229 x 114 x   400 x 200
        size            x 100/190   70 mm         x 200 mm
                        mm
6       Cast in place   Any shape Not             Not
                        and size  feasible        feasible
7       Compaction      none        yes           Yes
8       Sound           superior    normal        Better
        insulation
9       Eco             Pollution   Create        No smoke
        friendliness    free        smoke
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APPLICATIONS
 Higher density range:
    density ranges from 1200 to 1800 kg/m3.
    It is utilized for construction of load carrying
  structural elements like walls, suspended floors or
  roof slabs.




     Reinforced CLC Load bearing walls for the 4 storey dwellings -
                                                                      20
                                                             Delhi
 Medium density range:
    Density ranges from 800 to 1000 kg/m3.
    Utilized for making precast blocks for non load
  bearing walling masonry for internal/external walls in
  framed structures.
    They also make it feasible to do dry fixing of door or
  window frames- saves time in fixing and grouting
  holdfasts.




CLC blocks of density 1000kg/m3 used in south towers south of New Delhi.   21
 Lower density range:
  Density ranges from 400-600 kg/m3.
 Ideal for thermal insulation applications.
 Ideal for laying sound insulating layer over
 structural slabs of intermediate floors in high class
 hotels and institutional buildings.




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SOME CLC DEVELOPMENTS IN INDIA

 BEVERLY PARK II                 REGENCY TOWERS




                                                  23
RICHMONDPARK   HAMILTON COURT,DLF
               GURGAON




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CONCLUSION
 Fly ash CLC is a far superior alternative to factory
 made aerated concrete or man made light weight
 aggregate blocks.
 CLC has diverse applications and properties some of
 which cannot be offered by conventional alternatives.
 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 this material in their
 constructions.
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REFERENCES
 Site produced cellular light weight concrete-a boon for
    housing. paper presented at CIDC conference,
    New Delhi sept.2004(by G.B.Singh)
   Relevance of fly ash based CLC for greener buildings and
    environment. paper presented at Architectural Engg.
    Institute of ASCE ,Austin ,Texas, sept 2003(by G.B.Singh)
   Concrete technology.(by M.S.Shetty)
   Basic concrete engineering for builders, vol 1(by Max
    Schwartz)
   Significance of tests and properties of concrete and
    concrete making materials.(by Joseph .F. Lamond and
    J.H. Pielert)
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