High Strength Self-Compacting Foam Concrete

M.A. Sipple1

A mix design and method to manufacture self compacting foamed concrete that
possesses significant compressive strength while still maintaining its light weight
properties has been described. This thesis also intends to correlate the air content of the
concrete with its strength properties. This correlation will be used to control the
creation of a mix design which incorporates modern hyperplastisticiser, fine aggregates,
water, cement, and foam. Different ratios of these materials will be experimentally
tested to determine the flowability, air content, modulus of elasticity, compressive and
tensile strength of each mix design. The intended outcome of this thesis is to produce self
compacting foam concrete that possesses structural qualities.

Contents
High Strength Self-Compacting Foam Concrete ....................................................................................................1
Contents..................................................................................................................................................................1
I. Introduction ....................................................................................................................................................1
II. Superplasticisers.......................................................................................................................................2
III. Viscosity Modifying Admixtures .............................................................................................................3
IV. Materials...................................................................................................................................................3
A. Lime .........................................................................................................................................................3
B. Fly Ash .....................................................................................................................................................3
C. Silica Fume...............................................................................................................................................4
D. Blast Furnace Slag....................................................................................................................................4
V. Foaming Agent.........................................................................................................................................4
VI. Curing.......................................................................................................................................................5
VII. Testing Methods.......................................................................................................................................5
A. Pre Curing Tests .......................................................................................................................................5
B. Post Curing Tests .....................................................................................................................................6
VIII. Review of Previous Mixes .......................................................................................................................8
IX. Updated Mix Design ................................................................................................................................8
X. Summary ..................................................................................................................................................8
References ..............................................................................................................................................................9
Appendices .............................................................................................................................................................9

I. Introduction

S ELF-COMPACTING concrete (SCC) is considered as being a concrete that once poured will compact under
its self-weight with no requirement for vibration. In addition to this, it remains cohesive enough to be
handled without segregation or bleeding. These characteristics allow SCC to completely fill formwork even
when congested with reinforcement (N. Bouzoubaa and M. Lachemi, 2001).

These concretes require a very high slump in order to have these properties. This can be achieved by a
superplasticiser being added into the mix, which increases the chance of segregation. To counter this, the
amount of coarse aggregate is reduced and replaced by fines to increase fluidity as well as improve cohesiveness
and resistance to segregation. An alternative to this is the use of a viscosity-modifying admixture (VMA) to
improve the cohesion of the mixture (Vic Roads, 2006).

Foam concrete is a concrete which in its most basic form consists of cement, water and air pores. The air
pores are usually introduced into the system by separately adding or injecting a foaming agent into the mix
water producing manufactured foam. This foam is then mixed with the cement slurry to create a foamed slurry.

ZACM 4252, Civil Engineering: Project, Thesis & Practical Work Experience.

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 Compressive loads in concrete are transferred through a composite of cement paste matrix and coarse and
fine aggregates. In foam concrete the coarse aggregate of traditional concrete are replaced with foam bubbles of
typically 0.3-0.4mm in diameter. These bubbles create weak points within the concrete matrix and the
compressive loads must be transferred around the bubbles.

Structural concretes possess compressive strength higher than 25 MPa. Foamed concrete is usually lower in
compressive strength than traditional concrete and hence is used in non-structural or light load carrying
applications. Achieving self compaction in foam concrete poses a particular challenge and has not yet been
overcome (R. Jones, et al, 2005).

This project will attempt to (1) establish a method that overcomes the difficulties encountered in creating
self compacting foam concrete and (2) being able to produce such concrete with structural strength that will
allow it to carry structural loads.

The following sections will discuss the ingredients that are essential in the producing of self compacting
concrete and foamed concrete, namely super and hyperplasticisers, viscosity modifying admixtures and foaming
agents. This section will be followed by the methods used to test the different characteristics of concrete.

II. Superplasticisers
New generation superplasticisers are based on modified polycarboxylic ethers (PCE) polymer technology.
These polymers are capable of acting as strong cement dispersants as well as providing excellent workability
retention without segregation. PCE superplasticisers makes improvements to both the dispersion and slump
retention of the concrete even with low water content ratios. For these reasons the new generation
superplasticisers are known as hyperplasticisers (B. D’Souza and K. Fletcher).

The dispersion mechanism of PCE superplasticisers can be explained by two different types of repulsive
forces. They are the electrostatic repulsion and steric hindrance effect due to the trunk polymer. The
electrostatic force due to the adsorption of negative charges from the carboxylic group is relatively small
compared to the steric hindrance. The dispersion of cement particles is due to the polycarboxylate ether pushing
the particles apart, as seen in Figure 1.

The most effective way of using a PCE superplasticiser is combining it with a multi-ion polymer. The PCE
is absorbed by the cement particles and keeps the cement separated due to the above mechanisms. The
unabsorbed multi-ion polymer moves between the cement particles interfering with the cements ability to
flocculate, as illustrated in Figure 2. These admixtures are known as Viscosity Modifying Admixtures (VMA)
and provided specific benefits to self-compacting concrete.

Figure 1: Polycarboxylate ether pushes

cement particles apart. Multi-ion polymers Figure 2: If particles flocculate than the multi-
move between particles reducing friction. ion polymer will interfere.

Studies have shown that PCE admixtures will reduce the risk of shrinkage, creep, required water and setting
times. Whilst at the same time improves the workability, increases early and ultimate compressive strength,
flexural and tensile strength, and adhesion to reinforcement. Due to this, PCE superplasticisers are suitable for
manufacturing workable, cohesive, self-compacting concrete.

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 III. Viscosity Modifying Admixtures
Viscosity modifying admixtures (VMA) are incorporated in the mix design of self compacting concretes in
order to improve the rheology and cohesion of the cementitious paste. Bury and Christensen (2002) have
devided VMA into two different categories, the thickening variety and the binding variety. The first of these
categories thickens the concrete and makes it more cohesive without affecting the fluidity of the fresh concrete
paste. The second category works by binding the water within the fresh concrete mix, as a result increasing the
viscosity of the mix.

An example of a VMA which falls into the second category is a high molecular weight polyelectrolyte with
high affinity to water. The VMA binds itself to water resulting in the increase in the pore water, concurrently
forming a three dimensional network. The combination of the two actions allows the effective control of the
viscosity of the mix and prevents bleeding and segregation, this process is illustrated in Figure 3 (J. Walraven,
2003).

Figure 3: The effect of the viscosity modifying admixture on the concrete.

The ionic interactions caused by the VMA molecules are flexible and can be partially or fully broken down
when a shear force is applied. It is these interactions that result in the homogeneity of the mix and prevents the
segregation of the concrete paste (J. Walraven, 2003).

IV. Materials
Pozzolanic materials are siliceous or siliceous and aluminous materials which by themselves have little to no
cementitious value. However, when water is added the chemicals react to form stable calcium silicates
possessing cementitious properties.

A. Lime
During the processing of limestone a fine powder is produced containing a high concentration of lime.
There are three main ways that lime can be incorporated into the mix design of concrete. All three involve the
incorporating a percentage of lime from 5-35% depending on the type of Portland cement being used (i.e. CEM
I and II).

The properties of concrete made from Portland limestone cement (PLC) are similar to those of traditional
Portland concrete. However, the PLC concrete tends to have a reduction in bleeding. The 28 day compressive
strength of the PLC concrete is slightly less than traditional concrete. Hence more cement would be required to
obtain the same ultimate compressive strength.

The benefit of using limestone fines is associated with the environmental and economic reductions. The use
of lime leads to a reduction in the CO2 emission and reduces the energy consumption in the production of the
concrete.

B. Fly Ash
Fly ash is a byproduct from the exhaust gases of coal-fired power stations. Individual fly ash particles are
very fine and spherical in shape. The majority of particles have a diameter between less than 1µm and 100µm
and the specific surface is usually between 250 and 600m2/kg. The specific surface is high which means the
material is able to react with calcium hydroxide (A.M. Neville, 2005).

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 The most common fly ash is a byproduct from bituminous coal and is known as Class F fly ash. Due to the
high carbon content of fly ash it has the potential to affect the colour of the resulting concrete, it will appear
darker. This will affect the appearance, especially if placed next to existing concrete.

SCC incorporates a large percentage of fine aggregates in the mix to avoid segregation of the fresh mix. The
fineness of fly ash particles is therefore beneficial to a SCC mix as it reduces the chance of segregation. In
addition to this is improves the workability and long term strength of the concrete. Fly ash reduces the quantity
of superplasticiser required to achieve the same slump as a concrete only using cement as a binder (J.M. Khatib,
2008).

C. Silica Fume
Silica fume, also referred to as microsilica or condensed silica fume, is a byproduct of the manufacture of
silicon and ferrosilicon alloys. The gas released in this process is SiO, which oxidizes to form extremely fine
spherical particles of SiO2. Small silica particles are highly reactive and speed up the reaction with calcium
hydroxide produced by the hydration of cement.

The small silica particles are capable of filling the space between particles caused by free water, known as
particle packing. As a consequence the cement will increase in compressive and bond strength. The reduction
in the number and size of capillaries will reduce the permeability of the concrete, in turn increasing its design
life. (A.M. Neville, 2005).

Silica Fume consists of very fine vitreous particles with a surface area ranging from 13,000 to 30,000m2/kg.
Each particle is approximately 100 times smaller than the average cement particle. Due to its extreme fineness
and high silica content, Silica Fume is a highly effective pozzolanic material (Luther 1990).

D. Blast Furnace Slag

Ground granulated blast furnace slag (GGBS) is a byproduct in the manufacture of pig iron. For every one
tonne of pig iron produced there is approximately 300kg of slag. The slag forms on the surface of the molten
steel and is made up of silicates which are removed, cooled and then finely ground. The slag is made up of the
same chemical components as Portland cement but the ratios of lime, silica, and alumina are not the same. For
this reason the slag can be used to replace up to 85% of the Portland cement in concrete while improving its
characteristics (A.M. Neville, 2005).

The benefits associated with replacing Portland cement with a percentage of GGBS include an increase in
the workability, higher ultimate compressive strength, lower early age temperature, and longer durability. In
addition to this the environmental benefits of incorporating GGBS include a decrease in the emission of CO2,
NOx and SO2 into the atmosphere (R.N. Swamy, 1983).

V. Foaming Agent
Air entrainment is the process whereby many small bubbles are incorporated into a mix, in this case through
a foaming agent. These bubbles become a part of the cement matrix which binds and hardens the concrete.
These bubbles are dispersed, preferably uniformly, throughout the concrete slurry but, by definition, are not a
part of the paste (V.S Ramachandran, 1984).

To be classified as a foamed concrete the air content of the concrete must be greater than 25 per cent. Air
can be introduced into the concrete mix to form a foamed slurry by using two principal methods. The first being
pre-formed foam created by a foam generator and injected into the mix with the other constituents in a normal
mixer. The second method involves a foam producing admixture being added to the other constituents in a high
shear mixer (J.Newman and B.S. Choo, 2003).

In both these methods the foam must have ‘walls’ that remain stable during mixing, transporting (which
could include pumping) and placement of the fresh concrete. These methods should result in bubbles in the
hardened concrete between 0.1 and 1mm in diameter. The foaming agent produces discrete, nearly spherical
bubbles within the foamed slurry so that there are no channels for the flow of water, reducing permeability.

The requirements of foam within a concrete are that it quickly produces stable bubbles in a uniform
distribution through the fresh mix. In addition, the foam must not contain any chemicals which will have a
harmful chemical effect on the cement (A.M. Neville, 2005).

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 VI. Curing
In order to develop optimum concrete properties the concrete must be properly cured, as it takes time for
concrete to gain strength. Curing supplies a constant supply of moisture to the concrete to ensure that hydration
is sufficient to cause the chemical reaction of the cement, resulting in the concrete reaching design strengths. It
is desired but not essential to this work to steam cure concrete at elevated temperatures.

Steam curing with elevated temperatures at atmospheric pressure increases the rate of strength development
in concrete. Maximum curing temperatures should range between 40 to 100°C and for this work the optimum
temperature will be taken as 90°C. Analysis by S. Mindess and J.F. Young (1981) illustrates that lower curing
temperatures result in concrete achieving higher ultimate strengths. Curing at elevated temperatures requires a
controlled heating and cooling period of the concrete. The concrete should be allowed to undergo initial
hydration at room temperature to improve its stability.

For these reasons, in this work the freshly formed concrete elements will be left in normal curing condition
for the first 2 days followed but 1 day in a steamed oven at 90°C. For the remaining 25 days it will be returned
to normal curing conditions before testing.

VII. Testing Methods

A. Pre Curing Tests

1. Slump
The slump test is conducted to determine the workability of the fresh
concrete. Depending on the application of the concrete different slumps
will be desired, for a SCC a slump of 500 to 700mm is required (N.
Bouzoubaa and M. Lachemi, 2001). This slump will assist the concrete
to level under its self weight and flow around obstructions.

AS1012.3.1 outlines the procedure that should be followed whilst

conducting the slump test. For concretes that are prepared in the
laboratory the test will be commenced in accordance with AS1012.2, as
seen in Appendix B.

At the start of this test the mould needs to be clean and free from
dried concrete. The mould, shown in Figure 4, must be placed on a
horizontal surface free from vibration and held in place by standing on
the foot pieces. The mould is filled in three equal proportions, rod each
layer 25 times to the depth of that layer. Once the concrete is level with
the top of the surface lift the mould vertically to let the concrete subside.
Figure 4: Typical mould for the Ensure the time it takes to lift the mould its own height is 3 ± 1 second,
slump test. without causing any lateral or torsional displacement of the concrete.
Immediately measure the average height of the top surface of the
collapsed concrete and calculate the difference compared to the height of the mould (300mm). This difference
in these two values is known as the slump and for SCC it should be between 500 and 700mm (N. Bouzoubaa
and M. Lachemi, 2001). For slumps greater than 100mm the measurement is taken to the nearest 10mm.

2. L-Box
The L-Box test is used to determine the flowability of the freshly
mixed concrete in order to verify whether or not the concrete is self
compacting.

The L-Box, shown in Figure 5, consists of a ‘chimney’ section and a

‘channel section which is separated by a sliding gate, as illustrated in
Figure 5. In addition, there are three reinforcement bars located in the
channel which are designed to impede the flow of the concrete into the
channel, as seen in Figure 6 (T.L.H. Nguyen, et al, 2006).

In order to conduct the test all sides that will be in contact with the
concrete should be dampened. Ensure that the sliding gate is completely
Figure 5: Typical dimensions for closed to ensure that there is no premature flow into the channel. The
an L-box Test. chimney is then filled to the top with the fresh concrete and the surface is

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 leveled. The sliding gate is then raised at a constant rate of
1.5cm/sec. The concrete flows from the chimney into the channel
through the reinforcement bars. This is allowed to occur until the
concrete has ceased to flow or one minute has passed, which ever
occurs first.

Once the test has been completed the two required

measurements are the height of the concrete in the chimney (h1) and
the height of the concrete at the opposite end of the channel (h2).

The L-Box ratio equals h2/h1, a ratio of one means the concrete
has self leveled and a ratio of zero means the concrete has not
reached the far wall of the channel. For a concrete to be considered Figure 6: Dimensions of reinforcement
self compacting the ratio of h2/h1 must be between 0.6 and 1. bars in the L-box test.

3. Air Content

AS1012.4.1 details the procedure for determining the air

content of freshly mixed concrete. This method observes the
change in volume of the concrete once it has been subject to an
increase in air pressure.

This test should be conducted at the time specified by AS

1012.2, using the apparatus shown in Figure 7. Firstly, the
temperature of the concrete should be measured and recorded.
Figure 7: Apparatus used in determining The bowl should be filled with three equal layers of concrete. In
air content. order to prevent segregation use hand compaction on mixes with a
slump greater than 50mm.

Once the bowl has been filled the conical cover assembly is to be attached and then filled with water. The
test pressure is then applied and the height of the water (h1) is recorded. The air pressure is released gradually
though a vent at the top of the apparatus and the new water level (h2) is recorded. The apparent air pressure
content (A1) is equal to h1 – h2.

Air content is then calculated using the following equation:

A = A1 – G Where: A = air content, % by volume of concrete

A1 = apparent air content, % by volume of concrete (Clause 7 of AS1012.4)
G = aggregate correction factor, % by volume of concrete (Clause 9 of AS1012.4)

B. Post Curing Tests

1. Compression Test
In accordance with AS1012.9.5, the surfaces of test samples which are to come in contact with the loading
device platens are to be plane within 0.05 mm tolerance level. Otherwise, the surfaces of the test samples have
to be capped. As seen in Table 1, for our target strength of ≤ 50 MPa the cap would be required to age for at
least 1 hr before the test sample is allowed to undergo compressive testing.

Table 1: Capping methods in accordance with AS1012.9

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 Before conducting the compressive test two measurements of the concrete cylinders should be conducted.
The measurements should be taken at 90 degrees to each other and be rounded to the nearest 0.2mm. Ensure
that the platens of the testing machine are clean and wiped free from any small particles. The surfaces of the
specimens to be tested should also be wiped clean ensuring that they are free from any lubricants. Place the
specimen in the testing machine ensuring that its axis is aligned with the centre of thrust of the spherically
seated platen. Bring the upper platen and the capped specimen together so that uniform bearing is obtained and
being to apply a force. The force should be increased continuously at a rate equivalent to 20 ± 2 MPa
compressive stress per minute until no increase in force can be sustained. Record the maximum force applied to
the specimen as indicated by the testing machine.

The maximum force recorded on the specimen can be used to calculate the compressive strength of the
concrete. The maximum force divided by the average cross sectional area will result in the compressive
strength of the material.

For an accurate result for the compressive strength of a material a minimum of 3 test samples are required.
These specimens should be produced in a single mix, exposed to the same curing conditions and tested after 28
days. The compressive strength is calculated to the nearest 0.5 MPa where the strength is above 10 MPa. The
average of these three specimens will produce a compressive strength of the material with a probability that
95% will be within 10% of this mean.

2. Tensile Test
AS1012.10.6 details the procedure for determining the tensile strength of the
hardened concrete. Figure 8 shows the apparatus used to determine the maximum
tensile strength.

Prior to conducting the tensile test three measurements of the specimens diameter
need to be recorded to the nearest 0.2mm. In addition to this, the length of the
specimen to the nearest millimeter should be taken from two measurements. These
length measurements should be taken on the two lengths that will come in contact
with the tensile machine.
Figure 8: Tensile Test
Centre the specimen on the apparatus and lower the upper platen to apply a small
apparatus.
force on the specimen. Apply a force that will increase continuously at a steady rate
of 1.5 ± 0.15 MPa per minute of indirect tensile stress until the specimen can now longer sustain the load.
Record the maximum amount of force applied to the specimen.

In accordance with AS1012.10.6, we can calculate the indirect tensile strength by using the following
equation:

2000 P Where: T = indirect tensile strength (MPa)

T P = maximum applied force (kN)
LD L = length (mm)
D = diameter (mm)

In order to obtain an accurate measurement of the tensile strength of the material a minimum of two test
samples are required. These specimens should be produced in a single mix, exposed to the same curing
conditions and tested after 28 days. Indirect tensile strength is calculated to the nearest 0.1 MPa. The average
of these two specimens will produce a tensile strength of the material with a probability that 95% will be within
14% of this mean.

3. Modulus of Elasticity
From the compressive strength testing of the cylinders the modulus of elasticity
can be determined experimentally. In accordance with AS1012.17, 40% of the
average compressive loading determined in the compressive testing will be used as
the maximum test load for the samples. This is to ensure that loading is clear of the
plastic deformation zone.

The test sample will be fitted with a strain gauge reading apparatus, as shown in
Figure 9, before it is test loaded.
Figure 9: device used to measure
the Modulus of Elasticity
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 The modulus of elasticity can be calculated by using the following equation:

G2  G1
E
 2  0.00005

where G1 = applied load at strain 50 x 10-6 divided by the cross sectional area of the unloaded test samples
(MPa).
G2 = test load divided by the cross sectional area of the unloaded test samples (MPa).
ε2 = deformation at test load divided by the gauge length (10-6 m/m).

VIII. Review of Previous Mixes

Foam concrete consists of cement, water, foam, and various fillers. All materials that have fineness between
cement and sand can be incorporated into a foam concrete mix as filler. Examples of such materials are fly ash,
silica fume and granulated blast furnace slag (J.M. Khatib, 2008).

Studies have been preformed and concluded that the mix design of high strength foam concrete should
incorporate only fine fillers. This means that sand with a maximum grain size of 1mm will produce a higher
strength foam concrete than sand with a maximum grain size of 4mm. The minimum amount of concrete will
vary depending on the filler fineness but should not be lower then 150kg/m3 (L. Cox and S. van Dijk, 2002).

Table 2: Possible foam concrete mixes

It can be seen that cement content has significantly influenced the value of compressive strength. However,
the percentage of the foam in the mix design has also had a remarkable effect. It is evident by the 28-day
strength that foam concrete has a lower compressive strength compared to traditional concrete.

IX. Updated Mix Design

In order to develop a new mix design for self compacting foamed concrete there are several experiments
required to determine the properties of the materials to be used within the mix. The properties that are required
to start a mix design include the fineness modulus from a sieve analysis, moisture content of the fine aggregate,
particle density, and water absorption capacity. Due to the fineness of the aggregates being used in the mix
design traditional methods for determining these values cannot be used. Therefore, geotechnical engineering
testing methods will have to be incorporated so that results can be obtained.

Once these values have been obtained a mix design can commence. Alterations to the traditional mix design
procedure will be required to account for the large amount of fines, addition of foam, requirement for high
slump and flowability, and high compressive strength.

Once a mix design has been developed it will be tested experimentally and alterations will be made to the
mix design in order to develop a self compacting foamed concrete that can support structural loads. There is
also the possibility that the inclusion of glass fibers or steel fibers will be explored in order to achieve structural
capacity. Experiments will continue until the desired properties of the concrete are reached.

X. Summary
The different admixtures of a concrete mix design and the testing methods of the concrete properties have
been described. These admixtures will be selected in different proportions in the mix design in order to develop
a self compacting foamed concrete with an increased compressive strength. To ensure that the new mix design

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is capable of supporting structural loads the tests detailed above will be perform in order to prove the properties
of the concrete.

This thesis intends to expand on previous traditional mix designs in order to create a self compacting foamed
concrete that is capable of supporting structural loads. The design will aim to enhance the mechanical
properties and workability of the foamed concrete whilst still maintaining its light weight properties.

At the end of this thesis work, the author hopes to achieve an adequate understanding of interactions
between the different admixtures within the concrete mix. The knowledge acquired will facilitate the
improvement of the mix design so that potentially the self compacting foamed concrete will support structural
loads.

References
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Slump test, 1998.
Australian Standards Committee, AS1012.4.1, Determination of air content of freshly mixed concrete— Measuring
reduction in concrete volume with increased air pressure, 1999.
Australian Standards Committee, AS1012.9, Determination of the compressive strength of concrete specimens,
1999.
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splitting test), 2000.
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Appendices
A. Project Management
B. AS1012.2 – Mixing Procedure

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