TRL - Foamed Concrete Spec

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Specification for foamed concrete

Prepared for Quality Services, Civil Engineering,
Highways Agency
K C Brady, G R A Watts and M R Jones
Application Guide AG39

First Published 2001
ISSN 1365-6929
Copyright TRL Limited 2001.
This report has been produced by TRL Limited, underlas part

of a Contract placed by the Highways Agency. Any views
expressed are not necessarily those of the Agency.
T U is committed to optimising energy efficiency, reducing

waste and promoting recycling and re-use. In support of these
environmental goals, this report has been printed on recycled
paper, comprising 100% post-consumer waste, manufactured
using a TCF (totally chlorine free) process.
I
CONTENTS
Page
EXECUTIVE SUMMARY 1
ABSTRACT 2
1 INTRODUCTlON 3
2 FOAMED CONCRETE
2. I Definition, coiistitueiits and properties
2.2 History and background

2.3 Current usage
3 QUALITY CONTROL 6
3.1 Foam density and stability 7
I
3.2 Plastic density 7
3.3 Workability 7
3.4 Segregation 10
3.5 Cube strength 10
3 .G Soundness 10
4 SPECIFICATION 10
4.1 Documentation 11
4.2 Requirements 12
4.2.1 Essential iterns 12
4.2.2 Optional iteiiis 13
5 ACCEPTANCE CRITERlA 14
6 NON-CONFORMITY 15
7 SUMMARY 15
8 REFERENCES 16
I
APPENDIX A: GLOSSARY OF TERMS A- I
APPENDIX B: GUIDE FOR SPECIFICATION AND

QUALlTY CONTROL OF FOAMED
CONCRETE A-2
APPENDIX C: FOAMED CONCRETE A-3
...
111
Specification for foatiied concrete
EXECUTIVE SUMMARY
Despite the now relatively coninion use of foamed concrete as backfill to trench excavations, there is little published material
regarding its properties - in particular its long-term perfomiance and durability. This paucity of data may be restricting the
wider use of foamed concrete for ground engineering and structural applications.
The aim of this project is to address this lack of infonnation and to provide advice on the potential use and specification of
foamed concrete as backfill to substructures.
This rcport describes the nature of foamed concrete, its composition and properties and how it could be specified for use
in civil engineering works. Because the properties of foamed concrete can vary widely, and it can be used in a wide variety
of applications, it is important to define performance requirements for each case.
Current usage in the UK of foamed concrete is ofthe order of250,OOO tonnes per year. Despite this fairly significant tonnage
there is, as yet, no definitive guidance on how the material should be tested and specified for use. Furthermore there is a
paucity of infonnation on some of its properties, particularly regarding its long-term perfomiance. This situation might be
restricting the wider use of foamed concrete for ground engineering and structural applications. ~
The report provides a brief history of the development of foamed concrete and gives examples of contemporary uses. The
quality control tests that might be applied to foamed concrete are described; some of these differ from those used for normal
weight concrete. An example specification for foamed concrete is provided, which includes both mandatory and optional
requirements. Distinction is made between clauses for use with all applications and those required for specific applications.
Guidance on acceptance criteria and actions to be taken in the event of non-conformance is also provided.
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Specification f o r foamed concrete
ABSTRACT
Foamed concrete has unique characteristics that can be exploited in civil engineering works. It requires no compaction, but
will flow readily from an outlet to fill restricted and irregular cavities, and it can be pumped over significant distances and
heights. Thus it could be thought ofas a fi-ee-flowing, self-setting fill. This report provides a conspectus of foamed concrete:
covering its constituents, production, engineering properties and use.
Foamed concrete is simple to produce but, at present, there is a need to provide close control during its production and on-
site supervision during its placement and curing. The need for such special requirements will reduce as industry becomes
more familiar with the character and behaviour ofthe material. However, within the UK, there are no national specifications
for foamed concrete nor standard tests for measuring its workability, strength or other basic engineering properties.
Guidance on the specification and use of foamed concrete is provided in the report.
Research is still required on some aspects of the properties of foamed concrete - for example there is little published data
on its long-term properties. It seems likely that the increasing use of foamed concrete will lead to a better understanding of
its characteristics, and thus to improvements in methods of testing, specification and perhaps allso in its engineering
properties.
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1 INTRODUCTION
This report describes the nature of foamed concrete, its composition and properties and how it could be specified for use
in civil engineering works. Because the properties of foamed concrete can vary widely, and it can be used in a wide variety
of applications, it is hiportant to define performance requirements for each case.
Current usage in the UK of foamed concrete is of the order of 250,000 tonnes per year, see Pickford and Crompton (1996).
Despite this fairly significant tonnage there is, as yet, no definitive guidance on how the material should be tested and
specified for use. Furthermore there is a paucity of information on some of its properties, particularly regarding its long-
term performance. This situation might be restricting the wider use offoamed concrete for ground engineeringand structural
applications.
The report provides a brief history of the development of foamed concrete and gives examples of contemporary uses. The
quality control tests that might be applied to foamed concrete are described; some ofthese differ from those used for normal
weight concrete. An example specification for foanied concrete is provided, which includes both mandatory and optional
requirements. Distinction is made between clauses for use with all applications and those required for specific applications.
Guidance on acceptance criteria and actions to be taken in the event of non-confomiance is also provided.
The work described herein fomis part of a research project undertaken by TRL Limited, on behalf of the Highways Agency
(HA), aimed at addressing the shortfall in infomiation and thereby promoting the wider and proper use of foamed concrete.
Assistance in this project has been provided by the University of Dundee, British Cement Association (BCA) and Taywood
Engineering Ltd (TEL) acting under contract to the TRL.
This is the final report of this project; previous reports have addressed:
i materials, methods of production and applications of foamed concrete, Brady and Greene (1997);
ii use of foamed concrete as a backfill to retaining structures, Watts and Brady (1 999);
...
111 performance df a masonry arch bridge with a foamed concrete backfill, Watts (2000); and
iv properties of foamed concrete, Brady (2000).
A glossary of teniis is provided in Appendix A. A check list for the specification of foamed concrete is provided in Appendix B,
and details of its production, engineering properties and applications are provided in Appendix C.
2 FOAMED CONCRETE
2.1 DEFINITION, CONSTITUENTS AND PROPERTIES

Foamed concrete has been defined in several ways; indeed it has a number of synonyms - such as cellular concrete and
foamcrete and there is confusion in the early literature between foamed concrete and similar materials such as air entrained
concrete. A definition, cited by Van Deijk (1991). is that foamed concrete is a cenientitious material having a minimum of
20 per cent (by volume) of mechanically entrained foam in the plastic mortar. This differentiates foamed concrete from (a)
gas or aerated concrete, where the bubbles are chemically formed through the reaction of aluminium powder with calcium
hydroxide and other alkalis released by cement hydration, and (b) air entrained concrete, which has a much lower volume
of entrained air.
For most common uses, the air content is typically between 40 and 80 per cent of the total volume. The bubbles vary in size
from around 0.1 to 1.5 nun in diameter but coalescence might produce voids considerably larger than this, particularly at
the top of pours. The'typical appearance of foamed concrete can be seen in Figure 1.
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Figure 1 Typical nature of foamed concrete
Foamed concrete requires no compaction, and will flow readily from a pump outlet to fill restricted and irregular cavities:
it can be pumped successfully over significant heights and distances. The 28-day strength and dry density of the material
vary according to its composition, largely its air voids content, but usually they range from 1 to 10 N / m 2 and from 400
to 1600 kg/m3respectively: lower strengths are associated with lower densities. The most commonly specified strength is
4 Nlmm’. (Strengths of up to 40 N/mm2 have been produced, but so far this has been limited to laboratory-based research
work.) The plastic density of the material is about 150 to 200 kg/m3higher than its dry density, depending on curing regime
and specimen treatment.
Ordinary Portland cement (PC), to BS 12: 1996, is normally used as the binder, but other types of cement could be used.
Commonly, pulverized-fuel ash (PFA) is used as a partial replacement for PC or as a filler to partiallyior fully replace sand.
A fine sand, such as that conforming to BS 1200:1976, is normally used as bulk filler but sand to BS 882: 1992 can also be
used. Subject to limitations on grading, waste materials such as granite dust and single-sized tailings can also be used. Small
percentages ofcoarse aggregate, up to 14 mm in size, can also be added to increase the stiffness of the concrete. Admixtures
have been used to increase the rate of strength gain, particularly for highway trench reinstatement.
Foam is produced using specialised equipment, as shown in Figures 2 and 3. The type varies according to the volume of
the mix and required properties of the foam: further details are provided in Appendix C.
2.2 HISTORY AND BACKGROUND

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 (19881, in 1924 Linde described
its production, properties and applications. The application of foamed concrete for construction worlts was not recognised
until the late 1970s, when it began to be used in the Netherlands for filling voids and for ground engineering applications.
Significant improvements in production methods and the quality of foaming agents over the last 15 years have led to
increased production and broadening of the range of applications. An extensive research programme carried out in Holland
helped promote foamed concrete as a building material, see Van Deijk (199 L).
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Figure 2 Small-scale laboratory foam production and typical nature of foam
Figure 3 Large-scale on-site foam production
111 1987, in response t? the publication of the Home Report in 1985, a full-scale trial ofthe use of foamed concrete for trench
reinstatement was undertaken in the UK, details of which have been provided by Taylor (1990). The success of this trial
led to the widespread use of foamed concrete for trench reinstatements in the UK, and other applications followed. The
Highways Authorities and Utilities Conunittee’s (HAUC) ‘Specification for the Reinstatement of Openings in Highways’
( I 992) recommended the use of foamed concrete within the New Road and Street Works Act (1 991). Foamed concrete was
promoted as a replacement to granular fill for highway reinstatement works because of its following advantages:
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i Ease of application and re-excavation (if necessary).

ii Elimination of compaction plant.
iii Low in-service settlement.
iv Load-distribution properties.
2.3 CURRENT USAGE

Over the past ten years or so, foamed concrete has been used on a large scale in the UK for bulk filling, trench reinstatements
and a variety of other applications: the following is not an exhaustive list:
i Bulk filling, using relatively low strength material, for redundant sewerage pipes, wells, disused cellars and
basements, storage tanks, tunnels and subways etc.
11 Highway trench reinstatement (although it should be noted that controlled low strength mortar is increasingly being
used because it is easier to produce by ready-mixed concrete producers). I
...
111 Infill to the spandrel walls of arch bridges.
iv Backfill to retaining walls and bridge abutments.
V Stabilising soils, for example in the construction of embankment slopes.
v1 Various industrial applications and for domestic housing, iricluding as insulation to foundations and roof tiles,
blinding layers, cast in-situ piles, fire protection and high frequency sound insulation.
vii Sandwich fill for precast units.
viii Grouting for tunnel works.
3 QUALITY CONTROL
This sectioncovers the tests that may be specifiedin the production of foamed concrete: it includesthose that should be undertaken
by the supplier and those that might be by the Contractor or Client’s representative. Foamed concrete should be sampled in
accordance with the draft BS EN 12350: Part 1: 2000. The most commonly used tests are listed and described as follows:
Test carried out Tested by
Quality control test Atpoint CfdeZivety Laboratory Contractor Supplier
Foam: density J J 0 J
Foam: stability x J x I J
Fresh concrete: plastic density J x J J
Fresh concrete: workability of

base mix and/or foamed concrete 0 J 0 J
(several methods available)
Fresh concrete: segregation Y J J X
Hardened concrete: cube strength x J J J
Hardened concrete: soundness J x J X
J Recommended for most uses and sites

X Not usually recommended, or impractical
0 Might be useful for some particular applications or sites
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Specificatiori f o r foarrred corrcrete
3.1 FOAM DENSITY AND STABILITY

The properties of foamed concrete are critically dependent upon the quality of the foam. Measurements of foam density
should be taken as a matter of routine because density can vary according to the volume of the surfactant solution in the
containment vessel and also with the time of storage. Furthennore the level of expansion of the surfactant solution to foam
varies according to the type and details of the equipment, such as the type of the foaming gun, and with the valve settings
controlling the flow and feed pressure of the surfactant and air.
The density of a foam can be determined, quite simply, through weighing a known volume of foam -for example using a
glass measuring cylinder, as shown in Figure 4.
Foam stability can be quantified by measuringthe volume of foam which has collapsed into solution atregular t h e intervals,
as described in Section C1.2.2.
Figure 4 Use of glass measuring cyclinder for detemiining density of foam
3.2 PLASTIC DENSITY

The plastic density of the base mix and the foamed concrete mix can be determined simply from the weight ofa sample
in a container of known volume, of say 5 litres or so as shown in Figure 5. The method is described in BS EN 12350:
Part 6: 2000.
3.3 WORKABILITY
According to McGovem (2000), for most applications the slump of the base mix should be between about 75 and 100 mm.
I
The workability of the base mix could be assessed using a test developed for low-strength materials. As described by Brewer
(1996), workability can be quantified by the ‘spreadability’ of a 76.2 mm ( 3 inch) diameter, 152.4 mm (6 inch) long cylinder
of material as shown schematically in Figure 6. This could also be used to assess the workability of the foamed concrete mix.
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Workability or ‘flowability’ can also be assessed from the efflux time o f a litre sample through a modified Marsh cone: the
apparatus is shown in Figure 7.
From the tests on spreadability and flowability, an empirical flow classification was derived by Dhir et al. (1999), and this
is reproduced in Table 1.
Figure 5 Measurement of the plastic density of foamed concrete
(76.2mm) 3”
-i----t
t
I Spread
Figure 6 Test for the spreadability of the base mix and foamed concrete, from Brewer (1996)
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Specificatioti for foattred coticrete
, 152mm ,
I I 1.5 litre sample poured
+/
1.0 litre
Figure 7 Flow cone method for measuring the workability of foamed concrete, as used at Dundee University
Table 1 Classification of the workability of foamed concrete, from Dhir et al. (1999)
~ ~~~ ~~~ ~~~ ~~ ~~
Flow rate. using apparatus

Mairi class s h o w iri Figure 7 Sub -class Descriptiori offlow
1 1 litre in < 1 minute A+ Constant flow

2 1 litre in > 1 minute B+ Interrupted flow
3 0.5 litres < efflux < 1 litre C Completion of flow after gentle tamping
4 Efflux < 0.5 litres
5 No flow
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3.4 SEGREGATION
Segregation of foamed concrete in the fresh state can be detected through foam rising to the surface of the mix (noticeable
in a ready-mix truck or in recently poured concrete), or by the fomiation of a separate paste/sand mortar at the bottom of
the mixer (noticeable when mixing).
Segregation can be quantified through differences in the density of cores of hardened concrete taken from various depths,
or, as proposed by Dhir et al. (1999), by comparison of the oven-dry densities of 100 mm diameter, 25 mm thick slices
obtained from the top and bottom of a core.
I
3.5 CUBE STRENGTH
Compressive strength can be measured at 28 and/or 56 days essentially in accordance with BS 1881: Part 116: 1953. But,
because the strength of foamed concrete is relatively low, 150 mm cubes might be required to ensure reasonably accurate
measurements. Disposable polystyrene moulds are widely used for foamed concrete: these can be supplied with lids so that
a specimen can be left in the mould until immediately prior to testing. Steel moulds can be used but they should be lined
with anon-stick plastic film. Mould release oil should not be allowed to come into contact with the foamed concrete because
it can affect the properties of the concrete.
The specimens should be covered and, ideally, left undisturbed for least 3 days to prevent damage by movement and de-
moulding. After demoulding the cubes should be immediately wrapped in an air and watertight film (‘cling film’) and stored
at 20 2°C in plastic bags (i.e. sealed curing).
3.6 SOUNDNESS
The ‘soundness’ or ‘hardness’ of the surface of foamed concrete can be used to assess whether it has developed sufficient
strength to allow additional lifts to be poured, or further site works to commence. The screed tester developed by the Building
Research Establishment (BRE), and as shown in Figure 8, can be used to assess the ‘soundness’ of a surface. The rig
comprises a weight that slides along a bar and which is allowed to fall freely onto an expansion ring connected to a 6 mni
diameter pin. In testing foamed concrete the penetration of a single drop of the weight should be measured (multiple drops
are normally used with other materials).
4 SPECIFICATION
At present in the UK there are no standard specifications for foamed concrete. Basic requirements for its use for trench
reinstatement exist (as for example in the New Road and Street Works Act, 1991) but these are not necessarily satisfactory
for other applications.
It is recommended that the basic methods, clauses and fomiat of the draft BS 8500: 2000 and BS 5328 (various parts and
dates) are followed when specifying foamed concrete; but it is not possible to adopt all the clauses given in Parts I and 2
of the latter. The fundamental problem is that the requirements for coarse agfgegate and a minimum strength of 7.5 N/mm2
preclude the use of foamed concrete: the problem will persist with the replacement of those parts of BS 5328 by BS EN 206:
Part 1 and BS 8500 respectively.
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I
Specification for foanied coircrete
i
Figure 8 View of BRE screed tester
4.1 DOCUMENTATION
Quulity ussurutice
A producer must hold current product conformity certification, based on testing and surveillance, coupled with approval
of their quality system to BS EN I S 0 9001 : 1994 by a certification body accredited by the Secretary of State (or equivalent).
This requires that the technical regulations ofthe accredited certification body are available for examination. It also requires
the producer to inform the purchaser of the status of the concrete plant at the time of tender, and immediately where there
is any change of status in the period between the time of tender and completion of supply.
,sU/ll/l/;ll&! /lOiI?t
Samples of foamed concrete, required for continuous monitoring of production, are required to be taken at the point of
discharge.
Acceptatice testing
Acceptance testing by the purchaser is not normally necessary, but purchasers retain the right to carry out such testing.
Sampling, specimen making, curing and testing of fresh concrete shall be certified as conforming to the appropriate part of
the spccification. Tests for cube strength shall be certified as conforming to the specification and shall be carried out by a
laboratory accredited for the test by the United Kingdom Accreditation Service (UKAS).
11
Delivery note
Before discharging a batch of foamed concrete at the point of delivery, the supplier is required to provide the purchaser with
a delivery ticket forthe batch, on which is printed, stamped or written the information specified in Section 4.10.4 of BS 5328:
Part 3: 1990.
4.2 REQUIREMENTS
Foamed concrete should be specified as a designed mix. Carbon steel reinforcement should not be used in foamed concrete,
except where corrosion is precluded, or its effects are of no consequence. The specification for foamed concrete should
conform to Parts 1 and 2 of BS 5328: 1997, except as defined herein or as agreed by all parties. ,
4.2.1 Essential items
Identification
The producer shall provide the information as defined in BS 5328: Part 3: 1990.
Permitted materials
Permitted cements should conform to the British Standards listed in 'Table 2: this is based on Table 1 of BS 5328: Part 1
1997, but note that cements containing slag should not be used unless the results of mixing trials are satisfactory.
Table 2 Types of cements suitable for production of foamed concrete, based on Table 1 of BS 5328: Part 1: 1997
Type of binderf Standard
Portland cements
Portland (PC) BS 12: 1996
Sulfate-resisting (SRPC) BS4027: 1996
Cements containing pulveriserI-fird ash (PFA) or limestone I

Portland pulverised-fuel ash BS 6588: 1996
Pozzolanic pulverised-fuel ash BS 6610: 1991
Portland limestone BS 7583: 1996
Combinations made irp in a concrete mker Combiiiatiori of the proportions mid properties to
from Portland cement and PFA conform to Claims 6 to 9 ojl
PC conforming to BS 12: 1996 with BS 6588: 1996 (except Clause 63)
PFA conforming to BS 3892: Part 1: 1997 BS 6610: 1996 (except Clause 6.2)
Precluding cements containing slag.

' The notes to Table 1 in BS 5328: Part 1: 1997 also apply in this case.
Permitted fine aggregates should conform to the British Standards listed in Table 3: this is based on Table 2 of BS 5328:
Part 1: 1997. Some of the engineering properties of foamed concrete may be improved by the inclusion of a coarse
lightweight aggregate but, because little data are available, it cannot be recommended for unrestricted use at this stage. Some
data have, however, been provided by Regan and Arasteh (1984).
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Spccijicatioii for foamed coiicrete
Table 3 Aggregates f o r general use, based on Table 2 of BS 5328: P a r t 1: 1997
T1ye Desigtiatioti Staizdard
Lightweight Lightweight aggregates for concrete BS 3797: 1990
Nonnal weight Sand from natural sources for concrete BS 882: 1992
Building sand from natural sources BS 1200: 1976
Plastic rieiisity
The plastic density of each batch (of say 6 to 8 11-19 of foamed concrete should be measured, at the point of delivery or
discharge.
Clrbe .~treilgtk
Three cube specimens (preferably 150 m m in size) should be taken for every 50 in3of foamed concrete placed.
Pour depth
To prevent undue settlement due to the collapse of the bubble structure, normally the maximum pour depth should not be
greater than 1.5 in within any 16-hour period. Although greater depths and more frequent pours can be placed, the self-
weight of the concrete will increase its plastic density: thus where this is done it might be necessary to reduce the specified
plastic density by 100 to 200 k g h 3 to offset any such increase. Further lifts or other site works may recommence after 16
hours or so when a compressive strengh of at least 1 N/nnn2 has been achieved, or when the soundness indentation of the
material is less than 5 mm, in accordance with the method described in Section 3.5.
4.2.2 Optional items

The following might be requested for a particular end-use or site.
Workabil it)J
Workability can be detennined using either ofthe methods described in Section 3.2. Each batch, of say 6 to 8 m3,could be
checked where necessary.
Mu-viiizrrnz cirOe strength
Whcre required, a maximum acceptable characteristic cube strength should be specified: this should be agreed with the
supplier.
Resistmice to segregutioii
Segregation can be assessed in accordance with the method described in Section 3.3.
Durability
Foained concrete is not nonnally considered to require specification clauses for resistance to frost attack. Where specific
resistance to sulfate and/or acid attack is required, the appropriate type of cement used should be as specified in Table 7 of
BS 5328: Part 1: 1997. It might be prudent to undertake trials to c o n f i i the durability ofthe material in a particularly severe
environment .
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Sustained core temperature
Where considered necessary, for example to minimise the risk of thermal cracking and delayed ettringite fomiation
(DEF)', the sustained core temperature of a pour could be restricted to less than 65 "C for 12 hours or 100 "C for 3 hours,
see Lawrence (1993).
Soundness
A minimum value of soundness or hardness, as determined from the test described in Section 3.5, might be specified to
ensure that an adequate set has been achieved prior to the placement of overlapping pours.
5 ACCEPTANCE CRITERIA
Density
In most cases the acceptable tolerance for plastic density should be f 50 kg/m3 of the specified density, but this may be
increased to f 100 kg/m3 for particularly dense mixes, i.e. ones having a plastic density in excess of 1600 kg/m3.
The variability of the dry density of the hardened foamed concrete should not exceed f 100 kg/m3 of the mean density.
However such a check would not normally be carried out unless segregation was suspected.
Cube strength
For a particular pour, the mean 28-day strength of all the cubes should be higher than the specified characteristic strength.
Where strength in excess of 10 Nlmm' is required, consideration should be given to specifying the 56-day strength because
this widens the options available to the supplier for the mix design.
Workability
A value of workability could be set as a minimum below which the batch could be rejected because, for example, it might
affect the ability of the concrete to completely fill the void.
Resistance to segregation
The oven-dried density of two 25 mm thick slices taken from towards the top and bottom surfaces of a 100 mm diameter,
300 mm long cylinder, should be less than 50 kg/m3. I
Soundness
The result ofan indent test, undertaken say 24 hours following pouring and using the method described in Section 3.5, should
be less than 5 mm: note however that the timing of the test and the acceptance level can be varied to suit.
I There is no evidence to show that DEF, f i t were to occur, n v d d cause any deterioration nffnnrved concrete: e.Ipansion should he ~ I C ~ ~ I I ~ ~ I I ~ I [ / [ I ~ ~ , ~ ~
within the huhhle structure.
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Specifcatioti for foatrred coricrete
6 NON-CONFORMITY
The purchaser should detennine the action(s) to be taken when the result of a test fails to meet that specified. It might range
from qualified acceptance (in less severe cases) to rejection (and excavation and replacement). In selecting the action to be
taken, due regard should be given to the consequences and degree of non-conformity, and to the economic consequences
of alternative remedial measures. Furthennore, prior to any action, the validity of test results should '
be confirmed by
checking that the sampling and testing have been carried out in accordance with the specification.
The niost conunon non-conformities will be mismatches in strength and plastic density, excessive temperatures during
curing, and segregation of the mix.
I n estimating the quality of substandard foamed concrete and determining the action to be taken, the following should be
asked:
i What performance charactcristics ofthe foamed concrete, such as durability, strength, and insulationproperties, have
been affected adversely?
ii Are other site works likely to be affected by the non-conformity?
The purchaser (and/or the supplier) may wish to carry out tests on the hardened concrete. These might include non-
destructive methods (to BS 1881: Part 201: 1986) or taking cores (to BS 1881: Part 120: 1983). Provided the test data are
valid the results of any further tests do not annul the original non-conformity.
Advice on the interpretation of the results of non-destructive tests and on the strength of cores is given in BS 6089: 1981.
This Standard also lists the issues to be considered when deciding the action to be taken with substandard structural concrete,
and further infomiation on relevant Codes of Practice.
7 SUMMARY
Foanicd concrete is a versatile low-density free-flowing, self-levelling and self-compacting material. It can be pumped both
horizontally and vertically over long distances and large quantities can be placed quickly. In most cases the maximum depth
that can be poured in a single lift is about 1.5 m:the hardeningrate normally allows the concrete to be to be walked on within
24 hours, and for additional lifts of concrete to be poured on top. Considerable quantities of foamed concrete (mainly for
fill) have now been placed in the UK, with few reported problems.
The dry density of foamed concrete is usually between 400 and lGO0 kg/m3 and its compressive strength, which varies with
density, can typically range between 1 N/mni2 and 25 N/mm2 at 28 days. Foamed concrete has a satisfactory resistance to
freezdthaw and sulfate attack (at least in the short term). The penetrability of the material to various gases and liquids is
a function of the constituents and density of the concrete, but it can be dominated by the presence of cracking generated,
for example, during curing. Foamed concrete is, however, reasonably pemieable to water vapour and carbon dioxide (CO,),
and so the use of carbon steel reinforcement should only be considered where the risk of corrosion is precluded or its effects
are of no consequence.
Foamed concrete is not covered specifically in BS 5328 (various parts and dates) and so a specification has to be formulated
for its use. This report highlights the key aspects that must be addressed in drawing up such a specification. It is proposed
that the general requirements for normal weight concrete, as specified in BS 5328, should be adopted for foamed concrete
excepting those for compressive strengh and plastic density. Acceptance criteria have been proposed in the report, but it
is recogiised that these may be adjusted as more feedback from practice is gained.
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8 REFERENCES
Arasteh A R (1988). Structural application of liglzhrviglzt aggregate foanzed concrete. PhD theseis. London:
Polytechnic of Central London.
Brady K C and Greene M J (1997). Foamed concrete: a review ofniaterials, methods ~fproduc~iotz and
applications. Project Report PR/CE/149/97. Crowthorne: TRL Limited. (Unpublished report available on direct
personal application only)
Brady K C (2000). An investigation into the properties of foamed concrrte. Project Report PR/IS/99/00.
Crowthome: TRL Limited. (Unpuhlished report available on direci personal application onlv)
Brewer W E (1996). Controlled IOW strength materials (CLSM) Radical concrete technologq~.(Eds Dhir R K and
P C Hewlett). London: E & F N Spon. pp 655-667.
British Standards Institution. London.
BS 12: 1996 Specification for Portland cement.

BS 882: 1992 Specification for aggregates from natural sources for concrete.
BS 1200: 1976 Specifications for building sands from natural sources.
BS 1881: Part 116: 1983 Testing concrete. Method for determination of compressive strength of concrete cubes.
BS 1881: Part 120: 1983 Testing concrete; Method for determination of the compressive strength of concrete cores
BS 1881: Part 201: 1986 Guide to the use of non-destructive methods of test for hardened concrete.
BS 3797: 1990 Lightweight aggregates for masonry units and structural concrete.
BS 3892: Part 1: 1997 Pulverized-fuel ash. Specification for pulverized-fuel ash for use with Portland cement.
BS 4027: 1996 Specification for sulfate-resisting Portland cement.
BS 5328: Part 1: 1997 Concrete. Guide to specifying concrete.
BS 5328: Part 2: 1997 Concrete. Methods for specifying concrete mixes. I
BS 5328: Part 3: 1990 Concrete. Specificationfor the procedures to be used in producing and transporting concrete.
BS 6089: 1981 Assessment of concrete strength in existing structures.
BS 6588: 1996 Specification for Portland pulverised-fuel ash cements.
BS 6610: 1991 Specification for Pozzolanic pulverised-fuel ash cements.
BS 7583: 1996 Specification for Portland limestone cement.
BS 8500: 2000 Concrete. Complementary British Standard to BS EN 206: Part 1: 2000. [Draft only]
BS EN 206: Part 1: 2000 Concrete. Specification, performance, production and confomiity. [Draft only]
BS EN I S 0 9001: 1994 Quality systems model for quality assurance in design, development, production,
installation and servicing.
BS EN 12350 Part 1: 2000 Testing fresh concrete, Sampling.
BS EN 12350 Part 6: 2000 Testing fresh concrete. Density.
Dhir R K, Jones M R and Nicol L A (1999). Developnzent of structural gradefbanzed concrete. DETR Research
Project. University of Dundee.
Highways Authorities and Utilities Committee (1992). Specification for die reinstatement ofopenings in I z i g h ~ ~ a ~ ~ s
(A Code ofpractice). London: The Stationery Office.
Lawrence C D (1993). Lahoratoty studies of concrete e,upansion arising fLom delayed ettringite fbrmation.
Crowthorne: BCA.
Version No: 1 Applicntioii Giiide A G39 October 2001
16
Specification f o r foairied concrete
McGovern G (2000). Manu/acture and supply of ready-mix foarized concrete. One-day awareness seminar on foamed
concrete: properties, applications and potential. University of Dundee. pp 12-25.
New Roads and Street Works Act (1991). Specificatioii f o r the reinstatenzent of operiitigs in highways
Pickford C and Crornpton S (1996). Foanzed concrete in bridge construction. Concrete, Nov/Dec.
Regan P E and Arasteti A R (1984). Lightweight aggregatejbanzed cotwete. Low-cost and energy saving materials,
Ch.42, pp 123-138.
Sac11J and Seifert H (1999). Foanzed concrete technology: possibilities for tkernzal insulatioti at high temperatures.
CFI Forum of Technology, DKG 76, No. 9, pp 23-30.
Taylor R W (1990). First interim report oiifoanzed concrete. BCA Report No. RA1.007.00.1. Crowthorne: BCA.
Van Deijk S (1991). Foani concrete. Concrete, JulyIAugust, pp 49-54.
Watts G R A and Brady K C (1999). Assessnzent of the use offbanzed corzcrete as a bacl$ll to retaining structures.
Project Report PR/CEll76/99. Crowthorne: TRL Limited. (Unpublisked rcport available on direct personal
applicatioiz only)
Watts G R A (2000). Loading tests oii a nzasonty arch bridge bac&$lled with foanted concrete. Project Report PWIS/41/00.
Crowthome: TRL Limited. (Unpuhlislzed report available on direct personal application only)
Versiorr No: I Applicatiori Guide AG3 9 October 2001
17
Apixvidices Specification for foamed concrete
I
APPENDIX A: GLOSSARY OF TERMS
The cementitious mortar comprising cement, water, tiller and chemical admix-
tures into which foam is incorporated to produce foamed concrete.
Coalexetice The joining of two or more bubbles in the foam. (Because larger bubbles have
a tendency to rise to the surface, coalescence can lead to segregation and
reduced strength.)
The situation where there is no adverse interaction between a foam and chemical
admixture that reduces the stability of the foam in the mortar.
Scaled cii ring Curing through the use of an air and watertight film. (Where curing in water is
used, foamed concrete absorbs varying amounts of water.)
Delavecl ettritrgite,forniatioti (DEF) This reaction, which occurs at temperatures in excess of 65”C, involves the
decomposition and reformation of primary ettringite in the presence of mois-
ture: it generates disruptive expansive forces in the concrete matrix.
The ability of a material to flow under its own weight.
The ability of a foam to resist collapse into solution.
The separation of foam from the mortar, by various interactions between the
components, producing variations in composition and density with pour depth.
Heat of’li~~dratioti The temperature rise generated by hydration. (Foamed concrete has excellent
insulation properties and so a significant rise in temperature can be attained
through curing and retained for several days. The temperature rise can be
moderated by the use of PFA as a partial replacement for PC.)
Plastic iletisity The density of freshly placed foamed concrete: it can be determined by
measuring the weight of material in a container of known volume.
Plastic iiscosity Material characteristic associated with the energy required to sustain a reason-
able rate of flow of material.
A material that affects the properties of an interface between air and liquid such
that it provides a themiodynamically stable environment for foam.
Tlierttiul conductivity Material characteristic indicative of the ease ofheat transfer through a material.
IVixkability Material characteristic indicative of the ‘ability to be worked’.
Yi:iel‘l Difference between the target and actual plastic density.
Yield value Minimum stress required to initiate flow.

I
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A- 1
Specification f o r foamed concrete Appeiidices
APPENDIX B: GUIDE FOR SPECIFICATION AND QUALITY

CONTROL OF FOAMED CONCRETE
Mix constituents
0 Where possible avoid the use of superplasticizers to enhance workability. Where they are necessary, tests should be
camed out toconfirm compatibility ofthe foam and superplasticizer: dosage should not exceed 0.2 per cent by weight
of cement.
0 Bear in mind that the w/c ratio of the foamed concrete will be slightly higher than that of the base mix.
0 Take account of the retarding effect of PFA on the developinent of strength and on the reduction in the heat of
hydration.
0 Where possible do not specify PC contents greater than 500 kg/m3:the risk ofthermal cracking increases substantially
with higher contents and the resulting gain in strength is minimal. I
0 Carry out trial mixes at small and then large scales to confirm that the required workability can be achieved.
0 To minimise shrinkage the w/c ratio should be as low as possible.
Foam production
0 Carry out regular checks of the density of the foam: tolerance should be set at about *I0 kg/m3
Mixing
0 Carry out regular checks of the plastic density of foamed concrete. In most cases the tolerance should be set at f 50
kg/m3. If the plastic density is higher than the target density more foam can be added to the mix, but if it is lower by
more than the tolerance the mix should be rejected.
0 Carry out spread or flow measurements for both the base and foamed mix. To achieve Class 2 foamed concrete (see
Table 1 ofmain text), the spread ofthe PC/PFA base mix should be between 1 15 and 140 mm and for a PC/sand mix
between 85 and 125 mm. With the latter test, flow should be continuous, flow times should be shorter than 2 minutes;
and the corresponding flow class should be 2B or better (see Table 1 of main text). Note that such tests might only
be undertaken on trial mixes.
Casting
I
Cover the exposed surface as quickly as is practically possible with a barrier form of curing membrane.
0 Following the pour, erect barriers to isolate the area of the pour for about 24 hours or until an adequate strength has
been achieved.
0 Allow sufficient time for the concrete to gain an adequate strength before carrying out work on the surface.
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A-2
Appeit dices I Specification for foamed concrete
APPENDIX C: FOAMED CONCRETE

The following provides a brief review of the constituents, method of production, properties and uses of foamed concrete:
ftirthcr details can be obtained from the references quoted and as listed in the Bibliography. It also presents and discusses
the findings of research work undertaken at the University of Dundee; most of this concerned the properties of higher
strength foamed concrete, i.e. ‘structural grades’.
C l CONSTITUENTS
Low-density foamed concrete, i.e. having a dry density of up to about GO0 kdm3, is usually formed from cement (to which
other binders could be added), water and foam. Denser foamed concrete will include fine sand, which is suitable for making
concrete or mortar, and/or other fillers.
Cl.1 BASEMIX
C1.l.l Binders
Portlutirl cetiietits
Ordinary Portland cement (to BS 12: 1996 or BS EN 197: Part 1: 2000) is usually used as the main binder for foamed
concrete. However rapid-hardening Portland cement to BS 9 15: 1983 has also been used, and there does not seem to be any
evidence why sulfate resisting cement to BS 4027: 1980 could not be used.
Usually the total cement content will lie between 300 and 400 kg/m3, but up to 500 k g h 3 has been used to attain higher
strength concrete. According to Jones (2000) the gain in strength obtained by increasing the content above 500 kg/m’ is
sinal I.
Piilverised fuel ash (PFA)
PFA (to BS 3892: Part 1: 1997 or BS EN 450: 1995) is often added, at levels of up to 80 per cent of the cement content, to
reduce cost, enhance workability and increase the long-term strength of foamed concrete. But, particularly when casting at
a low temperature, account should be taken of the reduced rate of strength gain resulting from its addition to a mix.
Furthermore, because ofthe increased fineness (and hence greater surface area) of PFA, for equivalent workability PC/PFA
mixes have a greater water demand than PC/sand ones.
Kearsley (1 996) has reported on the effects of PFA on the properties of foamed concrete, and more recent research has been
undertaken at the University of Dundee. This work indicates that the addition ofPFA to a mix leads to a more uniform bubble
structure in the paste, which in turn improves some of the engineering properties of the concrete.
I
Groutid granulated blastfiirtiace slag (GGBS)
For the same advantages as mentioned above for PFA, GGBS (to BS 6699: 1992) has also been used for producing foamed
concrete; typically it would make up 30 to 50 per cent of the total cement content. However with some types of surfactant
the use of GGBS has led to instability (i.e. foam collapse) and segregation of the mix.
Silicu,fitme
Both Taylor (1988) and Kearsley (1996) report that the addition of condensed silica fume, of up to 10 per cent by weight
of cement, significantly increases the strength of foamed concrete where the foam content is less than about 30 per cent.
However the improvement in strength with higher foam contents is small.
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Specification f o r foamed concrete Apperrrlices
C1.1.2 Aggregates and fillers
Sand
Sachand Seifert(1999)recommendthat onlyfinesands suitable forconcrete (toBS 882: 1992)orniortar(toBS 1200: 1976)
having particle sizes up to about 4 mm and with an even distribution of sizes should be used for foamed concrete. This I S
mainly because coarser aggregate might settle in a lightweight mix and lead to collapse ofthe foam duringniixing. The effect
of the grading of the sand on the properties of the foamed concrete is discussed in a BCA (1991a) report.
For practical reasons, most sands can only be used to produce foamed concrete having a dry density in excess of about 1200
kg/m3.
Coarse PFA
Coarse PFA (to BS 3892: Part 2: 1997 or BS EN 450: 1995) can be used as a partial or total replacement for sand to produce
foam concrete with a dry density below about 1400kg/ni3.However for the same workability such mixes have a greater water
demand.
The presence of activated carbon within PFA has been shown, by for example Hoarty (l990), to impair the effectiveness
of air-entraining agents and thereby destabilize the air-void system within air-entrained concrete. However work at the
University of Dundee found no observable degradation of foamed concrete even with a relatively high proportion of coarse
high carbon-content ash.
Limestonefines
Limestone fines have been added, at up to 10 per cent by weight of cement, in conjunction with PFA to accelerate the setting
rate of foamed concrete, see for example De Rose and Moms (1 999).
Other
Lightweight aggregates up to 16 mm in size, such as expanded polystyrene granules and Leca expanded clay, have been
used to produce foamed concrete: see for example Regan and Arasteh (1984:).Any such aggregates should be of about the
same density of the foamed concrete and have minimal capacity for absorbing water.
C1.1.3 Water
The water used for foamed concrete should be potable. This is crucial when using a protein-based foaming agent because
organic contamination can have an adverse effect on the quality of the foam, and hence the concrete produced.
The watedcement (w/c) ratio of the base mix required to achieve adequate workability is dependent upon the type of
binder(s), the required strength of the concrete, and whether or not a water reducing or a plasticizing agent has been used.
In most cases the value will be between 0.4 and 0.8. The higher values are required with finer grained binders, such as PFA,
and the lower values where either a high strength is required or a superplasticizer has been employed.
Where the water content ofthe mix would be inadequate to ensure full hydration of the cement, water will be extracted froiii
the foam and might lead to its disintegration. On the other hand whilst high w/c ratios do not significantly affect the porosity
of the foamed concrete they do promote segregation and increase drying shrinkage.
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A-4
Appcrrrlices Specificatioii for foamed concrete
(21.1.4 Admixtures
Water t-educitig arid plasticizing ugeti t s
Because of its intrinsic high workability and modest strength requirements, plasticizers are not universally added to foamed
concrete. But they have been used to improve the workability o f a foamed concrete mix or to achieve the same workability
at a reduced w/c ratio.
Work a t the University of Dundee has shown that superplasticizers allow w/c ratios as low as 0.3 to be used withno adverse
effects on the properties of the foamed concrete: indeed their addition improved the stability and flow characteristics of a
mix. But Dransfield (2000) has questioned the use of such additives, and Bartos (1 992) claimed that they might reduce the
stability of the foam. The work at Dundee University showed that problems of compatibility with superplasticizers led to
segregation: the degree varied with the type of surfactant but it tended to be more noticeable with protein-based ones and
was less apparent with anionic ones.
To date no serious or common problems ofcompatibility have been reported from site works. However little is known about
the detailed effects of plasticizers, or indeed any other admixture, on the properties of the foamed concrete and SO dosage
should be based on information from the manufacturer arid confimied from trial mixes.
Set c0ntroller.s
To restrict the spreading of foamed concrete once placed, thickening agents and waterproofing materials have been added
to the mix. The effects that such viscosity modifiers have on the properties offoamed concrete have been discussed by Bartos
(1 992) and by Dransfield (2000).
Accelerators can be used to overcome the rather slow rate of stiffening and strength development of foamed concrete.
Because at this stage the mechanism for accelerated curing is not fully understood their use can only be recommended on
a n empirical basis. Dransficld (2000) states that calcium chloride is the most effective accelerator: this can be used in all
but a few cases because carbon steel reinforcement is rarely used with foamed concrete.
C1.1.5 Fibres
Polypropylene fibres have been used to improve the shear strength and stiffness of structural elements formed from foamed
concrete: see for example Kearsley and Mostert (1 997) and Mellin (1999). For this purpose Kessler (1998) proposed a
dosage level of 1 kg of fibres per m3 of foamed concrete.
I
C1.2 FOAM
To produce concrete with a reasonable strength the bubbles in the foam should not be irregular nor thin-walled and there
should not be much coalescence between them. Thus, as reported by Gutmann (1988), a foam composed of small spherical
bubbles is best suited for making foamed concrete.
C1.2.1 Foaming agents

Synthetic or protein-based foaming agents (surfactants) can be used to produce foam. Because of the possibility of
degradation by bacteria and other organisms, natural protein-based agents (i.e. fatty acid soaps) are rarely used to produce
foamed concrete for civil engineering works. However research is underway on the use of protein-based agents for
developing high strength, i.e. ‘structural grade’, foamed concrete. The chemical composition of a surfactant must be stable
in the alkaline environment of concrete. Because all surfactants are susceptible to deterioration at low temperatures they
should be stored accordingly.
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A-5
Specification for foamed concrete Appeir dices
There is a wide range ofsurfactants available, and whilst selection of the most suitable surfactant for a particular application
is difficult, it might prove crucial. Thus it might be prudent to undertake mixing trials prior to usage, particularly for large-
scale or critical applications.
Synthetic
Synthetic surfactants can be classified according to the nature of their hydrophylic group, i.e. that part of the molecule that
is soluble in water, for further details see Myers (1992) and Brady arid Greene (1 997).
Anionic: about 70 per cent of the surfactants used to produce foamed concrete are anionic, i.e. the active part
of their molecule (the hydrophile) is negatively charged.
Cationic: less than 5 per cent of the surfactants used to produce foamed concrete are cationic, i.e. the
hydrophylic group cames a positive charge.
Non-ionic (orpolar): about 25 per cent of surfactants used to produce foamed concrete are non-ionic, i.e. they
are electrically neutral. This lack of electric charge may give a greater stability to a foamed concrete mix.
Amphotevic and Zwitterionic surfactants are rarely used to produce foamed concrete. Depending on the pH
of the solution the molecules can sustain either a positive or negative charge, or both charges.
The chemical nature ofthe above is intrinsically and functionally diverse. At present the effect ofthe nature ofthe surfactant
on the properties of the foamed concrete is largely unknown, and so surfactants are selected, by and large, on an empirical
basis, The performance ofthe various types of surfactant might vary with the type of binder. Although cement particles are
known to have both positive and negative charges, the surfaces of particles in a composite mix tend to become negatively
charged with the addition of PFA, see Helmuth (1987). Therefore non-ionic or amphoteridzwitterionic surfactants might
be more stable in PC/sand mixes whilst single-charge surfactants might be more suitable for PC/PFA mixes. This topic
warrants further study. I
Protein-based
According to McGovern (2000), compared to the foams produced by synthetic surfactants, those formed from protein-based
agents have smaller bubble sizes, are more stable (i.e. exhibit less water drainage) and have a stronger closed bubble
structure. Protein-based surfactants might therefore be best suited to the production of foamed concrete of relatively high
density and high strength.
C1.2.2 Foam
The surfactant solution usually consists of one part surfactant to between 5 and 40 parts of water. Optimum performance
is commonly attained at a ratio of 1:25, but the optimum value is a function of the type of surfactant and the method of
production. The dilution ratio should be chosen with regard to the critical micelle concentration (cmc) of the foam, this is
the point at which the properties of a foam exhibit a significant change, for example in density as shown in Figure C 1.
The surfactant solution is foamed to a consistency similar to that of shaving foam and to a density of between 20 and 90 kg/ni':
the density will vary according to the application but in many cases it will be at the upper end of this range.
The density of foam produced with protein-based surfactants is often about 50 kg/m3. Dhir et al. (1999) explored the use
of foams formed from such surfactants for manufacturing structural elements: the density of the foams ranged from 30 to
50 kg/m3 and the w/c ratio ranged between 0.3 and 0.5.
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A-6
Apiwtrrlices Specijicatioit f o r foamed concrete
0 20 40 60 80 100 120
Surfactant solution concentration (ginsnitre)
Figure C1 Variation of foam density with concentration of surfactant solution, after Anon (2000)
,S/lllli/i/~
The stability of foam is a function of its density and the type of surfactant. In general, protein-based surfactants tend to form
a more stable bubble structure than synthetic ones.
The foam has to survive its incorporation into the mortar mix and the chemical environment of the concrete until it has
achieved a reasonable set.
Stability can be affected by a number of external environmental factors including vibration, wind, evaporation and
temperature: some or all of these might be present on a site and so some breakdown in the foam is inevitable.
The inherent stability of a foam can be assessed quite simply by measuring its collapse or drainage with time using a glass
measuring cylinder, as shown in Figure 4 of the main text: typical data are shown in Figure C2.
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Specification for foamed concrete Appendices
90
80
70
F I
5!
x 60 ,\ .
-
m
E
-0-
+
60kg/m3
50kglm"
50 35kg/rn3
-m
8
5 40
.e
Ic
0
-g 30
3
20
10
0
0 20 40 60 80
Time (min)
Figure C2 Measurements of drainage of a foam, after Anon (2000)
C2 MIX DESIGN
The basemix comprises the solids (cement, sand, any other filler) and water. Its intrinsic strength depends on its constituent
proportions and density. Usually the latter would be about 2250 kg/ni3, but it has to be measured to calculate the amount
of foam required.
The strength of the base mix defines the maximum strength of the foamed concrete. By reducing the w/c ratio the strength
ofthe basemix can be increased but only at the expense ofreducing workability. With normal weight concrete, workability
could be restored with a superplasticizer, but their use in foamed concrete increases the risk of segregation. At this stage it
is suggested that the dosage of superplasticizers to foamed concrete is limited to 0.2 per cent by weight of cement.
It should be appreciated that some foam collapse will occur during the mixing, placing and maturing of the concrete on site,
and so the final wlc ratio will be slightly higher than calculated from the batch proportions.
Proportioning
There is at present, no guidance or standard method for proportioning foamed concrete. Because the hardened density of
foamed concrete depends on the saturation level in its pores, it is difficult to obtain an accurate measure of its density on
site. Thus in most cases, foamed concrete is proportioned on a volumetric rather than a weight basis, for example I 1n3of
base mix to 4 m3 of foam.
A-8
Ajiperr (lites Specification for foamed coticrete
An approach followed at the University of Dundee is as follows:
0 Calculate the water and superplasticizer contents from the total cement content, which includes cementitious fillers
such as PFA. Ignore the amount of water contained in the foam.
0 Determine theI amount of air (kg/m3) in the mix from consideration of a unit volume, and from the target density of
the foam estimate the required quantity of foam.
Assuniinga target plastic density (D, kg/m3), waterkement ratio (w/c) and cement content (C, kg/m3), the water (W, kg/m3),
sand (S, kdm’)or PFA (F, kg/ni’), contents of the base mix are calculated as follows:
PCLsur7d tnix:
From D = C + W + S
water content: W = (w/c) x C
sand content: S = D - C - [(w/c) x C]
PUPFA n1i.r:
From the above,
water content: W = (w/c) x (C + F)
PFA content: F = [D - C - (w/c) x C] / [(w/c + 13
C3 CHARACTERISTICS AND PROPERTIES
C3.1 FRESH MIX
C3.1.1 Workability and rheology

Foamed concrete is a free-flowing, self-levelling material and should therefore be expected to give a collapse slump. Thus
neither the slump test (to BS EN 123.50: Part 2: 2000) for normal weight concrete nor the flow test (to BS EN 12350: Part
5 : 2000) for concrete with a high slump are applicable. Usually, therefore, the workability of foamed concrete is evaluated
visually: in most cases it would not be difficult to spot when workability was unacceptably low.
As described by Dhir et al. ( 1 999), the tests used at the University of Dundee to assess the workability of the base mix and
foamed mix includemeasurement of ‘spreadability ’, as described by Brewer (1996) and ‘flowability’,as described by Bartos
(1992). Such measurements can be taken to represent, respectively, the yield and plastic viscosity of the mixes. The tests
are briefly described in Section 3.2 of the main text. Dhir et al. (1999) recommended that for adequate workability, i.e. for
a Class 2 niix to Table 1 of the main text, the spread of the base mix should be between 1 15 and 140 rmn for a PC/PFA mix
and between 8.5 and 125 mni for a PC/sand mix.
As could be expected, and as shown in Figure C3 for example, the workability of foamed concrete increases with increasing
w/c ratio and increasing dosage of superplasticizer.
All other things being equal, of the types of cement used to produce foamed concrete those with GGBS have the highest
workability, but separation of foam and paste has been noted with high GGBS contents and at low w/c ratios.
The effect of the type of surfactant on the properties of the foamed concrete has been investigated at the University of
Dundee, and data frdm this work are reproduced in Table C1. The ‘spreadability’ of the various types of concrete are
reasonably similar but, for otherwise identical mixes, concrete formed from a protein-based surfactant has a much shorter
Versiorr No: I Applicatiorr Guide AG39 October 2001
A-9
Specificationf o r foained concrete Appendices
300
A A
250
200
-pE
E
150
E
n
(I)
100 0
U
50
0 I
0.2 0.25 0.3 0.35 0.4 0.45 0.5

wlc ratio
Figure C3 Effect of w/c ratio and superplasticizer content on the spreadability of foamed concrete, after Anon (2000)
Version No: 1 Applicntion Giiide AG39 October 2001
A-10
Apperrrlices Specification for foamed concrete
Table CI Effect of the type of surfactant on the properties of foamed concrete, from Anon (2000)
~~
Sutjactatit type Syitlietic' Anipkoteric A tiioiiic Protein-based
wlc ratio 0.35 0.40 0.45 0.35 0.40 0.45 0.35 0.40 0.45 0.35 0.40 0.45
Surfactant content 0.4 0.2 0.0 0.4 0.2 0.0 0.4 0.2 0.0 0.4 0.2 0.0
wt cement
'%I
Spread, mni 185 215 175 305 255 205 240 200 155 345 270 195
(see Section 3.2)
'
Flow time >4 >4 - 35 25 30 1.5 2 2 - 15 15 3

(see Section 3.2) inins inins secs secs secs mins niins secs secs mins
Segregation", kdm3 + 20 +I3 +3 +87 +65 +37 +78 + 14 + 13 + 1150 + 180 +32
(see Scctioii 3.3)
Compressivet 1-day 5.0 3.5 3.0 6.0 4.0 3.5 6.5 2.5 3.0 3.5 4.0 2.5
strength, Nliiim' 28-day 9.5 10.5 10.0 10.5 9.0 9.0 12.0 5.5 7.0 12.0 11.5 8.0
(see Section 3.4) 56-day 9.0 12.0 8.5 10.0 9.0 9.0 10.0 6.0 7.5 10.5 11.5 8.0
Sorptivity index, 0.077 0.061 0.096 0.123 0.075 0.084 0.041 0.079 0.073 0.051 0.0652 0.0476
mnl/min'"
(see Section C3.3.3)
Water vapour 2.980 2.430 2.580 2.356 3.244 2.587 2.724 4.626 3.830 1.694 2.285 2.984
permeability,
yn1sln1nl/s x 10'3
(see Section C3.3.3)
PCLsatid mix with PC content qf500 kg/ni': plastic density of 1400 kg/m3, all specinlens sealed cured
Cotiiliiercially available surfactant ef uiikiio~vielectrical charge: the others are, as yet, /lot coniniercially available
.*Diffiretice beli.cleeij top atid bottom of pour
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A-1 1
Specification for foamed concrete Apiiei1dicc.v
flow time, which is indicative of a much lower plastic viscosity. However mixes formed from protein-based surfactants are
prone to segregation, probably due to incompatibility of the surfactant with the superplasticizer.
Dhir et al. (1999) attempted to quantify the rheology of foamed concrete using a Brookfield RVT viscometer: some of their
data are reproduced in Table C2. The yield values were all less than 2 Nm, which, according to Tattersall(1991), indicates
self-flowing behaviour. The less viscous mixes exhibited lower values of yield and plastic viscosity. It was also found that
PC/sand mixes were more viscous than equivalent PC/PFA mixes, which suggests that the latter have better flow
characteristics.
C3.1.2 Heat of hydration

The cellular structure of foamed concrete provides it with good insulating properties. Consequently the temperature rise
developed through hydration is higher and lasts for longer than for normal weight concrete. The temperature-time relation
is a function of the dimensions of the pour, the cement content and the density of the foamed concrete. According to Ansell
(2000), temperatures of up to 100 "C could be sustained for 3 days. Such persistent high temperature might result in thermal
strains and cracking ofthe concrete, but such problems have not been reported in the literature. The risk ofdelayed ettringite
formation, which is promoted by temperatures above 65 "C, is low because ettringite is formed in the pores of the concrete
and expansion can thus be accommodated.
In a series oftests undertaken at the University of Dundee, measurements were made of the temperatures developed during
the maturing of 170 mm cube specimens. The cubes were placed in an insulated box and a thermocouple was installed in
the core of the specimen; maturity curves obtained from a few of these tests are given in Figure C4 and Table C3. The data
show that the peak temperature and the period of time for which the temperature exceeded 65°C tended to reduce with
increasing PFA and GGBS content. Furthermore the time taken to reach the peak temperature tended to increase, and so the
rate of temperature rise was also reduced.
The effect of the density of foamed concrete on the temperatures developed during curing is unclear, but with decreasing
density increasingly higher temperatures might be generated and sustained over a longer period of time due to the Beater
volume of air bubbles and hence better insulating capacity. However this might be offset by the lower cement content within
a lower density concrete.
Further data from work at the University of Dundee are reproduced in Table C4. These data suggest that neither the type
of surfactant nor the w/c ratio had any effect on the heat of hydration.
C3.1.3 Rate of hardening

There is no standard method for determining the initial and final setting times of foamed concrete. However the methods
given in BS 4550: 1978 and ASTM C266-89 for cements might provide the basis of suitable methods for foamed concrete.
I
Dhir et al. (1999) reported that 'stiffening' of a foamed concrete mix occurred about 5 hours after casting and, as shown
in Figure C5,9 to 10 hours were required to achieve the set limits given in BS 4550: 1978. This slow build-up in hardening,
in comparison with normal weight concrete, is probably due to the retarding properties of the foam.
The 'setting' time of foamed concrete is usually between 12 and 24 hours.
C3.1.4 Plastic settlement

A 1990 BCA report stated that, for a trench reinstatement, within the first year of service foamed concrete settled about 22
per cent less than a typical granular fill. But it should be recognised that the plastic settlement of foamed concrete may be
higher than of normal weight concrete, and special care should be taken where inclusions such as void formers and the like
are used. However no problems of excessive settlement have been reported in practice.
Version No: 1 Application G i d e AG39 October 2001
A-12
Appeirilices Specification f o r foamed concrete
Table C2 Rheology of foamed concrete, from Dhir et al. (1999)
Plastic deiisity Flow time' Yield Plastic viscosity"

n4i.Y typet kg/tnj secoiirls Ntn Ns/m2
PCIsand 1400 14 0.82 0.034

1600 I6 1.13 0.040
1800 80 1.80 0.05 1
PCIPFA I400 80 0.44 ' 0.025

1 600 17 0.52 0.032
1800 95 0.69 0.075
Assessed usitig Brookfield R VT visconieter

t w/c ratio = 0.30.PC cotitetit = .500 kg/ni'
See ,Sectioti C3.2
tt
For- cotiiparisori the plastic viscosity of water and s y w p are 0.001 and 1 N s / d respectively
80
25% PFA
70
60
50
v
E
I
2
40
+E
I
30
20
r Plastic density = 1000 kglm3
Total binder content = 600 kglm3
10 I I I I 1
0 20 40 60 80
Time (hours)
Figure C4 Effect of the percentage of PFA on the temperature developed by curing of foamed concrete, after Anon (2000)
Versiorr No: 1 Application Guide AC39 October 2001
A-I3
Specification f o r foamed concrete Appendices
Table C3 Effect of PFA and GGBS on temperatures developed during curing of foamed concrete, from
Leptokaridis (2000)
Plastic Peak Time to peak Period when

density temperature temperature temp> 65°C:
kg/m3 Binder’ “C 111:s 11rs
~~~~
1000 PC I 20% PFA 76 11 12

PC 125% PFA 67 12 6
PC 130% PFA 62 13 0
PC 130% GGBS 92 14 18
PC 140% GGBS 74 19 13
PC I 50% GGBS 74 15 12
1200 PC I 20% PFA 79 11 17

PC 125% PFA 75 14 14
PC I 30% PFA 81 14 20
PC 130% GGBS 89 14 21
PC 150% GGBS 82 19 21
’ Total cement (all combinations) content = 600 k g / d
Table C4 Effect of surfactant type and wlc ratio on the curing temperatures developed in foamed concrete, from
Anon (2000)
Peak Time to peak

temperature temperature
Type of suflactant w/c ratio “C hrs
Anionic 0.35 61 15
0.40 59 12
0.45 60 11
Amphoteric 0.35 62 12
0.40 62 12
0.45 59 12
Protein-based 0.35 60 15
0.40 63 12
0.45 60 12
PCLsand mix with plastic density of 14OO kg/m’ and total cement content of 500 kg/m3
Version No: I Application Guide A G39 October. 2001
A-14
Appeiidices Specification f o r foamed concrete
I
10 7
,
+ P U P F A - Flow time 95s. Plastic density 1800 kg/m3

-
PC/sarrd Flow time 76s. Plastic density 1600 kg/m3
Laboratory Temp. = 2OoC

9 kg stiffened limit given in BS 4550 (1978)
w/c ralio = 0.30
545 c
c
= 4
0
0 1 2 3 4 5 6 7 8 9 1 0 1 1 1 2
I Time (hours)
Figure C5 Typical hardening times of foamed concrete, after Dhir et al. (1999)
C3.1.5 Plastic shrinkage

The high pastehggregate ratio and lack of coarse aggregate in foamed concrete makes it vulnerable to shrinkage cracking.
However no particular problems associated with plastic shrinkage cracking on pours with high surface aredvolume ratios
have been reported in the literature: further investigation is required. This apparently good performance of foamed concrete
could be attributed to its high air content, but this has yet to be confirmed. Further work is warranted on this important issue.
Curing foamed concrete with a barrier-form of membrane reduces plastic shrinkage. Fibres can also be added for this
purpose but their presence adversely affects the workability of the concrete.
C3.2 HARDENED CONCRETE
C3.2.1 Compressive strength

The compressive strength of foamed concrete is a function of the characteristics of both the base mix and foam.
Detzsi~vof nih
I
As could have been expected, and as confirmed in Table C5 and Figure C 6 , the colnpressive strength of foamed concrete
reduces with decreasing density. For mixes of similar constituents, the density-strength relations should be reasonably
similar. But, because constituents can vary widely, density is not necessarily a reliable indicator of strength (or quality).
A-15
I
Specification f o r foamed concrete Appeit dices
Table C5 Summary of properties of hardened foamed concrete, from BCA (1994)

~
7-day
DY compressive Thermal Modulus of Drying
density strength conductivity elasticity s h i n kuge
kg/m' N/mm2 W/mK kN/mm' 96
400 0.5 - 1.0 0.10 0.8 - 1.0 0.30 - 0.35

600 1.0 - 1.5 0.08 - 0.1 1 1.0 - 1.5 0.22 - 0.25
800 1.5 - 2.0 0.17 - 0.23 2.0 - 2.5 0.20 - 0.22
1000 2.5 - 3.0 0.23 - 0.30 2.5 - 3.0 0.18 -0.15
1200 4.5 - 5.5 0.38 - 0.42 3.5 - 4.0 0.09 - 0.11

1400 6.0 - 8.0 0.50 - 0.55 5.0 - 6.0 0.07 - 0.09
1600 7.5 - 10.0 0.62 - 0.66 10.0 - 12.0 0.06 - 0.07
I
Plastic density 1200 kg/rn2 Plastic density 1400 k g h 2
0 30%PFA
28 56 28 56
Time [days) Time (days)
Figure C6 Effect of cement type and plastic density on compressive strength of foamed concrete; after Anon (2000)
Version No: 1 Applicntiori Girirle AG39 October 2001
A-16
Ajipeir J i u s Specifcatioii for foamed concrete
i d c ratio
The effect of the w/c ratio on compressive strength seeins to vary with the density of the foamed concrete. The data reported
by Tan1 et ut. ( 1 987) and Dransfield (2000) show decreasing compressive strength with decreasing wlc ratio. But this is the
reverse of the trend reported by De Rose and Morris (1999) for foamed concrete (with a w/c ratio of up to 0.45) and for mortar
pastes and normal weight concrete. Data obtained from research undertaken at the University of Dundee are summarised
in Table C6. These data show that strength increased with reducing w/c ratio for a 1200 kg/m3density mix, the reverse was
the case with the 1000 k g h j density mix, and there was no consistent trend for the 1400 kg/ni3density mix.
Table C6 Effect of wlc ratio on compressive strength of foamed concrete, from Anon (2000)
Plastic Cotiipre.ssi~strengtli. N/niniz

~l~~i.Sil,v
kg/ni.’ i d c ratio 28-d0.v 56-day
I000 0.25 1.5 2.0

I 0.28 2 .O 2.5
0.30 3 .O 3.5
1200 0.25 6.5 9.0

0.28 4.5 6.0
0.30 3 .O 5.0
I400 0.25 11.5 12.0

0.28 12.0 15.5
0.30 10.5 14.0
All specitiieii.~sealed ciired

SRPC coiiteiit = 500 k&i’
Kearsley (1 996) found that the sand content did not have a marked effect on the compressive strength of foamed concrete.
As shown in Figure C7, taken from Dhir (1999), slightly lower early strengths might be obtained with mixes containing
ccinentitious fillers than ones containing sand. But the strength of the former continues to increase beyond 28 days (due to
pozzolanic reaction), while the strength of the latter does not increase significantly. Increasing the amount ofPFA and silica
fume increases the 28-day strength, with a more marked effect at higher foamed concrete densities: see De Rose and Morris
( I999), Kearsley (1996 and 1999) and Taylor (1 988).
i
ppe C?ffi,Olll
The compressive strength of foamed concrete is a function of the density of the foaiu and the type of surfactant. In general
higher strengths are achieved when the air bubbles are of small, uniform size, see BCA (1994), and when protein-based
surfactants are employed; see Dransfield (2000). The latter can be attributed, in part, to the ability of a protein to hold water
and make it available to the cement mortar at a much slower rate. The hydration process is therefore prolonged, resulting
in a thicker and more compact coating around the air void, which contributes to the development of strengths up to 70 per
cent higher than those achieved with synthetic agents, see Aldridge (2000a). Further, as shown by the data provided in
Table C I and Figure C8, the strength of foamed concrete formed with different surfactants varies with the wlc ratio.
Vevsiorr No: I Applicatioii Guide AG39 October 2001
A-17
Specification for foamed concrete Appenrlices
-0- Sand - plastic density = 1400 kg/rn3

I -k
E
0 10 20 30 40 50 60
Time (days)
-& -
PFA plastic density = 1600 kg/m3
4J -- plastic density = 1600 kg/m3
Sand
-E
L T
40-
01 I I I I I
0 10 20 30 40 50 60
Time (days)
50
N^ -
-@ Sand plastic density = 1800 kg/m3
.
z
40
-------
/
30
C
2
c
U)
.-9 20
U)
0
10
n
"
td
0 10 20 30 40 50
69
Time (days)
Figure C7 Development of compressive strength of foamed concrete, after Dhir et 01. (1999)
Version No: 1 Application Girirle AG39 October 2001
A-18
Apj~eiriliccs Specification for foamed concrete
14 14
I Synthetic Amphoteric
12
t2
0 20 40 60 0 20 40 60
Anionic Protein-based
12
10
R
6
1 2
0 20 40 610 0 20 40 60
Time (days)
-E- w/c 0.40
1400 kglm3 plastic density

500 kg/m3 plastic density
w/c: 0.35-0.45
Figure C8 Effect of the type of surfactant on the development of strength of foamed concrete, after Anon (2000)
Versioir No: I Applicatioir Guide A G3 9 October 2001
A-I9
Curing regime
The curing regime can have a dominant effect on the strength of foamed concrete. And clearly, for quality control and
I
comparative purposes, it is necessary to establish a standard curing regime. This subject deserves further study.
Kearsley (1996) examined a number of curing regimes. Of the methods, the highest strengths were obtained on specimens
cured at 50”C, and on specimens sealed in plastic bags and heldat a constant temperature of 22°C. Kearsley ( 1996)concluded
that testing water-cured specimens gave low strengths due to the build-up of pore water pressure in the saturated
microstructure of the foamed concrete. Thus he recommended that foamed concrete test specimens be sealed cured, i.e.
wrapped in cling film and stored in plastic bags. Variations of this regime include wetting the specimens after demoulding
and before wrapping, or storing them in a high humidity environment.
Kearsley and Booysens (1998) found that air-cured specimens at 40°C had higher strengths than ones cured in water. As
shown in Figure C9, Dhir et 01. (1999) also found that specimens cured in air had a higher strength than those sealed-cured,
the difference was particularly marked with PC/PFA mixes.
Fibres
Mellin (1 999) found that the 28-day strength of ‘structural-grade’ foamed concrete was substantially increased by the
addition of 0.25 and 0.5 per cent by weight of polypropylene fibres: some data are reproduced from Mellin in Table C7.
C3.2.2 Tensile and flexural strength

As with compressive strength, for the same constituents the tensile strength of foamed concrete (subject to bending) will
increase with increasing density of the mix. ASTM C869-91, reconmends that foamed concrete should have a minimum
tensile strength of 0.17 Nlmm’. Van Deijk (1991) reported (56-day) tensile strengths of 0.06,O. 17,0.32 and 0.5 1 for mixes
having plastic densities of 600,900, 1200 and 1500 kg/m3 respectively.
Jones (2000) reported that the splitting tensile strength (determined to BS 1881: Part 1 17: 1983) of ‘structural grade’ foamed
concrete was only slightly lower than that estimated for lightweight concrete; data are reproduced in Table C8. As shown
in Figure C10, foamed concrete formed from PC/sand mixes have slightly higher splitting tensile strengths than PC/PFA
mixes, but the tensile/compressive strength relations of the two are significantly different, possibly due to sand providing
strength through interlocking.
De Rose and Morris (1999) reported that the flexural strength of low-density foamed concrete (determined to BS 1 SS 1 : Part
1 18: 1983) reduced with increasing w/c ratio. As shown in Table C7, a substantial increase in the flexural strength of foamed
concrete was generated by the addition of a low percentage of 19 mm long polypropylene fibres. Kearsley and Mostert
(1997) also reported increases in tensile strength through the addition of fibres: in this case higher strengths were obtained
throughtheadditionofincreasingamountsof12 mm longpolypropylene fibres. However in practice fibrecontents arelikely
to be limited by cost considerations.
C3.2.3 Modulus of elasticity

As shown in Table C5, the modulus of elasticity (E) (determined to 13s 1881: Part 121: 1983) for foamed concrete ranges
from 1 to 12 kN/mm2for dry densities of 500 to 1600 kg/m3respectively. By comparison the E value for structural concrete
having a compressive strength of 40 N/mm’ is about 28 kN/mm2.This large difference can be attributed to lack of coarse
aggregate in the former.
Relations between E and the 28-day compressive strength for PC/sand and PC/PFA mixes are provided in Figure C1 1. For
the same strength, the former have much higher E values; again this is probably due to the interlocking ofthe fine aggregate.
I
As shown in Table C7,the addition of0.5 per cent ofpolypropylene fibres to foamed concrete beams increased their stiffiiess
by a factor ofbetween 1.7 and 4.6. These enhanced values are still much lower than for normal weight concrete. Thus much
greater deflection is observed in foamed concrete beams than ones formed from normal weight concrete: furthermore the
former exhibit a slightly more brittle failure but one that was not sudden or explosive.
Version No: 1 Application Guide A C39 October 2001
A-20
Apperrrlices Specijication for foamed concrete
50
dT/
a) PClPFA mixes
45
40 -
0
0
35 -
30 -
25 -
20 -
15 -
10 -
>
5 -
0
1100 1200 1300 1400 1500 1600 1700 1800 1900 2000
Hardened density (kg/rn3)
30
b) PCI sand mixes
N
25
//
E
-
E
z
a,
m
20 O 0/
C
2
c
A
g
._
15
U)
g
E
8 10
2
N
5
I I I I 1 I I I
0
I100 1200 1300 1400 1500 1600 1700 1800 1900 2000
Hardened density (kglrns)
Figure C9 Effect of curing regime on 28-day compressive strenghs of foamed concrete, after Dhir et al. (1999)
Ver.viori No: 1 Application Ciiide AC39 October 2001
A-2 I
I Specification for foamed concrete Apjmulices
Table C7 Effect of the addition of polypropylene fibres on properties of foamed concrete, from Mellin (1999)
Plastic Fibre Compressive strength , N/m ni2 Flexirral ModtllLls of

density content? strength* elasticity"
kg/m3 %
! 2 day 7 day 28 day N/niniz kN/nini'
1400 0.00 9.0 15.0 25.0 1.3 10.0

0.25 17.0 35.0 62.0 4.1 19.0
0.50 14.0 22.0 40.0 2.9 17.0
1
1600 0.00 8.0 16.0 26.0 1.0 4.0

0.25 13.0 30.0 43 .O 2.5 18.0
0.50 16.0 33.0 58.0 3.2 18.5
All specimens sealed cured

19 mm long polypropylene fibres
' See Section C3.2.2
'* See Section C3.2.3
Table C8 Splitting tensile strength of concrete, from Jones (2000)
28 day Stditting tensile strength tt,N/nini?

Plastic compressive -
density strength Nornial Lightweight
Mix kg/m' N/mni' Foamed weight' aggregute"
PCIsand 1400 13.5 0.8 1.2 1.3

1600 19.5 1.8 1.6 1.7
1800 28.5 2.1 2.1 2.2
PCRFA 1400 21.5 1.5 1.7 1 1.8

1600 33.5 2.0 2.3 2.4
1800 48.0 2.5 3 .O 3.1
t All specimens sealed cured with PC content of 500 kg/ni3

tt See Section C3.2.2
'
Calculated using the expression& = 0.20f)'l 70 by Oluokun (1991)
**
Calculated using the expressionx = 0.23f)i'h7 by CEB-FIP (1993)
Version No: I Application Guide A G39 October 2001
A-22
Apperrdices Specification for foattied concrete
PC/PFArnix
&- 3 -
--z
E
E
2.5 -
5
-
W
0.5 -
I I I I I I I I
0 5 10 15 20 25 30 35 40 45
28-day compressive strength (Nlmrnz)
Figure ClU Relationship between splitting tensile and 28-day compressive strengths, after Dhir et al. (1999)
E (sand mixes) = 0.94 f, - 2.8 , (3
0 5 10 15 20 25 30 35 40 45
2E-day compressive strength f, (N/mm2)
Figure C11 Relationship between E-value and 28-day compressive strength, after Dhir et al. (1999)
Ver:siorr No: I Application Guide AG39 October 2001
A-23
Specification f o r foamed concrete Aypert dices
C3.2.4 Drying shrinkage

As shown in Table CS, the drying shrinkage offoamed concrete typically ranges from about 0.1 to 0.3 per cent: i.e. between
about 4 and 10times that ofnormal weight concrete. The higher values for foamed concrete can be attributed to its (relatively)
high cement content, its high water content and the lack of coarse aggregate in the mix. The amount of drying shrinkage
tends to increase with increasing foam content (i.e. with decreasing density ofthe concrete) and with increasing temperature,
see Sach and Seifert, (1999).
Drying shrinkage can be reduced by (a) partially replacing PC with PFA (b) adding sand and/or adding lightweight aggregate
to the mix and (c) decreasing the w/c ratio (to about 0.45) but maintaining workability with a superplasticizer. Foaming
agents have also been developed to reduce the settIenient/shrinl<ageof foamed concrete, for example ‘Barracell’ (FEB/
Master Builders, 1997). Such agents might be used to ensure that a cavity was completely filled.
According to McGovern (2000), shrinkage usually occurs within 20 days or so of casting.
C3.2.5 Creep strain

A thorough search of the literature, prior to this research project, found no data on the creep behaviour of foamed concrete.
The results oftests undertaken as part of this study are provided in Table C9 and Figure C12. Creep perfonnance is better
expressed in terms of a creep coefficient or specific creep strain rather than simply in ternis of creep strain. The creep
coefficient is the ratio of the creep and elastic strains, whilst specific creep strain is the creep strain per unit stress. The creep
coefficients given in Table C9 are broadly consistent with those derived for normal weight concrete, see for example Field
and Barnforth (1991). Figure C12 shows, as could be expected, increasing specific creep strain with decreasing density: the
values are higher than for normal weight concrete.
Table C9 Creep coefficient values, after Brady (2000)
Type 1 Tvpe 2 Tvpe 3
Elastic Strain (microstrain) 24 1 151 117

Creep Strain (microstrain) 508 325 256
Creep coefficient 1.11 1.15 1.19
Density (kg/m3) 1330 1570 1750
28-day compressive strength (N/mm2) 2.8 6.3 10.8
All specimens sealed cured with a PC coiztent of 270 kg/n13 p y p e I), 255 kghd p y p e 2), and 355 kg/ni3 Fype 3).
I
C3.2.6 Shear capacity

Kearsley and Mostert (1997) found that the shear resistance of reinforced foamed concrete beams was about 35 per cent
lower than the strength of comparable beams formed from normal weight concrete. This difference might be due to the lack
of coarse aggregate in the foamed concrete.
Mellin (1999) found that the addition of fibres and/or stirrups at 125 to 150 mm centres increased the shear strength of the
foamed concrete beams. He found that the shear capacity of fibre reinforced foamed concrete and normal weight concrete
beams were comparable, but for the same load the former exhibited greater deflection.
A-24
.+)pertdices Specificatiori for foamed concrete
600
500
2
.
E
.-
c 400
?!
t-.
v)
g
'E 300
v
.-C
?!!
I
U)
.-0 200
c
0
a,
0.
cn
100
0
1 10 I00 1000
Log time (t+1 days)
Figure C12 Specific creep profiles for three foamed concrete mixes, after Brady (2000)
C3.3 DURABILITY
C3.3.1 Freeze-thaw resistance

Because the hollow voids can accoinmodate the expansive forces resulting from water freezing, foamed concrete has good
freeze/thaw resistance: data on the freeze/thaw resistance of foamed concrete have been provided by BCA (1994) and
Ba si iirslu (2000).
A selectioiiofresultsfroiii fieezehhaw tests whichinvolvedcyclesof4 hrsfieezing inairat-10°C followed by4hrsthawing

in water at 5 "C (as required by ASTM CGGG: 1990) are provided in Figure C13. It can be seen that for a dry density of
I400 kg/11i3both PC/PFA and PC/sand mixes showed good freeze/thaw resistance, but the performance of a denser mix
(1800 kg/ni3) was much poorer, due to the lower void content.
Brady (2000) reported on the resistance of foamed concrete to freeze/thaw in the presence of a salt solution. Assessment
was based on data derived in accordance with RILEM CDC 2 (RILEM, 1977) salt scaling tests in which the exposure regime
is intended to simulate the worst case conditions for structural concrete. The deterioration of foamed concrete in the rather
scvere conditions was rapid and extensive, and perfomiance was poorer than for a 'low' resistance concrete.
C3.3.2 Resistance to sulfate attack

BCA (1991b) reportkd that foamed concrete could be used in sulfate-bearing grounds. Some short-term data on the
perfoniiance of PUPFA and PC/sand foamed specimens in a severe environment (Class 5 exposure conditions using a
solution ofmagnesium sulfate) are reproduced from Dhir (1999) in Figure C14. Further data, reported by Brady (2000), are
reproduced in Table C10. Measurements of ultrasonic pulse velocity (UPV) were determined according to BS 1881: Part
203: 1986. These provide a good indicator of changes in the properties of a material: an increase in velocity would usually
indicate an increase in density and vice versa, but velocity would also reduce with cracking of the material. Both sets of data
confirm that foamed concrete has a good resistance to sulfate attack, at least in the short-term. But there is a pressing need
to investigate its longer-tenn perforniance.
Versiort No: 1 Application Guide AG39 October 2001
A-25
I i
Specification for foamed concrete Appertdices
PFA mixes Sand mixes
25 I I
N^
E 20
.
E
E '5
3
I 10
-0 50 100 150 200 0 50 100 150 200

Cycles Cycles
I
40
o^
0
U
2 35
0
x 30
- 0
P
2)
2 25
P
20
0 50 100 150 200 0 50 100 150 200
Cycles Cycles
0.2 I J,
E
C
0.15
0.1
0.05
t z 0.05 I- I
.e 0
2
j1 4.05
a
4.1
-0.15
c1 , I I -0.15
I
-0.2 I I
4.2
0 50 100 150 200 0 50 100 150 200
Cydes Cydes
+ Plastic density 1400 kg/m3 (wic ratio 0.3) U- Plaslic density 1800 kglm? (w/c ratio 0.3)
+ Plastic density 1400 k g / d (w/c ratio 0.4) -Q- Plastic density 1800 k g / d (w/c ratio 0.4)
Figure 13 Freezehhaw resistance of foamed concrete, after Dhir et al. (1 999)
Version No: 1 Application Ciiide AG39 October 2001
A-26
Apperrdices I Specificatiort for foamed concrete
PFA mixes Sand mixes

25 25
P 20 .-E 20
'2 U
U,
P
,
a
z2 15 GN
lE
a 15
I
-g 0s
L
25
U
3-
10 -U
2-
10
9 5 2 5
I I I 0
0 1 2 3 4 0 1 2 3 4 5
Time (weeks) Time (weeks)
40 I I
._
2.
2F 35 1 a
._ 40
2 u 20
0 0.5 1 1.5 2 2.5 3 3.5 4 0 1 2 3 4 5 6
1.6 I , 1.6
1.4 1.4
-
?5 1
1.2 -
?5 1
1.2
.- .-
!g 0.8 !g 0.8
-
.-5 0.6 $
.- j,0.6
2 0.4 $ 0.4
0.2 0.2
0 0
0 0.5 I 1.5 2 2.5 3 3.5 4 0 1 2 3 4 5 6
".""
0.03 i-
4.m ,
0 q.5 1 1.5 2 2.5 3 3.5 4 0 0.5 1 1.5 2 2.5 3 3.5 4
+ Plastic densily 1400 k g l d (w/c ratio 0.3) -0- Plastic density 1800 kg/m3 (wlc ratlo 0.3)
--A- Plastic densily 1400 kg/m3 (w/c ratio 0.4) -C- Plastic density 1800 kg/m3 (wlc ratio 0.4)
Figure C14 Sulfate resistance of foanied concrete, after Dhir et al. (1999)
Vcr,siorr No: I Appliccitiorr Guide A C39 October 2001
A-27
Table C10 Effect of sulfates on properties of foamed concrete, after Brady (2000)
~~~
Compressive Hardened
UPv strength densiy
(kmh) (N/mm2) (kg/m,i
Time in
Age at solution Mean % of Mean % of kfean % of
test (days) (days) of3 control of3 control 0f3 control
(a) Foamed concrete type 1

28 0 2.2 1 100 2.83 100 1330 100

(control)
28 ' 21 2.33 105 2.83 100 1340 101
56 0 2.32 100 3 .OO 100 1290 100

(control)
56 49 2.50 108 3.00 100 1370 106
90 0 2.54 100 3 83 100 1400 100

(control)
90 83 2.56 101 3.67 96 14101 101
(b) Foamed concrete type 2

28 0 2.58 100 6.33 100 1570 100
(control)
28 21 2.71 105 6.50 103 1580 10 1
56 0 2.71 100 7.17 100 1590 100

(control)
56 49 2.71 100 7.50 105 1590 100
90 0 2.71 100 7.83 100 1600 100

(control)
90 83 2.14 101 7.83 100 1590 100
(c) Foamed concrete type 3

28 0 3 .OO 100 10.83 100 1750 100
(control)
28 21 3.04 101 10.33 95 1710 98
56 0 2.78 100 9.67 100 1650 100

(control)
56 49 2.93 105 11.00 114 1710 103
90 0 3.04 100 10.67 100 1700 100

(control)
90 83 3.09 102 12.83 120 1720 101
Details offoamed concrete given in Table C9
Version No: 1 Application Guide A G39 October 2UUl
A-2 8
Aiilierr dices Speci$catioit for foained coitcrete
C3.3.3 Permeation characteristics

Transport processes through foamed concrete include absorption, penneation and diffusion: for any particular agent these
can operate individually or, inore commonly, in combination. Chemical reactions and electrochemical processes can play
an important role, for example in detemiining the rate of carbonation. Ions can be transported through the movement of
water. Thus the penetrability of foamed concrete plays an important role in detemiining its susceptibility to degradation.
The penetrability of foamed concrete is strongly dependent upon its porosity, and the size distribution and connectivity of
the pore spaces. Its permeability to gas or water could therefore be governed by the extent of cracking in the bulk. Where
air voids are interconnected by micro-cracks, permeability will be much higher than for normal weight concrete having the
same w/c ratio. But where the voids are isolated the reverse will be the case.
Through its role in affecting cracking (at Least at the surface), the curing regime might have a dominating influence on the
penetrability of concrete. When assessing site perfomiance, tests should be done on cores recovered from the site, or the
in situ curing regime should be replicated (as best can be) on laboratory cured specimens.
Water ahsorptioti
Dhir et ul. ( I 999) found that the initial surface absorption (ISA) test, as described in BS 188 1 : Part 5: 1970, was not suitable
for foamed concrete having a dry density of less than about 1400 kg/m’. This might be due to the coarse porous structure
and perhaps interconnectivity of such concrete giving rise to leakage from under the test cap a n d o r the sides of the test
specimen. The results of (ISA) tests undertaken on relatively dense foamed concrete are provided in Table C l l : it can be
sccn that the ISA values of a PCYPFA mix are almost an order of magnitude higher than for a PC/sand mix.
Table C11 ISA values of foamed concrete, from Dliir et al. (1999)
ISA’ (ml/m2/s)
Mixt w/c ratio 10 min 30 min 60 min

~~~ ~~~
PC/sand 0.3 0.213 0.131 0.079

0.4 0.105 0.05 1 0.033
PC/PFA 0.3 0.981 0.785 0.703

0.4 1.439 0.458 0.31 1
tplostic deiisity = ISOO /ig/in’ utid PC cotitetit = 500 icg/nz”

‘See Scction C3.3.3
Dhir c / U / . ( I 999) also reported that measurements of the water absorption of totally immersed specimens indicated similar
behaviour and absorption levels for PC/sand and PC/PFA mixes. For both types of mix the absorption rate reduced
significantly with the period of inmiersion.
Thc results of water absorption tests (to BS 1881: Part 122: 1983) undertaken on foamed concrete have been reported by
Brady (2000). Some of the data are reproduced in Table C12. The test method requires specimens to be oven-dried prior
to the test but this might lead to excessive cracking of foamed concrete specimens, which would increase absorption.
Nonetheless, the absdrption levels, and the values ofporosity derived from them, are much lower thanthe air voids calculated
from thc mix design infonnation. Thus it can be concluded that a significant number of discrete, or unconnected, air voids
were present in the hardened concrete. By comparison with these data, according to a 1988 report of the Concrete Society
the nieati absorption value for concrete is between 3 and 4 per cent. Thus, as could perhaps have been anticipated, foamed
concrete has a much higher capacity for absorbing water than nomial weight concrete.
Vcrsioir No: 1 Application Guide AG39 October 2001
A-29
Specification f o r foamed coricrete Appeitdices
Table C12 Results of water absorption tests, after Brady (2000)

I
Foamed concrete Water absorpioti (!!)
30.5 (mean of 3 measurements)

18.3 (mean of 5 measurements)
1 6 5 (mean of 5 measurements)
tSee Table C9
Sorptivity indices, calculated using the method given by Hall (1 9S9), from capillary rise tests are given in Table C I . The
values for foamed concrete (with a dry density of 1400 kg/m3) range from 0.04 to 0.12 mnl/min’”: this compares with a value
of about 0.020 mm/min”’ for normal weight concrete having a compressive strength of 35 Nlmni’, see for example Jones
and Scorey (2000). It can also be seen that foamed concrete formed with a protein-based surfactant had the lowest sorptivity
index, thus confirming the efficiency of the closed cell structure of such concrete.
Waterpermeability
Brady (2000) reported the results of permeability tests undertaken on specimens of foamed concrete according to Concrete
Society Technical Report 31 (Concrete Society, 1988). Data from these tests are reproduced in Figure C1S. Because of
differences in preparing and testing specimens it is difficult to make direct comparisons, but it would seem that the three
types of foamed concrete tested were more than 100 times more permeable to water than normal weight concrete.
I
Water vapour diffusivity
The results of tests for water vapour diffusivity, using the method described by Dhir et al. (1989a), show, as expected, an
increase in the ease of diffusivity with reducing density. They reported that, for a dry density of 1400 kg/m3, the rate of
diffusivity for foamed concrete formed from PC/sand was twice that of one formed from PUPFA.
The values quoted in Table C 1 for foamed concrete are almost double those reported by Jones and Scorey (2000) for normal
weight concrete having a compressive strength of40 to 50 N/mm2.The effect ofthe type of surfactant on the ease of diffusion
of water-vapour has not yet been fully explored, but it could be expected to be in line with the trends observed for other
permeation properties.
Gas permeability
A selection of the results of air permeability tests, using the method described by Dhir et al. (1989b) is given in Table C13.
The air permeability of foamed concrete is higher than that of normal weight concrete by almost an order of magnitude: the
difference increased with decreasing dry density of the foamed concrete.
Kearsley and Booysens (1998) found that the permeability to oxygen increased with decreasing density of the foamed
concrete. At a dry density of 1500 kg/m3,foamed concrete had a lower permeability to oxygen than nomial weight concrete
having a compressive strength of 25 N/mm2.
Brady (2000) reported the results of oxygen permeability and diffusion tests undertaken on foamed concrete in accordance
with the TEL in-house procedure and as defined in TP 1303/90/4672 (TEL, 1990a). The data from these tests are reproduced
in Table C14. The weakest mix, type 1, was too permeable for the diffusion tests. The diffusion coefficients for types 2 and
3 were about two orders of magnitude higher than quoted for normal weight concrete having a w/c ratio of 0.7.
A-30
Appciiilices SpeciJicatioti for foamed coticrete
*\Type 1 (see Table C9)

1000 1250 1500 1750 2000
Hardened density (kglrns)
Figure C1S Relation between water permeability and hardened density, after Brady (2000)
Table C13 Air permeability of foamed concrete, from Dliir et al. (1999)
Iiilet pressure (jmjf Intrinsic

permeability'
Mix M/C ratio 110 90 70 50 30 m2xIO-i7
PC/sand 0.3 I30 105 75 46 21 18.2

0.3 400 340 245 164 91 25.8
0.4, 139 118 82 50 25 21.4
0.4 133 125 90 56 28 18.9
PUPFA 0.3 25 --
77 16 8 - 5.9
0.4 42 35 24 12 - 10.1
Versiorr No: I Application Guide A C39 October 2001
A-3 I
Specification for foamed concrete Appelr dices
Table C14 Permeability of foamed concrete to oxygen, after Brady (2000)
Oxygen pernieability (m2)
Foamed concretet I 2 3 4 5 6 hfcui?

Oxygen diffusion coeficietit (nz2/s)
Foamed concrete? I 2 3 4 5 6 A4cu11
(6) Coefficients of oxygen diffu,sion

Type 2 4.6~10.~ 4.8~10'~ 7.2~10'~ 5 . 1 ~ 1 0 ~ 6 . 6 ~ 1 0 ~ 5.4~10.~ 5.6~10"'
Type 3 1.9~10.' 1 . 71~0-6 1 . 51~0-6 1 . 0 ~ 1 0 - ~ 6. lx 10.'' 6. lx 10-6 1 . 2 1~0-6
See Table C9
Carbonation
Brady (2000) reported the results of accelerated carbonation tests undertaken on foamed concrete in accordance with pr EN
104-839: 1997. The results are summarised in Figure Cl6: note that each data point represents the mean of I8 individual
readings. The mean rate of carbonation was reported to be about 5.7 m m / ~ e a r and
" ~ at least 50 per cent higher than quoted
by Bamforth (1998) for normal weight concrete having the same cement content.
4.5 ,
4.0 4 --t Type 1 (see Table C9)
d@
0.5 -
0.0
d
.@
0 5 10 15
Square root of time ( ~ i a y s ~ . ~ )
Figure C16 Relation between carbonation depth and square root of time for foamed concrete, after Brady (2000)
The carbonation resistance of relatively high strength, i.e. 'structural grade', foamed concrete (using the test method
described by Dhir et al., 1999) is much lower than that of normal weight concrete. As shown in Figure C17, over a period
of three months or so the depth of carbonation in a PC/sand mix, having a plastic density of 1400 kg/m3, was in excess of
20 mm. The much higher resistance of the denser foamed concrete might be attributed to its denser structure and its higher
cement content.
I
Version No: I Application Guide A G39 October 2UU1
A-32
Aliperrdices Specification for foamed coiicrete
25
20
C. w/c ratio 0.4

E
-‘0 15
E
-
.-
5
f
0
B 10
5
CL
a,
L3
0
0 2 4 6 8 10 12 14 16
Time (weeks)
Figure C17 Carbonation resistance of foamed concrete, after Dhir et al. (1999)
Kearsley and Booysens (1998) reported the results of accelerated chloride corrosion tests undertaken using a galvanostatic
system. The results ofthese tests indicate that the durability of foamed concrete was about equivalent to low-strengthnormal
weight concrete.
Brady (2000) reported the results of chloride diffusion tests undertaken on foamed concrete in accordance with the TEL in-
house procedure laid down in TP I303/90/4670 (TEL,I 990b). Some ofthese results are reproduced in Table C15. In contrast
to the results ofthe absorption and permeability tests (see above) the results ofthese tests did not seem to be much influenced
by the hardened density of the concrete. Comparison with the data reported by Bamforth et al. (1997) suggests that the
diffusion coefficient ofthe three types of foamed concrete at 28-days was about an order ofmagnitude higherthan for normal
weight concrete having a w/c ratio of between 0.5 and 0.6. The coefficient for the foamed concrete reduced about five fold
over a period of about a year, but the chloride ion concentration at the surface increased: such trends are found with normal
weight concrete.
C3.4 OTHER PROPERTIES AND CONSIDERATIONS
C3.4.1 Thermal conductivity

The cellular structure of foamed concrete provides it with a low thermal conductivity, which, according to BCA (1994),
typically is 5 to 30 per cent of that of normal weight concrete. As pointed out by Kessler (1998), in practical terms normal
weight concrete elements would have to be 5 times thicker than foamed concrete ones to achieve similar thermal insulation.
The thernial conductivity of low density foamed concrete can be as low as 0.10 W/mK (the lower the value the better the
I
insulating properties) - see Walker and Clark (1988). This coinpares to values of between 1.1 and 1.4 W/mK for normal
weight concrete (CIBS, 1980).
Versioir No: I Applicatioti Guide AG39 October 2001
A-3 3
Table C15 Calculated chloride ion diffusion coefficients, after Brady (2000)
Meun
28 day chloride d$,i,iisioncoeficient (nz2/s) surfbce
chloride
Foamed concretet Specimen 1 Specimen 2 Specinten 3 Mean (%)
(a) 28 days exposirre

Type 1 1.22x10"' 1.54~10-~" 3.73x IO-"' 1.04~10'~'' 0.322
Type 2 2.34x10-"' 4.13x10-"' 2 . 1 6 10-I"
~ 2 . 8 8 1~O-"' 0.304
Type 3 1.10x10-"' 1.81x 10-1'1 1.76xlO-"' 1.56x10-"' 0.355

~
Meun
I year chloride diffusion coefficient (ni?Ls) surface
chh i d e
Foamed concretet Specimen 1 Specimen 2 Specimen 3 Meun (!A)
(b) I year exposure

Type 1 5.96x10-" 5 . 6 7 1~0." 4 . 4 4 10'"
~ 5 . 3 6 10.'
~ 0.71 1
Type 2 7.23x10-" 5.16~10'" 6 . 7 2 10-"
~ 6.3 7x 10.' ' 0.753
Type 3 6.2 1x 10." 2 . 7 0 10-"
~ 4 . 3 3 1~0." 4.4 1x 10-I I 0.733
See Table C9
C3.4.2 Fire and flame spread resistance
The fire resistance offoamed concrete is excellent; at low temperatures it is better in terms ofthe proportional loss in stren$h
than normal concrete (Kessler, 1998). But at high temperatures, it suffers from excessive drying shrinkage (Sach and Seifert,
1999). The flame spread resistance of foamed concrete has not been reported but, following from the above, it could be
expected to be better than that of normal weight concrete.
C3.4.3 Embedment of services
Provision for services cast within foamed concrete should be similar to that for well-compacted branular fill. Foamed
concrete is easily re-excavated, and so access to services for future repair is simple.
C3.4.4 Risk of rodent attack

Since foamed concrete is a relatively low strengthmaterial, there may be a small riskof rodent attack, particularly when used
to embed sewer pipes. Although no such occurrence has been reported the issue might need to be addressed.
C4 PRODUCTION METHODS
Foamed concrete is usually manufactured by mixing together pre-formed cement paste (or mortar) and a relatively stiff
foam, but it can also be formed by adding a foaming agent to the base mix and intimately mixing.
According to Walker and Clark (1988) the rate of production of foamed concrete from a mobile mixer ranges from 3 to
50 m3/hr.
A-34
Apperr dices Specificatioti for foamed concrete
C4.1 FOAM !
A ‘wet’ or a ‘dry’ foam can be manufactured. The quality of both types is similar, but dry foam is thought to be more stable,
and hence to produce better quality but lower density concrete, but its rate of production is lower, see Aldridge (2000b) and
McGovern (2000).
C4.1.1 Wet foam

Wet foam can be produced either by compressed air or through the use of a Venturi generator. With the former an aqueous
surfactant solution is pressurised in a vessel and then forced through a small diameter outlet, i.e. the foam gun. With this
technique, the bubbles are quite small and the foam is relatively stiff. With a Venturi generator, the surfactant is sprayed on
a metallic gauze placed inside a metal tube. Air is then sucked through the back ofthe tube, which combines with the solution
and produces foam with relatively large bubbles. The selection of the foam-generating device is dependent on the volume
output requirements: a Venturi generator is normally used on larger-scale projects.
C4.1.2 Dry foam

Dry foam is produced by spraying a surfactant solution through baffles, this produces a foam with small bubbles. The
resulting foam has a volume of between 20 to 25 times that of the surfactant solution (EABASSOC, 1996) and a density of
between 25 and 80 gndlitre (BCA, 1994). The foaming agents employed can be synthetic compounds (e.g. alkyl sulfates)
or natural organic compounds (e.g. hydrolysed proteins and keratin) that have a stable cellular structure to withstand the
mixing process (Bartos, 1992).
C4.2 MIXING PROCESS
C4.2.1 Direct ready-mix method (preformed)

Following the mixing and testing of the mortar, to ensure that it is homogeneous and of adequate workability, the foam is
prepared and blended gently into the mortar to produce a flowing mix of the required density. (To date little work has been
carried out to determine the minimum workability of a base mix required for adequate incorporation of foam.)
The blending of the foam with thc cement paste or mortar can be carried out either at a ready-mix plant or on site, but it must
be undertaken carefully to prevent breakdown of the bubbles of the foam.
The type of mixer, the speed of rotation and mixing time all affect the quality of the foamed concrete. Because they allow
the foani and mortar to flow into each other, rotary drum mixers are effective (Sach and Seifert, 1999). Mixers with paddles
rotating on a horizontal shaft or a screw action in a trough are strongly recommended by Dransfield (2000) because these
encourage ‘folding action’ of foam into the base mix. The speed of rotation of a ready mix truck mixer will affect the foam
dosage required and the properties of the fresh mix. Mixing time is important: short mixing times result in inhomogeneous
foamed concrete, but prolonged mixing at high speeds leads to disintegration of the foam (Kearsley, 1996).
C4.2.2 In-line production

In-line mixing is an alternative to the direct injection of foam into a concrete mixer. In this case the base mix is discharged
into a unit where it is blended with the foam. The density of the material is monitored via an on-board density monitor and
adjustments made to achieve the target plastic density: details of the method have been provided by Aldridge (200021).
Pumping capability is provided in the unit through a single helical screw pump. According to Aldridge (2000a), the accurate
control of density and the efficiency of this method has led to it being increasingly used to produce foamed concrete on site.
Applicntiori Guicle AG39 October 2001
A-3 5
I
Specification for foamed concrete Appenrlices
C5 PRACTICAL CONSIDERATIONS
C5.1 FORMWORK AND MAXIMUM POUR DEPTHS

Unless particular precautions are followed, and the consequences are known and accepted, the depth of a pour should not
exceed 1.5 metres: thicker pours increase the risk of segregation and settlement of the material. Where thicker depths are
required, pours should be carried out in layers of about equal thickness.
C5.2 CURING
As discussed in Section C3.2.1, a number of curing regimes for foamed concrete have been explored. A barrier fonn of
membrane is recommended for curing on site.
C5.3 ENVIRONMENTAL IMPACT

In terms of environmental issues, there are no additional implications arising from the use of foamed concrete than with
normal weight concrete.
It should be appreciated that because no coarse aggregates are used in the production of foamed concrete, such natural
resources are conserved. Furthermore industrial by-products, such as PFA, are often employed to replace both PC and sand,
particularly in low-density foamed concrete.
C5.4 HEALTH AND SAFETY, CDM REGULATIONS AND COS"

All health and safety issues raised in the Construction Design and Maintenance (CDM) regulations (i.e. use of goggles,
gloves, ear defenders, etc.) apply to the production, placement and treatment of foamed concrete in both fresh and hardened
states.
Due to the nature of the material special attention must be paid during placing as splashing can occur, and so the use of
goggles should be mandatory. Protective barriers should be placed around the area of the pour to prevent site workers, the
general public and materials from falling in. Such barriers needs to be in place for about 24 hours to allow the foamed
concrete to achieve sufficient strength: the period will vary with the type of cement, the density of foamed concrete, and
the strength, size and depth of the pour.
As regards COSHH, no measures beyond those applying to normal weight concrete production need to be taken for foamed
concrete.
I
C6 APPLICATIONS
C6.1 TYPICAL USES

Foamed concrete is used for a variety of applications, ranging from thermal lnsulation and fire protection to void-filling and
building elements with successively increasing density and strength requirements.
The Home report (New Roads and Street Works Act, 1991) recommended the use offoamed concrete forreinstating trenches
in roads. This was followed in 1992, by the HAUC specifications, which required minimum strengths of 2 or 4 N/mm2
(depending on use) and a minimum density of 1050 kg/m3, see Chandler (2000). Such reinstatements are necessary after
pipe laying orrepairs are completed. Foamed concrete is self-compacting, does not suffer from excessive internal settlement
Version No: I Applicntion Guide .4 G39 October 2001
A-3 6
Apperrrlices Specification for foamed concrete
and its load-spreading characteristics prevent the direct transmission of axial loads to the buried services. As a result further
maintenance is seldom required. In addition, foamed concrete develops sufficient strength in a day, and so disruption to
traffic from the street works is low. Because low-density foamed concrete will float, care must be taken when the trench is
partially filled with water: on the other hand pipes may float where a high density concrete is used and in such cases the pipe
might have to be restrained at the bottom of the trench.
The ability of foamed concrete to flow easily under its own weight has led to its use for void filling, particularly where access
is a problem. The most coninion applications are filling sewerage pipes, wells, cellars and basements ofold buildings, storage
tanks, tunnels and subways, see for example FEB/Master Builders (I997). However the same precautions as above must
be taken when water is present in the void.
A few bridge abutmekts in the UK have been built with foamed concrete as the backfill. Because of its strength, the lateral
load imposed on the structure is negligible. And because of its light weight, settlement is much lower than it would be with
a conventional backfill: it therefore allows a substantial reduction in the size of the bridge foundations. For the samereasons,
foamed concrete has been used rather than granular backfill to provide stability on embankment slopes (BCA, 1991b) and
to build-up embankments to support overlying bridges.
The light weight and excellent thermal insulation properties of foamed concrete have led to its use as roofing insulation in
the Middle East (EABASSOC, 1996) and South Africa (De Rose and Morris, 1999). Its low density and high thixotropy
enables roof slopes to be foiined (Dransfield, 2000).
Because of its self-levelling properties, foamed concrete has also been used for blinding layers (Basiurski, 2000), and as sub-
floor material to provide thennal and sound insulation to both new and renovated structures (BCA, 1991b).
Other applications include its use as:
an insulating fill in fire walls or other precast elements;
a replacement for soils and backfills;
the construction of cast-in-place piles;
0 raft foundations to low rise buildings, such as houses;
a foundation to sports fields and athletics tracks;
grouting the ihterior of tunnels;
backfilling of voids behind a tunnel lining;
a foundation base for storage tanks.
C6.2 INNOVATIVE USES

Some innovative applications, as described by Basiurslu (2000), include its use as an underfloor heating system, a sprayed
insulating material for concrete domes, decorative panels for wall fences and low-height retaining walls, and for producing
light-weight GRC panels and precast elements (e.g. fence posts, poles, lintels, window and door frames). It has also been
considered for constructing igloos, dog kennels, bullet-absorbing walls, concrete aeroplanes and ornaments.
Vecsiorr No: I Applicatioii Giride AC39 October 2001
A-3 7
C6.3 DETAILS OF PARTICULAR PROJECTS
Approach embankment, Colchester
Foamed concrete was used for the construction of approach embankments to a railway bridge in Cqlchester, details have
been given by Pickford and Crompton (1996) and Anon (1996). The foundation subsoil at the site was a soft clay and by
using foamed concrete rather than normal weight backfill, the required number of piles to the embankment reduced
substantially and the wall thickness ofthe abutment was halved: see Aldridge (2000b). As both a relatively low density and
high strength were required, two mixes were used. The upper metre was formed from foamed concrete having a compressive
strength of 4.5 N/mm2(28-day) and a plastic density of 1450 kg/m3.Below this a lower density (1250 kg/m3),lower strength
(3.0 N/mm2) mix was specified. The concrete was foamed on site, and measurements of plastic density and specimens for
monitoring compressive strength were taken every few loads. A total of 4000 m3of foamed concrete was placed at this site.
Bridge deck, North Wales

Foamed concrete was used to replace the failed waterproofing mernbrane of the 25-year old bridge deck of a flyover
connecting Llandudno junction and Deganwy. A PCIsand (340//660/) mix having a dry density of 1300 kg/m' and a
28-day strength of 4 N / m 2 was specified. This was placed to a depth of up to 400 mm and then covered with a black top
wearing course: details have been provided by Pickford and Crompton (1996).
Kingston bridge
The existing 7-arch masonry bridge at Kingston had to be widened to increase traffic capacity: a weight limit was placed
on the existing bridge in 1993. The work involved the use of precast concrete arch shells, to resemble the older structures,
with a concrete saddle cast over the arches and foamed concrete used to fill the voids between the arches and final road
surface. For the upper 700 mm, a PC/sand (3 1/69) mix was specified with a dry density of 1400 k g / d and a 28-day strenLqh
of 7 N/mm2. At greater depths, a PC/PFA/sand (64/12/24) mix having a density of 1600 kg/m3 and strength of
1 N/mm2 (28-day) was specified: details have been provided by Aldridge, (2000b). I
Access road, Canary Wharf
The Canary Wharfproject in London Docldands involved the construction of two access roads, the foundations of which
were formed from foamed concrete to reduce the vertical load on the foundations and thereby reduce settlement. Two mixes
were specified. The upper layer, for use a metre below the road surface, was 0.5 ni thick and had a dry density of
670 kg/m3 and a minimum 28-day compressive strength of 0.87 N/mn2.Beneath this layer, the concrete had a density of
480 kg/m3 and 28-day strength of 0.27 N/mm2: details have been provided by Van Deijlc (1991).
Numerous examples exist of the use of foamed concrete for filling voids as part of stabilisation works. These include:
i the Heathrow railway tunnel, part of which collapsed during construction;
ii an undermined road in Lublin, Poland, which was threatened by collapse when the ground below was washed away
by heavy rain. Old sewer pipes and inspection chambers were also filled with foamed concrete, prior to the
construction of a new sewer system;
...
111 the placement, in 1986, of 19,500m3offoamed concrete, having a dry density of500 kg/m3,as harbour fill in Holland.
The maximum permissible amount of settlement in the first year was specified to be less than 80 mm: details have
been given by Basiurski (2000).
Version No: 1 Application Guide A C39 October 2001
A-3 8
Apperrclices Specificatiorr f o r foamed coricrete
C7 REFERENCES
Anon (1996). UK’s largest,foanied concretepour,for railway enilianknient. Quality Concrete, Vol 2, NO 2, p 53.
Aldridge D (2000a). Foanied concrete. Concrete, Vol. 34, No. 4, pp 20-22.
Aldridge D (2000b). Foanied concrete.for highway bridge works. One-day awareness seminar ‘Foamed concrete:
properties, applications and potential’ held at the University of Dundee. pp 33-41.
Anon (2000). Interini DETR project report ‘Developnient offoatlied concrete f o r insulating trenchfill foundations and
ground-supported slabs o f lowrise doniestic buildings ’. Dundee: University of Dundee.
Ansell T (2000). Personal communication.
ASTM C266-89. Test nietliod,for time of setting qfliydraulic cement paste by Gillniore Needles.
ASTM C666-90. Te.st,for the resistance o f concrete to rapid freezing and thawing.
ASTM C869-91. Standard .s~ecificatiotiforfoamiiigagents used in niaking preforniedfoarn f o r cellular concrete.
Banifortli P B, Price W F and Emerson M (1997). An international review of chloride ingress into structural
concrete. Contractor Report CR359. Crowthorne: TRL Limited.
Bamfortli P B (1998). Appendix I : Modelling carlmiation rates using the concept of equivalent chemical buffering
capacity. In Guidance on the selection of measures for enhancing reinforced concrete durability. Report prepared under
the DOE Partners in Technology Programme Contract CI 39/3/367 (cc 967). To be published by the Concrete Society.
Bartos P J M (1992). Fresh concrete. Properties and tests. Amsterdam: Elsevier.

I
Basiurski J (2000). Foanied concrete.for voidjIZing, insulation and construction. One-day awareness seminar
‘Foamed concrete: properties, applications and potential’, held at University of Dundee. pp 42-52.
Brady K C (2000). An investigation into the properties qf foamed concrete. Project Report PRAS/99/00. Crowthorne:
TRL Limited. (Unpuhlished report available on direct personal application only)
Brady K C and Greene M J (1997). Foanied concrete: a review of niaterials, niet1iod.s ofproduction and
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British Standards Institution. London
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Appetiilices Specification for foamed coricrete
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A-42
Apperrdices I Specification f o r foatned coticrete
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Versiori No: 1 Application Giiide AC39 October 2001
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Specification for foamed concrete

K C Brady, G R A Watts and M R Jones

Application Guide AG39

This report has been produced by TRL Limited, underlas part

T U is committed to optimising energy efficiency, reducing

2.2 History and background

APPENDIX B: GUIDE FOR SPECIFICATION AND

APPENDIX C: FOAMED CONCRETE A-3

of applications, it is important to define performance requirements for each case.

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iv properties of foamed concrete, Brady (2000).

2.1 DEFINITION, CONSTITUENTS AND PROPERTIES

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Figure 1 Typical nature of foamed concrete

2.2 HISTORY AND BACKGROUND

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Figure 2 Small-scale laboratory foam production and typical nature of foam

Figure 3 Large-scale on-site foam production

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i Ease of application and re-excavation (if necessary).

2.3 CURRENT USAGE

Test carried out Tested by

Quality control test Atpoint CfdeZivety Laboratory Contractor Supplier

Fresh concrete: plastic density J x J J

Fresh concrete: workability of

Hardened concrete: cube strength x J J J

Hardened concrete: soundness J x J X

J Recommended for most uses and sites

Version No: 1 Application Giiiile AG39 October. 2001

3.1 FOAM DENSITY AND STABILITY

Figure 4 Use of glass measuring cyclinder for detemiining density of foam

3.2 PLASTIC DENSITY

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Figure 5 Measurement of the plastic density of foamed concrete

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Flow rate. using apparatus

1 1 litre in < 1 minute A+ Constant flow

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4.2.1 Essential items

Type of binderf Standard

Cements containing pulveriserI-fird ash (PFA) or limestone I

Precluding cements containing slag.

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Table 3 Aggregates f o r general use, based on Table 2 of BS 5328: P a r t 1: 1997

T1ye Desigtiatioti Staizdard

Lightweight Lightweight aggregates for concrete BS 3797: 1990

4.2.2 Optional items

Mu-viiizrrnz cirOe strength

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Sustained core temperature

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ii Are other site works likely to be affected by the non-conformity?