Materials Today: Proceedings 68 (2022) 2026–2031

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Use of industrial wastes as a filling materials in foam concrete: A short

review
Y. Sivananda Reddy, S. Anandh ⇑, S. Sindhu Nachiar, P.T. Ravichandran
Department of Civil Engineering, College of Engineering and Technology, SRM Institute of Science and Technology, Kattankulathur, Chengalpattu 603203, India

a r t i c l e i n f o a b s t r a c t

Article history: The building sector is concerned about the environment, so dedicated to fabricating more strong and dur-
Available online 2 September 2022 able concrete is a responsibility for the new era. As a result, normal concrete materials can be replaced
with innovative and sustainable materials, reducing environmental issues. Foam Concrete (FC) is one
Keywords: such material, which is a lightweight substance made from cement, sand, water, and a foaming agent.
Sustainable concrete It has numerous benefits. Yet, it fails to offer enough strength and shrinkage behavior to concrete. The
Foaming agent paper’s major goal is to look at industrial wastes as a filler material for concrete that can substitute for
Shrinkage behavior
the shortcomings of foam concrete. The review also looks at the stability, bulk densities, strength qual-
Pore size & pore structure
ities, pore size and pore structure, and other aspects of the material.
Copyright Ó 2022 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the 4th International Con-
ference on Advances in Mechanical Engineering (ICAME 2022).

1. Introduction
Construction is a major industry that consumes heavy
resources, which in turn results in the economic development of
a country. In another light, it is also an industry that has a greater
impact on environmental. Cement production alone contributes 8–
10 % of global greenhouse gas emissions, with the value expected
to rise to from time to time [1]. It is obvious that wasting natural
resources has negative environmental consequences. Green con-
crete should be used to limit the usage of natural resource. Foam
concrete is a type of material made from foam, cement, sand,
and water. Green concrete is made by mixing industrial wastes
with foam in the concrete mix.
Globally, industrial wastes are a major cause for concern. Envi-
ronmental, economic, and health problems arise when this waste is
primarily buried in landfills. fly ash, silica fume, ground granulated
blast furnace slag, and copper slag are all examples of significant
industrial wastes [2]. India has the most coal mines and thermal
power plants that use coal to make electricity. On the other hand,
bituminous and non-bituminous coal both have a 40 % ash content.
At present, thermal power plants make 120–150 million tons of fly
ash [3]. Silica fume is a by-product of the silicon and ferrosilicon
alloy industries. It is an ultrafine powder, also known as micro sil-
ica, that contains 75 % silicon [4]. GGBS is a by-product of the iron
and steel manufacturing processes. It is made by reducing smelted
iron and blast furnace slag with water or steam. One tone of GGBS
production uses 1300 MJ of energy and emits 0.07 tonnes of CO2
[5]. Copper slag is generated from smelting ores. Most of the time,
it is granulated into the size of sand, with particles size not bigger
than 5 mm and not smaller than 1 mm [6].
Cement, fine aggregate, and water make up the slurry. A foam-
ing agent and water are used to make foam. Foam solution and
cement-based slurry are combined together to make foam con-
crete. Foam Concrete (FC) provides a number of advantages over
standard concrete, including high flowability, density, excellent
temperature resistance, and the requisite compressive strength.
By maintaining the optimum foam dosage, FC density can range
from 400 kg/m3 to 1800 kg/m3. FC could be used in a variety of
structural components, including partitions, insulation, and infill
grades [7–9]. Fan and Wang were the first to get a patent for FC
with Portland cement [10] and Valore was the first one to study
on cellular concrete in 1954 [11].

⇑ Corresponding author.
E-mail addresses: sy3802@srmist.edu.in (Y. Sivananda Reddy), anandhs@srmist.
edu.in (S. Anandh), sindhus@srmist.edu.in (S. Sindhu Nachiar), ravichap@srmist.
edu.in (P.T. Ravichandran).

https://doi.org/10.1016/j.matpr.2022.08.354
2214-7853/Copyright Ó 2022 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the 4th International Conference on Advances in Mechanical Engineering (ICAME 2022).
Y. Sivananda Reddy, S. Anandh, S. Sindhu Nachiar et al.
2. Materials and properties
2.1. Fly ash (FA)
The coal ash that is left over after burning coal is one of the
principal factors of FA production. Fig. 1 shows how much FA is
used in different parts of India. The hydrated cement ingredients
from the Gateway cement plant are put to good use when FA is
used in concrete. Also, FA in foam concrete tends to make the con-
crete stronger because the pores are spread out evenly and the
number of connected pores goes down [12,13]. For better results,
foam concrete should have a high level of FA activity [14].
2.1.1. Impact of FA on the properties of foam concrete.
Foamed concrete showed greater results in its hardened state
properties when FA is used in concrete to a certain extent. Wet
ground FA can enhance the hydration activity and bubble distribu-
tion of foamed PC-WGFA concrete [15]. Using the FA/C ratio in lar-
ger content makes the hydration action slower and leads to slow
compressive strength [16]. Foam Concrete has a compressive stress
that is directly proportional to its dry density [13,17,18]. The
amount of FA added and the strength of concrete are directly
related. This is because the amount of calcium (CaOH2) in the con-
crete is going down [19]. But strength development is low after
28 days. However, concrete with 30 % FA has a small increase in
compression stress [20].
Some studies say that FA made foam absorb more water for the
same amount of foam. So, the amount of FA used depended a lot on
its experimental conditions, like the type of foaming agent, mineral
admixture, and density [21]. Table 1 shows how the properties of
foamed concrete change when FA is introduced. Porosity is a cru-
cial element that impacts the physical, thermal, and durability
properties of foam concrete. In comparison to lightweight aggre-
gates in concrete, foam concrete has a lower splitting tensile
strength. On the other hand, fly ash-based mixtures did better than
fine aggregate [13,22,23]. FA and silica fume (SF) were added to
foam concrete to increase its flexural strength, which ranged from
4.02 Mpa to 5.29 Mpa [24].
Fig. 1. Utilization of Fly Ash in India [51].
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Materials Today: Proceedings 68 (2022) 2026–2031
2.2. Silica fume (SF)
As a waste product, SF is made when silicon material or ferrosil-
icon alloys are made. Most of the time, you can get SF in two colors,
as seen in Fig. 2. SF is a cementitious additive that makes concrete
much stronger and more durable. Adding SF to concrete makes it
less likely to break down by reducing the porous permeability
and improving the pore structure. This makes it less likely for cal-
cium hydroxide to move through the concrete and makes it more
resistant to sulphate attacks by increasing its content. One of the
best ways to use silica fume is in concrete.
2.2.1. Impact of SF on the properties of foam concrete
Chung et al. [28] used 10 % of SF along with cement, and it is
observed that in the early stage of growth, SF can stop bleeding
and make the concrete paste more uniform and stick together.
When 10 % SF was added to lightweight concrete, the percentages
of strength went up based on how heavy the two materials were
[29].
In his research [30], author used SF as a stabilizer in FC and
found that it might be helpful for stabilizing foam. But stabilizing
has different effects when added at different times. Table 2 shows
how the properties of the foam concrete change when SF is added.
When SF and slag powder are mixed together in a mortar with
foam, the structure of the pores can be improved. Once 30 % of slag
and 6 % of SF are added to foam concrete, it makes the concrete
more resistant to freezing. Compared to the control group, the test
group lost mass by up to 1.99 %, stress by up to 14.49 %, and poros-
ity by up to 0.513.
2.3. Ground granulated blast furnace slag (GGBS):
GGBS was made from iron and steel production. Slag is formed
as limestone, iron ore, and coke are combined in a kiln, and iron is
generated. There are many different ways to cool and harden iron
ore, but one common method is immersion in water. GGBS is cre-
ated by drying the resulting liquid to a fine powder. In 1972, Joseph
Davidovits began developing GGBS as an alternative to OPC [33].
Every year, 400 million tons of steel slag are produced by steel
companies around the world [34,35]. Fig. 3 shows the increase in
the use of GGBS in concrete manufacturing since 2015. Environ-
Y. Sivananda Reddy, S. Anandh, S. Sindhu Nachiar et al. Materials Today: Proceedings 68 (2022) 2026–2031

Table 1
Characteristics of concrete made with fly ash as a cement substitute.

Effect of fly ash on Hardened properties of foam concrete

S. No Major Hardened state properties References
Ingredients
MC WD CS TC DEM WA Porosity
(%) (kg/m3) (Mpa) (W/m.K) (Mpa) (%) (%)
1 PC, FA, LSP 20 800 7.26 x x x x [15]
2 FA, FS, MP 30 500 3.19 0.134 x x x [19]
3 FA, RFA F.A-4 & RFA-25 600 2.69 0.16 2357 70.5 40.8 [25]
4 FA 66.67 1245 6.2 0.035 x x x [12]
5 FA-f, FA-c FAf-30, fAc-50 1400 5.7 x x x 0.252 [13]
6 FA 40 700 1.18 x x 42 x [26]
7 FA 25 1600 16.63 x x x x [27]
8 FA, P-F 50 1500 40 x xx x x [16]

Note: MC-Material Content, WD-Wet Density, CS-Compressive Strength, TC-Thermal Conductivity, DEM-Dynamic Elastic Modulus,
WA-Water Absorption, PC-Portland Cement, FA-Fly Ash, LSP-Lime Stone Powder, FS-Furnace Slag, MP-Mineral Powder, RFA-Recycled Fined Aggregate, FAf-Fly Ash Fine, fAc-
Fly Ash Coarse, P-F- Pozz Fill.

Zhao [37] used different amounts of GGBS with cement and

found that the strength of GGBS increased by 25 % when cement
was used to replace 30 % of it. If you use more than 30 % GGBS,
it could make the foam concrete less strong. It has been seen that
carbonation goes up when 50 % of the GGBS is replaced with
cement. This can be fixed by giving it more time to cure [41].

2.4. Copper slag (CuS):

CS comes from a pyrometallurgical process used to make cop-

Fig. 2. Silica fume in white and grey colour.
mental risks and ecological degradation have resulted from the
dumping of byproducts like slag from factories and mills in open
places over the years. Since steel slag has become increasingly
important in research and development, it is being used to create
new recycling and utilization methods around the world [35,36].
2.3.1. Impact of GGBS on the properties of foam concrete
Due to its higher fine content, GGBS, when used as a 50 %
cement replacement, which shown to reduce the slump value of
mortar with foam [37], Using GGBS can increase the workability
of concrete, but the mix is still sticking together. GGBS have a flat
finish and less water is seen when they are mixed [38]. When 30 %
to 70 % GGBS is used in foam concrete, compressive strength
increases by a lot [37,39]. Table 3 shows properties of foam con-
crete with GGBS as a cement replacement. A high dose of GGBS
could make volume changes in foam concrete. The lowest shrink-
age strain is seen when 20 % of the concrete is replaced with GGBS
[40].
per. It is also considered to be an oxide-based waste [43]. In gen-
eral, compounds of iron, silica, aluminum, calcium, and copper
are found in CuS, In order to make 1 ton of pure copper, about
2.2–3.0 tons of CuS will be made [44]. More than 24.6 million tons
of CuS are made annually. When there is less than 0.8 % copper in
slag, it’s also sold as a product that is similar to regular basalt
(which is crystalline) or obsidian (which is not crystalline) [43].
When the amount of calcium oxide in this material goes up or
when sodium hydroxide is added, it can be used as a partial or full
replacement for Portland cement [45]. Many researches were done
on using copper slag as fine aggregate replacement and succussed
in gaining required properties.
2.4.1. Impact of CuS on the properties of foam concrete
The smooth surface of CuS aggregate makes it easier to work
with mortar mixes. Workability also goes up as content grows.
The flow value of the mortar made with 100 % CuS is 107 % higher
than the flow value of the control mix [46]. Table 4: Properties of
concrete with copper slag as a fine aggregate replacement, The
specific gravity ranges from 2.8 to 3.8, depending on how much
iron is in the rock [43].
The unit weight of CuS is a little bit higher than that of the tra-
ditional aggregate. The ability of the material to soak up water is

Table 2
Characteristics of concrete made with silica fume as a cement substitute.

Effect of silica fume on hardened properties of foam concrete

S. No Major Hardened Properties References
Ingredients
Density C.S F.S T.S Porosity T.C W.A
(kg/m3) (Mpa) (Mpa) (Mpa) (%) (W/m.K) (%)
1 SF, LWA 1000 8.3 1.5 x 30 0.32 x [28]
2 SF, ECA 1300 24.3 x 1.63 34 x 22.1 [29]
3 SF as stabilizer 1400 24.8 x x x x x [30]
4 SF, FA 1900 51.88 x x 22.4 x x [31]
5 SF, FA, FGBFS 1500 23.7 x x x 0.74 x [32]

Note: SF-Silica Fume, LWA-Light Weight Aggregate, C.S-Compressive Strength, F.A-Flexural Strength, TS-Tensile Strength, TC-Thermal Conductivity, ECA-ceramsite based
expanded clay aggregate, W.A-Water Absorption, F.A- Fly Ash, FGBFS-fine granulated blast furnace slag.

2028
Y. Sivananda Reddy, S. Anandh, S. Sindhu Nachiar et al. Materials Today: Proceedings 68 (2022) 2026–2031

Fig. 3. GGBS consumption from 2015 to 2018 in cement production.

Table 3
Characteristics of concrete made with GGBS as a cement substitute.

Effect of GGBS on hardened properties of foam concrete

S. No Major MC Hardened Properties References
Ingredients (%)
Density C.S F.S T.C (W/m.K)
(kg/m3) (Mpa) (Mpa)
1 GGBS 1300 6.8 x 0.7 [37]
2 GBS, GGBS 30 1450 19.2 1.2 x [39]
3 FA, GGBS FA-50, 1690 21.76 x x [42]
GGBS-10
4 GGBS, FA FA-40, 1550 44.1 x 0.75 [32]
GGBS-8

Note: MC-Material Content, GGBS-Ground Granulated Blast Furnace Slag, C.S-Compressive Strength, F.A-Flexural Strength, TS-Tensile Strength, W.A-Water Absorption, TC-
Thermal Conductivity, F.A- Fly Ash.

Table 4
Characteristics of concrete made with copper slag as a fine aggregate substitute.

Effect of Copper slag hardened properties of concrete

S. No Ingredients MC Hardened Properties References
(%)
Density C.S F.S T.S W.A
(kg/m3) (Mpa) (Mpa) (Mpa) (%)
1 CuS, GGBS 100 2336 30 4.43 x x [46]
2 FA, CuS 100 2200 33 x x x [47]
3 CuS 30 x 48 7.4 5.1 x [48]
4 CuS 20 x 33.6 x x x [35]
5 CuS, Pumice 5 x 28.8 4.62 4.5 x [49]
6 CuS 100 x 56.3 5.3 x 8.5 [50]

Note: MC-Material Content, C.S-Compressive Strength, F.A-Flexural Strength, TS-Tensile Strength, TC-Thermal Conductivity, W.A-Water Absorption, F.A- Fly Ash, GGBS-fine
granulated blast furnace slag, CuS- Copper Slag,

often very low (0.1 percent). Granulated CuS has a lower specific
gravity and can absorb more water than CuS that has been cooled
by air. Granulated CuS is made up of sharp, regular-shaped pieces
that typically range from 4.75 to 0.075 mm (No. 200 sieve) [43].
3. Conclusion
Introducing foam into concrete is beneficial in the construction
industry as well as for the environment. Foam concrete reduces the
consumption of natural resources. It also has high flowability and

2029
Y. Sivananda Reddy, S. Anandh, S. Sindhu Nachiar et al.
low self-weight with the required strength. There have always
been environmental-related issues due to the construction indus-
try, which has led to substantial progress in using industrial and
natural wastes to reduce the consumption of natural resources.
This paper covered a variety of topics related to industrial and nat-
ural wastes and their use in concrete. Industrial wastes like fly ash,
GGBS, and silica fume can be successfully used to replace cement
content in foam concrete.
1. Many researchers have done their work on FA utilization in
plain concrete and foam concrete. It is suggested that as the
FA content increases, compressive strength increases up to a
certain extent and then decreases. For a density of 800 kg/m3,
When FA was used, the compressive strength was observed to
be 7.26 Mpa. FA in foam concrete helps to increase the hydra-
tion process.
2. Silica fume stops bleeding in concrete and increases the consis-
tency and cohesiveness of cement paste in concrete. 10 % silica
fume exhibited greater results than conventional concrete.
3. Due to its smooth surface nature and less absorption of water
during the mix, GGBS shows more workability and cohesive
nature. 8–30 % replacement of GGBS enhances strength up to
44.1 to 19.2 Mpa. But there is an increase in carbonation that
occurred while using GGBS in concrete, which can be reduced
by curing for a longer period.
4. CuS as a fine aggregate enhances the workability and strength
properties of concrete. For 100 % replacement of CuS, it is
observed that there is a change in flexural strength up to 4.3–
5.3 Mpa. Mortar made with 100 % CuS showed a 107 % flow
value.
CRediT authorship contribution statement
Y. Sivananda Reddy: Writing – original draft, Visualization. S.
Anandh: Conceptualization, Methodology, Project administration.
S. Sindhu Nachiar: Supervision, Project administration. P.T.
Ravichandran: .
Data availability
The data that has been used is confidential.
Declaration of Competing Interest
The authors declare the following financial interests/personal
relationships which may be considered as potential competing
interests: Dr. S. Anandh reports administrative support and equip-
ment, drugs, or supplies were provided by SRM Institute of Science
and Technology. Dr. S. Anandh reports a relationship with SRM
Institute of Science and Technology that includes: employment.
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