The American Concrete Institute

Committee 229
Controlled Low Strength Material
(CLSM) presents:
A Case Study of Mass Placement of Enhanced
Extremely Low Density CLSM

By Ned Glysson, Director of Research & Operations, Elastizell Corp. of America &
Trevor Towery, Materials Research & Design Engineer, Elastizell Corp. of America
 This presentation will describe a project utilizing
66,000 cyds of enhanced Extremely Low Density
CLSM (XLD-CLSM) or cellular concrete containing
upwards of 40% fly ash as a cement replacement,
placed at a density of 25 3pcf.

The enhanced XLD-CLSM was used to load balance a

network of bridge approaches in lieu of other more
expensive alternatives. Discussion will include
advantages achieved by use of the recycled materials
such as reduced project cost, enhanced pump ability,
reduced heat of hydration, reduced carbon footprint
and less landfilled waste.
 How is an XLD-CLSM achieved?
The slurry of cement, fly ash and water has a
predetermined volume of preformed foam
added to attain a specific cast density.

The foam is a specialized concentrate

specifically formulated for use in concrete. It is
diluted in water and expanded under pressure
producing the preformed foam.

The shaving cream like foam blends with the

cementitious paste creating a discrete cellular
matrix which sets as such.
 XLD-CLSM Production Process

Fly Ash
Placement
Enhancement
Enhancement Properties
Pumpability

Reduced powder cost

Reduced heat of hydration

Greater ultimate strength

Foam Concentrate
Preformed Foam
XLD-CLSM as pumped into place
 The XLD-CLSM or cellular
concrete is a matrix of hardened
cement paste surrounding
discrete air bubbles
 The Port Huron I-94 / I-69 interchange project
was enhanced through use of 10.7 million pounds
of fly ash as a component of cellular concrete.
 I-94/I-69 Interchange
Near border crossing between US and Canada

12% commercial traffic

6 bridges remove and replace

3.7 miles of new pavement

 S-28 Bridge

55 new embankment for bridge

Traditional embankment
10-15 settlement occurring over 5 to 25 years

H-Piles being driven to support bridge abutments

Excessive settlement would create a 275 kip/pile
down drag.
Foundation designed for 500 kips per pile.
 Value Engineering (VE)
Design Comparison
Granular Fill 1 square yard area
(120 pcf)

25 feet high
Lightweight
Fill Material Cost of granular fill
not included in
comparisons.
Original Design VE Design
550 PSF 510 PSF
Granular Fill
(120 pcf) XLD CLSM (25 pcf)

Concrete (150 pcf)

PVC Liner

XLD CLSM (20 pcf)

EPS (2 pcf)
 As Built
XLD CLSM
815 PSF
Granular Fill 40% Fly Ash
(120 pcf)

60% Cement
XLD CLSM (25 pcf)
75% Air by Volume
 Load Balancing
Load balancing involves excavating existing
heavy material and replacing it with an equal or
greater depth of low density XLD CLSM
Original Design As Built Design
$2,100 per syd $1,700 per syd
Granular Fill Granular Fill
(120 pcf) (120 pcf)

Concrete (70 $/syd)

PVC Liner
(7.20 $/syd) XLD CLSM
(76.81 $/cyd)
EPS
(95 $/cyd)
Carbon and Embodied Energy
EPS LWIC
(XLD CLSM)
Construction Footprint

XLD CLSM
produced on site

Lower transportation
impact:
congestion
emissions
XLD CLSM Pumped Into Place
Densities are monitored on the job
and samples taken for testing
 Cast Density of Project Cylinders
Average Cast Density = 25.5 pcf, Standard Deviation = 1.19
 Some XLD CLSM Challenges
Fly ash availability
Quantity
Quality

Lift heights

Additional lifts place

only after material is
below 180F
Addressing temperature
limitationsis this really
necessary?
Mass Concrete Specification
 Benefits of Fly Ash
Reduction in hydration temperature test mix
cast in 30 gallon insulated container
Field Temperatures
Removing Temperature Slab
 XLD CLSM by the Numbers
66,000 cubic yards for entire project

16 million pounds of cement

10.7 million pounds of fly ash used

Pumped up to 1500 through 2.5 hose

2 Phases (5 of 6 bridges)
Phase I - 4 months
Phase II - 1 month
 Thanks to:
Elastizell Systems, Inc.
Walter Toebe Construction Company
MDOT
Thank You!

Questions?