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Foam Concrete Experimental Investigation of its
Properties
Dr. Geetha K Jayaraj1, Supriya Siddharth More 2
Shivajirao S. Jondhle College of Engineering and Technology, Asangaon , Thane, India 1 2
Abstract Foam Concrete is a type of concrete which
contains an expanding agent which increases the volume
of the mixture while giving additional qualities such as
flow ability and reduces the dead weight. Foam concrete
is a vast majority of concrete containing no large
aggregates, only fine sand and with extremely lightweight
materials containing cement, water and foam. It can be
considered relatively homogeneous when compared to
normal concrete, as it does not contain coarse aggregate
phase. It is lighter than the conventional concrete used.
Countries like USA, United Kingdom and Sweden has
been using Foam concrete regularly in recent times.
Foamed Concrete has been successfully used and it has
gained popularity due to its lower density than
conventional concrete. It is created by uniform
distribution of air bubbles throughout the mass of
concrete. Recently, most studies on Foam Concrete
concern on the influence of filler type and the particle
size of sand on the strength. Foam Concrete has low
density as well as low thermal conductivity. Other
advantages include reduction of dead load, faster
building rates in construction and lower haulage and
handling costs. Foam Concrete maintains its large voids
also the feature of not forming laitance layers or cement
films when placed on the wall. This report is based on the
experimental investigation of its properties.
Keywords:-CLC Cellular light weight concrete
I INTRODUCTION
Concrete is a composite construction material
composed of cement (commonly Portland cement) and other
cementations materials such as fly ash and slag cement,
aggregate (generally a coarse aggregate made of gravel or
crushed rocks such as limestone, or granite, plus a fine
aggregate such as sand), water and chemical admixtures.
Concrete is used more than any other man-made material in
the world .In this way or by substitution for the
cementations and aggregate phases; the finished product can
be tailored to its application with varying strength, density,
or chemical and thermal resistance properties. The adverse
development in the field of concrete has led to the
innovation of lightweight concrete materials. The
development of lightweight concrete is made with a good
achievement of performance in their characteristic. In
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lightweight concrete it is possible for cement with partial
replacement of some other additives, thereby reducing the usage
of cement. There are many types of lightweight concrete such as
cellular concrete, foamed concrete, aerated or gas concrete.
There are many studies going around the world regarding all
types of lightweight concrete. Foam concrete is produced when
foam is added to cement based slurry. The foaming agent is
diluted with water and aerated to create the foam. The cement
paste or slurry sets around the foam bubbles and when the foam
being to degenerate, the paste has sufficient strength to maintain
its shape around the voids. The density of foam concrete is
determined by the amount of foam added to the basic cement
and sand mixture. Foam concrete is both fire and water
resistant. It possesses high (impact and air-borne) sound and
thermal insulation properties. A foam aeration agent is used to
absorb humidity for as long as the product is exposed to the
atmosphere, allowing the hydration process of the cement to
progress in its ever-continuing strength development. The
difference between foam concrete and normal concrete is the
use of aggregate in the foam concrete is eliminated and been
replaced by the homogeneous cells created by air in the form of
small bubble which utilize a stable air cell structure rather than
tradition aggregates. It can be categorized as cellular material
because it contains a higher amount of pores. Based on its
morphology, foam concrete can be easily known as cellular
material and the behaviour must be same as cellular solid
behaviour. The quality of foamed concrete is depends on the
quality of foam, so that the foam is very important factor for the
foamed concrete. To ensure that the desired percentage of air is
entrained in the mixture pre-foaming, where the foaming agent
is aerated before being added to the mixture, is recommended
[2].
II BACKGROUND OF FOAM CONCRETE
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 (1988), in
1924Linde described its production, properties and applications.
The application of foamed concrete for construction works was
not recognized 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 last15 years have
lead to increased production and broadening of the range of
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applications. An extensive research program carried out in
Holland helped promote foamed concrete as a building
material. [6]
III PROPERTIES OF FOAM CONCRETE
There are various properties of foam concrete
which influenced by :-
1. Water Absorption:
Due to its closed cellular structure the water
absorption of foamed concrete is very low. However, higher
the air content, higher the water absorption. Generally, it is
less than 5 percent by volume.
2. Compressive Strength:
The compressive strength of foamed concrete is
influenced by many factors such as density, age, moisture
content, the physical and chemical characteristics of
constituent materials and mix proportions. For uniform
quality, it is desirable to control the variations in the mix
proportions, type of cement and sand or other fillers as well
as the method of production. With the same materials and
testing conditions, the compressive strength increases with
the density. Compressive strength will continue to increase
indefinitely due to the reaction with CO2 present in the
surrounding air. However, the increase in strength with age
is virtually linear over the first 12 month, unlikely dense-
weight concrete which levels out much earlier. The rate of
development strength in foamed concrete is higher than that Methods dependent on mechanical beating
in the dense weight concrete, for products such as foamed- A hybrid method, dependent on both mechanical beating of a
concrete building blocks and panels, it is desirable that
curing process should assist in the moisture retention for
longer periods. Steam curing is another option, if curing
time is crucial
3. Tensile Strength
Depending on the method of curing, the tensile
strength of foamed concrete can be as higher as 0.25 times
its compressive strength with and ultimate strain of about
0.1 percent.
4. Shear Strength
The shear strength generally varies between 6 and
10 percent of the compressive strength. Shear reinforcement
may be required in flooring and roofing units.
5. Shrinkage
Like all cement products, foamed concrete shrinks
during the setting stage. The shrinkage depends upon the
type and amount of cement in mix; water-to-cement ratio,
type of curing process, size of element, quantity of sand and
density of foamed concrete. The most shrinkage occurs
during the first 28 days, after and soundproofing screeds in
multi-storey residential and commercial buildings. The
concrete of this density range is also suitable for bulk-fill
applications.[6]
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IV MIX CONSTITUENT PROPORTIONS AND FOAM
CONCRETE PRODUCTION
Although there are no standard methods for
proportioning foamed concrete, the general rules regarding w/c
ratio, free water content and maintaining a unit volume apply,
but it is a specified target plastic density that becomes a prime
design criterion. It should be noted that it is difficult to design
for a specific dry density, as foamed concrete will desorp
between 50 and 200 kg/m3 of the total mix water, depending on
the concrete plastic density, early curing regime and subsequent
exposure conditions. Assuming a given target plastic density (D,
kg/m3), water/cement ratio (w/c) and cement content (c,
kg/m3), the total mix water (W, kg/m3) and fine aggregate
content (f, kg/m3) are calculated from equations (1)and (2) as
follows.
Target plastic density, D = c + W + f (1)
Where c = PC +FA fine,
f = FA coarse + sand
Free water content
W = (w/c) X (PC + FA fine +FA coarse)[8]
A. Method of Cellular Concrete Production
Though there are many proprietary production methods
and agents used in cellular concrete production, they can be
summarized in three broad categories:
Methods dependent on the chemical
preformed foam produced from smart foam liquid concentrate
and a chemical reaction Methods dependent on the chemical
reaction of a rising agent are best used for cellular concrete
production in manufacturing and pre-casting plants. Methods
dependent on mechanical beating are best used for cellular
concrete production for on-site applications. The hybrid
method can be used for cellular concrete production for on-
site applications, in manufacturing and pre-casting plants.[8]
B. Constituents of Foam Concrete
Cement -Cement is used as the main binder for foam concrete.
Foam concrete can be produced with all types of cements and is
less affected with changes in cement types. However, 53 Grade
cement is generally preferred in the production process.
Flyash - Fly ash has been widely used in construction practices.
A good fly ash should have high fineness, low carbon content
and good reactivity which would enhance the technical
advantage of the properties of foamed concrete. About seventy
five thermal plants are distributed evenly across India, hence
hauling cost is minimal.
Water -Water used in the manufacture of foam concrete is
potable water free from suspended solids and other wastes
Foaming Agent - The surfactant is a key factor in the types of
bubbles generated. Surfactants are wetting agents that lower
the interfacial tension between two liquids and also lower the
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surface tension of liquid, allowing easier spreading. There
are extensive varieties of surfactants (foaming agent)
available in the market. Surfactants are formulated to
produce stable air bubbles which can resist the physical and
chemical forces imposed during mixing, placing and
hardening in the process of making foamed concrete. But it
is very important to store all surfactants accordingly
because they are inclined to deterioration at low
temperatures. The surfactant solution consists of one part
surfactant and between 5 to 20 parts water. But the
optimum value is a function of the type of surfactant and
the technique of production.[8]
Generally two types of surfactants can be used to produce
foam
Protein based Surfactants and,
Synthetic based Surfactants.
Protein-based surfactants are the original
surfactants, produced from refined animal products such as
hoof, horn and skin. They are relatively crude materials
derived from hydrolysed animal carcass residues which are
subjected to biodegradation. Protein-based surfactants
produce foamed concrete with strength/density ratio of
about 50% to 100% higher compared to synthetic
surfactants
Synthetic based surfactants are produced using
man-made chemicals such as the ones used in shampoos,
soap powders and soaps. It is stated that synthetic
surfactants are stable, easy to formulate and consistent in
performance. However, the bubble size is larger and the
cells are more open due to higher expansion. Or it can be
stated as Foams formed from protein based surfactants
have smaller bubble size, are more stable and have a
stronger closed bubble structure compared to the foam
produced using synthetic surfactants. This results in
foamed concrete of lower strengths compared to foamed
concrete produced using protein-based surfactants.[8]
C. Microstructure of Bubbles
The individual bubbles or cells in cellular concrete
vary from microscopic size to the size of a sand grain.
Microstructure refers to the microscopic description of the
individual constituents of a material. Foamed concretes
consist of air voids of approximately 0.1 to 1 mm in size,
uniformly distributed in a matrix of fillers and cements .On
a microscopic scale, the most important properties of
foamed concrete are the air void shape, spacing factor and
size Distribution. Bubbles produced from a protein
surfactant are defined, not connected and closed cell. In
contrast, bubbles produced using synthetic surfactants are
more open, have holes in hole and are undefined. Within
the same surfactant type, the most significant finding was
that density had the greatest effect on the bubbles sizes.[8]
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D. Phase of Foam Concrete
Foam phases can be distinguished into two categories:
1. Production of cement paste, foaming and processing
2. Foam stability until hardening
During the first phase, method, requirements of air-
entraining and workability are the determining factors for the
specification of the cement paste and its properties. A quick
stabilization of the interface between air and cement paste is
essential. This can be managed by surfactants (air-entraining
admixture or foaming agent) in high dosage. In the second
phase the focus is on foam stability. Therefore the separation of
air and cement paste by bubble up or flow out has to be reduced
to a minimum. This can be achieved by fine, fast cements which
stop foam collapsing by rapid hardening[8]
E. Production Process of Foam Concrete
The compressed air, foaming agent and water are let
into the foam generator. The combination of foaming solution
and air is then forced through restrictions in the foam lance,
where it expands and foam is created to the required density.
The base materials and the foam are fed into the mixer where all
the components are mixed together. These mixers have the
effect of blending foam and base materials together into a
completely homogenized mix ensuring a repeatable process.[8]
Figure 1 Generation of Foam
F. Material Properties of Foam Concrete
The density of foam concrete is the volumetric function
of foam that is added to the cement paste. When undertaking the
design of foamed concrete mixture, a target casting density is
determined using the dry density which is the most important
factor affecting the properties of the mixture. The relationship
between dry density and casting density between 600 kg/m3 and
1200 kg/m3 can be calculated using the following linear
equation.
Where m is the target casting density (kg/m3) and dry is the
dry density (kg/m3 )
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Foam Concrete is more sensitive to water content Table 2. Trial Mix 01 Results
than normal concrete. Concrete normally has a certain water
demand to obtain workability. The strength of concrete
decreases as the water-cement ratio increase. For foamed
concrete, workability is not a major factor, but if adequate
water is unavailable for the initial reaction of cement paste,
the cement withdraws water from the foam, causing rapid
degeneration of the foam, If excess of water is added,
segregation takes place, causing variation in density .The
reported Investigations point out the water cement ratio in Table3 Trial Mix 02 Results
the range of 0.4 to 0.8 for foam concrete.[8]
G. Relationship between Density and Compressive Strength
The compressive strength of foam concrete is an
inverse function of the density of the material. This
relationship between density and compressive strength is
exponential, the value of exponent varying with size and
distribution of air voids.[8]
V CASE STUDIES ON FOAM CONCRETE
Following are the case studies done by the
B. The Use of Additives to Enhance Properties of Pre Formed
researches to implement their ideas regarding Foam
Foamed Concrete
Concrete mix designs and its applications.
The study shows enhancement of pre-formed foamed
A. Experimental Study on Foam concrete concrete, 1300-1900 kg/m3,by utilising two types of additives,
The Density of Foamed Concrete is inversely silica fume and fly ash, to partially replace Portland cement
proportional to the percentage of foam that is added to the and fine sand. It focuses on consistency, mechanical and
slurry/mortar. The Compressive Strength and Density of thermal properties .The FC mixes had 28-daycompressive
Foam Concrete increases with age The Compressive strengths from 6 to 23 MPa and corresponding thermal
Strength of Foamed Concrete increases with increase in the conductivities in the dry state from 0.475 to 0.951W/mK,
Density. Fine aggregate had a beneficial effect on whereas for the same density range. The mineral admixtures
significantly increase in Compressive Strength of Foamed Silica Fume and Flyash and super plasticizer combination
Concrete. De-moulding of higher density foamed concrete provides improvement in both the workability and the strength
panels is possible after 24 hours but it requires minimum 3 properties of foamed concrete. The results for mixes
days for lower density foamed concrete panels. The starting investigated in this study showed higher compressive strength
of Strength gain for foamed concrete is on higher side than to density ratios compared to foamed concrete mixes from
that of normal weight concrete and Strength gain beyond 28 other studies produced by using sand and/or fly ash as a filler
days is faster than normal weight concrete. The addition of material. While indirect tensile, flexural and splitting strengths
fly ash of equal amount of cement makes it possible to gain were significantly higher for FCa mixes than FC mixes. [1]
the target strength with Age. This study has shown that the
use of fly ash in Foam Concrete, can be greatly improves its
properties. The mixed proportion for foamed concrete used
in this research report cannot be used for structural purpose
because there 28 days Compressive Strength is less than 17
MPa. Improved structural efficiency in terms of strength to
density ratio resulting load reduction on the structure and
substructure. Strength to Density ratio is much higher for
foam concrete mix 2 compared to conventional concrete.

Table 1 Mix proportions for trials

Figure 2 Compressive strength vs Age of Foam concrete with

different mix proportions

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Table 4 Different mix proportions for trials
C.Durability Properties of Foamed Concrete with Fiber
Inclusion
A Study was conducted on foamed concrete with
synthetic and natural fibres consisting of AR-glass,
polypropylene, steel, kenaf and oil palm fibre. The foamed
concrete mixtures produced had a target density of
1000kg/m3 and a mix ratio of (1:1.5:0.45). The fibres were
used as additives. The inclusion of fibre was maintained at
a volumetric fraction of 0.25 and 0.4%. The water
absorption, thermal and shrinkage were determined to
study the effect of the fibre on the durability properties of
foamed concrete. The results showed that AR-glass fibre
has the lowest percentage value of drying shrinkage
compared to others. The water absorption rate is enhanced
by adding steel and polypropylene fibre. But AR-glass,
kenaf and oil palm fibre resulted higher absorbance than
the control mix. It can be concluded that type of fibre plays
a different role in controlling water absorbance. Each kind
of fibre has a different surface morphology that plays an
important role in the water absorption rate of LFC. Fibres
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inclusion is absolutely effective in handling drying shrinkage
problems by LFC. All of the specimens with fibre inclusions
resulted lower shrinkage compared to the control specimen.
AR-glass fibre is the most effective measure among all fibres
in controlling drying shrinkage. In comparison of all 5 fibres
used in the test, steel fibre is found to be the poorest in thermal
insulation. It recorded the highest among all samples in
thermal conductivity and specific heat. Polypropylene fibre is
found to be the best sample in thermal insulation among all
samples. The higher the percentage of fibre included in a
sample, the poorer the thermal efficiency will be regardless of
the type of fibre used. [5]
D. An Investigation for foam concrete with quarry dust
replacement for filler in mix design
A study on the effect of quarry dust as sand
replacement material on compressive strength of foam concrete
was conducted. This project was carried out to determine the
compressive strength of foam concrete by using quarry dust as
partial sand replacement material. This report presents the
feasibility of the usage of quarry dust as 10 %, 20 %, 30 %,
40% and 50% for sand in foam concrete. Mix design was
formulated and developed for four different proportion of
quarry dust in foam concrete. Tests were conducted on cubes to
study the compressive strength of concrete made of quarry dust
and results were compared with the control foam concrete. It is
found that the compressive strength of foam concrete made of
quarry dust is nearly 43% more than the control foam concrete.
Based on the results of the experimental investigation, it is
proposed that burnt clay bricks can be effectively replaced with
the foam concrete blocks. Finally cost benefit assessment was
done to prove the economy of the foam concrete bricks. It is
observed that potential material savings are applicable when
sand is partially of fully replaced by quarry dust. The traditional
bricks are completely replaced by foam concrete blocks with
quarry dust, by which about 23% of total brick cost is reduced.
The key advantage seems to be its low density which enables it
to be handled without carnage. Single process installation
reduces transportation charges considerably. Cast in situ
production, simply pouring and levelling property reduces labor
and supervision costs. As the dead load of building is reduced to
a great extent, the quantity of reinforcement can be minimized.
Foam concrete (1200kg/m3) is two times more thermally
resistant than burnt clay bricks hence usage of internal air
conditioning cost can be reduced. Allows controlled discharge
into narrow openings and hence directly reduces wastage of
concrete at the site. Self -compacting and self-levelling nature
of foam concrete with quarry dust completely eliminates the
need for compaction equipment. [3]
E. Shrinkage Behaviour of Foam Concrete
As the filler-cement ratio increases, shrinkage reduces
due to the restraining effect of increased aggregate content.
Shrinkage of foam concrete is lower than the corresponding
base mix. Shrinkage decreases with an increase in foam content.
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The lower shrinkage value at higher foam volume content is caused by the foam and hence the decrease in the compressive
caused by lower content of paste in the mix and thus the strength of the concrete. Foam concrete requires no vibration or
lower content of pores affecting shrinkage. Higher the fly compaction and it fills all cavities voids and seams over a long
ash content in the foam concrete mix replacing sand, higher distance. It offers fast and settlement free construction with
the Higher the fly ash content in the foam concrete mix good heat Insulation and air content. It has good thermal
replacing sand, higher the shrinkage. This is attributed to (i) insulation; good freeze /thawing properties and has excellent
Low shrinkage resisting capacity of fine flyash than sand (ii) fire resistance properties Attempts have been made to
Greater volume water-solids ratio requirement with fly ash summarize the various Foam concrete and its properties
for a stable and workable mix (iii) Greater volumes reduced recommendations[6]
foam volume requirement at a given density. Even though Table 6 cost comparison between Foam CLC Block and brick
addition of fly ash causes a small increase in shrinkage it has wall [6]
got a major contribution towards increasing the strength of Construction of 100 sq feet 6 inch wall Rate 3400
foam concrete of comparable density. It can also be seen Material Brick Wall Foam Block Wall
that irrespective of type of mixes low density products are Quantity Prices/unit Cost Quantity Prices/unit Cost
stable for drying shrinkage in spite of its low strength.
Brick/Block 600 8.5 5100 56 76.51 4284.4
Artificial air voids may have an effect on volume stability
Mortar
by allowing some shrinkage; this effect increases with
Cement (Bag) 3.38 275 928.13 1.28 275 350.63
increase in foam volume. [4]
Sand (brass) 0.15 5500 825 0.06 5500 330
F. Density Variation with Foam Concrete
Plaster
The initial findings have shown that the foam
Cement (Bag) 4 275 1100 2 275 550
concrete has a desirable strength to be an alternative
Sand (brass) 0.16 5500 880 0.08 5500 440
construction material for the industrialized building system.
8833.1 5955.1
The strength of foam concrete is low for lower density
Savings (%) 32.6
mixture. Significant reduction of overall weight results in
saving structural frames, footing or piles and rapid and
Table 7 Comparison of Various Building Blocks
relatively simple construction. The density is reduced due to
Parameters Lightweight Concrete Burnt Clay Concrete
the increment of voids throughout the sample caused by the CLC AAC Bricks (Hollow Core)
foam and hence the decrease in the compressive strength of Foam Concrete Aerated Autoclaved Blocks
the concrete. Foam concrete requires no vibration or Concrete
compaction and it fills all cavities, voids and seams over a Basic raw Cement, fly ash, water and Cement, lime, specially
long distance. It offers fast and settlement free construction materials foam grinded sand, aeration Top agricultural
compound, high primary soil, primary Cement, sand,
with good heat insulation and air content. It has good
energy input energy input aggregate
thermal insulation; good freeze/thawing properties and has Production Using ribbon mixer and
excellent fire resistance properties. [7] process and foam generator Produced only in well- Processed in
Table 5 Properties of Foam Concrete with varying set-up established plant, equipped specially erected
densities with steam boiler and high or central brick Mobile or
pressure auto-claves kilns stationary
Dry density 300-600/ 800-1000 /1200- 400-700 1900 1700
kg/m
1800
Compressive 4-10 / 25-35 / 125--250 20-40 30-80 30-150
Strength
kg/cm2
Thermal insulation , Load bearing & Load bearing &
partitions, non-load bearing Non-load bearing panels non-load non-load
Usage blocks and blocks bearing walls bearing walls
Block /
VI COMPARATIVE SUMMARY
element size Any size, shape given by Any size, shape given by Typically shape
The foam concrete has a desirable strength to be an and shape mould/cut mould/cut and size Typically size
alternative construction material for the industrialized Compaction
building system. The strength of foam concrete is low for during
production None None Yes Yes
lower density mixture. Significant reduction of overall
No aging
weight results in saving structural frames, footing or piles Gains strength with age Loses strength, if not
and rapid and relatively simple construction. The density is Aging (like conventional concrete) protected against humidity No Yes
reduced due to the increment of voids throughout the sample

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