Case Studies in Construction Materials 8 (2018) 79–86

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Case Studies in Construction Materials

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Short communication

Study on polyurethane foamed concrete for use in structural

T
applications
Iman Kattoof Harith
AL-Qasim Green University, College of Water Resources Engineering, Babylon, Iraq

AR TI CLE I NF O AB S T R A CT

Keywords: Recently, foamed concrete is being widely used in civil construction and building, because of its
Polyurethane foamed concrete high fluidity and settlement, low self-weight and low thermal conductivity. However, it has some
Curing conditions major setbacks such as low strength and increased shrinkage at later ages. The strength gain of
Fly ash concrete depends upon several variables; one of these is the curing conditions. This work aims to
Compressive strength
study the potential production of foamed concrete as a sustainable structural material by varying
Static modulus of elasticity drying shrinkage
the curing methods. For this purpose, sample cubes, cylinders and prisms were prepared to find
the compressive strength, modulus of elasticity and drying shrinkage at different ages. Samples of
the polyurethane foamed concrete cured under four different curing regimes (water, moisture,
sealing by membrane-forming curing compound and air curing). At the end of the study, poly-
urethane foamed concrete used for this study has shown the potential for use in structural ap-
plications. Also, the results show that the samples cured by moisture have the highest com-
pressive strength at all ages.

1. Introduction

Structural lightweight concrete has an in-place density (unit weight) of the order of (1440–1840) kg/m3 compared to normal
weight concrete with a density in the range of (2240–2400) kg/m3. For structural applications, the concrete strength should be
greater than (17 MPa) according to ACI 213R [23]. Foamed concrete is a type of lightweight aerated concrete which consists
principally of a cement paste or mortar with at least 20% of its volume as air. Foamed concrete is produced by two methods: the first
is the pre-foaming method and the second is the mixed foaming method. The pre-foaming method involves the isolated production of
the base mix cement slurry (cement paste or mortar) and production of a stable foam (foam agent with water) and then mixing this
foam into the base mix. In the mixed foaming method, the foaming agent is added to the pre-prepared base mixture and during the
mixing foam is produced resulting in a cellular structure in the concrete [17,14].
Foamed concrete can have a wide range of dry densities (400–1600) kg/m3 and compressive strengths (1–25) MPa. The increase
in compressive strength of foamed concrete formed of fly ash, micro silica, and SiO2 powder is in the range of (20–25) MPa, this
increment in strength shows that this foamed concrete is satisfactory to be used for structural applications or load bearing purposes
[11]. The strength of foamed concrete is little affected by the percent cement replaced by fly ash and even when replacing a high
amount of cement with fly ash it does not much affect the later compressive strength of properly cured foamed concrete [13]. The
best-pulverized fly ash content for greatest strength of foamed concrete is around 20% to 30% [18].
The properties of foamed concrete differ with the difference in curing type and duration. Correct curing will enhance the dur-
ability and increase strength, volume stability, abrasion resistance, impermeability and resistance to freezing and thawing [16].
Falade et al. [9] found that air cured specimens developed a higher strength than water curing for foamed concrete with 10%

E-mail address: eman1988@wrec.uoqasim.edu.iq.

https://doi.org/10.1016/j.cscm.2017.11.005
Received 14 September 2017; Received in revised form 15 November 2017; Accepted 16 November 2017
2214-5095/ © 2017 The Author. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/BY-NC-ND/4.0/).
I.K. Harith Case Studies in Construction Materials 8 (2018) 79–86

replacement of cement with ground bone and noticed that no difference in strength occurred progressive at later ages of 60 days and
90 days for samples cured in water and air. This study agreed with a study performed by Arif et al. [1] and Kearsley [12]. Whilst the
results of the study by Zhao et el [19] showed otherwise; the water cured specimens led to better strength development of foamed
mortar. However, the natural weathering regime (air curing) produced the lowest compressive strength for foamed mortar and led to
an average reduction in compressive strength of 28.2% as compared with the water curing condition. This was also found acceptable
with a study performed by Laing and Chang [15].

1.1. Benefit of research

The goals of this work are to:

• Find applicability to produce foamed concrete using polyurethane as a foaming agent and its applicability as a construction
building material.
• Test the effect of different curing conditions on some mechanical properties of polyurethane foamed concrete.
• Find some mechanical properties of polyurethane foamed concrete with and without fly ash.
2. Experimental work

2.1. Materials

Combinations of the following constituent materials were used to produce foamed concrete in this study:

• Ordinary Portland Cement type (I): The chemical and physical properties of this cement conformed to BSEN 196-1; 2005 [8].
• Class F fly ash supplied by a local supplier and conformed to ASTM C618 [3].
• Natural sand supplied locally and conformed to the requirements of BS 812-103.1:1985 [7] for verifying distribution and particle
size. The specific gravity of the sand was 2.6.
• High range water reducing agent (HRWRA) Glenium 51; the normal dosage for Glenium 51 is (0.5–0.8) l/100 kg of cement.
• Tap water was used for both mixing and curing.
• Liquid membrane-forming curing compounds: Setseal 22 is a water based curing compound formulated from selected emulsified
paraffin to form a low viscosity wax emulsion. The color is a white liquid, which creates a white film when applied to concrete
surfaces and reflects (60–80)% of the sunlight.
• Foam: The foaming agent of density 45 kg/m3 used in this study was polyurethane (PU) foam. As shown in the pictures below:

Pictures: Elucidation the polyurethane.

Tables 1–3 illustrate the details of the ingredients of the materials used in this work.

2.2. Mix proportions

The mix proportion guideline of ASTM C796 [4] was followed in the laboratory mixing. The mix proportions of foamed concrete
for this study are given in Table 4. The final mix proportions were established by laboratory trials to achieve a target density of
1600 kg/m3.

2.3. Specimens preparation

For this investigation, a pre-foaming method was adopted to provide polyurethane foamed concrete. The mixing procedure
started with the cleaning of the laboratory mixer and emptying the excess water, one-third of the calculated mixing water was added,
then the fine aggregate followed by the cement. The materials were allowed to mix for three minutes, then the fly ash and the
remaining water was added. This was allowed to blend together till an appreciable slurry was achieved. The ready-made foam was
added to the base mix through the nozzle of the foam can according to the calculated amount by trial and error. The density of the
foamed concrete produced was then checked against the target density, 1600 kg/m3.

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I.K. Harith Case Studies in Construction Materials 8 (2018) 79–86

Table 1
Chemical and physical properties of cement, fly ash and fine aggregate.

Cement Fly Ash

Oxides composition
Oxides Content Oxides Content % ASTM
% C618(Class F)
CaO 62.8 5.0 <10
SiO2 22.3 54.2
Al2O3 4.5 31.6 70 (min)
Fe2O3 1.9 3.8
Na2O 0.1 0.7
K2O 0.7 0.6
MgO 4.4 1.3 5 (max)
SO3 2.0 0.1
CO2 2.5
Free CaO 1.2
Loss on Ingition 0.8
Blain Surface Area m2/kg 250 350
Relative Density 3.15 2.2

Table 2
Grading of fine aggregate.

Sieve size (mm) Passing by weight% ASTM C33-03

2.36 100 85–100

1.18 85.7 75–100
0.60 71.2 60–79
0.30 29.6 12–40
0.15 3.5 0–10

Table 3
Typical properties of Glenium 51.

Main action superplasticizer

Color Light brown

pH Value 6.6
Form Viscous liquid
Relative density 1.1 at 20 °C
Viscosity 128° 30 cps at 20 °C

Table 4
Mix Proportions for Polyurethane Foamed Concrete.

Mix details Target Density Cement kg sand kg fly ash kg water kg w/C + FA HRWRA L foam kg

Mixed with fly ash 1600 440 960 160 300 50 3.6 60

Mixed without Fly ash 1600 600 960 0 300 50 2.64 60

The specimens remained in the same condition till 24 h later when the specimens were demolded and the fresh density of concrete
measured. Each sample was marked before being separated and transferred to the place where they cured using four different curing
conditions, which were: water curing; moist curing; membrane compound curing and air curing. All the specimens remained under
same curing condition till the date of testing except the water and moisture cured samples that were removed and placed in an oven
for 24 h before testing. The density was checked before placing in an oven and after placing in an oven.
The curing regime adopted was as below:

• Air curing: in laboratory air entire time with the constant range (25 ± 2) °C and an average relative humidity of 60%.
• Water curing: in air under laboratory conditions after seven days of water curing with the constant range of temperature
(25 ± 5)° C.
• Moisture curing: covered with wet burlap for seven days.
• Liquid membrane-forming curing compounds: Setseal 22 was applied after 24 h from casting, except for the top face of the casting
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I.K. Harith Case Studies in Construction Materials 8 (2018) 79–86

mold where the liquid compound was applied after 1 h from casting.

Most of these adopted curing conditions in this study chosen were completely compatible with the curing conditions which are
performed in the field.

2.4. Testing methods

2.4.1. Fresh state properties

The fresh properties of polyurethane foamed concrete
consists of flow and fresh density. A flow table test was performed to find the consistency of the freshly mixed mortar as described
in ASTM C 1437 [6]. The fresh polyurethane foamed concrete produced was first poured into an inverted slump flow cone without
any compaction and vibration in accordance with ASTM C 1611 [5]. The fresh density was established according to ASTM C 138 [20]

2.4.2. Hardened properties

a) Compressive Strength

The compressive strength tests were performed according to (BS. 1881: Part 116: 1983) [10]. A total number of 72 cubes of
(100 × 100) mm were tested by using a hydraulic compression machine of 1800 kn, at a loading rate of 18 MPa per minute. The
average of three cubes was taken for each test and the test was conducted at ages of (7, 28, and 56) days.

b) Shrinkage

Shrinkage was measured by apparatus with dial gauge of 0.002 mm accuracy. Prisms of (100 × 100 × 400) mm were used for this
test. Measurements of the shrinkage strain were made according to (ASTM C157-2008) [2]. After removing the samples from the
mold at an age of 24 h, shrinkage nails were installed on the surface of prisms after being demolded. The readings were taken at ages
(3, 7, 14, 21, 28, 56) days for different curing conditions. Two specimens were prepared for each test condition.

c) Static Modulus of Elasticity

The static modulus of elasticity was measured according to (ASTM C 469). A total number of 48 cylinders of (150 × 300) mm
were tested at ages of (7, 14, and 28) days. The average of two cylinders was taken for each test.

3. Results and discussions

3.1. Fresh properties

a) Flowability and Fluidity

For this study, the flowability of polyurethane foamed concrete mixes was measured by the diameter of the slump. It was found
that the flowability for a mix without fly ash had a lower diameter of a slump than the mix with fly ash. The average slump flow
values obtained for fly ash mix and mix without fly ash were 230 mm and 200 mm, respectively. This phenomenon is due to the
lubrication effect of the spherical shape of most fly ash particles which led to greater workability.
The fluidity of polyurethane foamed concrete mixes measured by the diameter of four different angles of the slump. The inverted
slump cone spread values are given in Table 5 clearly indicated that the fluidity of the polyurethane foamed concrete was dependent
on the fly ash in the mixes.
Slump cone spread values obtained for the fly ash mix and the mix without fly ash were 478 mm and 452 mm, respectively. This
may be ascribable to the higher fineness of fly ash compared to that of the mix without fly ash.

b) Consistency and Stability

The consistency of the fresh polyurethane foamed concrete represented by a measured fresh density to designated density ratio
was kept to nearly unity, without segregation and bleeding. Stability can be represented by a measured fresh density to measured

Table 5
Properties of the fresh polyurethane foamed concrete.

Sample Consistency Stability Inverted slump cone spread value (mm) Slump value(mm)

Mix with fly ash 1.04 1.015 478 230

Mix without fly ash 1.05 1.018 452 200

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30

25

20

15

10

5
0 10 20 30 40 50 60
Age of concrete, days
Fig. 1. Compressive Strength development of foamed concrete mixes without fly ash under different curing regime.

hardened density Lim et al. [21]. The measured hardened density of the foamed concrete produced was (1640 and 1650) kg/m3 for
the fly ash mix and the mix without fly ash respectively.
The fresh density of polyurethane foamed concrete is measured in a container of known volume in order to determine density
(unit weight). The use of fly ash resulted in a slight decrease in the fresh density of polyurethane foamed concrete samples. The
average fresh density values obtained for the fly ash mix and the mix without fly ash were 1665 kg/m3 and 1680 kg/m3, respectively.
However, such results are attributed to the low specific gravity of the fly ash.
Portland cement has a higher specific gravity than that of fly ash so they increase the overall density of the polyurethane foamed
concrete to a greater extent.

3.2. Hardened properties

a) Compressive Strength

The average of the tests results are shown in Figs. 1 and 2 for polyurethane foamed concrete mixes with and without fly ash for
different curing conditions. The compressive strength results for mixes without fly ash range between (7.8–20.1) MPa, (10.3–24.2)
MPa and (11.1–26.2) MPa at (7, 28 and 56) days while the results for the mixes with fly ash range between (8.1–22.5) MPa,
(11.1–29.2) MPa and (12.1–32.1) MPa at (7, 28 and 56) days.
From Figs. 1 and 2, it can be seen that the results of mixes without fly ash give lower results of compressive strength when
compared with mixes with fly ash under different curing conditions at all ages with percent (9.2, 29.1 and 40.4) for water curing,
(11.6, 20.6 and 22.6) for moisture curing, (3.4, 8.7 and 9.4) for air curing and (8.7, 23.7 and 32.2) for the membrane forming curing
compound at (7, 28 and 56) days respectively. This behavior is explained by the densified effect of fly ash with a decrease in the
porosity at early ages, while at later ages, in addition to the densified effect of fly ash, a pozzolanic reaction occurs with calcium
hydroxide released from cement hydration reacting with the fly ash resulting in a filling effect in the voids among the cement and
other powder particles.
From Fig. 1, it can be seen that moisture cured specimens improve compressive strength more than membrane curing compound,
water and air cured specimens respectively by (14.9, 44.9 and 177.3)% at 7 days, (5.0, 18.0 and 162.3)% at 28 days, (6.3, 10.0 and
165.5)% at 56 days. That can be ascribed to the gel stiffening by drying for moisture curing, however, it is due to relaxation in the gel
of filler type due to the presence of water by water curing. An important observation is drawn here, which reflects the same previous
trends for mixes with fly ash and for all type of curing conditions at a different age.
The results also yielded that curing by membrane forming curing compound was effective in improving the compressive strength
of foamed concrete mixes with and without fly ash more than water and air curing.
Like other types of concrete, the compressive strength for polyurethane foamed concrete specimens with air curing is lower than
that of the other types of curing. However, the extent of strength reduction for air cured specimens up to an age of 56 days was due to
the insufficient curing.

35
compressive strength, MPa

30
25
20
15
10
5
0 10 20 30 40 50 60
Age of concrete, days
Fig. 2. Compressive Strength for foamed concrete mixes with fly ash under different curing regime.

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0
0 10 20 30 40 50 60
-100

-200

-300

-400

-500

-600
Age of concrete, days
Fig. 3. Drying shrinkage of control foamed concrete mixes without fly ash under different curing conditions.

b) Shrinkage

The average results of two prisms are plotted in Figs. 3 and 4 for mixes with and without fly ash under different curing conditions.
The results clarify that the values of drying shrinkage are higher for mixes without fly ash than those for fly ash mixes. The values
range from (160–610) microstrain for the mixes without fly ash and these values decrease to (150–550) microstrain when fly ash is
added at the age from 3 days to 56 days. The drying shrinkage for all mixes extends with time till the age of 56 days. Indicating to the
earlier Figures there is a small decrement in drying shrinkage for water cured specimens. Moreover, moisture cured samples showed
slightly lower values than those for compound cured samples. An important observation is drawn here, which reflects the same
previous trends for mixes with and without fly ash and for all type of curing conditions at a different ages.
Fig. 4 indicates that the internalization of fly ash as a partial replacement of cement leads to a slightly decrease in shrinkage of
mixes during the time of drying as compared with mixes without fly ash. This phenomenon is ascribed to the reaction of fly ash
consuming more free water in the system, leaving less water evaporation during shrinkage. This promotes the deduction that fly ash
mix has a lower porosity and finer pore structure, which encourages loss of water by self-desiccation and not by diffusion to the
surrounding environment.

c) Static Modulus of Elasticity

The secant moduli for all the mixes was experimentally determined for each testing age (7, 14 and 28) days as the average of two
cylinders for different curing conditions. The results of static moduli are plotted as shown in Figs. 5 and 6.
The modulus of elasticity results for mixes without fly ash range between (4.0–9.1) MPa, (4.8–11.5) MPa and (6.0–16.3) MPa at
(7, 14 and 28) days while the results for the mixes with fly ash range between (4.5–9.8) MPa, (5.1–12.4) MPa and (6.1–16.5) MPa at
(7, 14 and 28) days. This behavior may be attributed to the incorporation of fly ash as a partial replacement of cement in the mixes
that increases the densification of concrete and leads to lower strain under compression at transition zone, thus leads to higher static
modulus of elasticity of those mixes.
From Fig. 5, it can be seen that moisture cured specimens improve modulus of elasticity more than the membrane curing
compound, water and air cured specimens respectively by (10.4, 12.2 and 55.6)% at 7 days, (5.2, 11.6 and 58.3)% at 14 days, (8.1,
9.0 and 63.3)% at 28 days. An important observation is drawn here, which reflects approximately the same previous trends for mixes
with fly ash and for all type of curing conditions at different ages.

d) Oven-dry density

The oven-dry density of hardened polyurethane foamed concrete was measured according to ASTM C 642 [21].
For polyurethane foamed concrete, the oven-dry density increased slightly by adding fly ash. The average density values obtained
for fly ash mix and mix without fly ash were 1590 kg/m3 and 1600 kg/m3, respectively.

0
-100 0 10 20 30 40 50 60

-200
-300
-400
-500
-600
-700
Age of concrete, days

Fig. 4. Drying shrinkage of foamed concrete mixes with fly ash under different curing condition.

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I.K. Harith Case Studies in Construction Materials 8 (2018) 79–86

17
15
13
11
9
7
5
3
5 10 15 20 25 30
Age of concrete, days
Fig. 5. Modulus of Elasticity of foamed concrete mixes without fly ash under different curing conditions.

19
17
15
13
11
9
7
5
3
5 10 15 20 25 30
Age of concrete, days
Fig. 6. Modulus of Elasticity of foamed concrete mixes with fly ash under different curing conditions.

4. Conclusions

Based on the tests results of the present study on influence of curing methods and fly ash on progressive compressive strength, the
following conclusions are drawn:

1. The flowability and fluidity are increased by the presence of fly ash in comparison to mixtures without fly ash of the polyurethane
foamed concrete.
2. The compressive strength of samples cured under moisture and membrane forming curing compound produce higher compressive
strength range (20–32) MPa. This revealed that polyurethane foamed concrete is satisfactory to be used for structural applications.
3. The samples cured under moisture curing achieve higher strength at all ages than all others curing conditions considered. This
revealed that moisture curing affects the compressive strength of foamed concrete more than those cured by a membrane forming
curing compound, water, and air curing.
4. Curing by a membrane forming compound was effective in developing the compressive strength of foamed concrete mixes with
and without fly ash more than water and air curing.
5. The fly ash utilized improves workability and diminishes the drying shrinkage of foamed concrete.
6. At all ages, the compressive strength of polyurethane foamed concrete without fly ash is lower than that of the polyurethane
foamed concrete with fly ash for all curing conditions.

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