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Investigation the Properties of Foam Concrete: A review

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 Investigation the Properties of Foam Concrete: A review

Saeid Paknehad
M.Sc student in Structural Engineering, Department of Civil Engineering, University of Birjand,
Birjand,Iran
saeid-paknehad@birjand.ac.ir

Hamed Hasani
M.Sc in Structural Engineering, Department of Civil Engineering, University of Birjand, Birjand, Iran
hamed.hasani@birjand.ac.ir

Hamid Reza Paknehad

M.Sc in Structural Engineering, Department of Civil Engineering, Azad Islamic University of
Zahedan, Zahedan,Iran
paknahadhamidreza@gmail.com

Mohammad Bashir Azizi

B.Sc. Student of Civil Engineering, Department of Civil Engineering, University of Birjand, Birjand,
Iran
mohamadbashir.azizi@birjand.ac.ir

HamidReza Nasseri*
Assistant Professor, Department of Civil Engineering, University of Birjand, Birjand, Iran,
hrnasseri@birjand.ac.ir

Abstract
Due to its high thermal conductivity and high dead weight, ordinary concrete is
being replaced by alternatives due to global warming. One of the newest trends in
building today is foamed concrete, a lightweight concrete with similar properties
but densities ranging from 300 - 1800 kilograms per cubic meter. The construction
and transportation process result in reduced dead weight on the structure and
eliminated labor costs as well. Its large number of pores also makes it suitable for
a variety of climate conditions due to its low heat and sound absorption. Various
aspects of foamed concrete are examined in this study, including its ingredients, its
fresh state, and its physical characteristics, including its consistency, its stability,
its workability, shrinkage during drying, and its air-void system and water
absorption ability. Various types of foam concrete, such as air-cured foam and
chemically expanded foam, are also discussed somewhat briefly. Additionally, we
discuss several mechanical properties other than strength and flexural strength. In
addition to discussing functional characteristics, it is hoped that the reader will
gain a deeper understanding of the variable aspects that contribute to a habitable
environment across the climate spectrum. Further, the paper provides an overview
of how foam concrete is used for various applications.

Keywords: Foam concrete, consistency, stability, compressive strength and

workability
Introduction
Air bubbles are introduced into cement mortar using a foaming agent to create foam concrete. In terms
of density, they can be categorized as cellular concrete, aircrete, or reduced density concrete, which
can range from 300 to 1800 kilograms per cubic meter [1]. Additionally to having low weight, good
heat insulation, and fire resistance, it also has low aggregate consumption, high flowability, high
porosity, and is highly compressible. It is possible to categorize two types of aerated concrete by terms
of pore formation, namely air-entrained concrete and foam concrete [2]. Mixing chemicals that form
gas with mortar is done using the air entraining method. Chemical reactions occur during mixing,
which results in the production of porous structures. Aluminum powder, calcium carbide, and
hydrogen peroxide are common aerating agents. When pores are formed by foaming, they are created
either as a result of prefoaming (in which the foaming agent is mixed with water) or by mixed foaming
(in which the foaming agent is combined with mortar). Concrete that has been autoclaved to acquire
its unique properties is termed autoclaved concrete (concrete that has been autoclaved to acquire its
unique properties). Additionally, it is classified by its density [3]. Insulation and filling applications
commonly use a density between 300 and 600 kilograms/cubic meter, while structures without load
bearing parameters usually use a density range between 600 and 1200 kilograms/cubic meter.
Construction of load-bearing structures usually involves the use of a foam concrete with a density
between 1200 and 1600 kg/m3 [3]. By using animal blood to agitate the lime mortar mix [1], bubbles
were introduced to make the mix more workable. In 1923, foam concrete was used as an insulation
material [4]. Foamed concrete was first studied in the 1950s and 1960s for its physical properties,
composition, and manufacturing. Before it was more commonly used for building purposes, the
material was used for filling voids and stabilizing ground. Foam concrete can be applied to the
construction of industrialized buildings without vibration or compacting to fill cavities over long
distances, according to research conducted by Jalal et al. [3]. Fast and settlement-free construction is
possible with the system due to its excellent freeze-thaw properties, as well as its fire resistance [5].
As an example, foamed concrete can be used for soundproofing and thermal insulation in floors, to
insulate monopitch roofs, double-pitch roofs, to fill wells and cavity spaces, to make masonry grout,
and to produce building blocks and wall panels. Similarly, the material can be used to build road sub-
bases, bridge abutments, and to stabilize the ground. [6][7][8][9]. It is not exactly surprising that foam
concrete is far from being a popular construction material, as global exposure to foam concrete in
North America, Australia, Europe and Africa is just 5.6%, 5.6%, 33.3% and 5.6% respectively.
Therefore, because of lack of awareness about foam concrete and doubts about its reliability, the
contribution of foam concrete to the construction industry is underappreciated [10].
In studies conducted by Tikalsky et al. [11], it was found that cellular concrete exhibited excellent stability
during freeze-thaw. The researchers proposed an improved method for measuring its stability. Cold-climate
tunnel insulation will be more efficient thanks to absorption depth, which has been found to play a major role in
development of freeze-thaw-resistant concrete. Sun et al. [12] investigated the differences in compressive
strength, drying shrinkage, and workability of different foaming agents to determine the details of FC
specification and implementation. The study by Amran et al.[1] investigated the properties, composition, and
creation of FC, and the review by Ramamurthy et al. [13] evaluated the literature on foaming materials, foaming
agents, cement, fillers, mix proportions, production methods, and fresh and dried properties of FC. Over the past
few decades, FC applications have made significant progress. As a sacrificial tunnel lining system using foam
cement as a structural cladding material that could withstand blasting load action, cement based FC is commonly
used in Canada [14]. Zhao et al. have developed a foam cement lining system for tunnels in the United States
[15]. In tunnels with blasting loads, the use of this material can alleviate the dynamic response. A two-lane
highway tunnel in South Korea was successfully constructed using lightweight FC implemented by Choi and Ma
[15]. In this case, the open-cell foams with excellent permeability effective in forming and distributing in the
system.

(Figure 1) Over last 30 years, FC are widely used for retaining wall [8], housing insulation [1], bulk filling [13],
slab structure of concrete floor [16], ditch repair, and bridge abutment backfill [17], etc.. Undercurrents are
widely used in underground engineering as nonstructure and semistructure components, including for damage
treatment, tunnel grouting, and lining.
 Fig. 1. Different applications of FC

2. Materials

Water: It is dependent upon the composition, flexibility, and stability of the material on how much water is
incorporated into the mortar [13]. With less water, the mixture becomes hard and the bubbles are more easily
destroyed [18]. As a result of having too much water in the mixture, the bubbles separate and the mixture
becomes too thin [1]. The American Concrete Institute (ACI) suggests using fresh, clean, and easy-to-drink
mixing water [19]. If FC of 90 percent strength can be achieved within the specified curing period, the mixed
water can be substituted with municipal water of equivalent performance [13].

Binder: In general, cement or calcium sulphoaluminate cement are the most common types of binder used. Rates
of cement can vary from 25% to 100% [20], [21].

Foaming agent: Using a resin-based foaming agent was one of the earliest forms of foaming agent used in FC. It
controls the generation rate of bubbles in cement paste. In the current state of research, synthetic, protein-based,
composite, as well as synthetic surfactants have been developed and tested, with synthetic and protein-based
surfactants being the most popular [22].

Filler: There have been relatively wide adoption of a wide range of filler materials such as fly ash, silica fume,
granulated blast furnace slag, limestone powderand fly-ash ceramicite [18] to enrich the mechanical properties of
FCs [23]–[25]. By adding such fillers, the mix proportions and long-term performance of FC are improved, and
the cost of FC is reduced. Other fine aggregates, such as surface-modified chips [26][27], sand [28], and recycled
glass powder [29] are used to produce high-density FCs.

Additive: Plasticizers are always considered as additives to enhance compatibility [11]. Common additives
include water-reducing agents, water-proofing agents, retarders, coagulation accelerators, etc. Concrete fluidity
and plasticity are reduced in these substances to improve their performance [30], [31]. However, no noticeable
change is noted in their ability to prevent concrete separation.

Fiber: FC is made more durable and shrink-resistant by adding fibers of different densities. The main substances
are polypropylene [25], [32], glass and polypropylene [33], red ramie[34], [35], palm oil, steel [36], coconut
[37], waste paper cellulose [38], carbon, and polypropylene [39], which are usually introduced between 0.2%
and 1.5% of the mixture volume.
Foam concrete Properties
Consistency
Marsh cones and flow cones are used to test the stability and consistency of foam concrete in a fresh
state. The consistency of foam concrete was found to be good when the flow time and flow values
were below 20s [40][41]. Due to the increased cohesion and decreased self-weight of the mix, the
combination of foam and superplasticizer increased the consistency of the mix significantly, while
foam reduced it significantly [40][42]. When water and cement are mixed at a higher ratio, foam
concrete gets more solid, but an overabundance of water causes segregation. Foam concrete's fresh
state characteristics were studied using ground granulated blast furnace slag (GGBS) in place of
cement and fine aggregates with fly ash. According to the study results, adding ultrafine GGBS to
mixes did not significantly alter workability, whereas if fly ash were added to mixes, consistency
decreased because more fines formed and water was consumed [43]. Fly ash contributed to the
consistency increase of low density aggregate in addition to aggregate density [1][44]. Figure 3 shows
that foam concrete consistency is classified into five categories according to the Marsh Cone Modified
Test Method (Table 2) [45].

Fig. 3. Flow time test using modified Marsh cone [3]

Table 2. Classification of foam concrete based on flow time [45]

Description Flow time
Constant flow 1L< 1 min
Interrupted flow 1L> 1 min
Completion of flow after tamping 0.5 L < Efflux < 1 L
gently
Limited flow Efflux < 0.5 L
No flow Efflux = 0 L

Stability
To be considered stable, a foam concrete mix must have a fresh density to-design density ratio of one
and no bleeding or segregation. As an experiment, we measured the reduction in height over a period
of 24 hours using cylinders made of polycarbonate and coated with polyethene film, with a 500 mm
height and a 75 mm diameter. The proportion of portland cement to calcium sulfoaluminate in foam
concrete was between 5% and 10%, up to 400 kg/m3. Below that density, the proportion of cement to
calcium sulfoaluminate was greater than that of cement to achieve stable foam concrete [46]. In order
for foam concrete to remain stable, the consistency of the base mix into which it was added greatly
influenced the spread flow of the foam. The proportion of water to solids in foam concrete must be 45
percent in order for it to be stable. Fly ash increases the amount of water required. With the addition of
superplasticizers, it was possible to reduce the water/cement ratio by less than 0.3 and increase
stabilization by 43%. Bubbles in the concrete were stabilized by a minor concentration of bubbling
agent [47][48]. Mixing caused bubbles in the base mix and particles in the bubble mix to create an
adhesive force that stiffened the mix; air foams collapsed during mixing consequently affecting its
stability. By increasing the water-solids ratio, this was prevented [40][49]. In different studies,
researchers have used different methods to find the stability of mixes, including i) comparing the
density of fresh foamed concrete with the target density, and ii) checking the difference between
calculated and actual water/cement ratios and keeping it close to 2%. As Jones et al. found, density
levels below 500 kg/m3 have a higher instability risk than densities above 500 kg/m3 [46][50]. When
bubble size increases, buoyancy force increases as well, and when buoyancy force exceeds the
buoyancy force surrounding the solids, bubbles rise to the top, causing instability. The thinner
partition walls caused by small solid fractions and large bubble sizes allowed gas from high internal
pressure (small bubbles) to diffuse more easily and the bubbles became lighter. CSA cements were
used as a partial replacement for portland cement to produce stable, lower density mixes.

Workability
Checking viscosity will give you an idea of the workability of foam concrete. Slump workability tests
are ineffective on foam concrete of low density [51]. As a method of finding the workability of
lightweight concrete, Brewer [52] suggested the spreadability method. It is possible to calculate the
spread volume along two directions using the average of two diameters of a 150mm-diameter
cylindrical device. According to a study, foam concrete made with a sand cement mix should have a
spreadability between 85 and 125 mm, while foam concrete made with fly ash should have a
spreadability between 115 and 140 mm. As foam volume increases, mixes become stiffer, so the
amount of water added is determined by the amount of cement used in the mix. In a study on quar dust
mixes, a lower water-solid ratio was found to be more workable than mixes containing bottom ash
[53], and in Table 3 are the proportional spreads for the workability of foam concrete according to
flow rates [40][54].

Table 3. Percentage spread as a measure of the workability of foam concrete [40].

Flow values Description
0–20% Very low
20–40% Low
40–60% Medium
60–80% High
80–120% Very High

Compressive strength
Foam concrete's compressive strength is directly related to its density. Dry density, porosity, and age
have all been reported to influence foam concrete's compressive strength [55][56]. A study of foamed
concrete showed that density at dry density was 1200 kg/m3 and density at dry density was 400
kg/m3, giving tensile strength at dry density of 10 MPa and compressive strength of 1 MPa [57][58].
The amount of water in the cement, the form of the foaming agent, the curing, type of filler, shape of
the air voids, spacing factor, and size distribution are also factors affecting compressive strength.
Further, it was found that concrete containing fine sand and evenly distributed pores was stronger than
concrete with coarse sand and irregular pores [59][60][61]. Researchers from the University of Georgia
discovered that foam concrete with spherical air voids had a greater compression strength than foam
concrete with irregular perimeters or large irregular openings [62]. There was a greater number of
evenly distributed air voids in foam concrete with fine sand than in concrete with coarse sand [63].
With the addition of lightweight porous aggregates, glassy aggregates, waste paper sludge ashes
(WPSAs), clay aggregates, and quarry dust aggregates, foam concrete's compressive strength shot up
[64][24][65][66][67]. Fine recycled concrete aggregate (FRCA) can be added to foam concrete up to
10% by mass, improving its compressive strength. The irregular aggregate surface, combined with
pozzolonic aggregate, is what gives foam concrete its strength. Adding shredded rubber waste reduces
the elastic dynamic modulus and produces sound insulation because of its higher specific area and
rough texture. There were no significant differences in workability, tensile strength, and compressive
strength between specimens with and without pulverized bone at a design density of 1600 kg/m3 [68].
Foam concrete's compressive strength was decreased by adding lightweight porous aggregate [64].
Microcracks in foamed concrete were prevented by adding fibers. In foam concrete [100-104], fibres
of polyolefins, polypropylenes, polyvinyl alcohols, glass fibers, polyamides, and carbon fibers have
been used to improve strength. Steel fibers used in foam concrete are not recommended due to the
tendency for them to settle due to their density [69][70]. As a result of the plasticizer and micro fiber
reinforcement, Steshenko et al. [71]found that the void size was reduced, and the addition of
modifying additives increased the closed pore size significantly.

Tensile and flexural properties

The tensile strength of foam concrete is lower compared to normal weight or lightweight concrete with
aggregate. Unlike normal concrete (0.08 and 0.11), foam concrete has a higher ratio between flexural
and compressive strength [72]. For foam concrete with a density less than 300 kg/m3, the ratio of
flexural strength to compressive strength is almost zero according to Krishnan and Ramamurthy [73].
It is possible to prevent foam concrete from cracking at an early age by incorporating fibers with
sufficient length, size, and modulus of elasticity. Fibers were added to foam concrete to make it
flexural and elastic and to turn brittle behavior into flexural strength. Several studies have shown that
natural foaming agents have a higher flexural strength and are more accessible than synthetic foaming
agents [74][75]. A foam concrete mix without superplasticizers, silica fume, fly ash, or lightweight
aggregate was found to have greater ductility when compared to mixes with them. With increasing
density and increasing lateral deformation before failure, foam concrete with additives shows a greater
critical stress and crack width [76]. Shear strength is low in foam concrete, so reinforcement bars fail
too soon. Polypropylene and carbon fiber, on the other hand, have higher shear strengths [77][78]. It's
also important to consider that the flexural strength of foam concrete (with constant binder content) is
influenced by its water content, where excessive water reduces it [79][80][81].

Elasticity modulus
For a density of 500 to 1600 kg/m3, foam concrete exhibits a modulus of elasticity of between 1 and
12 kN/m2, which is 25% less than normal concrete [82]. Foam concrete's modulus of elasticity can be
affected by the fineness of aggregates. Due to the high proportion of fine aggregate in the sand mix,
the modulus of elasticity of foam concrete with fly ash as fine aggregate (paste without sand) was
lower than foam concrete with fly ash as fine aggregate [83]. By adding polypropylene fibers to foam
concrete, the modulus of elasticity can be increased by 0.50% by mix volume contrary to foam
concrete with a higher proportion of coarse aggregates [82].

Conclusions
Analyzing the publications, research has tended to evaluate and compare the properties of foamed
concrete rather than study its characteristics or stability. A significant aspect of foam concrete strength
has to do with its foam stability. Stable foamed concrete requires a variety of factors, including the
method of making the foam, the type of foaming agent, the accuracy of the mix, and the types of
additives and surfactants used. Currently, there is no standard design method for foam concrete. A
minimum proportion of cement to water should meet the consistency and stability requirements. The
consistency of foam concrete depends on how much water is in it; it becomes less foamy as it gets
more foamy. The amount of moisture is also influenced by the amount of connected pores to total
pores. The greater the connected pores, the more contaminants will be brought into the concrete. In
addition to having good mechanical and thermal properties, concrete with circular air voids increases
in compressive strength as density increases. The strength to density ratio of foam concrete with
additives like fly ash and silica fume was higher. As a result, it can reduce dead loads in load-bearing
structures and hence make foundations smaller.

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