Progress on Preparation and Characteristics of Ultra-lightweight Foam Concrete

doi:10.19691/j.cnki.1004-4493.2020.04.001

China's Refractories ›› 2020, Vol. 29 ›› Issue (4): 1-5.DOI: 10.19691/j.cnki.1004-4493.2020.04.001

• Original article • Next Articles

Progress on Preparation and Characteristics of Ultra-lightweight Foam Concrete

ZHENG Juanrong¹^,^*(), ZHANG Simi¹, ZHAO Zhenbo²

1 School of Civil Engineering, Zhengzhou University, Zhengzhou 450002, China
2 Zhengzhou Gongda New Building Material and High-Tech Co., Ltd., Zhengzhou 450002, China

Online:2020-12-15 Published:2020-12-15
Contact: ZHENG Juanrong
About author:Zheng Juanrong received her Ph.D. in the materials for civil engineering from Mining University of China (Beijing Campus) in 2011. After that she has been working as a professor in Civil Engineering School of Zhengzhou University. Her research focuses on the preparation and application of low-carbon cement-based materials and porous concrete.

Abstract

Abstract:

With the increase in global warming, building energy saving becomes a principal policy for most countries. About 70% of the energy consumption loss of buildings is through the external walls of the buildings. Ultra-lightweight foam concretes with dry density of 150-300 kg·m ^-3as the thermal insulation materials have been commercially prepared and used in building insulation engineering in China. This paper reports the raw materials and procedures for preparation of ultra-lightweight foam concretes by chemical foaming (UFC-C) and physical foaming (UFC-P). The characteristics of the air-voids structure, the mechanical properties, the water absorption, the thermal conductivity and the fire resistance of UFC-C and UFC-P were summarized in this paper. Based on existing research progress, the future research works were presented.

Key words: ultra-lightweight micron-pore, air-voids structure, mechanical properties, water absorption, thermal insulation, fire resistance

ZHENG Juanrong, ZHANG Simi, ZHAO Zhenbo. Progress on Preparation and Characteristics of Ultra-lightweight Foam Concrete[J]. China's Refractories, 2020, 29(4): 1-5.

Figures/Tables 4

References 25

[1]	R. C. Valore. Cellular concrete part 1 composition and methods of production. ACI J., 1954, 50: 773-796.
[2]	R. C. Valore. Cellular concrete part 2 physical properties. ACI J., 1954, 50: 817-836.
[3]	M. R. Jones, A. McCarthy. Preliminary views on the potential of foamed concrete as a structural material. Magazine of Concrete Research, 2005, 57(1): 21-31. DOI URL
[4]	K. Ramamurthy, E. K. Kunhanandan Nambiar, G. Indu Siva Ranjani. A classification of studies on properties of foam concrete. Cement & Concrete Composites, 2009, 31: 388-396.
[5]	Amritha Raj, Dhanya Sathyan, K M Mini. Physical and functional characteristics of foam concrete: A review. Construction and Building Materials, 2019, 221: 787-799.
[6]	Gu Yancheng, Chen Sinuo, Huang Enxing. Present situation and development of building energy-saving insulation materials. Building Energy Efficiency (in Chinese), 2016, 44(6): 34-38.
[7]	Kong Xiangfei, Liu Shaoning, Zhong Yuliang, Rong Xian, Yang Hua, Qi Chengying. Analysis and optimization of multi-factor heat characteristics of phase change storage wall. Building Science (in Chinese), 2016, 32(8): 40-46.
[8]	Recommended technical regulations for construction of Jiangsu Province, Technical specification for external thermal insulation systems of composite foam cement panel (JG/T 041-2011), Published by Department of Housing and Urban-rural Development of Jiangsu Province (in Chinese), 2011-03-01.
[9]	Construction standards of Chongqing City, Technical specification for application of modified foam cement insulation board thermal insulation system on building (DBJ 50/T-185-2014), Published by Department of Housing and Urban-rural Development of Chongqing City (in Chinese), 2014-04-03.
[10]	Construction standards of Henan Province, Technical specification for the application of inorganic plasticized micro-porous insulation board (DBJ 41/T 200-2018), Published by Department of Housing and Urban-rural Development of Henan Province (in Chinese), 2018-09-03.
[11]	Huang Zhengyu, Sun Qingfeng, Zhou Zhimin. Study on pore structure and properties of super-lightweight foam concrete with OPC-SAC mixture. Bulletin of the Chinese Ceramic Society (in Chinese), 2013, 32(9): 1894-1899.
[12]	Zhaoming Huang, Tongsheng Zhang, Ziyun Wen. Proportioning and characterization of Portland cement-based ultra-lightweight foam concretes. Construction and Building Materials, 2015, 79: 390-396.
[13]	Wu Jiandong, Zhang Zerui, Zhang Yi, Li Dongxu. Preparation and characterization of ultra-lightweight foamed geopolymer (UFG) based on fly ash-metakaolin blends. Construction and Building Materials, 2018, 168: 771-779.
[14]	Lv Qingang, Pan Zhihua, Li Hengzhi. Effect of ultrafine slag powder on preparation and performance of foamed concrete. New Building Materials (in Chinese), 2013, (3): 56-58.
[15]	Zhao Zhenbo, Zheng Juanrong, Zhang Linlin, Li Haiyu, Xiong Jinxiu. Preparation and properties of inorganic plasticized microporous thermal insulation board. New Building Materials (in Chinese), 2019, (3): 148-150+154.
[16]	Zhang Xu, Wang Wuxiang, Yang Dingyi, Zhang Leilei. Study on control measures of pore structure of ultra lightweight foam concrete. Bulletin of the Chinese Ceramic Society (in Chinese), 2019, 38(7): 2255-2267.
[17]	Li Hengzhi, Pan Zhihua. Investigation on the improvement of water resistance property of the super low density foam concrete. Concrete (in Chinese), 2014, 296(6): 88-91.
[18]	Pan Zhihua, Li Hengzhi, Liu Wenqing. Preparation and chara-cterization of super low density foamed concrete from Portland cement and admixtures. Construction and Building Materials, 2014, 72(15): 256-261.
[19]	Xu Wen, Qian Guanlong, Hua Zilong. Experimental study on the preparation of foam concrete by chemical method. China Concrete and Cement Products (in Chinese), 2011, (12): 1-4.
[20]	E. K. Kunhanandan Nambiar, K. Ramamurthy. Influence of filler type on the properties of foam concrete. Cement and Concrete Composites, 2006, 28(5): 475-480.
[21]	E. K. Kunhanandan Nambiar, K. Ramamurthy. Models relating mixture composition to the density and strength of foam concrete using response surface methodology. Cement and Concrete Composites, 2006, 28(9): 752-760.
[22]	E. K. Kunhanandan Nambiar, K. Ramamurthy. Air-void characterisation of foam concrete. Cement and Concrete Research, 2007, 37(2): 221-230.
[23]	E. P. Kearsley, P. J. Wainwright. Porosity and permeability of foamed concrete. Cement and Concrete Research, 2001, 31(5): 805-812.
[24]	Wu Zhiju, Yan Qiuhui, Luo Jieren. Experimental study on improving the thermal insulation performance of rock wool by silica aerogel. Building Energy & Environment (in Chinese), 2019, 38(5): 13-16.
[25]	Classification for burning behavior of building materials and products (GB 8624-2012), Published by China National Standardization Administration Committee, 2012-12-31.

	UFC-P	UFC-C	Foam concrete	Ordinary concrete
Dry density /(kg · m^-3)	150-300	150-300	400-1 600	2 200-2 400
Compressive strength /MPa	0.5-1.5	0.5-1.1	0.5-10.0	30-80
Flexural strength /MPa	-	-	0.5-0.7	3.0-8.0
Tensile strength /MPa	0.10-0.13	0.10-0.13	-	-
Modulus of elasticity /GPa	-	-	0.3-1.2	20-30
Dry shrinkage /×10⁶	≤3000	≤3 000	1 500-3 500	600-900
Thermal conductivity /(W · m^-1 · K^-1)	0.045-0.068	0.050-0.071	0.11-0.3	1.63-1.74
Freeze-thaw resistance /%	-	-	90-97	90-97
Fluidity of fresh slurry /mm	-	-	200	~180
Water absorption /%	≤5	≤10	-	-
Fire-resistance grade	A	A	-	-

	UFC-P	UFC-C	Foam concrete	Ordinary concrete
Dry density /(kg · m^-3)	150-300	150-300	400-1 600	2 200-2 400
Compressive strength /MPa	0.5-1.5	0.5-1.1	0.5-10.0	30-80
Flexural strength /MPa	-	-	0.5-0.7	3.0-8.0
Tensile strength /MPa	0.10-0.13	0.10-0.13	-	-
Modulus of elasticity /GPa	-	-	0.3-1.2	20-30
Dry shrinkage /×10⁶	≤3000	≤3 000	1 500-3 500	600-900
Thermal conductivity /(W · m^-1 · K^-1)	0.045-0.068	0.050-0.071	0.11-0.3	1.63-1.74
Freeze-thaw resistance /%	-	-	90-97	90-97
Fluidity of fresh slurry /mm	-	-	200	~180
Water absorption /%	≤5	≤10	-	-
Fire-resistance grade	A	A	-	-

For preparation of UFC-C^[18]	For preparation of UFC-P^[15]
Cement, slag, water, chemical and physical admixtures are mixed thoroughly	Cement, fly-ash, water, chemical admixtures are mixed thoroughly and ball milling for 30-60 minutes
Foaming agent is added and mixing quickly	Foam and physical admixtures are added and mixing quickly
Placing and Foaming (dimensions: 1.25 m×1.25 m×0.64 m)	Placing (dimensions: 1.25 m×1.25 m×0.64 m)
Rest and curing at room temperature	Rest and curing at 50-90 ℃
Demoulding	Demoulding
Products by cutting (dimensions: 600 mm×300 mm×(30-80) mm)	Products by cutting (dimensions: 600 mm×300 mm×(30-80) mm)

For preparation of UFC-C^[18]	For preparation of UFC-P^[15]
Cement, slag, water, chemical and physical admixtures are mixed thoroughly	Cement, fly-ash, water, chemical admixtures are mixed thoroughly and ball milling for 30-60 minutes
Foaming agent is added and mixing quickly	Foam and physical admixtures are added and mixing quickly
Placing and Foaming (dimensions: 1.25 m×1.25 m×0.64 m)	Placing (dimensions: 1.25 m×1.25 m×0.64 m)
Rest and curing at room temperature	Rest and curing at 50-90 ℃
Demoulding	Demoulding
Products by cutting (dimensions: 600 mm×300 mm×(30-80) mm)	Products by cutting (dimensions: 600 mm×300 mm×(30-80) mm)

China's Refractories

Progress on Preparation and Characteristics of Ultra-lightweight Foam Concrete

RichHTML

PDF

Knowledge

Abstract

Cite this article

share this article

Figures/Tables 4

References 25

Related Articles 15

Recommended Articles

Metrics

Comments

Dry density /(kg · m^-3)	Porosity /%		Pore size distribution /%		Connected pore volume /%
	Porosity /%		1.0-4.0 mm	0.05-0.1 mm	Connected pore volume /%
	UFC-C	UFC-P	UFC-C	UFC-P	UFC-C	UFC-P
150	78	76	85	90	8.5	4
200	75	73	90	92	7.8	3
250	74	70	95	95	7.5	2
300	70	65	90	100	7.0	0

[1]	HU Chen, WANG Xing, LIU Zhenglong, DING Jun, YU Chao, DENG Chengji. Effect of ZrC Modified Graphite on Structure and Properties of Low-carbon Al₂O₃-C Refractories [J]. China's Refractories, 2024, 33(1): 18-22.
[2]	CHEN Yang, DENG Chengji, DING Jun, YU Chao, LOU Xiaoming. Effect of Ferric Nitrate Loading Mode on Properties of Si₃N₄ Composite MgO-C Refractories Prepared by Nitridation [J]. China's Refractories, 2023, 32(3): 6-9.
[3]	GAO Qianyu, WU Aijun, WANG Qi, YIN Hongji. Zirconia Hollow Spheres and Their Application [J]. , 2018, 27(4): 26-30.
[4]	WANG Fucheng, WEI Guoping, LUO Ming, FANG Binxiang. Effects of Resins with Different Molecular Structures on Properties of MgO-C Bricks [J]. , 2017, 26(4): 31-36.
[5]	YU Renhong, LIU Pengcheng, DONG Gaofeng, DONG Hongqin. Effects of Spherical Light-weight Aggregates Additions on Workability and Mechanical Properties of Al2O3-SiO2 System Castables [J]. , 2017, 26(4): 1-6.
[6]	Ali Baghaei, Mehdi Naeemi. Impact of Functional Additives on Properties of Al2O3–C Slide Gate Plate Refractories [J]. , 2017, 26(3): 19-22.
[7]	YU Renhong1, LIU Pengcheng1, ZHOU Xiwen1, ZHOU Ningsheng1, YANG Dahui1, DONG Gaofeng2. Effects of Spherical Aggregates Addition on Properties of Al2O3-SiO2 System Castables [J]. , 2017, 26(1): 13-17.
[8]	Sergey M. LOGVINKOV*,Galina N. SHABANOVA,Alla N. KOROHODSKA, Elena V. KHRYSTYCH. Modified Alumina Cement with High Service Properties [J]. , 2016, 25(4): 1-5.
[9]	GAO Jianying, ZHANG Ziying, BRUNO Touzo. Thermo-mechanical Properties of In-situ Formed Al2O3-SiC-SiAlON Composites [J]. , 2016, 25(2): 1-6.
[10]	LIAO Ning, LIYawei,SANG Shaobai, CHEN Songlin, ZENG Luju. Effect of Nano Carbon Black and Graphite Flake on Properties of Low Carbon Al2O3-C Refractories [J]. , 2016, 25(2): 17-24.
[11]	HUANG Yalei,GUQiang,WENYubin, LIU Zhifang, LIU Xinhong. Thermo-mechanical Properties of In-situ Formed Al2O3-SiC-SiAlON Composites [J]. , 2016, 25(2): 48-52.
[12]	WANG Yujin*,WEI Boxin,CHEN Lei, OUYANG Jiahu, ZHOU Yu. Research Progress on Preparation and Properties of Zirconium Carbide Matrix Composites [J]. , 2015, 24(3): 1-11.
[13]	YUAN Bo*,CHEN Kuo,HAN Jianshen, DONG Binbin, WANG Gang, LI Hongxia. Thermal Insulation Materials of Alumina Based Porous Ceramics [J]. , 2015, 24(3): 29-33.
[14]	LIN Sen*,YAO Dongxu,XIA Yongfeng, ZUO Kaihui, YIN Jinwei, ZENG Yuping. Influence of Yb2O3-MgO on Mechanical Properties and Thermal Conductivity of Silicon Nitride Ceramics via Gas Pressure Sintering [J]. , 2015, 24(3): 34-39.
[15]	REN Zhen, GE Tiezhu, ZHONG Xiangchong. Effects of Al-Si Addition on Thermomechanical Properties of Low-carbon MgO-C Materials [J]. , 2013, 22(2): 11-14.