Lightweight concrete mix- Types,

Preparation, Merit, and Demerit

What is Light weight Concrete?
Lightweight concrete mix is those concrete that have low specific gravity
compared to the other concrete due to the presence of minute voids or air
entrainment. The void can be created either as in form of microscopic
pores in a mortar or through the improper intersectional joint between
particles of concrete or within aggregate itself.

Lightweight concrete has distinctive low structural strength compared to the

normal or high-density concrete. As we know not all the parts of the
structure are responsible for the strength of the structure, such concrete is
very useful to those parts construction.

Lightweight concrete
mix
They can decrease dead load up to 20% – 80% depending on their types
and components used within them with alteration in strength. Moreover,
even they have low structural strength; their strength is still higher than
the masonry elements like a brick.

The air is an excellent insulating agent. As the lightweight concrete

contains air entrainment within it, this lightweight concrete has extremely
high thermal insulation and sound insulation.
How lightweight concrete are made and what are the
components of light weight concrete?
Lightweight concrete can be made in different ways, either by creating
numerous intersectional joint void or by modifying the cementing agent with
numerous pores giving cellular structure or by using extremely lightweight
aggregates.

Whatever method is accepted, the principal mechanism of lightweight

concrete is to introduce the air voids or entrainment in order to decrease its
weight and increase volume.

On the basis of how lightweight concrete are made they

are divided into three types:
1) Light weight aggregate concrete:
The lightweight porous aggregate such as pumice, thermally treated shale,
diatomite, scoria, volcanic cinder, etc is used for decreasing the density of
concrete. The specific gravity of such concrete is generally less than 2. The
structural strength difference in concrete form by using normal aggregate
and such aggregates keeping all other material as in the same quality and
proportion is only 30%.

Thus due to these reasons, the concrete using lightweight are also
subjected to structural strength design along with the purpose of
decreasing its density. The density of such concrete varies from 1400
kg/m3 – 1800 kg/m3 and the strength of such concrete generally starts with
17MPa and more which depends upon their design mix.

2) Aerated concrete:
The microscopic pores of evenly well-distributed form in concrete is
achieved by using the additional foam-forming materials like aluminum in
the concrete mix. The aluminum powder reacts with the calcium hydroxide
to give hydrogen gas, which forms the bubble of the air entrains gas within
the concrete while setting.

Also, some times foam-forming materials (hydrolyzed protein or resin

soaps) are used to form the foams. The air entrainment makes the
concrete spongy or cellular in structure.
The concrete along with a comparison of its equivalent density with other
material, it can be said it has comparative high strength. This concrete
can decrease the load up to 80% but are not good for structural strength.
Thus this concrete is also precast in the forms of blocks which can easily lift
and placed as masonry units. Moreover, these long precast blocks are also
used as a slab for the steel structures.

Due to high air entrainment voids, it can facilities the function of internal
curing to concrete. They have extremely less density ranges from
550kg/m3 – 990kg /m3, so that can even float on water. The help of using
both light aggregate, aluminum, and other admixture can make this.
However, they have very little structural strength ranging from 4MPa-
12MPa.

3) No fines use concrete:

In this, the fine aggregate is completely omitted from the mix to create the
interstitial voids. This concrete is prone to internal cracks formation and are
not well compacted due to which there is a decrease in density.

The gap graded aggregate is preferred in order to prevent the interstitial

bonding or compaction. They are useful for damp proof coursing,
temporary structures, and external load-bearing walls. The density of this
concrete is also 25%-30% less than normal concrete.

There density can ranges from 700kg/m3 (using lightweight aggregate) -

1600/1900kg/m3(using normal aggregate). And their strength lies within
4MPa-14MPa. They exhibit low shrinkage on drying and tend to segregate
less. But it must be noted that compaction via vibrating machines is
prohibited however simple compaction through rod are allowed.

How to make lightweight concrete mix?

As already discussed, there are different types of lightweight concrete
depending on their method of preparation. Thus the design of mixes and
the proportion ratio of the constitution of the mix may vary or depend upon
which type of approach is adopted. However, the generally adopted
procedure and mix are explained below

1) For no fine aggregate

 The coarse aggregate passing from the sieve of 20mm and
retain in 10 mm is preferred for the preparation of such
 concrete with absolute no used of fine( no material smaller than
5mm) aggregates. Moreover gap graded aggregate is more
preferable in order to create more interstitial voids.
 Aggregate with round edges is preferred as they form a more
interstitial gap.
 The cement to the aggregate proportional ratio for such
concrete generally ranges from 1:6 to 1:10.
 The water ratio is also adopted of range 0.38 to 0.52 which
depends upon the cohesiveness of the mixture.
 This concrete generally doesn’t have significant strength. Thus
are not subjected to the design mix approach and general
thumb rule or conventional method as explained in the table
below are accepted to prepare.
Aggregate /cement ratio by Water cement Density In Compressive strength (28 days)
volume ratio kg/m3 In MPa

6 0.38 2020 14

7 0.40 1970 12

8 0.41 1940 10

10 0.45 1860 7

Table 1: Different aggregate /cement ratio with varying strength and water
content
2) For the aerated concrete
 The general procedure for the concrete mix preparation can be
adopted along with the addition of the aluminum powder as an
admixture in the fresh concrete mix.
 Moreover, the use of lightweight aggregate is also used to
formless density concrete instead of normal aggregates. And
sometimes even coarse aggregates are omitted (generally
in AAC blocks)
 However, this concrete is more preferred in form of precast
concrete blocks as Autoclave Aerated Concrete Blocks. So the
general procedure for AAC block preparation can also be
considered as its design method.
  The water-cement ratio for such concrete is 0.5-0.4 with
cement sand ratio 1: 2 and if the coarse aggregate is also
added then 1:1:2.and aluminum content should be 0.05%-
0.08% of the concrete mass.
3) For light weight aggregate concrete (DESIGN MIX
PROCEDURE)
 The above-formed concrete might not have the distinctive
strength. Thus by use of the lightweight aggregate the specific
concrete of designated grade can be formed. The minimum
strength of such concrete must be 17MPa. The lightweight
aggregate concrete can be designed by a design mix method if
required for the structural purpose.
 Also the adaptation of the material to make such concrete
varies the design procedure and quality of concrete.
 Some basic information needed to know before the design is
that the aggregate must sufficiently leave for the absorption
over 10% for better performance. Also, the well-graded
material must be selected to use less volume of fine aggregate.
 The ACI 211.2-98 method of design is popularly adopted to
design the lightweight aggregate concrete for higher strength
greater than 17MPa limiting density to 1840 kg/m3. The
cement-content strength method is used to form fully
lightweight aggregate concrete. (However, the normal mass
method design used for normal aggregate can also be used to
form semi lightweight aggregate concrete)
Lightweight concrete mix design
1. Assume the appropriate slump value according to the
requirement of concrete whether to use it in the beam, RCC
works, column, Slab according to from the table1 given below.
Types of construction Slump value (in mm)

RCC foundation wall and footings 20 – 80

Plain concrete footings, structure wall 20 – 80

Beam and RCC wall 20 – 100

Building Column 20 – 80
 Pavements and slab 20 – 80

Mas concrete 20 – 80

Concrete for canal lining 70 – 80

Table 1 : slump value recommendation according to ACI 211.1-

91(reapproved 2002)
 The maximum size of aggregate should be 1/5th of smallest
dimension of member (generally cover in RCC), 1/3 of depth of
slab and ¾ of reinforcement bar minimum spacing.
 Determine the air entrained required for higher durability
requirement. From table 2.

Table
2 : air content for air entrained and non-air entrained concrete given by ACI
211.2-98(reapproved 2004)
 Determine rough cement content from Table 3.

Compressive strength in MPa Cement content (kg/m3 )

17 350 – 520

21 400 – 550

28 500 – 650
 34 600 – 750

41 700 – 850

Table 3: Approximate relation between cement content and strength of

lightweight concrete mix according to ACI 211.2-98 (re-approved 2004)
 Assume that the total volume of loose and dry aggregate
required for compacted 1m3 concrete mass is 1.2m3. assume
the amount of fines is about 50 percentage of the coarse
aggregate.
 After that with known dry loose densities of aggregate and
required strength, the amount of aggregate, cement is
determined and the trial mix is made using sufficient required
water to produce required or assumed slump value.
 Then, the density of fresh concrete is measured and the yield is
estimated to calculate batching quantities.
 The volume of water already presented in aggregate must be
accounted during batching of concrete as the sample
aggregate use for the trial mix are completely oven dry and
loose aggregate. Thus is deducted from the total constant
water content required.
 If the strength and other property such as air content,
workability ,cohesiveness are satisfactory volume of aggregate
and content of cement are just slightly altered. The general
thumb rule is increasing dry aggregate by 0.0006 m3 for each
1kg decrease in cement content and vice versa.
 But if the strength and other property are drastically different,
(like 20 MPa strength has need to form using trial mix for
17Mpa) then as such situation the huge amount of cement is
needed to be altered. The pycnometer specific gravity factor
are used to modify the density of material and so to their mass
content.
The pycnometer specific gravity factor (S) is given by formula

Where, A = mass of aggregate tested

B = mass of pycnometer with aggregate filled with water (10 min of full
immersion in water)
C= mass of pycnometer filled with water,

This formula is generalized in graph by varying different water content of

aggregate given by as in fig 1.

And so cement content is increased abruptly , the volume of only fine

aggregate is decreased. Thus other are maintain at constant. The new
volume of fine aggregate is estimated by deducting sum of volume of
cement, coarse aggregate, eater and air entrap obtain after correction.
Moreover, with known sp. Gravity correction factor the mass of individual
can be determined as well.

Example:
Prepare the light weight concrete of average strength 18 MPa at 28 days
with air content 7 percent (assume if not given) and slump value of 75mm
(assume if not given).

Then,

Dry density of coarse aggregate = 720 kg/m3 , moisture content at site = 5%

Dry density of fine aggregate = 900 kg/m3 , moisture content at site = 10%
From table 3, with reference of strength of 17MPa trial

Assume cement content =350 kg/m3 of concrete

In addition, according to design procedure consider the volume of total

loose and aggregate required for 1m3 concrete mass be 1.2 m3, where 0.8
m3 is coarse aggregate and 0.4 m3 is fine aggregate (50 % of coarse
aggregate)

Then for the trial mix of the volume 0.02m3 is required to prepare.

Cement required = 350 * 0.02 = 7 kg

Fine aggregate = 0.4* 900*0.02 = 7.2 kg

Coarse aggregate = 0.8 * 720 * 0.02 = 11.52 kg

Water content for required slump = 4 kg

Total mass = 29.72 kg

If the density of the fresh concrete trial is found to be 1450 kg/m3

Thus actual quantity rate on dry basis is,

Cement: 7/0.02015= 346 (Approx.)

Fine aggregate: 7.2/ 0.02015= 356

Coarse aggregate: 11.52/0.02015= 570

Water content: 4/0.02015 = 198

Total = 1470 kg/m3

The cement content in trial mix is 4 kg less than the specified

Case I:
If the property including strength is satisfactory,

Then

We decrease the volume of aggregate on dry loose basis by 0.0006m3 for

each increase in 1kg cement. Allocating reduction in equally. Then

Fine aggregate rate = 356 – 0.5 *(4 *0.0006*900) = 355 kg/m3 of concrete

Coarse aggregate rate = 570 – 0.5 * (4*0.0006*720) =569kg/m3 of concrete

For small adjustment water content is kept constant

But the water moisture present on site must be considered. So, the final
design mix rate of constituent for batching is,

Cement = 346+4 =350 kg/m3 of concrete

Fine aggregate (of site) = 355* 1.1 = 391 kg/m3 of concrete

Coarse aggregate (of site) =569*1.05 = 598 kg/m3 of concrete

Added water = 198 – [391- 355] – [598- 569] = 191 kg/m3 of concrete

Case II:
If the strength is not achieved sufficient along with improper requirement
and quality in concrete then. The cement content must be abruptly
increased. Let the cement content is increased by 50 kg/m3 of concrete
mass. So that, 400 kg/m3 is taken for next trial.

Also according to design procedure, let us assume specific gravity

correction factor from fig 1. Or by formula and pycnometer analysis.

Let the factors is found to be 1.78 and 1.35 on a dry basis and 1.75 and
1.36 on wet basis.

On dry basis, volume of concrete with initially use trial of 350 kg/m3 of
concrete is,
Thus the volume of fine aggregate is 1.00- 0.816 = 0.184m3

The mass of fine aggregate on dry basis is,

0.184* 1000*1.78 =328 kg/m3 of concrete mass

To estimate considering moisture (on site)

Fine aggregate = 328* 1.10 = 361 kg/m3 of concrete mass

Coarse aggregate = 569*1.05 = 598 kg/m3 of concrete mass

The added water here is obtain more accurately by,

thus mass of water required = 0.157* 1000 = 157 kg/m3

Hence the quantity required for batching is ;

Cement : 400 kg/m3 of concrete mass

Fine aggregate: 361 kg/m3 of concrete mass

Coarse aggregate: 598 kg/m3 of concrete mass

Water : 157 kg/m3 of concrete mass

Total =1516 kg/m3 of concrete mass

And at last the 2nd trial is made and subjected to test its compressive
strength. If the requirements are not achieve then, again the cement
content and dine particles are altered or any other parameter with help of
general thumb rule.

Advantages of Lightweight concrete mix

1. Lightweight concrete can reduce the dead load of the structure.
This concrete has ranges of 20% – 80 % less mass than the
normal concrete.
2. They contain numerous voids and thus these decrease the
thermal conductivity and increase the sound insulation.
3. Precast Lightweight concrete blocks and slabs are very easy to
handle, transport, and place.
4. They have a variable range of strength, which can be useful for
the nonstructural component of masonry units to the load-
supporting structural units.
5. They consume less aggregate.
6. They don’t show the problems associated with freezing and
thawing due to numerous pores in cement material
7. They are comparatively more fire-resistant as they have a
lesser tendency to spall. Also, concrete strength is less
sensitive to the rise in temperature.
8. The sound absorption is also more due to the presence of
microspores. Thus they are useful for the auditorium, halls for
good sound effects.
9. The internal curing is possible in such concrete leading lesser
cracks due to heat of hydration.
Disadvantages of Lightweight concrete mix
1. These concrete are extremely hard to maintain, supervise for
the proper placement and workmanship. The smallest
negligence can cause great decrease in quality.
2. Contains many voids and pore so they don’t give higher density
and strength as that of normal concrete for same volume and
cement use.
3. Due to less density, they are not use for foundation purpose.
4. No proper compaction and vibration of the concrete mass leads
to the honeycomb in the concrete structure.
5. The porous aggregate might absorb more water causing
frequent change in the water to be added in mix.
 These concrete have high absorption rate especially, no fines
used concrete and aerated concrete.
 No fines used concrete are not usually preferred with
reinforcement bars as there is a high probability of rusting and
the improper bonding within the concrete.