WITH OF OF

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PRODUCTION OF FOAMED CONCRETE WITH A METHOD OF MIXING

Norasyikin ht. Md. Yusof

Bachelor of Engineering with Honours (Civil Engineering)

2009

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UNIVERSITI MALAYSIA SARA WAK BORANGPENGESAHAN

JUDUL: PRODUCTION OF FOAMED CONCRETE WITH A METHOD OF MIXING

SESI PENGAJIAN: 2009-2010 Saya NORASYIKIN BT. MD YUSOF

(HURUF BESAR)

mengaku membenarkan tesis

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ini elisimpan di Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dengan syarat-syarat kegunaan seperti berikut:

1. Tesis adalah hakmilik Universiti Malaysia Sarawak.

2. Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dibenarkan membuat salinan untuk tujuan pengajian sahaja.

3. Membuat pendigitan untuk membangunkan Pangkalan Data Kandungan Tempatan.

4. Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara institusi pengajian tinggi.

5.

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Sila tandakan ( ...j ) eli kotak yang berkenaan

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^SULIT (Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia seperti yang termaktub di dalam AKTA RAHSIA RASMI 1972).

TERHAD (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan).

TIDAK TERHAD

Disahkan oleh

(TANDATANGAN PENULIS) (TANDATANGAN PENYELIA)

Alamat Tetap: Pos l14A Bt 5 1f4 JIn Muar, Mukim 2 Bagan,

DR MOHAMMAD IBRAHIM SAF A WI (Nama Penyelia)

Tarikh:

Catatan:

83000 Batu Pahat, Johor.

Tarikh:

- - - - - - - -

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Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah, Sarjana dan Sarjana Muda.

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Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasaJorganisasi berkenaan dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULIT atau TERHAD.

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This project report attached here to, entitle "PRODUCTION OF FOAMED CONCRETE WITH A METHOD OF MIXING" prepared and submitted by NORASYIKIN BT. MD YUSOF (13431) as a partial fulfillment of the requirement for degree of Bachelor of Engineering with Honors in Civil Engineering is hereby read and approve by:

(Dr Mohammad Ibrahim Safawi) Project Supervisor

Faculty of Engineering Universiti Malaysia Sarawak

Date:

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PRODUCTION OF FOAMED CONCRETE WITH A METHOD OF MIXING

NORASYIKIN BT. MD. YUSOF

This project is submitted to Faculty of Engineering, University Malaysia Sarawak

in partial fulfilment of the requirement for the

Degree of Bachelor of Engineering with Honours (Civil Engineering) 2009

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For my beloved father and mother,

Sister, Brother in law, younger brother and fiance Thanks for everything.

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ACKNOWLEDGEMENTS

Alhamdulillah, first and foremost, thank you to Allah S.W.T with His companion, guidance, and wishes this project complete successfully. Thanks to my supervisor, Dr. Mohd Ibrahim Safawi B.Mohd Zain for his help, guidance and attention in accomplishing this thesis successfully.

Special thanks also for UNIMAS Civil Engineering Laboratory technicians En Nur Adha b. Hj Abdul Wahab for their help and cooperation during laboratory work. Their willingness to share their knowledge and time with me during the research is a valuable experience.

I would like to express my utmost thanks and gratitude to my beloved family, my mother, father, sister, brother in law, younger brother and my fiance. I would never have been able to complete this thesis without your continuous love and support.

Lastly, not forgetting to all my coursemates and friends, who give me support and help whenever I needed them.

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ABSTRACT

In the history of the construction industry, lightweight concrete or foamed concrete is a special concrete which can very useful in the construction sector because it is very lightweight and it can compact by itself at each angle of foamwork.

Many researchers have been done in overseas, and show that foamed concrete is free flowing material which is ideal for wide range of application. Moreover, material used to produce concrete is cheap to normal concrete. The objective of this thesis is to determine strength of concrete by using different material such as superplasticizer and without using superplasticizer follow by mixing by using water and without using water. The addition of chemical admixture such as superplasticizer (in the form of liquid) can help achieve as it can produce mortar of normal workability but with an extremely high strength owing to a very substantial reduction in the water/cement ratio. There are three test that been through at concrete laboratory such as Flow Table Test, Curing Test and Strength test in order to understand and look out character of the concrete. An inspection from this project can show the nature of foamed concrete when strength test will be done.

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ABSTRAK

Dalam sejarah industri pembinaan, konkrit ringan atau konkrit busa adalah konkrit khas yang amat berguna dalam industry pembinaan kerana sifatnya yang ringan dan boleh mampat dengan sendiri di dalam setiap ruang acuan. Banyak kajian yang telah dijalankan di luar Negara, menunjukkan bahawa konkrit busa mempunyai sifat yang mengalir dengan sendiri di mana ianya digunakan secara meluas.

Tambahan lagi, bahan yang digunakan untuk menghasilkan konkrit ini murah dan dapat mengurangkan kos pembinaan. Tujuan kajian ini dijalankan adalah untuk menentukan kekuatan konkrit dengan mengunakan bahan yang berbeza seperti bahan menggunkan superpemplastikan dan tidak mengunakan bahan superpemplastikan diikuti dengan campuran yang mengandungi air dan campuran yang tidak menggunkan air. Penambahan bahan tambah kimia seperti superpemplastikan (dalam bentuk cecair) dapat membantu untuk menghasilkan ciri yang lebih baik dengan menghasilkan mortar dengan kebolehkerjaan biasa bagi mempunyai kekuatan yang tinggi apabila nisbah airlsimen dikurangkan. Terdapat tiga jenis ujian yang dijalankan seperti ujian kebolehkerjaan, ujian rendaman dan ujian kekuatan untuk mengetahui dan melihat sifat-sifat concrete tersebut. Pemerhatian daripada kajian ini menunjukkan sifat konkrit buih apabila ujian kekuatan dilaksanakan.

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LIST OF TABLE

Tables Page

Table 2.1 Typical Properties of Foamed Concrete 13 Table 2.2 Main Features and Characteristic of Foamed Concrete 16

Table 2.3 Classification, Composition and Particle characteristic

ofPozzolan for Concrete 22

Table 2.4 Typical Properties ofPF A 25

Table 3.1 Sample of mix 42

Table 3.2 Fine Aggregates Grading 44

Table 3.3 Sample without Water 44

Table 3.4 Sample with Water 44

Table 3.5 Sample Without Superplasticizer 44

Table 3.6 Sample with Superplasticizer 44

Table 3.7 Material used for Sample 45

Table 4.1 Mortar Flow Table Test Result without Water 58 Table 4.2 Mortar Flow Table Test Result with Water 59 Table 4.3 Mortar Flow Table Test Result without Superplasticizer 60 Table 4.4 Mortar Flow Table Test Result with Superplasticizer 61

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LIST OF FIGURES

Figures Page

Figure 2.1 Micrograph ofPF A 25

Figure 3.1 Flow Table Test 35

Figure 3.2 Drum Mixer 36

Figure 3.3 Concrete / Mortar mixer 37

Figure 3.4 Foam Generator 37

Figure 3.5 Air Compressor 38

Figure 3.6 Cylinder 39

Figure 3.7 Polystyrene mould 39

Figure 3.8 Cement 40

Figure 3.9 Sand 41

Figure 3.10 Pulverized Fly Ash 43

Figure 3.11 Flow Table Test 47

Figure 3.12 Strength Test 48

Figure 4.1 Result Average Compressive Strength 50

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Figure 4.6 Cube D5 56

Figure 4.7 Cube D1 57

Figure 4.8 Flow Table Test without water 58

Figure 4.9 Flow Table Test with Water 59

Figure 4.10 Flow Table Test using Superplasticizer 60

Figure 4.11 Flow Table Test without using Superplasticizer 61

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CHAPTERl

INTRODUCTION

1.1 Background

Foam concrete is a type of porous concrete. According to its features and uses it is similar to aerated concrete. The synonyms are aerated concrete, lightweight concrete or porous concrete. The term foam concrete is containing no aggregates only sand, cement, water and stable foam to perform the concrete. This action incorporates small enclosed air bubbles within the mortar there by making the concrete lighter.

Basically, there are two method of producing foamed concrete such as pre- foam method and inline method. The inline method can divided into wet method and dry method. To produces foamed concrete, there are two type of foam will be used by wet foam and dry foam. A foamed concrete is described as having an air content of more than 25% which distinguishes it from highly air entrained materials.

Foamed concrete may have density from as low 500kg/m³to 1600kg/m³and strength from less than IN/mm²to 25N/mm².

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The strength of foamed concrete will be affected by the cement content of the mix, the water/cement ratio, the proportion of cement to sand and the properties of the sand. High compressive strength is generally achieved by using high cement content, a low water/cement ratio and a sand.

Basically, the workability test and strength test will be tested to investigate properties of foamed concrete. To measure of workability test and strength test will be tested in the experiment such as slump test. This concrete will be tested before concrete is casting into mould, therefore the fresh concrete will be used to determine the workability of concrete mix, and after the concrete harden, strength test will be measure on 7 days and 28 days.

1.2 Objectives of Study

The aims of this project were to investigate and to improving of workability of foamed concrete. There are two main objectives of the project are:

1. To produce foamed concrete in laboratory.

11. To determine the effectiveness of using super plasticizer in mortar.

111. To determine and compared strength of foamed concrete, first using super

plasticizer and secondly without using super plasticizer.

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1.3 Limitation of Study

Foamed concrete is one field that is too wide to discuss. To achieve the objective of this project, the study is just to focus on the related foamed concrete.

The following are the main limitation of study:

1. This study also by using target density lOOOkg/m³

11. These theses also look out by using water and without water followed by using super plasticizer and without using super plasticizer.

1.4 Outline of the Thesis

This thesis contains five chapters starting with the introduction in chapter 1, followed by literature review in chapter 2 and methodology in chapter 3. Chapter 4 also contains result and analysis and the end of the thesis is providing conclusion and recommendation in chapter 5.

• Chapter 1: Introduction

This chapter discusses about background of foamed concrete and the objectives and followed by limitation of study.

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• Chapter 2: Literature Review

This chapter discussed the detail about foamed concrete and properties of foamed concrete and the application. The properties are strength, water cement ratio, density and cement content. The application is using a foam concrete that depend to the density of foam concrete. In this chapter also discussed about the production of the foamed concrete.

• Chapter 3: Methodology

This chapter discussed about equipment used to produce foam concrete, the material and mix proportion. In this chapter also contain the test uses to achieved the objectives this project. The test is checking the strength and workability of the foamed concrete.

• Chapter 4: Analysis and Discussion

This chapter analyzed and discussed about the data obtained from experiments.

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• Chapter 5: Conclusion and Recommendation

This chapter discussed the conclusion base on data and the recommendation for the further work.

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CHAPTER 2 LITERATURE REVIEW

2.1 Introduction

This thesis is to produce the foam concrete and test the foamed concrete at laboratory to identify the suitable density and the mix proportion to use for produce the foam concrete for structure. All properties of foamed concrete like dry density, compressive strength, thermal conductivity, and drying shrinkage are describe in this chapter. Also describe in this chapter is the typical application and the production of foam concrete.

2.2 Foam Concrete

The term foam concrete is containing no aggregates only sand, cement, water and stable foam to perform the concrete. This action incorporates small enclosed air bubbles within the mortar there by making the concrete lighter. A foamed concrete is described as having an air content of more than 25% which distinguishes it from highly air entrained materials. Foamed concrete may have density from as low 500kg/m³to 1600kg/m³and strength from less than IN/mm²to 25N/mm².

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The stable foam is the most important gradient in the production of foamed concrete. The foaming generator made foam, where is blend of sand, cement, and water (the base mix) and foaming agent either protein or synthetic are mixed and produced stable foam is foamed.

According to a study by (Norizal, 2002) state that foams from protein foaming agent comes from natural sources and has a weight of around 80g/litre and expansion of about 12.5 x using portaform foam generator. They generally are more stable then synthetic foams but have a shorter shelf life of about 12 month in open conditions.

They also give a higher strength of concrete compared to synthetic foams. This is suitable for densities from 400kg/m³to 1600kg/m³.

According to a study by (Norizal, 2002) state that synthetic foams have density of about 40g/litre with an expansion of about 25 x using portafoam. They are very stable at concrete densities above 1000kg/m3 and give good strength. Their shelf life is about 16month under sealed condition. This is suitable for densities of 1000kg/m³ and above.

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2.3 Type of foam concrete

2.3.1 Wet foam

Wet foam is produced by spraymg a solution of foaming agent (usually synthetic) and water over a fine mesh. This action causes a drop in pressure across the mesh allowing air to be sucked from atmosphere to equal the pressure. This equalization of pressure causes the solution to expand into what can best be described as a foamed similar in appearance to bubble bath foam. With the bubble size ranging 2-Smm. The foam has a large "loose" bubble structure and although relatively stable it is not recommended for the production of low density (below 1100kg/m³) foamed materials. It is also not suitable for pumping long distance or pouring to any great depth.

When tends to happen is that as pressure on the materials increases (this pressure increase can be as simple as pouring the material over a certain depth), the bubble basically burst causing a decrease in yield along with an increase in density.

2.3.2 Dry foam

Dry foam is produced by forcing a similar solution of foaming agent and water through a series of high density restrictions whilst at the same time forcing compressed air into a mixing chamber. The action of forcing this pressurized air into the solution expands the solution into thick, tight foam, similar in appearance to

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shaving foam. The bubble size is typically less than lmm in diameter and of an even size. The type of foam is extremely stable and these stable properties are passed onto the foamed materials when the foam is blended with the base materials.

As detailed previously this stability is particularly important when the ratio of foam to base materials is greater than 50:50. When the foam becomes the dominant partner within the mix it has to retain its stability to avoid collapse during, pumping, curing, and pouring. Foamed concrete produced using dry foam can be pumped further, poured deeper and exhibits better flow characteristics than a like for like mix produced with a wet foam system.

2.4 Method of Mixing

There are two method of producing foamed concrete such as pre-foamed method and the inline method:-

2.4.1 Inline system (Wet method)

This system has been driven in the main part by the need for both higher product quality control and the commercial requirement for lower density material. These systems incorporate the same type of foam generator and foaming chemicals as used in the pre-foam method, but differ in that it except wet base materials into an abroad hopper and add the foam through a completely separate process together.

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WITH OF OF

PRODUCTION OF FOAMED CONCRETE WITH A METHOD OF MIXING

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PRODUCTION OF FOAMED CONCRETE WITH A METHOD OF MIXING

ACKNOWLEDGEMENTS

ABSTRACT

ABSTRAK

TABLE OF CONTENTS

LIST OF TABLE

LIST OF FIGURES

CHAPTERl

INTRODUCTION

CHAPTER 2

LITERATURE REVIEW