Lightweight Construction Materials Research Articles

Analysis of the Meso‐Mechanical Deformation Behavior of Al Foams and Ni/Al Hybrid Foams Using Time‐Lapse Micro‐Computed Tomography Measurements and 3D Optical Flow

Metal foams are an interesting class of bio‐inspired materials for lightweight construction and energy absorption. Commonly, aluminum (Al) foams are used. However, the mechanical properties have been improved by coating pure Al foams with a nanocrystalline nickel (Ni) coating resulting in Ni/Al hybrid foams. Herein, the meso‐mechanical deformation mechanisms in Al foams and the changes in the mechanisms in Ni/Al hybrid foams are studied using time‐lapse micro‐computed tomography measurements in comparison between numerical modeling using voxel finite element models and evaluation of displacement fields using 3D optical flow. This gives never‐seen insights into the highly localized 3D deformation mechanisms within the entire volume of the foams and not only on the surfaces as given by conventional digital image correlation methods. Displacements calculated by the 3D optical flow algorithm demonstrate its possibility to reveal a significant concentration of plastic deformation, particularly evident when deformation occurs within a distinct, slightly inclined band in the central region. Common numerical simulations using standard plasticity models do not accurately capture this localized deformation, underscoring the need to integrate damage and softening models into the simulation.

Calculating Flanking Transmission for Improved Airborne Sound Insulation in Buildings

The complexities of airborne noise insulation in tropical buildings provide challenges for predicting the value of airborne noise in buildings. The analysis employs standardized metrics, the Weighted Sound Reduction Index (DnT,w), to evaluate the impact of wall, floor, and ceiling combinations on acoustic performance. Notably, the study addresses the persistent challenge of flanking transmission, contributing to disparities between predicted and measured values. This study focuses on common construction materials in Indonesia. The outcomes reveal that lightweight construction materials, such as lightweight brick walls, consistently exhibit superior sound reduction, emphasizing their potential benefits in tropical regions. Additionally, the choice of ceiling materials, particularly gypsum board over wooden ceilings, significantly influences acoustic outcomes

"Exploring Aerated Autoclaved Concrete (AAC) Acoustic Properties Across Diverse Frequency Bands"

Aerated Autoclaved Concrete (AAC) stands out as an environmentally friendly and lightweight construction material. Known for its durability, load-bearing capacity, and excellent insulation, AAC surpasses traditional concrete blocks and red bricks in construction preferences. Its suitability as a wood alternative is evident, given its resistance to decay and comparable lightweight characteristics. Comprising a blend of cement, fly ash, limestone, and gypsum in an 8:69:20:3 ratio, with aluminum powder as the expansion agent, AAC serves as a versatile building material. In addition to its various attributes, understanding the acoustic properties of AAC is essential. Structures such as schools, hospitals, hotels, offices, and multi-family housing demand effective sound insulation, necessitating the use of materials with favorable sound absorption coefficients and minimal sound reflection coefficients. Due to its porous composition, Aerated Autoclaved Concrete exhibits notable sound absorption coefficients, making it ideal for applications in environments like schools and hospitals. This research delves into the determination of AAC's sound absorption coefficient and sound reflection coefficient across a spectrum of frequencies ranging from 1 kHz to 10 kHz. The analysis extends beyond frequency variations to encompass different sound intensities, offering a comprehensive exploration of AAC's acoustic characteristics.

Influence of Expanded Clay Aggregate on the Engineering Properties of Lightweight Concrete

In seismically active locations, civil infrastructures, such as buildings, bridges, and dams, are frequently subjected to earthquakes. Using lightweight construction materials is one method for enhancing the seismic resistance of infrastructure. This study examined the engineering properties of lightweight concrete manufactured using expanded clay aggregate, with the purpose of developing sustainable and environmentally friendly building materials. Laboratory tests focused on the effects of the aggregate shape and the supplementary superplasticizer, as well as on the influence of the concrete age. Experimental studies were conducted to measure fresh (slump) and hardened properties (compressive strength, splitting tensile strength, and density). The expanded clay aggregate was produced by burning at a temperature of 800 to 1 200 °C. Cubic, oval, and round aggregate shapes with a maximum size of 20 mm were evaluated. This study also examined the effect of superplasticizers on the engineering properties of lightweight concrete. The composition of the superplasticizer varied from 0 to 2,5%. According to the experimental results, the engineering properties of lightweight concrete made with oval aggregates are advantageous in comparison with those using cubic and round shapes. It is also demonstrated that optimal amounts of superplasticizer are necessary to develop materials with adequate properties. It can be concluded that expanded clay aggregate can be used as an alternative material to produce lightweight concrete.

Potential of Pressmud Waste from Sugar Industry in Brick Manufacturing for Green Business and Sustainability

The construction industry in Malaysia is currently witnessing sustained expansion, as seen by the rising demand for residential properties, commercial structures, and other infrastructures throughout our country. Therefore, the present study seeks to identify suitable materials and proportions for manufacturing lightweight bricks utilizing industrial waste materials. This study investigates the feasibility of using pressmud, a sugarcane refinery waste, as a fine bio-aggregate for the production of construction materials. Binary blended cement-pressmud bricks were formed by mixing Ordinary Portland cement with pressmud at various weights percentages (50%, 40%, 30%, 20%, and 10%). Various experiments were undertaken to investigate and compare the characteristics of pressmud bricks and commercial sand bricks. The experiments focused on density determination and compression tests (standard brick). The compression tests demonstrated that cement-pressmud bricks with a weight ratio of up to 20% exhibited a compatible strength to standard brick, with values ranging from 17.16 MPa to 23.01 MPa. The pressmud bricks exhibited reduced weight, with 10% and 20% variants weighing 17-23% less than the standard brick. Thus, it can be concluded that pressmud possesses significant potential as a bio-aggregate for producing lightweight and cost-effective construction materials when used in appropriate proportions.

Thermomechanical Properties of a Concrete Composed of Cherry Tree Resin and Expanded Clay (Exclay) Aggregate

Expanded clay (exclay) aggregate and cherry tree resin are used in this study to produce a lightweight construction material. Based on the grain diameter, exclays are classified as d = 2–4 mm and d = 4–6 mm. Cement is added to each group as the binder material. The exclay ratios vary as 10%, 20%, 30%, 40% and 50% of the total volume in the samples. The cherry tree resin is poured into the concrete mixture with a ratio of 1% and 1.5% of cement + exclay mixture in order to form artificial pores in each sample group. The produced samples are subjected to some tests, such as thermal conductivity, water absorption and compressive strength. It is determined that due to the increase in exclay ratios and particle diameter, there is an increase in porosity along with water absorption, but there is a decrease in density, thermal conductivity and compressive strength. Hence, these newly produced concretes are recommended for panel walls, brick, concrete briquettes, inner and outer plaster and concrete partition elements.

Evaluating the fire behaviour of cement-based lightweight materials with textile waste incorporation using a cone calorimeter

The conscientious utilization of natural resources and the efficient waste management have become a matter of great concern in recent years due to the harmful impacts on the environment. The construction sector presents itself as one of the sectors that most contributes to raw materials consumption and waste generation, demanding the investigation of more sustainable and eco-friendly building materials, where the valorisation of wastes originated from other industries can be promising. Following the sustainability concept in construction materials, this work investigates the potential use of textile waste in cement-based lightweight construction material, evaluating the fire reaction of the material using the cone calorimeter equipment. The samples were tested at three different radiant heat fluxes (35 kW/m², 50 kW/m², 75 kW/m²) to simulate different fire situations. For the highest heat flux, the lightweight construction element with textile waste incorporation showed a Heat Release Rate Average ≤ 18 kW/m², a peak Heat Release Rate Average ≤ 60 kW/m², and a Total Heat Release Average ≤ 33 MJ/m². These results reveal a very satisfactory fire behaviour compared to other materials and show the suitability of using textile waste as lightweight cement-based materials.

Facile preparation, characterization, and investigation of mechanical strength of Starchy NaCl-binder as a lightweight construction material

Sodium chloride (NaCl), commonly known as salt, is a substance that is utilized in a variety of businesses, including the tourism and construction industries. Therefore, the main purpose of this article is to accommodate a salt-based building material called NaCl-binder for tourist and industrial applications. By utilizing salt mortar with varying grain sizes, food-grade corn starch as an exclusive binder agent (without using any non-starch binder), and water under microwave-cured conditions, environmentally friendly hydrophobic hybrid NaCl-binder samples with low bulk density were successfully produced. The fabrication of these samples involved an inventive utilization of small quantities of starch. This study evaluated the impact of microwave exposure time on the strength of salt samples, particle interconnectivity and chemical composition using SEM, XRD, and XRF analyses. The compressive strength of the samples showed a remarkable increase, with a 600% improvement when using 0 to 1% corn starch, and a 137% increment when using 1 to 10% corn starch, indicating a lower rate of increment with higher starch consumption. A key aspect of this research is the significant reduction in starch consumption compared to other corn starch-based materials during the manufacturing process of the incorporated materials, highlighting its novelty and importance.

A REVIEW OF THE EFFECT OF ADDITIVES ON THE MECHANICAL PROPERTIES OF LIGHTWEIGHT CONCRETE

Many organizations around the world have recognized lightweight, long-lasting, cost and environmentally-friendly construction materials as a future necessity. The lightweight concrete is manufactured mainly either by replacing the original aggregate with lightweight aggregate or addition foam production materials to concrete mixtures. These additions lead to a decrease in the lightweight concrete density and change mechanical properties such as compressive strength. Therefore, there is much experimental research has been conducted to add different material types that can improve lightweight concrete compressive strength while maintaining low density. In this review, the effect of various additions such as steel fiber, product waste materials, and nano-materials on the lightweight concrete compressive strength and density have been explained. The various effects of these additive materials on lightweight concrete properties, some additives lead to improving the properties of lightweight concrete, while other materials lead to a decrease in those properties, and this depends on the type and amount of material additive, the method lightweight concrete manufacturing, and their mixture composition.

Thermo-physical and mechanical performances of a new lightweight construction material made with clay and Posidonia-Oceanica fibers

This paper investigates a recently developed composite material composed of clay and Posidonia-Oceanica Natural Fibers (PONFs). The main objective of this work is to evaluate the thermal insulation characteristics and mechanical performance of the composite material developed for the purpose of thermal insulation in buildings. The investigation involves varying the concentration of Posidonia-Oceanica Natural Fibers (PONFs) within the composite, ranging from 0% to 20%. To achieve a thorough understanding of the material's behavior, a combination of experimental testing and theoretical analysis was carried out. Specifically, the periodical method (DICO) was utilized in tandem with an inverse technique featuring the Levenberg–Marquardt algorithm. This methodological approach enables a comprehensive exploration of the composite material's characteristics and performance, with implications for its use in enhancing the thermal insulation of buildings." Additionally, the mechanical properties of this composite material were systematically evaluated. The findings indicated that higher PONFs content significantly reduced thermal conductivity (by 63.5%), thermal diffusivity (by 26.9%), and density (by 49.5%). Consequently, the most favorable mechanical properties were observed when the PONFs content reached approximately 10% of the total mass. The outcomes of this study revealed that the incorporation of PONFs has a beneficial impact on the thermo-mechanical characteristics of the composite material. Specifically, PONFs enhanced the material's insulation capabilities, increased its ability to attenuate heat diffusion, and reduced its overall weight. This work conclusively showed that the inclusion of PONFs, up to a maximum of 10%, meets the structural requirements for lightweight clay and encourages its potential use as a novel insulating construction material.

The Influence of Pulverized Fuel Ash (PFA) on the Thermal and Transport Properties of Foamed Concrete

The incorporation of materials derived from industrial waste presents a viable avenue for mitigating the exorbitant production expenses associated with building materials, while concurrently ameliorating the deleterious ecological ramifications of said waste. The utilization of pulverized fuel ash (PFA), an industrial residue resulting from the combustion of powdered coal in an electricity-generating facility, as a substitute for cement in the composition of concrete, is a viable option owing to its inherent pozzolanic properties. The present study endeavours to investigate the potential of Partially-Fumed Ash (PFA) as a viable substitute for cement in the production of foamed concrete (FC). The thermal and transport properties were meticulously assessed, with a particular focus on thermal conductivity, thermal diffusivity, specific heat capacity, water absorption, and porosity. A series of experiments have been undertaken wherein varying proportions of Portland Pozzolan Cement have been substituted for PFA, specifically at levels of 10%, 20%, 30%, 40%, and 50% by weight. The findings suggest a prospective application of PFA in the manufacturing of FC. The utilization of PFA (Pulverised Fuel Ash) assumes a pivotal role in enhancing the thermal conductivity, thermal diffusivity, specific heat capacity, water absorption, and porosity of FC. Therefore, it can be inferred that the utilization of PFA holds promising potential in the production of cost-effective, lightweight construction materials, while simultaneously mitigating the adverse environmental consequences.

Study of lightweight foamed concrete with the addition of industrial waste

Another sort of lightweight construction material is foam concrete. Its characteristics include heat insulation, lightweight, low elasticity modulus, and high fluidity. It is tough to burn and has good heat preservation and fire defense qualities. Foam concrete is porous because it is created by equally combining cement slurry with prefabricated foam before setting. It is extensively employed in the engineering of walls, roofs, floor heating, cushions, and backfill. There are still many flaws in the mix design of this concrete that need to be resolved. The technical advancement and quality assurance of foamed concrete are impacted by these flaws and imperfections. This work used fly ash and GGBS in various proportions to replace cement in the compressive strength analysis. This paper examines the primary variables influencing the performance of this concrete and determines the ideal design scheme for the amount of foamed concrete mix to serve as a guide for future research and foamed concrete manufacturing.Foamed concrete is also referred to as CLC and is made by combining Portland cement, sand or fly ash or GGBS, foam and water. Fly ash and GGBS together are used for the replacement of sand and to make concrete lightweight. The percentage of air in the entire volume should range from 40 % to 75 %. The diameter of the bubbles ranges from about 0.1 to 1.55 mm.In a typical concrete mixer or ready mix facility, the elements can be combined to create foamed concrete. It can be successfully pumped over considerable heights and distances. The material has a plastic density that is 150 to 200 kg/m3 to 300 kg/m3 higher than its dry density. The dry density at 28 days varies greatly depending on the composition but typically ranges from 350 to 1700 kg/m3.

Finding the Weight Difference of a Rectangular Structure with a Parabolic Arc for Mathematical Models Made of Steel and other Composite Materials

The most popular materials for lightweight constructions, including building and aircraft structures, industrial, military, and aerospace technology, are armored composites. Composites made of carbon fiber are typically employed in lightweight applications. The ANSYS program was used to produce four mathematical models. Steel is used in the construction of the first and second versions whereas composite materials are used in the third and fourth variants. To find all the deformations, stresses, and strains that appear on the four models, as well as to calculate the weights of those four structures and compare them, these four models were tested with the ANSYS 15.0 program to obtain equal deformation resistance for all models under the influence of different loads. The results show that the composite models had lower strains, stresses, and deformations than the steel models. Among other results, it was discovered that the weight of the third model made of composite materials decreased by (32.72%) compared to the steel-based first model, and after doing the necessary calculations and assessing the results, the fourth model made of composite materials' weight was reduced by (19.21%) when compared to the second model made of steel.

Assessment and Characterization of Duck Feathers as Potential Source of Biopolymers from an Upcycling Perspective

A comprehensive characterization of the physical and chemical properties of whole duck feathers from French mulard species, including their various categories and fractions (barbs, rachis, and calamus), was conducted to explore potential ways for utilizing this waste product. This analysis aimed to identify opportunities for valorizing these feathers and unlocking their untapped potential. Hence, the duck feathers were thoroughly characterized by a proximate analysis to determine their composition and theoretical heating value. Additionally, feathers underwent other analyses as Sodium Dodecyl Sulfate Polyacrylamide Gel Electrophoresis (SDS-PAGE) analysis, solvent behavior and chemical durability assessment, hydrophobicity testing, Fourier Transform Infrared (FT-IR) spectroscopy, Thermogravimetric Analysis (TGA), Differential Scanning Calorimetry (DSC), X-ray diffraction (XRD), and Scanning Electron Microscopy (SEM). The analyses revealed duck feather composition, molecular weight, stability in different environments, hydrophobicity, functional groups present, thermal behavior, crystallinity, and structural arrangement. Upon analysis, it was determined that duck feathers contain pure fiber keratin and possess characteristics that make them suitable for the production of high-value keratin-based products, including cosmetics, activated carbon for purification, materials for waterproofing, lightweight construction, and textile innovations, underscoring their potential to support sustainable and eco-friendly initiatives across various sectors.

Experimental Study on Axial Compressive Performance of Light-Steel Skeleton–Cement–Fly Ash Foam Wallboard

Foamed cement fly ash is a new type of lightweight construction material that can be combined with a light steel frame to form light-steel skeleton–cement–fly ash foam wallboard (LSSCFAFW). The research on the axial compressive performance of light steel and light concrete composite wallboard is relatively limited. Four pieces of LSSCFAFWs were manufactured, and the impact of stand column quantity and various filler parameters on the LSSCFAFW was investigated. The failure mode of the wallboard and the influence of different parameter variables on its axial compressive performance were obtained through experiments. Moreover, the test results indicated essentially the same damage patterns in terms of stand-column buckling, filler crushing, and self-tapping screw failure. The addition of polypropylene fiber to this wallboard can prevent filler from falling off. The axial compressive performance of the LSSCFAFW demonstrates a direct proportion with the number of columns and cement content, improving as the number of stand columns and the cement content increase. However, the addition of polypropylene fiber to the filler has a minimal effect on the axial compressive performance of this wallboard. Compared to the control group, increasing the number of stand columns, adding 0.4% polypropylene fibers, and increasing the cement dosage to 50% improved the ultimate bearing capacity of the wallboards by 12%, 8%, and 56% respectively. The result of this study can provide references for the research and application of light steel frame to form LSSCFAFW.

STUDY THE EFFECT OF DIFFERENT REINFORCEMENT RATIOS ON THE EXPANDED LIGHTWEIGHT GEOPOLYMER MORTAR PROPERTIES

Nowadays, the demand for the production of lightweight construction materials is increasing in order to reduce the cost, which is economically beneficial, as well as reducing the weight of the building as a whole. In this work, a lightweight geopolymer based on fly ash (type F) was developed using an alkaline activator at a concentration of 12 M and the ratio of the activator to the binder was (0.6). The natural sand was partially replaced with expanded perlite (EP), at replacement rates of 10, 30, and 50% by weight. Then the lightweight geopolymer (50% by volume of perlite) was reinforced with polypropylene fiber (PPF) with an addition ratio of (0.25, 0.5, 0.75, and 1%) of the total volume. Laboratory tests were carried out on the produced samples to determine the extent of the properties change after the addition of perlite. The density, insulating and absorbent properties of the lightweight geopolymer composite, which showed a decrease in unit weight with increased porosity and absorbency due to increased interstitial pores, were improved. A clear improvement in flexural strength was also observed when adding 1% polypropylene fibers. As for compressive strength, the improvement was slight. The lower density of the fibers also supports the weight of the unit.

The Use of Recycled Tire Rubber, Crushed Glass, and Crushed Clay Brick in Lightweight Concrete Production: A Review

Worldwide, vast amounts of waste are produced every year and most waste is sent directly to landfills or burnt, which has severe and harmful impacts on the environment. Recycling waste materials is considered the most visible solution to protect the environment. Using scraps in concrete production is a proper method for getting rid of wastes, improving the characteristics of concrete, reducing the consumption of natural aggregates, and can be used as cementitious materials that decrease cement production so that the CO2 that is produced during cement manufacturing decreases. This review paper summarizes the use of recycled waste materials, including rubber tires, crushed glass, and crushed clay brick in concrete, as a fractional replacement of aggregates, cement, etc., to develop eco-friendly lightweight construction materials. It has been concluded that the dry density of sustainable concrete decreased to 4, 21.7, and 31.7% when crushed glass, clay brick, and rubber tire were incorporated into the concrete instead of traditional aggregate, respectively. Waste rubber has good results in sulfate, thermal, and impact resistance, while glass powder and finely crushed clay brick helped to improve mechanical properties by increasing reach by 33% for glass and a slight increase for crushed clay brick, as well as thermal resistance compared to normal concrete. Moreover, due to the low particle density of these waste materials compared to that of normal-weight aggregates, these materials can be utilized efficiently to produce lightweight concrete for structural and non-structural applications such as road engineering, flooring for mounting machinery, highway and rail crash barriers, permeable pavement, interlocking bricks, insulation, filling concrete, and bearing walls.

Numerical and Experimental Study on Loading Behavior of Facade Sandwich Panels

This paper focuses on the study of the strength of facade sandwich panels used in building construction. The paper describes the results of experimental and numerical research on the behavior of sandwich panels made of polyisocyanurate core (PIR) and their structural connections when exposed to tensile and compressive loads. In the initial phase of this study, laboratory tests were performed to determine the physical and mechanical characteristics of the material from which the sandwich panels are made. Laboratory tensile and compression tests were performed on small samples of sandwich facade panels. In order to verify the obtained results, they were compared with the numerical analysis performed in the ANSYS software. The numerical model was found to accurately predict the results of the laboratory tests, suggesting that the model can be used to predict the behavior of these panels under different loads in service. The study showed that the foam core sandwich panel exhibits excellent mechanical properties. The results indicate the suitability of foam-based composite structures in the construction industry for various applications, such as roof and wall structures. The findings of this study may help in the development of lightweight and durable construction materials for the industry.

Preparation of bamboo scraps/magnesium oxychloride lightweight composites with high water resistance by PVAc

In this paper, in order to continuously promote the carbon peak and neutrality targets, and accelerate the construction of the waste material recycling systems, a lightweight construction material was prepared by compounding magnesium oxychloride cement (MOC) inorganic cementitious material and waste bamboo scraps, and foaming them with hydrogen peroxide. However, the poor water resistance of MOC composites makes it difficult to meet the needs under special environmental conditions, which seriously affects their popularization and application range. To solve this problem, Polyvinyl acetate (PVAc) was used to enhance the water resistance. It was deduced that the hydrolysis products of PVAc combined with each other, under the effect of hydrogen bonding induction, can form a hydrated polymer protective film covering the exterior of MOC crystals, thus reducing the contact of water with the crystals. In addition, the protective film and the hydroxyl groups on the cellulose of bamboo scraps are interconnected by hydrogen bonding, which improves the bonding strength of MOC gelling particles to bamboo scraps. Moreover, the PVAc hydrolysis products were combined with water molecules, bamboo scraps, and phase 3 crystals in MOC by hydrogen bonding to form a gelling structure, which further improved the adhesive tightness of MOC gelling particles. These three aspects led to the increase of the softening coefficient of the modified material by approximately 14%, and a substantial increase of the water resistance. Furthermore, the addition of PVAc improved the foaming effect of the material and increased the porosity, leading to a further decrease of the density and strength of the foamed material. The study of the water resistance of this lightweight composite material effectively provides a theoretical support and technical reference for the application of water-resistant and energy-saving materials in the construction fields.

Experimental and numerical simulation of bond-slip in textile-reinforced concrete for multiple bond lengths

The rise in the use of lightweight and sustainable structural systems in the construction industry opened the chance to improve conventional construction methods. To produce a slender structural member, the use of textile in concrete, herein referred to as textile-reinforced concrete (TRC), has been explored. The textile used is primarily carbon, producing a lightweight and durable construction material. The TRC possesses vast possibilities in terms of its usage, however, identification of accurate bond-slip behaviour at the materials interface is one of the limitations that need to be addressed. Based on the literature, there are difficulties in determining the bond-slip relationship both experimentally and numerically, creating inconsistency in the results. This study aims to determine the bond-slip relation of TRC through pull-out tests and finite element analysis in order to replicate the actual bond-slip behaviour at the interface. The bond characteristics of TRC were assessed using pull-out specimens with different bond lengths of textile, i.e.; 20 mm, 40 mm, and 60 mm. A double-sided unsymmetrical test setup with equal clamp lengths is used for the experimental work. Using a tri-linear bond-slip interface relation, the numerical model is developed to establish the microscopic interface behaviour. The bond failure due to pull-out and rupture are observed in the pull-out test. Finally, the experimental results are compared with numerical modelling, and the results are in good agreement.