Structural Lightweight Concrete Research Articles

Impact of fine lightweight aggregates and coal waste on structural lightweight concrete: Experimental study and gene expression programming

Light Expanded Clay Aggregate (LECA) is one of the materials used to make lightweight concrete. In this study, two types of lightweight aggregates including LECA in both coarse and fine aggregate forms and pumice in fine aggregate form have been used to produce lightweight aggregate concrete. Coal waste is also used as partial replacement for cement. The results show that the usage of pumice as partial replacement for sand and LECA as coarse aggregate is applicable and can used for producing structural lightweight aggregate concrete. Furthermore, by using and increasing in the amount of LECA as fine aggregate, the slump of lightweight concrete in comparison to using sand, is also increased. The mixtures with LECA in both fine and coarse aggregate forms have the best results. Also, the results show that adding the coal waste improves the properties of lightweight concrete, and the optimal ratio is about 15% as partial replacement for cement by weight. In addition, gene expression programming is employed to establish empirical connections derived from experimental outcomes. In this regard, a relationship is proposed to determine the compressive strength of lightweight aggregate concrete based on the experimental data. The outcomes of gene expression programming demonstrate that the suggested formula exhibits good accuracy and efficiency in forecasting the specified parameter.

New strategy for closing the plastic loop: Lightweight concrete by the waste of recycled synthetic fibers

Environmental protection related to the mismanagement of plastic waste and rational consumption of natural raw materials is an essential goal of the building materials industry and the production of structural lightweight concrete. Plastic waste is not a degradable polymer and increases severe environmental burdens each moment due to its significant quantity. In addition, the recycling of plastic materials is lower than that of other materials. It is usually described as an inefficient and complex process. The textile industry offers an eco-green, effective part of the recycling loop of plastics. Therefore, many textile mills consider recycled plastics as synthetic fiber raw material, particularly for household applications. Unfortunately, such a process results again in another waste known as popcorn. This study aims to introduce an end-of-life management option for the waste of synthetic textile fibers manufactured from recycled plastic materials in construction. Furthermore, the study presents a novel approach to develop an eco-green lightweight structural concrete by incorporating a unique type of lightweight aggregate (popcorn aggregate) as a 100% environmentally friendly product. To achieve that, fourteen mixes of fine and coarse popcorn aggregate contents (25%, 50%, and 100%) are considered to replace the fine and coarse natural aggregate by volume. In addition, the workability, compressive, splitting tensile, flexural strength, microstructure analysis, and Energy Dispersive X-ray Spectrometry are assessed. The results revealed that the higher the substitution ratio of ordinary aggregates by popcorn aggregates, the higher the slump value. Meanwhile, the unit weight of hardened concrete exhibited a tangible decrease at a 100% replacement ratio of fine and coarse natural aggregates; a 56% reduction achieved a dry density of 1059 kg/m³. Moreover, the compressive strength results indicated a decrease of 32% for mixing 25% fine e popcorn aggregate with 100% coarse popcorn aggregate, resulting in a compressive strength of 45 MPa. Fine ally, no evidence of chemical interactions between the popcorn aggregate and the cementitious element during hydration is found.

Investigation of the Mechanical and Physical Properties of Structural Lightweight Concrete Produced with Expanded Clay Aggregate from Söğüt Region

The use of mild materials shows an increasing tendency in industrial areas. These materials are also preferred to reduce the unit weight of the building elements in the construction sector. Various light aggregates are used to produce light concrete with a lower density than normal concrete, and the properties of these light aggregates significantly affect the properties of the concrete. In this study, the use of expanded clay aggregate (ECA) produced in the Söğüt region in structural lightweight concrete was examined. Expanded clay, sand, and crushed stone aggregate were used as aggregates in concrete mixtures. The mixture granulometry was kept the same for each group. For this purpose, 60 samples were prepared for a total of 4 mixtures with different contents. Slump and unit volume weight tests were carried out on fresh concrete samples, and compressive, flexural, and splitting tensile strength tests were carried out on 7- and 28-day-hardened concrete samples. Some of the concrete mixture samples were subjected to tests after being kept in the curing pool for 7 days, and some for 28 days. As a result of the experiments, the unit weight and compressive strength values obtained from the samples produced with ECA as coarse and fine aggregate in order to achieve the highest strength target are 1413 kg/m³ and 30 MPa, respectively. The same values were found to be 1652 kg/m³ and 39 MPa in the samples produced with river sand as fine aggregate and ECA as coarse aggregate. In the samples produced using ECA as fine aggregate and crushed stone aggregate as coarse aggregate, these values were also found to be 1689 kg/m³ and 50 MPa.

Sustainable Structural Lightweight Concrete with Recycled Polyethylene Terephthalate Waste Aggregate

Plastic is a widely consumed material with a high decomposition time, occupying significant space in landfills and dumps. Thus, strategies to reuse plastic waste are imperative for environmental benefit. Plastic waste is a promising eco-friendly building material for cement-based composites due to its reduced specific gravity and thermal conductivity. However, this waste reduces the composites’ mechanical strength. This work aims to produce and evaluate lightweight concretes made with only lightweight aggregates and mostly recycled plastic aggregates. Initially, an optimized dosage approach for lightweight concrete is presented. The mixture proportion of the lightweight concrete was based on the performance of mortars with the complete replacement of natural aggregate by recycled polyethylene terephthalate (PET) aggregates. The PET aggregates showed irregular shapes, impairing workability and providing lightweight concretes with around 18% water absorption and 21% void index. However, the concretes presented significantly low-unit weight, approximately 1200 kg/m3. This work presented a structural lightweight concrete (ACI 213-R) using only lightweight aggregates and mostly plastic waste aggregate, with a compressive strength of up to 17.6 MPa, a unit weight of 1282 kg/m3, and an efficiency factor of 12.3 MPa·cm3/g. The study shows that with an optimum dosage, reusing plastic waste in concrete is a viable alternative contributing to environmental sustainability.

Recycling water treatment sludge into a novel eco-friendly core–shell lightweight aggregate and its application

AbstractDisposal of water treatment sludge (WTS) has become an important issue of global environmental concern due to problems and costs. This study explored the feasibility of cold-bond methodology to produce an eco-friendly core–shell lightweight aggregate (LWA) from WTS, expanded perlite (EP), and cement. The effect of cement and WTS content on the properties of the LWA was studied. The findings revealed that the crushing strength, loose bulk density, 24-h water absorption, and 28-d water absorption of produced LWA ranged from 0.45 to 3.1 MPa, 1.05 to 1.25 g/cm3, 12.4 to 22%, and 22 to 27%, respectively. In addition, increasing the WTS content in the shell has a positive impact on the pH of the produced LWA. Furthermore, the SEM microstructure graphs revealed the efficient interference in the LWA particles between the cement–WTS composite and the perlite. The results also prove the possibility of using the produced LWA to produce structural lightweight concrete, with compressive strength, splitting tensile strength, and dry density of 24 MPa, 2.98 MPa, and 1840 kg/m3, respectively, with a consistent thermal conductivity of 0.72 W/m K and good acoustic insulation. Graphical abstract

The Use of Recycled Polyethylene in Water-Oil Emulsion for Lightweight Concrete

This study was to determine the suitability of recycled waste polyethylene (WPE) processed into water-oil emulsion for lightweight concrete applications. The processed WPE in the form of polyethylene emulsion (PE-e) is to promote physical interaction between the polymeric material and the cementitious matrix. The PE-e used was also to partially replace concrete mix composition by PE-e_1, PE-e_2.5, PE-e_5, and PE-e_10 percents for reference concrete and to introduce plasticity into the mechanical behaviour of the concrete. The PE was processed into PE-e to promote affinity for water, and this hydrophilicity was prominent in PE-e_1 and PE-e_2.5 percent concretes. Concretes with PE-e_1 and PE-e_2.5 percent formed good miscibility with the cementitious matrix. The density of the PE-e concrete decreased to 13.68% with 10% PE-e at 28 days. The replacement of mix constituents of PE-e_1, PE-e_2.5, and PE-e_5 percent induced elastic to plastic behaviour in the concrete coupled with low water absorption. The FTIR data showed characteristic peaks of 3378 cm-1, 1740 cm-1, and 1148 cm-1 in the PE-e. Using optical microscopy, it was shown that the PE particles were homogenously dispersed in the concrete matrix. The study shows the feasibility of using PE-e_1 percent to produce structural lightweight concrete and up to PE-e_10 percent for nonstructural applications mainly for light non-load-bearing partitions.

Modeling of Strength of Concrete Produced with Fine Aggregates from Different Sources

Abstract: In this study, the compressive strength of concrete was determined from concrete made with fine aggregate sourced from three different locations. Fine aggregates were sourced from Onitsha, Uli, (Anambra State) and Njaba (Imo State) and constrain to several tests namely: sieve analysis, initial and final setting time. The mix ratio of 1:1.5:3and the water/cement ratio of 0.6 were used to produce these concrete samples. Both the slump test and compressive strength test were carried out on these samples. A total of Thirty-six (36) concrete cubes (150mm x 150mm x150mm) were cast, cured and tested after 7, 14, 21and 28 days of curing for each of the fine aggregates. The results for the mean compressive strength of the concrete produced, showed that all of them had average strength greater than 20N/mm2 , with fine aggregate from Uli having the highest mean at 33.2N/mm2 after 28days of curing. Thus, any fine aggregates could be used to produce structural light weight concrete, but fine aggregate from is highly recommended for projects that requires higher strength. A mathematical models used for the prediction of the compressive strength of concrete produced with different fine aggregate were also created by the Response Surface Method (RSM) using the design Expert Software Application. The optimizations were done and the results were validated.

Comparative Study of the Seismic Behaviour of G+20 Storey Building for Unsymmetrical Plan Area Using Light Weight Concrete and Normal Weight Concrete

Abstract: This research examines and compares the performance of structural lightweight concrete (SLWC) made with scoria and normal weight concrete (NWC), and normal and light weight concrete (NAL) in multi-storey buildings. A G+20 multi-storey unsymmetrical plan building is analysed using the response spectrum method with SLWC and NWC. Bending moment, shear force, storey shear, axial force, storey drift, and storey displacement are considered. The results show that SLWC can be used to reduce the weight of buildings without sacrificing strength or performance. This can lead to significant cost savings on construction and materials

Optimization of Tuff Stones Content in Lightweight Concrete Using Artificial Neural Networks

Tuff stones are volcanic sedimentary rocks formed by the consolidation of volcanic ash. They possess unique geological properties that make them attractive for a variety of construction and architectural applications. Considerable amounts and various types of Tuff stones exist in the eastern part of Jordan. However, the use of Tuff stones often requires experimental investigations that can significantly impact the accuracy of their physical and mechanical characteristics. To ensure consistent and predictable properties in their mix design, it is essential to minimize the effects of these experimental procedures. Artificial neural networks (ANNs) have emerged as a promising tool to address such challenges, leveraging their ability to analyze complex data and optimize concrete mix design. In this research, ANNs have been used to predict the optimum content of Tuff fine aggregate to produce structural lightweight concrete with a wide range (20 to 50 MPa) of compressive strength. Three different types of Tuff aggregates, namely gray, brown, and yellow Tuff, were experimentally investigated. A set of 68 mixes was produced by varying the fine-tuff aggregate content from 0 to 50%. Concrete cubes were cast and tested for their compressive strength. These samples were then used to form the input dataset and targets for ANN. ANN was created by incorporating the recent advancements in deep learning algorithms, and then it was trained, validated using data collected from the literature, and tested. Both experimental and ANN results showed that the optimum content of the various types of used Tuff fine aggregate ranges between 20 to 25%. The results revealed that there is a clear agreement between the predicted values using ANN and the experimental ones. The use of ANNs may help to cut costs, save time, and expand the applications of Tuff aggregate in lightweight concrete production. Doi: 10.28991/CEJ-2023-09-11-013 Full Text: PDF

A Comparative Study of the Seismic Behaviour of G+20 Storey Symmetrical Buildings Constructed with Light Weight Concrete and Normal Weight Concrete

Abstract: Concrete with a density of less than 2000 kg/m^3 is considered lightweight concrete. Structural lightweight concrete (SLWC) is used to reduce the dead load of concrete structures. The purpose of this research is to examine and compare the results of SLWC made with scoria and normal weight concrete (NWC) and normal and light weight concrete(NAL) multistorey buildings. Multistorey buildings are often constructed of ordinary concrete, steel, and other materials. They are subjected to heavy loads, requiring heavy construction that may not be cost-effective. In this paper, a G+20multistorey plan symmetrical building is analysed using the response spectrum method with SLWC and NWC. Bending moment, shear force, storey shear, storey drift, and storey displacement are considered. The results of the NWC and SLWC and NAL buildings are compared . Concluding the research work that when comparing symmetrical plan area cases of normal concrete, light weight concrete and combination of normal and light weight concrete for all the result parameters, light weight concrete seems to be very efficient and most favorable case. Hence should be recommended when this type of construction procedure will be adopted, i.e. always use building with lightweight concrete

Influence of Steel and Polypropylene Fibers on the Structural Behavior of Sustainable Reinforced Lightweight Concrete Beams Made from Crushed Clay Bricks

Structural lightweight concrete is preferred over traditional concrete due to its ability to reduce the dead load, minimize the size of load-bearing structural members, and provide more economical solutions for foundation deteriorations. This research sheds light on sustainable lightweight concrete using waste crushed clay bricks (CCB) as a lightweight aggregate. To reduce micro-crack propagation of the developed concrete, two types of fiber were implemented and investigated. Steel fibers (SF) with amounts of 0.5% and 1.0% by volume of concrete, and polypropylene fibers (PPF) with amounts of 0.1% and 0.2% by volume of concrete, were employed. Five reinforced concrete beams were made and tested in order to precisely evaluate the structural behavior of the proposed lightweight CCB concrete. Additionally, ABAQUS software for nonlinear finite element analysis has been utilized to simulate the tested beams and compare the numerical model predictions with the experimental findings. The findings revealed that the addition of SF and PPF exhibited a notable influence on enhancing the mechanical characteristics of lightweight CCB concrete. Adding 0.2% PPF increased the ultimate load and deformation capacity at failure by approximately 16% and 24%, respectively. Furthermore, after 28 days, the addition of 0.5% and 1.0% SF enhanced the compressive strength by around 11.7% and 17.6%, respectively. Moreover, a significant level of consistency between the results obtained from the numerical model and the experimental findings was observed. In general, the use of SF and PPF in CCB concrete successfully produced high-quality lightweight concrete with interesting results for use in reinforced concrete beams.

Microstructure, thermal conductivity and carbonation resistance properties of sustainable structural lightweight concrete incorporating 100% coarser rubber particles

An all-encompassing effort has been performed to utilize waste tire rubber particles for replacing binders and conventional aggregates in concrete, and very little work has been found in the current literature on structural lightweight concrete (SLWC) for the complete replacement of traditional aggregates by waste tire rubber. Notably, there is no available study addressing the microstructure, thermal performance, and carbonation resistance of SLWC with 100 % waste coarser rubber content. Therefore, this study investigated the thermal conductivity, carbonation, X-ray CT scan, and extensive microstructural properties of novel structural lightweight concrete (SLWC) with 100 % waste rubber to substitute conventional aggregate for the first time. Different variables, such as large and smaller rubber particles, normal and compressed samples, and steel fibers, were introduced. Maximum compressive strength of 18 MPa with a density of 2115 kg/m3 satisfied the prerequisite for SLWC prescribed by ACI 213R. Non-destructive tests, including electrical resistivity and ultra-pulse velocity tests, were conducted to identify the soundness of concrete. The microstructural properties, i.e., energy dispersive spectroscopy, scanning electron microscopy, and X-ray CT scan, were evaluated to demonstrate the effectiveness of the novel casting method. The thermal conductivity of 0.29 W/m.k indicated excellent thermal insulation performance of SLWC, denoted by ASTM C332. Carbonation resistance was also considerably improved. The results show that the SLWC in this study has excellent potential for both structural and non-structural applications.

Effects on structural light weight aggregate concrete cast using controlled permeable formwork liner

The porosity of the concrete surface has the greatest influence on the durability qualities of the concrete. The surface porosity of concrete can be lowered by lowering the water-to-cement ratio. The present study investigates the durability properties of structural light weight concrete using Sintered Fly Ash Lightweight Aggregate (SFLA) combined with Controlled Permeable Formwork (CPF) liners. The Structural Light Weight Concrete (SLWC) possesses a denser Interfacial Transition Zone (ITZ), internal curing effect, and absence of wall effect. By draining excess water and air bubbles near the surface, CPF liners improve the quality of the concrete surface. Various tests were conducted to measure water penetration depth, water absorption, surface resistivity, charges passed, rebound number, pulse velocity, and wear resistance. The experimental results show that the combination of CPF liners and SLWC produced excellent results and performance in terms of surface resistivity, water penetration, water absorption, charges passed, and wear resistance, in the range of 18, 55, 51, 86 and 13 % respectively. This study suggests that CPF liners enhance the surface of concrete and improve its durability by decreasing the water-cement ratio at the cover region, reducing porosity.

Lightweight cementitious composites incorporating fly ash cenospheres and perlite microspheres

The research on lightweight concrete has been an area of interest, especially in modular construction since low self-weight can ease the transportation process and speed up construction time. Past research found that conventional lightweight aggregate concrete (LWAC) developed using coarse lightweight aggregates and natural fine aggregates can fulfil the requirement of structural lightweight concrete. However, the dry densities achieved by these LWAC are relatively high, at around 1750–2070 kg/m3. To address this issue while producing structural LWAC with a lower density range, micro lightweight aggregates (MLWA) with closed pore structures are utilized. In this study, two types of MLWA: fly ash cenospheres (FAC) and perlite microspheres (PM) were used to produce two series of lightweight cementitious composite (LCC). The incorporation level of MLWA was 25%, 50%, 75% and 100% by volume of coarse silica sand which was utilized to optimize the content of MLWA. The performance of LCC was investigated through compressive strength, flexural strength, water absorption, drying shrinkage and thermal conductivity tests. Use of FAC and PM yielded satisfactory compressive strength of up to 46.7 MPa and 45.3 MPa respectively at low densities. While flexural strength of mixes with FAC and PM reached 8.0 MPa and 8.7 MPa respectively. Use of 75% FAC showed the lowest water absorption of 3.3%. Incorporation of 100% PM reduced thermal conductivity by as much as 82.4%. The optimum LCC mix in this study comprised 75% FAC and 25% coarse silica sand which achieved a specific strength of 29.0 kPa/kgm−3 and a dry density of 1406 kg/m3, while having an average compressive strength and flexural strength of 40.8 MPa and 6.3 MPa at 28 days, respectively. The overall results show that LCC made up of FAC is more suitable for structural applications, whereas LCC made up of PM exhibits better thermal insulation properties.

Lower Carbon Footprint Concrete Using Recycled Carbon Fiber for Targeted Strength and Insulation.

The production of concrete leads to substantial carbon emissions (~8%) and includes reinforcing steel which is prone to corrosion and durability issues. Carbon-fiber-reinforced concrete is attractive for structural applications due to its light weight, high modulus, high strength, low density, and resistance to environmental degradation. Recycled/repurposed carbon fiber (rCF) is a promising alternative to traditional steel-fiber reinforcement for manufacturing lightweight and high-strength concrete. Additionally, rCF offers a sustainable, economical, and less energy-intensive solution for infrastructure applications. In this paper, structure-process-property relationships between the rheology of mix design, carbon fiber reinforcement type, thermal conductivity, and microstructural properties are investigated targeting strength and lighter weight using three types of concretes, namely, high-strength concrete, structural lightweight concrete, and ultra-lightweight concrete. The concrete mix designs were evaluated non-destructively using high-resolution X-ray computed tomography to investigate the microstructure of the voids and spatially correlate the porosity with the thermal conductivity properties and mechanical performance. Reinforced concrete structures with steel often suffer from durability issues due to corrosion. This paper presents advancements towards realizing concrete structures without steel reinforcement by providing required compression, adequate tension, flexural, and shear properties from recycled/repurposed carbon fibers and substantially reducing the carbon footprint for thermal and/or structural applications.

Assessment of Properties of Structural Lightweight Concrete with Sintered Fly Ash Aggregate in Terms of Its Suitability for Use in Prestressed Members.

The main aim of the paper was to assess whether the lightweight concrete with a new type of sintered fly ash aggregate can be used as a structural material for post-tensioned elements subject to high effort. This purpose was achieved by comparison of the properties of lightweight aggregate concrete with Certyd aggregate (LWAC) and normal-weight concrete with dolomite aggregate (NWAC) of similar strength in terms of their suitability for use in prestressed members. Special emphasis was placed on long-term, relatively rarely performed tests of rheological properties such as shrinkage and creep. The research was conducted on standard specimens as well as on plain and post-tensioned beams of bigger scale, which could reflect better the behavior of the materials in a destined type of structural members. The carried out tests showed that, despite the expected lower density and modulus of elasticity, LWAC revealed comparable tensile strength and lower shrinkage and creep in the whole time of observations (ca 1.5 years) in comparison to NWAC. Moreover, the total loss of prestressing force for beams made of LWAC was slightly lower than for NWAC. Estimations of tensile strength and modulus of elasticity values according to the standard Eurocode EN-1992-1-1 for both concrete types turned out to be satisfactory. However, the rheological properties of the tested lightweight concrete seemed to be considerably overestimated.

Presenting a Novel Approach for Predicting the Compressive Strength of Structural Lightweight Concrete Based on Pattern Recognition and Gene Expression Programming

Presenting a Novel Approach for Predicting the Compressive Strength of Structural Lightweight Concrete Based on Pattern Recognition and Gene Expression Programming

Investigation of Durability Properties for Lightweight Structural Concrete with Hemp Shives Instead of Aggregate

The paper presents the results of testing the performance of lightweight structural concrete containing hemp shives as an aggregate. It has been analysed how the higher binder content and use of the Portland cement affect the thermal and microbiological properties of the lightweight concrete. The aggregates of the plant origin and cement are incompatible because the plant chemical compounds, dissolved in water or an alkaline environment, inhibit cement hydration. To avoid this, mineralisation of the aggregates of plant origin is necessary. The most often used binder in hemp concrete is hydrated lime, a mineraliser. An addition of hydrated lime and sodium trisilicate was used for hemp shiv mineralisation in the tested materials with a cement binder. Concrete containing hemp shiv and cement binder, of which volume share in the concrete was at most 15%, was prepared as a reference concrete. In the remaining three concretes, the total content of the binder in relation to hemp shiv (by mass) was increased 2.5 times. It was shown that lime-binder hemp concrete offers a promising antimicrobial strategy, as it can inhibit bacterial and fungal growth on their surface with superior efficacy. The best results were obtained for tested concretes with the cement–lime binder regarding compressive strength; the average compressive strength was 9.56 MPa.

The Effect of Different Types of Aggregate and Additives on the Properties of Self-Compacting Lightweight Concrete

The major aim of this research is study the effect of the type of lightweight aggregate (Porcelinite and Thermostone), type and ratio of the pozzolanic material(SF and HRM) and the use of different ratios of w/cm ratio(0.32 and 0.35) on the properties of SCLWC in the fresh and hardened state. SF and HRM are used in three percentage 5%,10%, and 15% as a partial replacement by weight of cement for all types of SCLWC. The requirements of self-compatibility for SCC are fulfilled by using the high performance superplasticizer (G51) at 1.2liter per 100 kg of cement. The values of air dry density and compressive strength at age of 28 days within the limits of structural lightweight concrete. The air dry density and compressive strength at age of 28 days for w/cm ratio(0.32) for SCLWC of Porcelinit aggregate are 1964 kg/m3 and 29.57 MPa, respectively. The corresponding values for the SCLWC of Thermostone aggregate are 1820 kg/m3 and 25.75 MPa, respectively. The results show that the HRM performance which is locally available is better than SF in production of SCLWC.

Performance evaluation on bond, durability, micro-structure, cost effectiveness and environmental impacts of fly ash cenosphere based structural lightweight concrete

The production of huge fly ash waste from thermal power plants and gradual depletion of natural aggregates due to their high consumption in concrete making are two major threats to the sustainability of the environment. The strategic utilization of this waste as a replacement of natural aggregate in production of concrete can solve both the problems simultaneously. Hence, this study aims to evaluate the performance of structural lightweight concrete (LWC) containing fly ash cenosphere (FAC), a by-product of fly ash, in order to check its suitability for construction. In this study, one control concrete mix, i.e., without FAC, and other ten concrete mixes utilizing FAC as the replacement of natural fine aggregate (NFA) at the increment of 20% and with/without superplasticizer (SP) are prepared. The Mechanical properties (compressive and bond strength), durability aspects (sulphuric acid, magnesium sulphate and sodium chloride resistance) and the microstructural characteristics from X-ray diffraction and scanning electron microscope analyses of these mixes are evaluated. Moreover, the environmental impact assessment and cost-effective analysis are also conducted. From this investigation, it is found that the structural LWC can be produced by utilizing high volume FAC with/without SP with the acceptable mechanical and durability performances. Further, the concrete with 80% FAC and SP is found to be optimum having compressive strength of 32.59 MPa, which satisfies M25 grade concrete as per IS 456 (2000), meets ACI 213 (2014) requirements of structural LWC and has also acceptable durability properties. The microstructure studies have also supported the strength and durability results of these mixes. Moreover, these mixes are found to be cost effective and environmentally friendly. Hence, structural LWC prepared with a high volume of FAC and SP can be recommended for construction, which reduces the cost and environmental impacts significantly and preserves natural resources for the future generations.