UNIT-1

LECTURE - 7
LIGHT WEIGHT CONSTRUCTION MATERIALS

Brig. S.K. Sharma (Retd.)

Pro Vice Chancellor and Professor
Department of Civil Engineering,
The Northcap University, Gurgaon

The Northcap University, Gurgaon

INDEX
WASTE MATERIAL BASED CONCRETE
INDUSTRIAL WASTES

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INDUSTRIAL WASTES
Some of the industrial by-product wastes can be
profitably used in the concrete construction industry
which requires large quantities of low cost raw
materials. This utilization offers triple benefits,
namely, conservation of fast-declining natural
resources, planned gainful exploitation of
waste materials and release of valuable land
for more profitable use.
The most influential factor that dictates the
utilization of industrial by-products is the economic
cost in comparison to the conventional materials
that would have been otherwise used.

The Northcap University, Gurgaon

BLAST-FURNACE SLAG: Large quantities of slag are

generated during the production of iron and steel.

Granulated or foamed or dense blast-furnace slag can be
produced depending on the rate and manner of cooling
the molten slag. The granulated slag can be used in
the manufacture of slag cements. Blast-furnace slag
cements contain slag up to 60 per cent, hence there is
considerable reduction in the rate of heat evolution and a
significant increase in the resistance to chemical attack.
For the same reasons, these cements can be
advantageously used in mass concrete, and for
high chemical resistance in marine structures. The
dense air-cooled slag aggregate may be used as a
replacement of natural aggregate in concrete. On the
other hand, foamed blast-furnace slag, a lightweight
aggregate, is mainly used for block making and
insulating roofs and floor screeds and is suitable for
structural reinforced concrete.
The Northcap University, Gurgaon

COAL ASH FROM POWER STATIONS : The main byproduct is fly ash or pulverized fuel ash which is the fine dust
carried upward by combustion gases and collected in wet
scrubbers and electrostatic precipitators. The bulk ash which is
greyish in color becomes darker with increasing proportions of
unburnt carbon. It is used as a cement replacement. The
contribution of fly ash to the strength of concrete has
been attributed to:
Direct water reduction.
Increase in the effective volume of paste in the mix
Pozzolanic reaction
However, fly ash reduces the rate of development of
strength and increases drying shrinkage. Since the early
strength of fly ash concrete is less than that of Portland
cement, its proportion is generally limited to 30 per cent in the
situations where early strength is important. The low rate of
heat evolution makes fly ash useful in mass concrete.
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SILICA-FUME CONCRETE: Silica-fume is a byproduct of the reduction of high purity quartz with
coal in electric arc furnaces in the production of
ferro-silicon metal. Because of its extreme fineness
and high glass content, Silica-fume is a very
efficient pozzolanic material i.e., it is able to react
efficiently with the hydration products of Portland
cement in concrete.

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Silica-fume in concrete can be used for the following

purposes:
To conserve cement
To produce ultra high strength concrete
To control alkali-silica reaction
To reduce chloride associated corrosion and
sulfate attack
To increase early age strength of fly ash/slag
concrete.

The Northcap University, Gurgaon

SHOTCRETE OR GUNITING
Shotcrete is mortar or very fine concrete deposited
by jetting it with high velocity (pneumatically
projected or sprayed) on to a prepared surface. The
system has different proprietory names in different
countries such as Blastcrete, Blowcrete, Guncrete, Jetcrete, Nucrete, Plneukrete, Spraycrete, Torkrete, etc.
Shotcrete
has
wide
applications
in
different
constructions, such as thin over-head vertical or
horizontal surfaces, particularly the curved or
folded sections; canal, reservoir and tunnel lining;
swimming
pools
and
other
water-retaining
structures and prestressed tanks. Shotcrete is very
useful for the restoration and repair of concrete
structures,
fire
damaged
structures
and
waterproofing of walls.
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Shotcrete has also been successfully used in the

stabilization of rock slopes and temporary
protection of freshly excavated rock surfaces. Its
utility has been proved for protection against longterm corrosion of piling, coal bunkers, oil tanks,
steel building frames and other structures as well as
in encasing structural steel for fireproofing.

The Northcap University, Gurgaon

TYPES OF SHOTCRETING
DRY MIX PROCESS: In the dry mix process, the mixture of
cement and damp sand is conveyed through a delivery
hose pipe to a special mechanical feeder or gun called
delivery equipment. The mixture is metered into the delivery
hose by a feed wheel or distributor. This material is carried by
compressed air through the delivery hose to a special
nozzle. The nozzle is fitted with a perforated main fold through
which water is introduced under pressure and intimately
mixed with other ingredients. The mortar is jetted from the nozzle
at high velocity on to the surface to be shot crated. The watercement ratio should be between 0.33 and 0.50.
Video:
C&D Waste (Construction & Demolition) Recycling Process - 3:51 min
Construction waste crusher, construction waste disposal equipment
4:10 min
Inground swimming pool building process - step by step 31:21 min
Bridge Repair, Gunite, Shotcrete, Concrete Repair, Cyclone Gunite
Machine Demonstration 7:36 min
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Thank You

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The Northcap University, Gurgaon