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Construction of building material is widely used for the development of any country. In that, conventional building material plays a major role generally, this is more expensive. Expanded polypropylene form is one type of solid foam material that is available at a low cost. The main Aim of this research work is the cost analysis of expanded propylene foam aggregate concrete with replacing 100 percent of natural aggregates, with manufacturing standards of low density lightweight concrete process. Moreover, the standard density is 800 kg/m3 is adopted for the research work. The w/c ratio of 0.32 was taken for high strength criteria. The results illustrate that the compressive strength of concrete is increased when compared to other lightweight concrete. Economical aspects also explain the cost reduction up to 0.83 % due to the use of Expanded polypropylene foam aggregates. In the end, it clearly explains that the use of Expanded polypropylene Foam aggregates has more capable in the manufacturing of Low density lightweight concrete.

Keywords: - Expanded Polypropylene Foam Aggregates, Air Entraining Admixture, Super Plasticizer, Sulphate Resisting Cement, Cost Analysis.

The modern construction industry adopts the new types of technologies and processes construction methods, to decrease the construction period and increase the life span of buildings against natural disasters like earthquakes, has uplift before it happens. To minimize these situations like, cost effective, long-moving, of the buildings has required some solutions to deliberate point to the specific use of new methods and conventional building materials to sensitize construction period, high durable and finally decrease the cost execution.

The current works is majorly going on minimize the weight of dead load of constructions by different conventional methods. For that reducing the density of material is the one of themethods used in construction industry and trying to get same strength. By using these types of techniques will helpful for the reduction in cost of construction and save the time, and to restrict the damage caused by natural disasters.

This report is presenting the cost analysis of expanded polypropylene foam aggregates in low density light weight concrete.

The early use of lightweight aggregates is started by ancient Romans[1].The‘Pantheon’ ware introduced the lightweight concrete for the first time in the construction field by replacing natural aggregates with pumice aggregates in 18 centuries. Then next, the USA and the United Kingdom started lightweight concrete manufacturing in the late 19 century, by partial replacement of natural aggregates with clinker, used in their construction of the ‘British Museum’ and some other works. The light weight aggregates concrete also used in construction during the period of ‘First World War’. Sweden also used the lightweight aggregates concrete in 1930 time for the construction of lowering houses and concrete blocks. The present generation technology will work on the different types of lightweight concretes for their growth nation.

Light weight concrete is a special type of concrete which have lower density than normal concrete. For the reducing the density concrete, using normal aggregates with expanded polypropylene foam aggregates is the one type of method. Because this aggregate has low specific gravity when compared to all other material and this aggregate has high compressive strength nature. In generally, light concrete can be divided in to 3 types, in that low density light weight concrete has particular position in all other, its density is less than 800 kg/m3. The main view of this work is to increase the strength and reduce the cost of low-density light weight concrete[2].

Sulphate-Resisting Cement could be a pressed production line delivered Portland impact heater cement made to the prerequisites of “BS EN 197-1 CEM III/A” quality lesson 42,5L. It moreover has sulphate-resisting properties and has the assignment ‘CEM III/A +SR’ as set out in BS 8500 Portion 2 ‘Concrete – Complementary British Standard to BS EN 206-1 Portion 2: Detail for constituent materials and concrete’ – Table 1 – General reason cement and combinations. Sulphates that will happen in soil and groundwater respond with the tri-calcium aluminate (C3A) show in most Portland types of cement causing development and extreme disintegration of the concrete. To play down the hazard of this response Sulphate-Resisting Cement is made with decreased levels of C3A, in this way guaranteeing that it meets the +SR prerequisites of BS 8500. The Sulphate Resisting Cement produced from Para SakthiCementss[3].

The fine aggregates were taken from Local River which is near to Amaravati in Andhra Pradesh. This has taken oven dry condition and the specific gravity were 2.65 and 1% respectively, as per the IS 2386 (Part-II, 1963). In that sample which is taken has retained in between 600 microns and 150 Microns for high strength propose.

This aggregates ware taken from the local Foam making factory. With 20×20×20 mm dimensions and the specific gravity of these aggregates is 0.018.

It too is known as tall extend water reducers are added substances utilized in making tall quality concrete. Plasticizer is chemical compounds that empower the generation of concrete with ca. 15% less water substance. Super plasticizer permits a lessening in water substance by 30% or more. These added substances are utilized at the level of some weight percent. Plasticizer and super plasticizer impede the curing of concrete. The specific gravity of the super plasticizer is 1.04, which was given by Ecomas Company.

Air Entraining Admixtures cause small consistent bubbles of discourse to create reliably through a concrete mix. The bubbles are for the most part underneath 1 mm breadth with a tall degree underneath 0.3 mm. The benefits of entraining examine inside the concrete consolidate extended resistance to freeze-thaw debasement extended cohesion and made strides compaction in low-workability mixes. The particular gravity of the Air Entraining Admixtures is 1.05, which was given by Ecomas Company.

In this phase the research work can be divided into 2 stages.

Stage .1 The mix design with Expanded polypropylene Foam aggregates.

Stage.2 Cost comparative analysis

The preparation of Mix design can be done by The Department of Environment’s Design Method (DOE Method) standards and previous research article. And then cost analysis is prepared.

Hear, the density is fixed 800kg/m3 is considered based on previous article research works.

Phase.1 Factors considers for preparation of preparation of concrete

Cement: Sulphate Resisting Cement

Aggregates Dimensions: 20×20×20 mm

Water Cement Ratio: 0.35

Exposure: Mild

Phase.2 Specific Gravities of Materials

1. Cement : 3.15

2. Coarse Aggregates : 0.018

3. Fine Aggregates : 2.65

4. Water : 1.0

5. Super Plasticizer : 1.04

6. Air Entraining Admixture : 1.05

Phase.3 Water Absorption of Aggregates

1. CoarseAggregates: 0 %

2. Fine Aggregates: 1 %

Phase.4 Mix Design Calculation

1. Volume of Concrete = 1m3

2. Volume of Cement

= ×

=×

= 0.113cm3

3. Volume of Water

= ×

= ×

= 0.125cm3

4. Volume of Super Plasticizer

= ×

= ×

= 0.00245 cm3

5. Volume of Air Entraining Admixture

= ×

= ×

= 0.00285cm3

6. Volume of Expanded Polypropylene Foam Aggregates

×

= ×

= 0.666 cm3

7. Volume of Fine Aggregates

×

= ×

= 0.117 cm3

Phase.5 Mix Proportions for 1m3 is

1. Cement : 358 kg/m3

2. Coarse Aggregates : 12 kg/m3

3. Fine Aggregates : 300 kg/m3

4. Water : 125 kg/m3

5. Super Plasticizer : 2 lt/ m3

6. Air Entraining Admixture : 3 lt/ m3

Comparison of conventional concrete material and low-density light weight concrete material in Table.1

Table.1Comparison between conventional concrete and low-density light weight concrete material.

Table .2 Comparisons between densities of conventional concrete and lowdensity light weight concrete.

The most complicated part is comparisons of two different concretes with their densities. The Table.2 clearly explains the comparison between their specific weights 800 kg/m3 and 2400 kg/m3. This difference will helpful for the high-raised buildings, because it reduced their dead load on the columns [4]. And most important thing is depth of foundation is minimized, it will lead to cost variance in construction.

Samples are prepared as per the standards [5] of Part 1-4: Lightweight aggregate concrete with closed structure   (EN 1992-1-4) and the samples with dimensions of 150mm× 150mm × 150 mm. After the preparation of all the samples and placed them in curing tank. The compressive strength was conducted after 7days and 28 days as per British standards. The maximum compressive strength of the specimen can be calculated by dividing maximum applied load on the specimens.

Table.3 Compressive strength of Conventional concrete and Low-density light weight concrete.

The cost analysis is explained by the quantification of materials used for the manufacturing of concrete. The prices of the material, machinery usage were taken from United kingdom standard only.

Table.4 Quantification of conventional concrete

Dry densities of the all the proportions is 2487 kg/m3

Bulk density of Coarse Aggregates 20 mm is 1621kg /m3

Bulk density of Coarse Aggregates 12 mm is 1609 kg /m3

Bulk density of Fine Aggregates is 1747 kg /m3

Table.5 Quantification of Low-density light concrete with Expanded Polypropylene Foam Aggregates

Dry densities of the all the proportions is 800 kg/m3

Table.6 Quantification of Low density light concrete with Expanded Polypropylene Foam Aggregates and Recron3S

Dry densities of the all the proportions is 800kg/m3

Table.7 Cost Analysis of the Conventional Concrete and Low density light weight concrete Materials

Note: - The Price of Water can be consider as 3.8 pounds per 1000 litters

The Output of the pump is 30cum/hr

Working power of the Pump is 50kW

1 m3 of Concrete would be pumped period is = hr

= 0.033hr

Energy consumed to pump = Power req × Time

= 50×0.033

= 1.65 kW

Cost of the Electricity is = 0.14 £ /kWh

Cost of the pumping for 1m3 = Cost of Electricity × Energy consumed

= 0.14 × 1.65

= 0.231 £

Table.8 Miscellaneous charges

Table.9 Overall Cost Analysis

Conclusion

1. The compressive strength of low density low dens light weight concrete with Expanded poly propylene foam aggregates is 8.72Mpa at the age of 28days

2. Cost comparison of the of density low dens light weight concrete with Expanded poly propylene foam aggregates 0.83% is less than conventional Concrete.

References