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Open AccessArticle

Lightweight Concrete Produced Using a Two-Stage Casting Process

School of Urban and Environmental Engineering, Ulsan National Institute of Science and Technology, 50 UNIST-gil, Ulju-gun, Ulsan 689-798, Korea
Structure Research Department, Corporate Technology Institute, Hyundai Heavy Industries Co., Ltd., Ulsan 682-792, Korea
Author to whom correspondence should be addressed.
Academic Editor: Luciano Feo
Materials 2015, 8(4), 1384-1397;
Received: 2 February 2015 / Revised: 12 March 2015 / Accepted: 16 March 2015 / Published: 25 March 2015
The type of lightweight aggregate and its volume fraction in a mix determine the density of lightweight concrete. Minimizing the density obviously requires a higher volume fraction, but this usually causes aggregates segregation in a conventional mixing process. This paper proposes a two-stage casting process to produce a lightweight concrete. This process involves placing lightweight aggregates in a frame and then filling in the remaining interstitial voids with cementitious grout. The casting process results in the lowest density of lightweight concrete, which consequently has low compressive strength. The irregularly shaped aggregates compensate for the weak point in terms of strength while the round-shape aggregates provide a strength of 20 MPa. Therefore, the proposed casting process can be applied for manufacturing non-structural elements and structural composites requiring a very low density and a strength of at most 20 MPa. View Full-Text
Keywords: lightweight concrete; two-stage concrete; volume fraction; aggregate; grout lightweight concrete; two-stage concrete; volume fraction; aggregate; grout
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Yoon, J.Y.; Kim, J.H.; Hwang, Y.Y.; Shin, D.K. Lightweight Concrete Produced Using a Two-Stage Casting Process. Materials 2015, 8, 1384-1397.

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