5/20/2016

AN INTRODUCTION TO CELLULAR
CONCRETE AND ADVANCED ENGINEERED LOW -DENSITY CELLULAR CONCRETE IS
FOAM TECHNOLOGY DEFINED BY ACI 523 AS
Not just productsSolutions
Concrete made with hydraulic
cement, water and preformed foam
to produce a hardened material with
an oven dry density of 50pounds
(22.7 kg) per cubic foot or less.

Preformed foam is created by

diluting a liquid foam concentrate
Nico Sutmoller with water in predetermined
Lightweight Fill Specialist proportions and passing this mixture
through a foam generator.

Revision Last updated 4/2016

CONFORMS TO ACI INDUSTRY STANDARDS CONFORMS TO ACI INDUSTRY STANDARDS

Types of Foam Preformed

Produced by Foam Generator

ACI 523
Preformed Agitated
Produced by Foam Generator Produced by the mixing action of
a concrete mixer

ACI 523 ACI 229

Cellular Concrete CLSM

CELLULAR CONCRETE REPLACES COARSE CELLULAR CONCRETE PORE STRUCTURE

AGGREGATE WITH AIR WHEN CURED

Cementitious materials
encapsulate the air bubbles,
The air cells must then dissipate leaving a
be resilient in order void structure as a
to withstand the replacement to traditional
rigors of mixing aggregate
and pumping in
various
applications Lightweight Cellular
Concrete differs from
conventional aggregate
concrete in the methods of
Foam has the stability to be calculated as a solid but production, the density of
the properties to be placed as a low density fluid the material and the
material extensive range of end
uses.

1
 5/20/2016

THE CELLULAR CONCRETE FULLY REBOUNDED CELLULAR CONCRETE BATCHING PROCESS

TO THE ORIGINAL FILL HEIGHT 1 CY OF SLURRY EXPANDS UP TO 4.6 CY

At 30 psi pressure, the *Note there was no visible

cellular concrete was reduced collapse of the cellular
in height to 9 inches concrete after the test.
*Inform ation provided by
Ardaman & Associates, Inc. Tampa, FL

PRODUCTION OF CELLULAR CONCRETE IS MORE

TYPES OF ON-SITE INSTALLATION EQUIPMENT ENVIRONMENTALLY FRIENDLY THAN ALTERNATIVE
INCLUDE METHODS

High production self-contained unit

for larger volume projects

Less trucking
Less pieces of equipment
Mobile Mixing units
Less Fuel
Less Carbon Emissions
Self-contained trailer
wet batch system Less congested jobsites

TYPICAL STRENGTH AND DENSITY TYPICAL STRENGTH CURVE OF CELLULAR

PROPERTIES OF CELLULAR CONCRETE MIXES CONCRETE

75% of
the
volume
PSI

is foam

PCF

2

CELLULAR CONCRETE FOLLOWS ASTM TEST
METHODS THAT APPLY TO LIGHTWEIGHT INSULATING
CONCRETE
ASTM C 495
Standard Test Method for:
Compressive Strength of
Lightweight Insulating
Concrete
Cylinder specimens are 3x6
Handling and storage
50% relative humidity curing
of samples is very
Air dried for 3 days before testing
important
28 day compressive strength testing
FOAM TECHNOLOGY HAS MADE HUGE
ADVANCEMENTS WITH STABLE BUBBLE
TECHNOLOGY
Typical Foams
3 foot lift thickness
Pumping distance limited
to 5,000 feet maximum
Only non-permeable
Viscosity was almost 1
Fly ash usage limited
CELLULAR CONCRETE IS AN IDEAL SOLUTION
FOR ANNULAR AND TUNNEL BACKFILL
Highly flowable material able to
completely fill annular space
Lightweight and easily pumped long
distances at low pressures
Will not float pipe or damage liner for
sliplining
Strength and density can be
customized to project requirements
Shrinkage of less than 0.3%
Quick and Easy Installation
Environmentally Safe
5/20/2016
QUALITY CONTROL IS ALWAYS MEASURED IN
THE FIELD
ASTM C 796
Standard Test Method for:
Foaming Agents for use in
Producing Cellular Concrete
using Preformed Foam
Weighing a sample of
material (ASTM C 796)
GEOTECHNICAL APPLICATIONS
Tunnel Backfill and Annular Fills
Advanced Foam Technology Subgrade Modification
4-20 foot lift thickness
Tremie Applications
Pumping distance increased to
more than 14,000 feet Bridge Approach
Permeable is also an option Retaining Wall Backfills
Thicker material Fill Underground Tanks & Pipelines
Higher fly ash usage and slag Fill for Abandoned Mines
cement usage
Fill Around Conduits and Pipes
BRIGHTWATER CONVEYANCE SYSTEM
W OODINVILLE, WA
Highly flowable material
Lightweightand
pumpable to fully
capsulate the pipes
Cellular Concrete has been pumped over 700
feet vertically and over 15,000 feet
horizontally
Strength and density were
designed for the specific
project requirements
Can accommodate any
diameter pipe
3
 5/20/2016

GAS PIPE LINE ABANDONMENT

ATLANTA GAS LIGHT (AGL) GEOTECHNICAL APPLICATIONS
Tunnel Backfill and Annular Fills
12 mile abandonment
1,000-1,500 ft placement points Subgrade Modification
6,500 yd of 40pcf Tremie Applications
Non-pervious
Bridge Approach

Retaining Wall Backfills

Fill Underground Tanks & Pipelines

Fill for Abandoned Mines

USE CELLULAR CONCRETE FOR SUBGRADE CELLULAR CONCRETE USED TO REPLACE

MODIFICATION WHEN EXISTING SOILS ARE UNSTABLE SOILS AT THE UNIVERSITY OF
UNDESIRABLE CONNECTICUT

Cellular Concrete Advantages

Reduce Vertical Dead Loads

Increase Strength/Stability with Minimal Weight

Improve Seismic Stability

Reduce Settlement Potential

Increase Bearing Capacity

Insulating Football stadium constructed on a landfill site with unstable soils

Lightweight Cellular Concrete sub-base equally distributed the loads
40,000 yds of 35pcf material placed at 150 cy per hour
Lightweight cellular concrete for unstable
soils at the Newark Airport

120 DAY W ATER ABSORPTION STUDY* GEOTECHNICAL APPLICATIONS

Non-Pervious Cellular Concrete Tunnel Backfill and Annular Fills
Sample Net Cast Net @ Avg. Subgrade Modification
ID PCF 120 days Absorption
pcf % Tremie Applications
30 pcf 30.3 34.6 16.6 Bridge Approach
36 pcf 34.9 38.7 12.5
Retaining Wall Backfills
42 pcf 41.5 45.4 12.4
Fill Underground Tanks & Pipelines

Fill for Abandoned Mines

*Haller Laboratory Report (No. L4538-2-R)

4
 5/20/2016

THE FLUIDITY OF CELLULAR CONCRETE MAKES IT

FAVORABLE FOR TREMIE APPLICATIONS
Coastal piers compromised
Placed sheet pile around existing
piers, to isolate wood from water
70 pcf Cellular Concrete used as
fill between the sheet pile and the
pier
Hudson River in New Jersey
GEOTECHNICAL APPLICATIONS
Tunnel Backfill and Annular Fills
Subgrade Modification
Tremie Applications
Bridge Approach
Retaining Wall Backfills

Fill Underground Tanks & Pipelines

DoD Project Overseas
Seawall needed to be reinforced Fill for Abandoned Mines
Backfill behind seawall with
sand mix
Cellular Concrete material
moved 35 in each direction
from tremie location

DoD Project Classified Location

CELLULAR CONCRETE IS IDEAL RETAINING

WALL BACKFILL SEGMENTAL W ALL CONFIGURATION
Cellular Concrete Advantages
Reduce Lateral Load

Ease of Placement

Increased lift heights

Reduces schedule impact

Allows for design flexibility

Engineered Permeability

T-W ALL BY THE NEEL CO. GEOTECHNICAL APPLICATIONS

Tunnel Backfill and Annular Fills
Subgrade Modification
Tremie Applications
Bridge Approach

Retaining Wall Backfills

Underground Utility Protection

Fill Underground Tanks & Pipelines

Fill for Abandoned Mines

Fill Around Conduits and Pipes

5

GEOTHERMAL MODEL UTILITY PROTECTION
**Illustration provided by Cematrix
FULLY EXCAVATABLE & VERSATILE
PERVIOUS VS. NON-PERVIOUS
Bubble Chemistry is
different
In non-pervious we need
to maintain the bubble
structure
With Pervious we need
to coalesce the bubble
structure
5/20/2016
IDENTIFY BURIED UTILITIES WITH A DYE
clear indicator for
future operators
Different colors can be
used
Red - fiber optics or
high voltage lines
Blue water lines
Yellow sewer lines
Photo Courtesy of Throop Cellular Concrete
EMERGING TECHNOLOGIES AND ENGINEERED
FOAM SOLUTIONS
Open Cell Technology
Pervious Cellular Concrete Permeability Drainage of 30 -1000/hr
Density of 25pcf 35pcf
MTSU testing shows that 97% of oil
and 79% of heavy metals were
retained in the sample
TYPICAL USES AND APPLICATIONS FOR
PERVIOUS CELLULAR CONCRETE
Sports Complex Field Drainage
Retaining Wall Backfill
Pervious Pavement sub-base filtration
Foundation Drainage
Pipeline Bedding / Culvert Fill
Landscaping
Pool Backfill
6
 5/20/2016

PERVIOUS CELLULAR CONCRETE USED AS A SUB-

BASE AT THE NEW YORK METS BALLPARK SAVING
PERVIOUS CELLULAR CONCRETE USED AS A SUB-BASE
THE OWNER OVER $500,000 DOLLARS

The original design called

for 4 of lightweight
The site of the new ball park was on poor aggregate. Cellular
soils. Pervious Cellular Concrete was used as Concrete was proposed
a sub-base under the playing field area to as a value engineering
allow for drainage. alternative.

The site of the new ball park was on

Picture courtesy of
organic clay
Civil Magazine
2009 Article

PERVIOUS CELLULAR CONCRETE USED ON BRIDGE 2,600 CUBIC YARDS OF 25PCF PERVIOUS
APPROACH TO ALLOW FLOOD WATERS TO DRAIN CELLULAR CONCRETE

Standing water from flooding

of Red River in Fargo, ND Pervious Cellular Concrete Advantages
had deteriorated the bridge
approach. Reduced Settlement

Increase Bearing Capacity

Improve Seismic Stability

Permeability of 1x10-2 cm/sec

Using pervious cellular concrete on
the bridge approach allowed the
flood waters to drain alleviating
pooling and potential deterioration

PERVIOUS CELLULAR CONCRETE USED FOR

RETAINING WALL BACKFILL TO PROVIDE DRAINAGE LOUIS ARMSTRONG AIRPORT
AT TOE OF LANDSLIDE NEW ORLEANS, LA

I-70
Pervious fill
behind lower
bin wall

US 6

Due to the close proximity of the

retaining wall to the concrete block
anchors installed to tie back the
landslide, the lightweight pervious
backfill reduced the lateral earth
pressure on the new block wall
while still allowing for proper
draining, which is key to reducing
the potential for future slope failure

7
 5/20/2016

LOUIS ARMSTRONG AIRPORT

NEW ORLEANS, LA INCORPORATION OF HELICAL ANCHORS

STUDY AT MIDDLE TENNESSEE STATE

UNIVERSITY PERVIOUS DENSITY VS. PERMEABILITY
Density of specimen, pcf
27.4
27.2
27
26.8
26.6
26.4
26.2
26
25.8
25.6
25.4
1 2 3 4

60.5

60

59.5

59

58.5

58
Void Content, %

APPLICATIONS FOR OTHER INDUSTRIES UNIQUE APPLICATIONS

Housing Sound Walls

ROOFING MINING Popular in Asia, Latin Lightweight
America, and Europe Sound absorption
Fast Construction Less bounce or
Vermin proof sound rebound
Roofing Backfill Fire Resistance
Re-roofing Annular fill
Tailling material transport

LWIC Top Coat

Engineered Material
EPS Application
Arresting System (EAS)
Slurry Coat FAA mandated longer runways
Application landing over runs
Airports that do not have room for
Metal Deck extended runways can use an
EAS
System will prevent a jet from
running off the runway but still
allow emergency vehicles to drive
on the EAS without sinking in.

8
 5/20/2016

W HAT CONCLUSIONS CAN WE DRAW ABOUT

CELLULAR CONCRETE?

Broad Range of Densities

Economical
Versatile
Easily Placed

Rapid Installation
Durable

Permanent and Stable

Environmentally Friendly

No One Foam Does it All

Questions?
We can customize our products to meet
your project needs