Process Safety and Environmental Protection 128 (2019) 77–84

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Process Safety and Environmental Protection

journal homepage: www.elsevier.com/locate/psep

Glass foams produced from soda-lime glass waste and rice husk ash
applied as partial substitutes for concrete aggregates
Fernando Antonio da Silva Fernandes a , Sabrina Arcaro a,b,∗ ,
Erwin Francisco Tochtrop Junior c , Juan Carlos Valdés Serra d , Carlos Pérez Bergmann a,e
a
Laboratório de Materiais Cerâmicos – LACER, Departamento de Engenharia de Materiais, Universidade Federal do Rio Grande do Sul, Av. Osvaldo Aranha
99/705, Porto Alegre, RS 90035-190, Brazil
b
Graduate Program in Materials Science and Engineering (PPGCEM), Laboratory of Technical Ceramics (CerTec), Universidade do Extremo Sul Catarinense
(UNESC), Av. Universitária 1105, P.O. Box 3167, 88806-000 Criciúma, SC, Brazil
c
Laboratório de Minas – CEULP-ULBRA, Av. Joaquim Teotônio Segurado, 1501 - Plano Diretor Sul, Palmas, TO, 77000-900, Brazil
d
Laboratório de Materiais Compósitos, Universidade Federal do Tocantins - Quadra 109 Norte, Avenida NS15, ALCNO-14 - Plano Diretor Norte, Palmas, TO,
77001-090, Brazil
e
Departamento de Engenharia Industrial, Universidade Federal do Rio Grande do Sul, Av. Osvaldo Aranha 99, Porto Alegre, RS 90035-190, Brazil

a r t i c l e i n f o a b s t r a c t

Article history: Concrete is one of the most widely consumed materials in the world. It is composed mainly of natural
Received 3 January 2019 aggregates - 70–80% of its volume. Extraction of natural aggregates for concrete production harms the
Received in revised form 4 May 2019 environment, and has decreased over the past years. The use of recycled aggregates that can replace nat-
Accepted 24 May 2019
ural aggregates in concrete and meet the specifications of structural projects can be an economical and
Available online 29 May 2019
sustainable solution for the construction industry. This study investigated the effects of partial replace-
ment of natural aggregates (pebbles) with glass foam (10–30 %wt), produced with soda-lime glass wastes,
Keywords:
rice husk ash and calcium carbonate, on the uniaxial compression strength (3, 7, 28, 56, and 90 days) and
Concrete
Recycled aggregate concrete
consistency (Slump test) of structural concrete. Results show that the larger the size and concentration of
Glass foam the recycled aggregates, the lower the mechanical compressive strength of concrete. Hence, the highest
Environment compressive strength at all ages was shown by the material with 4.8 mm glass foams and 10% addition -
Compressive strength 38 MPa after 90 days. Furthermore, partial replacement positively favors the slump of concrete (>90 mm),
Slump test enabling its commercialization and workability for pumping from mixer trucks.
© 2019 Institution of Chemical Engineers. Published by Elsevier B.V. All rights reserved.

1. Introduction concrete constituents (Yadav and Pathak, 2009). The construction

Environmental issues has been steadily raising concern world-
wide (Liu et al., 2017). Discussions on sustainability always include
the construction industry, mainly because of the strong environ-
mental impact associated with the production of construction
materials, the construction of buildings, and the subsequent use
of these structures, whose normally expected life span ranges from
50 to 100 years (Müller et al., 2014).
Concrete is one of the most consumed materials worldwide,
with annual production of approximately 10 billion cubic meters
(Thomas, 2018). Aggregates account for 70–80% of the volume of
∗ Corresponding author at: Graduate Program in Materials Science and Engineer-
ing (PPGCEM), Laboratory of Technical Ceramics (CerTec), Universidade do Extremo
Sul Catarinense (UNESC), Av. Universitária 1105, P.O. Box 3167, 88806-000 Criciúma,
SC, Brazil.
E-mail address: sabrinarcaro@yahoo.com.br (S. Arcaro).
industry shows great interest in the partial or total replacement
of concrete constituents by agricultural wastes with cementi-
tious properties (Khan et al., 2017). The production of aggregates
from recycled wastes for use in concrete (Xiao, 2018), without
impairment to its performance and durability, is an economical
and environmentally sustainable alternative that can contribute
to reducing waste disposal in landfills and improve quality of life
today without compromising that of future generations (Thomas,
2018). Incorporation of industrial and agricultural wastes in con-
crete has grown in recent years. The most frequently incorporated
wastes are fly ash, slag, silica fume, rice husk ash (Li et al., 2015),
glass (Shao et al., 2000), expanded polystyrene (Athanasopoulos-
Zekkos et al., 2012), lightweight cellular cementitious clays, tires
(Horpibulsuk et al., 2014), etc.
In this way, glass foams have attracted great interest from the
construction industry because of characteristics such as lightness,
stiffness, and good compressive strength, as well as because they

https://doi.org/10.1016/j.psep.2019.05.044
0957-5820/© 2019 Institution of Chemical Engineers. Published by Elsevier B.V. All rights reserved.
78 F.A. da Silva Fernandes et al. / Process Safety and Environmental Protection 128 (2019) 77–84
are chemically inert and non-toxic. For instance, these factors favor
their use in thermal insulation (Zhu et al., 2016). They can be pro-
duced from a glass matrix - which can be used from recycled glass
- (de Moraes et al., 2019a, 2018; Fernandes et al., 2014; Souza et al.,
2017; Teixeira et al., 2017a). Soda-lime glass accounts for 90% of
all glass produced worldwide (Akerman, 2013), thus presenting an
extremely high demand (Gonçalves et al., 2018). Moreover, can be
used pure CaCO3 (König et al., 2015a; Petersen et al., 2017), agroin-
dustrial CaCO3 fonts (Souza et al., 2017; Teixeira et al., 2017b)
municipal solid wastes (Wu et al., 2006), ash (Zhu et al., 2016),
extracted titanium tailing(Xi et al., 2018) sodium hydroxide(da
Silva et al., 2019) and others, as pore-forming agent. Glass foams
can be designed according to the properties required and their pos-
sible application, by modifying process parameters such as forming
technique, amount of foaming agent, etc. (Scheffler, 2005; Studart
et al., 2006).
However, the possibility of incorporation of in the manufac-
turing process of glass foams play an important role because
less energy generally is required for their production than that
needed for conventional materials (de Moraes et al., 2019b). Agro-
industrial waste, for example, can be used both as a source of SiO2
-without impairing the properties of the glass matrix. Among the
agro-industrial wastes, rice husk stands out the most, considering
that rice is most widely consumed food in the world, with esti-
mated production of 450 million tons for 2020 (Soares et al., 2015).
Rice waste corresponds to 20–33% of its weight. Rice rusk ash (RHA)
originates from the firing of rice rusk, and it corresponds to 18–20%
wt of the whole grain (Eliche-Quesada et al., 2017). RHA composi-
tion is chemically inert (Pode, 2016), has a large concentration of
SiO2 (>92%) (Sobrosa et al., 2017), and can be found in amorphous or
crystalline structure, depending on the firing temperature to which
is subjected (Eliche-Quesada et al., 2017).
Partial replacement of natural coarse aggregate with glass foams
in concrete production may contribute to minimizing aggregate
extraction. In addition, it can contribute to the correct destination
of soda-lime glass and RHA, which are wastes with large volumes of
landfill disposal. In this context, this study investigated the effects
of partial replacement of natural aggregates (pebbles) with glass
foam (10–30 %wt), produced by pelletization with soda-lime glass
wastes, rice husk ash and calcium carbonate, on the density, uniax-
ial compression strength (3, 7, 28, 56, and 90 days) and consistency
(Slump test) of concrete. The soda-lime glass and RHA was used as
glass matrix and CaCO3 as a pore-forming.
2. Experimental procedures
Initially, glass foams were produced for partial replacement
of the natural coarse aggregates in concrete. The following raw
materials were used in this process: soda-lime glass, from recy-
cled beverage bottles; rice husk ash (RHA) (D90 = 100 ␮m), burned
for the manufacturing of red ceramic products in the municipality
of Paraíso do Tocantins, Tocantins state, Brazil; industrial cal-
cium carbonate (CaCO3 ) (D90 = 4.86 ␮m), purchased from Dinâmica
enterprise. The glass bottles were washed and dried at room tem-
perature, manually ground, and then milled in ball mill (TS RUBENS)
to D90 = 94.00 ␮m particle size. Subsequently, the chemical com-
position of the raw materials was evaluated by x-ray fluorescence
(Shimadzu XRF 1800) (Table 1).
Differential thermal (DTA, SDT-Q600, TA instruments) and ther-
mogravimetric (TGA-50, Shimadzu) analyses was conducted at a
heating rate of 10 ◦ C/min in synthetic air atmosphere. The com-
position containing 78% soda-lime glass, 6% CaCO3, and 16% RHA
was defined in preliminary laboratory tests. All raw materials were
weighed on a digital scale, manually homogenized for 2 min in a
porcelain mortar and granulated with the addition of water (5%)
and PVA (solution containing 5% active material) (polyvinyl alco-
hol P.S, Dinâmica Brasil). Then, pellets were performed by a disc
pellet adapted in a concrete mixer. The disc rotates at a controlled
speed (100 rpm) for 3 min. This process agglutinates the particles
in spherical shapes – pellets. After that, the spheres were dried and
fired in a muffle oven (EDG 1800) at 850 ◦ C, 10 ◦ C/min for 30 min
(König et al., 2014). They were then cooled by inertia and charac-
terized by pellet size (ABNT-NBR-7211, 2005).
Porosity (␧) of glass foams was obtained from the ratio between
apparent density (␳a ) and theoretical density (␳t, 2,5 g/cm3 ) of the
powders according to Eq. (1).
 a

ε (%) = 1− (1)
t
Apparent density was determined by the mass and geometric
dimension of the samples (Francis and Abdel Rahman, 2013).
Pore microstructure can be visualized from the cross-section
images of the fired foams, obtained using an optical microscope
(Olympus, 3Z61). The mean pore size of the glass foams was
determined by quantifications corresponding to the specified pore
diameter ranges. The assay was based on the Average Grain Inter-
cept method, in which the relationship between the mean length
(t) and the mean diameter (D) of the pore is given by Eq. (2) to better
represent the measurement of a 3D unit (pore) by a 2D image(ASTM
E112-13, 2012).
D = 1.623 t (2)
In this case, five images of the fracture surfaces of each obtained
glass foams were used, and at least 50 measurements of each image
were made using the ImageJ® software.
Mechanical compressive strength of the glass foams containing
12.5 mm was determined using a universal hydraulic press (EMIC-
DL 2000; 10 mm/min crosshead speed) according to the ASTM C
133–97R15, 2015 standard. Five samples were used, and mean
and standard deviation were calculated. Mechanical compressive
strength was determined only for the 12.5 mm samples because of
the appropriate dimensions according to the standard. It is worth
mentioning that 2 mm-thick ethylene-vinyl acetate (EVA) foam
sheets were placed on the interface of the sample and the cell load to
ensure homogeneous load transfer and compensate for any surface
irregularities.
After production and characterization, the glass foams were par-
tially added to concrete. Portland CPII F32 cement was used as
binder to obtain the concrete. Natural aggregate was collected from
the Tocantins River close to the municipality of Palmas, Tocantins
state, Brazil, and classified by size similarity to the glass foams (4.8,
6.3, and 12.5 mm) (ABNT-NBR-7211, 2005).
Three compositions were formulated by replacing the aggre-
gates with glass foams at 10, 20, and 30%. The uniaxial compression
strength and consistency (Slump test) of the formulated compo-
sitions (Table 2) were evaluated after a hydration/curing process
(3, 7, 28, 56, and 90 days) (Bignozzi et al., 2015). In order to
compare the results of mechanical properties associated with the
uniaxial compression strength of the concrete formulations with
partial addition of glass foam, a sample of each formulation, with-
out addition, with the same ages was tested (Alex et al., 2016;
Yadav and Pathak, 2009). The following formulation was used:
1:1.68 (cement:sand), 1:2.68 (cement:crushed stone), and 1:0.482
(cement:water). Table 2 shows the proportions of concrete dosage
with and without addition of glass foam.
Concrete produced according to each composition was initially
homogenized using an electric mixer (120 liters). The concrete was
poured into metal test cylinders (100 mm diameter and 200 mm
height). After 24 h, the specimens were removed from the cylin-
ders for capping, and then immersed in saturated water tanks for
 F.A. da Silva Fernandes et al. / Process Safety and Environmental Protection 128 (2019) 77–84 79

Table 1
Chemical analysis of glass, RHA, and CaCO3 .

Composition*
Material
SiO2 CaO Na2 O Al2 O3 K2 O Fe2 O3 P2 O5

Soda-lime glass 72.26 12.01 12.61 1.48 0.87 0.77 –

RHA 89.43 2.67 1.60 0.99 3.67 0.65 0.99
CaCO3 0.40 97.77 – 0.06 – 0.14 1.09
*
Expressed in oxides.
**
MnO, MgO, SrO, and SO3 found at smaller proportions.

Table 2
Composition of the concrete formulation according to addition of glass foam.

Sample GF(%) GF(Kg/m3 ) Cement (Kg/m3 ) Water (Kg/m3 ) Sand(Kg/m3 ) Crushed stone (Kg/m3 )

Control 0 0.0 407 176 682 1089

CA-10 10 108.9 407 176 682 980.1
CA-20 20 217.8 407 176 682 871.2
CA-30 30 326.7 407 176 682 762.3

*GF – Glass foam.

curing (ABNT-NBR-5738, 2015). The Slump tests were conducted Table 3

Sphere size, porosity, mean pore size, and compressive strength.
subsequently.
Concrete consistency for each of the formulations was evaluated Sphere size Porosity Mean pore size (mm) Compressive strength
through the Slump test (ABNT-NBR NM 67, 1998). In this assay, the (mm) (%) (MPa)
concrete mixture was placed in a conical frustum mold in three 4.8 87 ± 2 1.2 ± 1 –
equally thick layers, each with 25 manual tamp down strokes. At 6.3 89 ± 2 2.3 ± 1 –
the end, the mold was slowly removed vertically and the difference 12.5 93 ± 2 1.5 ± 1 0.51 ± 0.01

between the mold height and the height of the concrete mixture
after it was set was assessed. Each formulation was evaluated in
triplicate.
Specimens of the formulated compositions, i.e., with and with-
out glass foams, had their uniaxial compressive strength assessed.
To this end, five samples were tested for each formulation and age.
Natural sand and crushed stone were characterized according to the
NBR 7217 standard (ABNT-NBR-7217, 1987). Compressive strength
was assessed at room temperature using a universal hydraulic press
(EMIC DL 3000). The test concrete was produced as illustrated in
Fig. 1.
3. Results and discussion
The potential to use soda-lime glass, calcium carbonate (CaCO3 )
and rice husk ash (RHA) in the production of glass foams was ini-
tially assessed by chemical analysis. It can be verified that soda-lime
glass is abundant in SiO2 , Na2 O, and CaO. The iron oxide (Fe2 O3 )
present in the sample is due to the green coloration of the glass
bottles used. Because the applications envisaged in this work, no
aesthetic requirements are necessary in terms of a specific color.
RHA is rich in SiO2 with some residual amounts of CaO, Na2O,
Al2O3, K2O and Fe2O3. It is an excellent source of SiO2 that can
be added to the glass matrix of glass foams. Already CaCO3, is a
commercial product and rich in CaO, as expected. The fire losses of
CaCo3 and RHA can be observed in the thermal analysis of Fig. 2,
since the release of CO2 can be harnessed as potential for use as
porogenic agents
Fig. 2 shows the differential thermal (DTA) and thermogravimet-
ric (TGA) analyses of the porogenic agents. Initially, it was possible
to observe that the RHA (Fig. 2(a)) shows an endothermic event
around 100 ◦ C, associated with a mass loss of 1% corresponding
to the presence of residual moisture in the sample. Subsequently,
an exothermic event was observed at 450 ◦ C, associated with a
mass loss of 2% that may be due to release of volatile substances
present in the sample. According to the literature (Della and Hotza,
2006; Umamaheswaran and Batra, 2008), one of these volatile sub-
stances is phosphorus oxide, which is present in RHA according
to chemical analysis. Subsequently, two other exothermic events
were observed close to 800 and 900 ◦ C, respectively. Also in this
region, a mass loss of approximately 4% was observed. This mass
loss refers to the decomposition of the residual carbon present
in the RHA in the form of CO2 (Fernandes et al., 2017). Fig. 2(b)
shows the thermal behavior of CaCO3 . It was possible to observe
that CaCO3 presents an exothermic event around 700 ◦ C, associ-
ated with a mass loss of approximately 40%. This value is close to
the expected theoretical value of 44%wt for pure CaCO3 , and it is
assigned to release of CO2 (Fernandes et al., 2014).
It is worth emphasizing that a suitable firing temperature is crit-
ical to produce glass foams, because it is directly associated with
the viscosity of glass. Glass expansion is caused by the release of
decomposition gas from the pore-forming agents when it shows
suitable viscosity. It was possible to observe that the largest ther-
mal decomposition of the porogenic agents started after 600 ◦ C.
According to the literature (Arcaro et al., 2016; Souza et al., 2017;
Teixeira et al., 2017a), above this temperature glass particles are
softened. Thus, the gases are trapped in the glass matrix because of
the adequate viscosity, which favors the formation of closed pores
(König et al., 2015b) and, consequently, the production of glass
foams (Chen et al., 2011; Fernandes et al., 2009).
Fig. 3 shows optical microscopy images of the spheres obtained.
It is possible to observe that all spheres presented essentially
closed, well distributed porosity, without cracks. In all cases, large
pores surrounded by a few smaller ones can be observed.
Table 3 presents the mean and standard deviation values of
porosity, mean pore sizes, and compressive strength (␴) of the
obtained spheres. Porosity of the 4.8, 6.3 and 12.5 mm spheres
varied between 87 and 93%, that is, they are relatively similar.
This similarity occurs because the samples were obtained using
the same process parameters, differing only with respect to the
size of the spheres. Only a slight increase in porosity was found
with the size of the spheres, which may be associated with the
larger amounts of mass in these samples and, consequently, with
the formation of a larger number of pores. The spheres produced
show porosity values similar to those found in the literature and in
commercial products processed under similar conditions (Arcaro
80 F.A. da Silva Fernandes et al. / Process Safety and Environmental Protection 128 (2019) 77–84

Fig. 1. Process for concrete production with partial addition of glass foam.

Fig. 2. Differential thermal (DTA) and thermogravimetric (TGA) analyses of RHA (a) and CaCO3 (b).

Fig. 3. Optical microscopy images of glass foams with sphere sizes of (a) 4.8 mm, (b) 6.3 mm, and (c) 12.5 mm.

et al., 2016; da Silva et al., 2018; de Moraes et al., 2018; Pokorny
et al., 2011; Scheffler, 2005; Teixeira et al., 2017b; Zilli et al., 2015),
demonstrating the efficacy of the wastes used in addition to CaCO3
to produce glass foams. Pore size can define the application of the
glass foam. In this case, the pore sizes ranged from 1.2 to 2.3 mm.
Also in this case, no significant variation was observed because the
samples were submitted to the same process parameters. The pore
size values are in good agreement with Fig. 3, which shows the
closed porosity obtained. It is worth noting that the larger pores are
probably associated with the porosity formed by the decomposition
of CaCO3 , which occurs at a temperature in which the glass viscos-
ity facilitates expansion. On the other hand, smaller pores can be
originated from new pores that were nucleated by CO2 and did not
have enough time to grow. The mechanical compressive strength
of the glass foams with 12.5 mm was 0.51 ± 0.01 MPa (Table 3). As
the values of porosity and pore size were relatively similar, it is
assumed that glass foams with 4.8 and 6.3 mm have similar com-
pressive strength. The values of mechanical compressive strength
of the samples with 4.8 mm and 6.3 mm could not be obtained,
because the spheres have sizes much smaller than those indicated
by the standard (10 × 10 × 10 mm3 ). It should be emphasized that
commercial glass foams typically have compressive strength values
between 0.4 and 6 MPa for porosity values >70% (Scheffler, 2005).
Thus, the glass foam spheres obtained in this study meet the basic
requirements of commercial glass foams.
 F.A. da Silva Fernandes et al. / Process Safety and Environmental Protection 128 (2019) 77–84
Fig. 4. Variation of concrete slump according to glass foam concentration (10, 20,
and 30%) and particle size (4.8, 6.3, and 12.5 mm).
Glass foams have a wide range of applications because of their
unique properties, such as lightness due to high porosity, ther-
mal insulation, sound absorption, and anti-flammability. From the
standpoint of engineering materials, the properties of glass foams,
together with their satisfactory environmental results, indicate that
the material is ideal for use as aggregates in concrete.
Concrete workability is strongly influenced by consistency. Con-
sistency, in turn, is associated with characteristics inherent in
concrete itself, consistency of the mixture, and cohesion between
its components. For this reason, the natural coarse aggregates and
the glass foams produced have the same size (4.8, 6.3 and 12.5 mm).
Fig. 4 shows the results obtained in the slump tests (Slump %) with
respect to the concentration of glass foam in concrete (10, 20 and
30%) and particle size (4.8, 6.3 and 12.5 mm).
Results show that all samples with addition of glass foam had
their plasticity modified, favoring a greater or lesser concrete slump
in relation to the analyzed efforts, as well as concrete workability
without the need to adhere any plasticizers. Results also show that
the formulations with addition of 30% glass foam had the highest
values (Slump). The results for sphere sizes of 4.8, 6.3, and 12.5 were
98, 97, and 96%, respectively. For formulations with addition of 20%
glass foam, sphere sizes of 4.8, 6.3, and 12.5 mm obtained values
of 95, 94, and 93%, respectively. Regarding the formulations with
addition of 10% glass foam, sphere sizes of 4.8, 6.3, and 12.5 mm
showed values of 92, 91, and 90%, respectively. The control for-
mulation showed values of 88, 87, and 86% for coarse aggregates
with sizes of 4.8, 6.3, and 12.5 mm, respectively. Therefore, it can
be observed that the consistency behavior (slump) and workability
of concrete improve with increased concentration of glass foam in
the formulations.
The glass foams improved the slump results without the need
of adding any type of plasticizer due mainly to the reduction in the
concrete density with the partial substitution of the aggregates by
glass foams. With the lower mass density, the plastic viscosity of the
mass is also smaller, as is the yield stress (Molaei Raisi et al., 2018).
It is worth noting that vitreous foams have a low water absorption,
which is a positive factor for the slump. In addition, glass foam may
have influenced slump growth mainly because of its surface rough-
ness and the chemical interactions between aggregate particles and
cement paste (Afshinnia and Rangaraju, 2016).
The results of this study for slump and workability could only
be obtained because the glass foams do not absorb the water in
the concrete mixture. This characteristic of glass foams contributes
to a reduction in the cost of concrete, which does not require the
addition of plasticizing admixtures to improve its slump and work-
ability. Countries like India use addition of plasticizing admixture
81
Fig. 5. Density of concretes with increment of glass foam concentration with sphere
sizes of 4.8 mm, 6.3 mm, and 12.5 mm.
up to 2%wt of cement to achieve slump values between 25 and
50% (Sneha, 2018). In addition, a study reported concrete formu-
lations with addition of glass as aggregate in concentrations of
10, 15, and 20% with slump values of 23, 30 and 33%, respec-
tively (Afshinnia and Rangaraju, 2016). The literature presents
studies on concrete with addition of RHA in concentrations of 10,
20, and 30% that reported higher slump values: 20, 22, and 34%,
respectively (Oyetola and Abdullahi, 2006; Tsado et al., 2014). This
occurs because the higher the concentration of RHA in the con-
crete mixture, the greater the consumption of kneading water,
which harms concrete consistency and workability (Fapohunda
et al., 2017). This condition is also observed in concrete mixtures
with addition of aggregates from construction site waste - recycled
concrete aggregates (RCA) (Tangchirapat et al., 2008; Xiao, 2018).
Although concrete mixtures have different levels of slump loss, they
are within the tolerance limits (±10 mm) described in the ASTM:
C143/C143M-15a standard (ASTM C143M, 2015). It is worth men-
tioning that all tested samples received the same amount of water,
thus not influencing the results presented in this study. Therefore,
the glass foams did not compete in the absorption of knead-
ing water with the cement components during hydration/slump.
According to Marta Sánchez de Juan et al. (de Juan and Gutiérrez,
2009), water absorption for recycled aggregates can be between 3
and 10%, whereas it can be 5% for natural aggregates depending on
the particle size.
Fig. 5 shows the apparent density result at 28 days of the con-
crete samples in relation to the addition of glassy foam. It is verified
that the density (2380, 2285 and 2332 Kg/m3 ) in the control trait
is within the expected for all the samples. The results show that all
the samples with glass foams addition has a reduction in density (±
5–11%) in relation to the control. Moreover, an increase in the con-
centration of glass foams, decreased the density to values around
1700 kg / m3 ) as expected. These values are considered adequate
for lightweight concrete (Ali et al., 2018). The reduction of density
was motivated by the addition of voids within the cementitious
conglomerate, improving the microstructure of the transition zone
(ITZ) between the cement paste and the aggregate in concrete (Park
et al., 2016). The increase of the glassy foam by the concrete mass
together with the natural aggregates influenced directly the prop-
erties of the concretes (Gomes et al., 2015). On the other hand,
the size of the spheres had practically no influence on the density
results. The results demonstrated by the density of the concrete
with the addition of the vitreous foams show the existence of a
correlation with the resistance to compression and Slump. That is,
82 F.A. da Silva Fernandes et al. / Process Safety and Environmental Protection 128 (2019) 77–84
Fig. 6. Compressive strength gains after 3, 7, 28, 56, and 90 days with increment of glass foam concentration with sphere sizes of (a) 4.8 mm, (b) 6.3 mm, and (c) 12.5 mm.
concretes with lower density showed lower mechanical strength
and higher slump.
Compressive strength characterizes concrete according to its
structural use. Knowledge about the compressive strength of con-
crete is important when any material is used to replace raw material
(Sharma and Bansal, 2016). Fig. 6 shows the mechanical behavior
of concrete with respect to the influence of glass foam sphere size
(4.8, 6.3, and 12.5 mm), concentration (10, 20, and 30%), and cur-
ing time (3, 7, 28, 56, and 90 days). Studies have reported that all
samples with addition of glass foam show resistance gain over cur-
ing time (Modarres and Hosseini, 2014), demonstrating that curing
time has a prominent effect on compressive strength gain with
addition of glass foams. Loss in compressive strength was verified
when results obtained for samples with addition of glass foams
were compared with those of the control mixture. This loss was
expected because addition of aggregates produced with recycled
material in concrete reduces its compressive strength due to the
porosity of this material. The size and addition of glass foams con-
tributed to compressive strength reduction. The best results, at all
ages, were observed with 4.8 mm glass foams and 10% addition,
namely, 13 MPa after 3 days, 14 MPa after 7 days, 29 MPa after 28
days, 33 MPa after 56 days, and 38 MPa after 90 days. As for 6.3 mm
glass foams and 10% addition, results were as follows: 11 MPa at
3 days, 12 MPa at 7 days, 24 MPa at 28 days, 28 MPa at 56 days,
and 32 MPa at 90 days. Regarding 12.5 mm glass foams) and 10%
addition, the following results were found: 12 MPa after 3 days,
13 MPa after 7 days, 27 MPa after 28 days, 31 MPa after 56 days,
and 35 MPa after 90 days. In contrast, for 4.8 mm glass foams, addi-
tion of 20 and 30%wt showed loss in uniaxial compressive strength
between 25 and 45% for all samples analyzed. Concerning the other
glass foam sizes (6.3 and 12.5 mm), even greater reductions in com-
pressive strength were verified (25–90%). These results show that
the smaller the particle size of the glass foam added to the con-
crete mixture, the higher the compressive strength. This occurs
because smaller particles fill a larger number of pores in the con-
crete, reducing its porosity and increasing its uniaxial compressive
strength (Kralj, 2009; Vishwakarma et al., 2016). It is worth noting
that, even with the reduction of the mechanical strength of the sam-
ples tested with increasing glass foam particle sizes, the obtained
values are still within the allowed limits (Limbachiya et al., 2012).
Furthermore, the fact that addition of glass foams as aggregates
brings gains in the sense of obtaining a lighter concrete should be
taken into account. The decrease in mechanical strength may also
be associated with the smaller amount of mortar adhered to the
recycled aggregate (Yadav and Pathak, 2009). This decrease impairs
the formation of an interface transition zone, which in turn is asso-
ciated with the movement of moisture and the chemical reaction
in concrete with recycled aggregates (Yadav and Pathak, 2009).
The stronger the bond developed in the interface zone between
the matrix and the coarse aggregate, the greater the compressive
strength of concrete (Yadav and Pathak, 2009).
Concrete may show variation in compressive strength values
over the curing time depending on the type of aggregate used. Con-
crete mixtures with curing times of 7, 28, and 90 days showed
different respective compressive strength values for addition of
natural aggregates (32.8, 41.5, and 54.7 MPa), construction site
wastes (26.2, 32.6, and 46.5 MPa), and industrial wastes (29.9, 38.7,
and 55.00 MPa). These results support the efficiency of the glass
foams produced in this study and their influence on compressive
strength gain during the concrete curing process, enabling its use in
structural projects. According to Frondistou & Yannas (Frondistou-
Yannas, 1977), recycled aggregates showed compressive strength
between 4 and 14%. Hansen & Narud (Narud, 1993) reported com-
pressive strength values similar to those of concrete with natural
aggregates. These researchers concluded that addition of wastes to
concrete can range from 30 to 60%.
Moreover, the advantage of using glass foam produced with
soda-lime glass and RHA is the elimination of the expansion caused
by the alkali–silica reaction (ASR) between the highly alkaline
cement paste and the reactive amorphous silica found in many
common aggregates, given sufficient moisture. This expansion
occurs mainly in residual glass (Park and Lee, 2004). In the case of
glass foams used as aggregate, the non-expansion enables the con-
 F.A. da Silva Fernandes et al. / Process Safety and Environmental Protection 128 (2019) 77–84
crete application, in addition to making it environmentally friendly
(Xiao, 2018).
4. Conclusion
Glass foams were successfully produced by pelletization from
soda-lime glass and rice husk ash and added as partial substi-
tutes to concrete. The glass foams were produced in three different
sphere sizes (4.8, 6.3 and 12.5 mm), with porosity of 87% ±2, 89% ±2
and 93% ±2, pore sizes of 1.2 mm ± 1, 2.3 mm ± 1 and 1.5 mm ± 1,
and mechanical compressive strength values ranging from 0.51 to
0.56 MPa.
The characteristics and properties of the glass foams obtained
show that they can be used as partial substitutes for concrete aggre-
gates. Compressive strength and slump of the concrete showed the
best results with addition of glass foam in the smallest sphere size
(4.8 mm), although the values for the 6.3 and 12.5 mm particle sizes
were also satisfactory. The best results, at all ages, were obtained
with 4.8 mm glass foams and 10% addition - 38 MPa after 90 days.
The concrete produced in this study showed compressive strength
and slump (>90 mm) adequate to be used in small constructions
due to its workability, enabling its commercialization and pumping
from mixer trucks. Addition of the glass foams produced as aggre-
gate in concrete can contribute to mitigating problems resulting
from the disposal of glass and rice husk wastes in the environment;
furthermore, it improves the properties of concrete - when glass
foams were used in partial substitution to the aggregates, it was
possible to obtain a lighter concrete with excellent mechanical and
slump properties (density: 1678–1904 K g / m3 ; Slump> 90 mm and
compressive strength: 20–29 MPa) - making it a sustainable and
environmentally friendly product.
Acknowledgments
The authors are grateful to the National Council for Scientific
and Technological Development (CNPq), the Coordination for the
Improvement of Higher Education Personnel (CAPES), and the Sup-
port Program for Excellence Centers of the Foundation for Research
Support of the State of Rio Grande do Sul (PRONEX/FAPERGS) for
their financial support.
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