CATeCA Lightweight Concrete (CATe-con)

Floatable concrete (SG 0.9) in the water

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Pontoon which continue to float for over 10 years

Usage ① To reinforce of earthquake-resistance on current building [load alleviation on foundation] ・ earthquake-resistant wall ・ expansion of post and beam

② Expansion & extension of bridge floor

③ Any other

Light and strong ！

CATeCA Lightweight Concrete (CATe-con)

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Delivery form ① Mainly mixed by a dual mixer

　 Mixing ready-mixed concrete → Transport → Placement

This concrete is artificial lightweight aggregate concrete mixed with alternative aggregate such as conventional Super MESALITE and G-Light that on site by using a simple mixer.

② Mixed by a flat panel mixer or a lightweight portable mixer

　 Mixing pre-mixed concrete on site→ Placement

Compressive strength

Weight per unit volume Specific gravity 　 0.9 ・ 1.2 ・ 1.430N/mm2

CATeCACATeCA

CATeCA Lightweight Concrete (CATe-con)

CATeCA Lightweight Concrete properties rangeAny concrete performance can be designed tailored to user’s requirements, for example, concrete with compressive strength and air-dried specific gravity of 90(ρ0.9 ） , 120(ρ1.2 ） and 140(ρ1.4 ） that can be mixed on site with a flat panel mixer, more lightweight concrete with ρ0.7 by using a dual mixer, and lightweight high-strength concrete with a compressive strength of more than 60 N/mm2 with ρ1.2.

0

10

20

30

40

50

60

0.5 0.7 0.9 1.1 1.3 1.5 1.7 1.9 2.1

Co

mp

ress

ive

str

en

gth

N/m

m2

Lightweight Type ILightweight

Type II

Lightweight 150

For structures, civil engineering works and ultra-high rise curtain walls(CWs)

For Middle-to-high rise CWs

Lighter and stronger

Commercially-available product

ALC

Lightweight 80

Lightweight 150HS

A

Heat-insulating mortar

Air-dried specific gravity(kg/l)

Properties range accommodating a slab mixer

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Lightweight 100

CATeCA Lightweight Concrete Doc.1

Concrete properties

PhysicalityFloatable　lightweig

ht　80

Lightweight　100

Lightweight　100High　

strength

Lightweight　150

(Ref)Lightweight　Type　I

Air-dried　weight　per　unit　volume （ kg/ ㎥） 900 1200 1200 1500 1900

Strength

Design　criterion　（ N/ ㎟） 21 21 46 36 21

Compressive　strength（ N/ ㎟） 27 30 61 49 32

Bending　strength （ N/ ㎟） 2.3 3 6.2 4.5 4

Tensile　strength （ N/ ㎟） 1.6 2 3.5 2.9 2.8

●Properties of concrete mix for ready-mixed concrete plants that use a dual mixer

*Using Super MESALITE coarse aggregate, G-Light fine aggregate

Major application: Secondary products: Curtain walls, slope pressure receiving platesPontoon was constructed with Lightweight 80 in 1999: Placed in a ready-mixed concrete plant → Transported after hardenedFreezing and thawing resistance (cycles and relative dynamic elastic modulus) Lightweight 100: More than 95% at 300 cycles Lightweight 150: More than 98% at 300 cycles

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●“Lightweight 80” used for construction of a pontoon in 1999

Cement Admixture Fine aggregate Coarse aggregate

Water-reducing admixture Admixture

Early-strength cement Silica fume G-Light Super

MESALITE

High-functional air-entrained

(AE)

Acrylic emulsion

W/B(%)

Amount of binder (Kg) S/A(%) Flow (cm) Weight per

unit volume

34 380 54 42×42 0.9

Strength development of Lightweight 80

CATeCACATeCA

CATeCA Lightweight Concrete Doc.2

15

20

25

30

3days 7days 14days 28daysMaterial　age

　 (days)

Com

pre

ssiv

e s

tre

ng

th N

/mm

2

Early-strength

Blast furnace

●Durability of pontoon constructed using “Lightweight 80”

An ultra-lightweight concrete pontoon (a floating bridge) used for anchoring ships at Shimabara Port, Nagasaki (1999)

3 meters wide, 12 meters long and 1.2 meters high

High durability and weather resistance has been maintained for more than 10 years causing few cracks and water ingress (2010)

CATeCACATeCA

CATeCA Lightweight Concrete Doc.3

●Lightweight concrete used for renovation of sidewalk in Chuo-bashi, Fujiyoshida City (in July 2009)

Delivery Mixed by a dual mixer at a ready-mixed concrete plant → Transported for 20 minutes → Placed after 40 minutes

Target < ρ1.6, compressive strength > 46 N/mm2, bending strength >46 kg/cm2

Result ρ1.56, compressive strength: 68.3 N/mm2, bending strength: 65 kg/cm2 (material age: 28 days)

Agitatability Checked by using a small slope mixer

Just after agitation ρ1.48Flow 60×55 cm

Agitated ready-mixed concrete 15 minutes after shipmentWeight per unit volume: 1.528Measured flow, instead of slump: 50×47cmSlump became less than 10 cm about 45 minutes after shipment

A test sample taken about 45 minutes after shipmentAir-dried specific gravity: ρ ＝ 1.59 (material age: 1 day)

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CATeCA Lightweight Concrete Doc.4

Lightweight concrete used for renovation of sidewalk in Chuo-bashi, Fujiyoshida City (in July 2009)

Concrete transported from a concrete mixer by an unicycle was placed.

Finishing work of hardened concrete about 50 minutes after concrete shipment.

Fabrication of 20-cm length, 10-cm OD cylinders

About 45 minutes after concrete shipment

Compressive strength of test sample

34.6 N/mm2 (material age: 1 day)

68.3 N/mm2 (material age:28days)

Construction

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Lightweight concrete used for renovation of sidewalk in Chuo-bashi, Fujiyoshida City (in July 2009)

Compressive strength:（ 66+68+71 ） /3=68.3 Nmm2

The measured value in the picture below is 71 N/mm2.It is considered that measured values varied depending on the maximum strength of mixed materials, not target strength. No explosive fracture occurred because fiber-reinforced concrete was used.

Weight per unit volume: ρ=1.56(A 20-cm length, 10-cm OD cylinder after standard underwater curing)ρ =5.9562÷4=1.48905 according to the picture below.ρ =1.56, a measured value of a 20-cm length, 10-cm OD cylinder is used in this document. It is expected that ρ will be 1.55 or less after October.

Bending strength: 65kg/cm2

(Standard underwater curing)The effect of fiber reinforcement was shown.

Measured value of concrete with a material age of 28 days (measured on August 12, material age of 27 days)

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Lightweight concrete used for renovation of sidewalk in Chuo-bashi, Fujiyoshida City (in July 2009)

Test　items Results

Slump　(cm) 10.2

Weight　per　unit　volume　(kg/l)

1.59

Concrete　temperature　(℃) 16.0

Chloride　content　(kg/m3) 0.022

Mechanical　properties

Curing　methods

Material　age　of　test　samples　(weeks)

1　day 1 4 6 8 10 13 17 21 26 52

Compressive　strength(N/mm2)

Standard　underwate

r

20.7

47.7 51.8 52.2 55.2 53.0 56.4 54.7 55.3 56.5 59.2

Sealed 48.2 52.9 56.7 56.1 56.2 58.1 56.6 58.0 60.2 63.6

Air 49.5 59.5 59.2 59.2 59.0 58.7 55.5 57.4 58.5 59.0

Young　modulus(kN/mm2)

Standard　underwate

r

－

16.4 18.0 17.9 － － 18.9 19.2 19.3 19.0 19.5

Sealed 17.7 17.7 18.0 18.0 19.0 17.9 18.9 18.9 19.4 20.2

Air 17.1 17.4 16.9 － － 17.7 17.6 17.8 19.8 18.2

Bending　strength(N/mm2)

Standard　underwate

r

3.62

4.23 4.79 4.80 4.90 5.25 5.13 5.43 5.17 5.12 5.35

Sealed 3.41 2.90 2.86 3.03 3.08 3.04 3.83 3.32 3.85 3.86

Air 2.82 2.24 2.25 3.49 3.55 3.57 3.69 3.83 5.11 4.10

Tensile　strength(N/mm2)

Standard　underwate

r

1.93

3.46 2.86 3.68 3.07 3.42 4.04 3.66 3.85 3.73 3.79

Sealed 3.53 3.42 3.00 3.67 3.78 3.86 3.62 3.64 4.06 4.10

Air 3.26 3.18 3.04 3.67 3.76 3.74 3.24 3.74 3.36 3.34

←Table 1: Example of test results of fresh concrete for comparison

<Past test examples >

↓ Table 2: Example of strength test results (average of three test samples)

CATeCACATeCA

Lightweight concrete used for renovation of sidewalk in Chuo-bashi, Fujiyoshida City (in July 2009)

<Past test examples>

1.50

1.55

1.60

1.65

Fresh 1D 1W 4W 6W 8W 10W 13W 17W 21W 26W 52W

Air

-drie

d w

eigh

t per

uni

t vol

ume

(t/m

3 )

Material age

No.1

No.2

No.3

Average

Material　age　of　test　samples　(weeks)

Fresh 1　day 1 4 6 8 10 13 17 21 26 52

1

1.59

1.608

1.633

1.598

1.601

1.625

1.580

1.587

1.582

1.578

1.582

1.565

21.61

41.60

81.58

21.60

01.58

91.58

11.58

11.58

11.57

81.57

21.57

2

31.60

61.59

91.58

71.59

81.57

31.58

11.58

61.58

61.56

81.56

61.57

6

Average

1.59

1.609

1.613

1.589

1.600

1.596

1.581

1.585

1.580

1.575

1.574

1.576

↓ Table 3: Example of measured values of weight per unit volume

↑ Figure 1: Example of temporal changes of air-dried weight per unit volume (A 20-cm length, 10-cm OD cylinder)

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●Development of lightweight concrete for road repair works Measured values of weight per unit volume (ρ) and compressive strength

N/㎟

ρ=1.32

ρ=1.47ρ=1.48 ρ=1.60

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CATeCA Lightweight Concrete Doc.5