A novel process for producing light weight concrete structures with increased compressive
strength. This novel process can precisely control the size, quantity and distribution of air voids
to achieve a higher strength than any other traditional foam concrete.

Increased compressive strength with
reduced weight

Non-brittle and high capacity at large
strain/deformation

Precise control of properties through
design process

Increased energy adsorption during
loading
THE CHALLENGE
Traditional foam concrete is a cellular
material fabricated from either a cement
paste or mortar via the introduction of air
voids.
Formation of air bubbles in traditional foam
concrete is random and failure of the
material occurs due to bending of the crust
of these bubbles.
Concrete is weak under bending, so the
strength of traditional foam concrete is
heavily compromised. As a result, the
compressive strength of traditional foam
concrete decreases exponentially with a
reduction in density.
Although foam concrete is highly
appreciated in the construction industry for
its light weight and good thermal properties,
the low strength substantially limits their
application as a load bearing construction
material.
There is an increasing industrial need for
light weight concrete materials that can
sustain high levels of compressive strength.
THE TECHNOLOGY
Monash researchers have invented a
process for precisely controlling the shape,
size and distribution of air voids within
concrete structures. The result is increased
compressive strength whilst simultaneously
reducing weight, giving a foam concrete
that meets the need for strength combined
with light weight.
To achieve the precise control of the pore
properties, three-dimensional micro-frames
are covered with specific cement paste
mixtures. Surface tension of the cement
paste aligns it into sheets in the direction of
the micro-frame lattice. This results in
highly aligned, thin-walled concrete
sections of almost any shape (see Figure
1). The micro-frames are specially
designed based on desired properties of
the final product.
Structures have been produced with a
compressive strength of up to 7.5MPa
whilst simultaneously having a dry density
of 445kg/m3.
Figure 1: High-strength light-weight structured
concrete column produced with precise control of
pores sizes, structures and distributions. This
column measures 22x 25x21 mm, weighs ~6g and
can support a compressive load of 0.5 ton.
The strength of these types of columns is
demonstrated in Figure 2.
Structures produced using this process
have shown non-brittle failure, providing
increased safety over existing lightweight
concretes.
During compression testing the columns
shown in Figure 1 are stable, and maintain
~ 80% of their capacity at more than 50%
strain, which is not achievable using
existing lightweight concretes.
THE OPPORTUNITY
Figure 2: A column weighing only 6 grams carrying
the weight of an adult.
Monash seeks a partner to license this
exciting new construction technology.
The Monash research team is led by
Wenhui Duan, ARC Futures Fellow –
Structural Engineering. Dr Duan and his
team at Monash Civil Engineering are
expert in cement and concrete composites.
KEY CONTACT
Jordan Thurgood
Commercialisation Officer
Monash Innovation
T: +61 3 9902 4363
E: [email protected]
CRICOS provider: Monash University 00008C
Produced by Monash Innovation: August 2016