Structural Lightweight Concrete

Structural lightweight concrete uses Llight expanded clay aggregate as the aggregate material to cut weight, improve strength, and enhance the overall durability of precast concrete and ready-mix concrete. Let’s explore the benefits of structural lightweight concrete with ECA® now, and discuss it in further detail.

What Is ECA®? Explaining Light Expanded Clay Aggregate For Structural Lightweight Concrete

ECA® is a class of lightweight aggregates made from clay and is used as a lightweight construction material. Light-expanded clay aggregate is made in a rotary kiln, which is heated to a temperature of more than 1200°C.

This causes the light-expanded clay aggregate to form oval or round balls, and the gases within the clay expand and create thousands of tiny air bubbles within each ECA® pellet. The process of creating light-expanded clay aggregate can be fine-tuned to create ECA® of varying densities and sizes.

Light expanded clay aggregate is one of the best lightweight aggregates for use in ready-mix concrete and precast concrete, and has lots of benefits when used in structural lightweight concrete applications, especially when compared to other lightweight aggregates. Structural lightweight expanded clay aggregate’s cellular structure provides internal curing through water entrainment which is especially beneficial for high-performance concrete, internal curing improves the contact zone which mitigates microcracking. Let’s take a look at the benefits of choosing ECA®during the concrete mix design process now, and explore this lightweight construction material in further detail.

The Benefits Of Light Expanded Clay Aggregate In Ready-Mix & Precast Concrete

So, why is ECA® used by leading concrete contractors over other lightweight aggregates? Here are a few reasons it’s the preferred lightweight construction material for concrete mix design.

• The reduced overall weight of ready-mix concrete – One reason ECA® is so popular in concrete mix design is that it reduces the overall weight of ready-mix concrete during shipping and when casting structural lightweight concrete components.
   
• Lower cost for shipping precast concrete components – Just like with ready-mix concrete, using light expanded clay aggregate for precast concrete panels and components means lower overall weight due to how light ECA® lightweight aggregates are – reducing concrete contractor’s shipping costs and the complexity of shipping precast structural lightweight concrete components to job sites.
   
• Excellent insulation – ECA® is one of the best lightweight construction materials for insulation when building concrete panels and other elements. Its thousands of tiny air bubbles hold air, which helps provide better overall insulation properties. This is always something to consider during the concrete mix design process. With ECA®, buildings save lots of energy when heating and cooling, which allows for cost savings and the implementation of smaller, less complex HVAC systems in some cases.
   
• Improved soundproofing – Lightweight expanded clay aggregate also helps absorb sound, which can be very useful when using structural lightweight concrete and ready-mix concrete to create sound barriers around roads, industrial areas, or even in buildings. The shape and structure of ECA® help absorb sound and reduce the sound load on nearby areas.
   
• Lower overall dead loads – This is one of the biggest reasons that ECA® lightweight construction material is so popular with concrete contractors. When ECA® is used in concrete mix design, dead loads can be reduced up to 20-30% due to the strength and lightweight of ready-mix concrete using ECA®. This helps reduce the overall use of concrete and steel components, improves overall structural function, and provides a better overall load-bearing structure, especially in areas where earthquake-resistant buildings are important. It is possible to obtain concrete with variable densities between the limits indicated, with strength levels starting from 15 N/mm2 up to 70 N/mm2. This concrete can be made directly on-site, mixed in concrete mixing plants, or at the prefabrication plant. Pre-mixed concrete in bags is also available and is mostly used for smaller interventions, generally in restoration works.
   
• Freeze-thaw durability – Because clay absorbs very little water and ECA® contains thousands of tiny air bubbles, this helps insulate structural concrete components and improves freeze-thaw durability, which is often a top concern in outdoor concrete structures located in areas with cold winters.

ECA® Is An Ideal Aggregate For All Structural Concrete Applications

For all of the above reasons and many more, concrete contractors, architects, engineers, and other building professionals have begun turning to ECA® as their aggregate of choice when mixing structural lightweight concrete. With a reputable ECA® supplier for lightweight aggregates, the potential of light expanded concrete aggregate is nearly limitless. Discover more and see how ECA® can transform your next construction project.