Replacement of Coarse Aggregate with Expanded Polystyrene Beads to Achieve Lightweight Concrete

Abstract

In this study, we explore how replacing traditional coarse aggregates with Expanded polystyrene (EPS) beads can enhance the properties of concrete. Lightweight concrete is valued in construction for its reduced self-weight, which eases handling and reduces load on structures, as well as for its superior thermal insulation and soundproofing qualities. By integrating EPS beads, which are known for being light and insulating, we aim to push these benefits even further. Concrete has to be designed based on density factor to accomplish reduction of the concrete self- weight with is ranging from 2000kg/m3 to 990kg/m3 total volume of EPS 0-100% and water cement ratio 0.45 Structural self-weight is quite important it shows a maximum portion of the load details. The main aim is to design EPS lightweight concrete according to standard concrete mix proportion. This mix proportion includes replacement of the conventional coarse aggregate by Partially or complete part with EPS beads, which ensures concrete workability and density. To study the properties of concrete like workability, compressive strength, Split tensile strength and Flexural strength test with partial replacement of course aggregate with expanded polystyrene beads EPS in concrete. Various test was conducted for fresh and harden concrete to know physical and mechanical properties of concrete at age of 7, 14 and 28days. Green construction is becoming a more important global problem and a key approach to conserve biodiversity and limit the amount of waste that ends up in landfills. To ensure the success of this investigation, coarse aggregate, cement, sand, water, and EPS beads with a diameter of not more than 10mm will be employed. In addition, four trial mixes must be made. The outcome indicates that increasing the quantity of EPS beads there will be decreasing strength of concrete with reduction in density. We can also Comparision strength for both conventional and lightweight concrete, which also makes us to the differentiate in cause of use.

Introduction

General Overview

Lightweight concrete made with Expanded Polystyrene (EPS) beads, fly ash, silica fume, and fibers improves strength, durability, insulation, and energy efficiency. Despite being lightweight, compressive strength can reach 2.5–20 MPa. EPS concrete is fire-resistant, eco-friendly, and seismically resilient, but not suitable for load-bearing structures. Applications include partition walls, precast panels, roofing, screeds, and void filling. Proper mix design and curing are essential for durability.

B. Expanded Polystyrene (EPS)

EPS is a closed-cell foam created by expanding polystyrene beads. Known for its low density (12–50 kg/m³), water resistance, and thermal insulation, EPS reduces concrete weight, improves insulation, and allows structural retrofitting. Replacing normal aggregates with EPS reduces structural mass and transport costs.

C. EPS Blending and Classification

EPS is produced from resin and steam, forming lightweight beads. Mechanical properties depend on density, classified by standards like IS 4671:1984 and ASTM C 578-95, with densities from 12 to 35 kg/m³. Higher density improves strength and insulation.

D. Scope and Objectives

This study investigates EPS as a replacement for coarse aggregate in concrete with a 0.45 water-cement ratio. Cubes and cylinders were tested at 7, 14, and 28 days to evaluate:

• Strength (compressive, tensile, flexural)

• Suitability in various building sections

• Thermal/sound insulation

• Density, durability, and mix behavior

II. Methodology

Six mix designs (M0 to M5) were created, with increasing EPS replacement (0% to 77%), targeting reduced density:

III. Materials Used

• Cement: OPC 53-grade, specific gravity 3.07

• Fine Aggregates: River sand, specific gravity 2.7

• Coarse Aggregates: Specific gravity 2.74

• EPS Beads: 98% air, non-biodegradable, strong insulation

• Water: Potable, compliant with IS specifications

IV. Material Properties

• Cement: Fineness 98%, Initial setting time 30 min, Final 210 min

• Fine Aggregate: Fineness modulus 2.32, Unit weight 1600 kg/m³

• Coarse Aggregate: Fineness modulus 6.62, Unit weight 1650 kg/m³

• Water: Within permissible limits (pH 7.6, low sulfate/chloride content)

V. Test Results and Discussion

1. Workability

• Slump Test: Higher EPS content slightly increases slump (from 85 mm to 97 mm).

• Compaction Factor: Lower for lightweight concrete (0.87 vs. 0.92 for normal).

2. Strength Tests

• Compressive Strength: Decreases with higher EPS content. Up to 10% EPS replacement maintains strength close to conventional concrete.

• Split Tensile Strength: Decreases with EPS, due to concrete’s brittle nature and lack of tensile strength.

3. Rebound Hammer Test

• Confirms destructive test results: compressive strength decreases as EPS increases.

4. Water Absorption

• Increases with more EPS (M5 showed 4.62% vs. M0 at 2.41%) due to increased porosity.

Conclusion

In the present work, an experimental investigation has been carried out on EPS LWC mixtures prepared with replacement of the conventional coarse aggregate with EPS beads. A study on the fresh concrete density as well as basic mechanical properties of the designed concrete was conducted. Based on the experimental results following conclusions are made. 1) EPS concrete Compressive strength increases with decrease in the replacements levels of the Expanded polystyrene beads Polystyrene can replace Polystyrene up to 10% without alternating the strength of concrete considerably. 2) The polystyrene we can achieve light-weight concrete. The density of concrete decreasing, the dead weight of the structure also by replacing the polystyrene we can achieve light-weight concrete. 3) Use of expanded polystyrene (EPS) beads in concrete can be you of the waste disposal method and one of the energy-saving method where EPS beads are completely replaces the aggregate. Hence, this type of LWC can be considered environmentally sustainable material for non-structural application. 4) EPS entails no complex production techniques and processes. Though, the most critical parameters in relation to producing EPS Light weight concrete to obtain a desired concrete quality is the order of dosage of mixture constituents and mixing process as well as the casting method. 5) Density of the concrete will reduce at maximum extent is about 990Kg/m3. 6) With an increase in the percentage of polystyrene replacement strength is decrease steeply compared to normal concrete. 7) The maximum strength (compressive, split tensile and flexural ) was attained at 10% of expanded polystyrene and was found to reduce for 30% of expanded polystyrene but it can be used for single floor building to make economical and to reduce the dead load. 8) The results reveal that all of the EPS Concrete, without the need of a specific bonding agent, has good workability and can be compacted and finished quickly. 9) The EPS particle size affects the flexural strength, primarily affecting the reduction of the effective cross-section flexural height. 10) The EPS beads have a closed cellular structure, increasing their volumetric proportion in the mixes decreases markedly the compressive strength

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Copyright

Copyright © 2025 M. Rama Manikanta, Ch. Srinivas, Bheesetti Yugeshwar Sai, Duvvuri Ganesh, Prince Kumar. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.