Comparative Study of Strength Parameters on Concrete Made Using Expanded Polystyrene Beads, Lightweight Expanded Clay Aggregate and Waste Iron Chips- A Review

Abstract

The demand for sustainable and cost-effective construction materials has accelerated the exploration of alternative aggregates to replace conventional coarse aggregates in concrete production. This review focuses on the comparative analysis of strength parameters in concrete produced using Expanded Polystyrene (EPS) beads, Lightweight Expanded Clay Aggregate (LECA), and waste iron chips. These materials offer promising advantages in terms of environmental sustainability, structural efficiency, and resource optimization. While EPS beads and LECA provide significant weight reduction and improved thermal insulation, waste iron chips enhance the density and potentially increase the compressive strength due to their metallic composition. This paper presents a detailed examination of existing studies to highlight the mechanical performance, workability, durability, and potential structural applications of concrete modified with these lightweight and waste-derived materials.

Introduction

The text reviews sustainable alternatives to conventional concrete by examining the use of Expanded Polystyrene (EPS) beads, Lightweight Expanded Clay Aggregate (LECA), and Waste Iron Chips (WIC) as partial replacements for natural aggregates. Since traditional concrete production heavily consumes natural resources and contributes to environmental degradation, lightweight concrete (LWC) has emerged as an effective solution by reducing structural dead load, improving thermal insulation, and enhancing sustainability without significantly compromising performance.

EPS beads significantly reduce concrete density and improve insulation and workability but cause a notable reduction in compressive, tensile, and flexural strength due to weak bonding with the cement matrix. As a result, EPS-based concrete is generally suitable for non-load-bearing and insulation applications. LECA offers a better balance between weight reduction and mechanical strength, providing good durability, fire resistance, and thermal performance, making it suitable for both structural and non-structural uses. Waste iron chips, derived from industrial machining processes, enhance compressive and flexural strength and toughness when used in controlled proportions, though issues related to corrosion, workability, and uniform dispersion must be addressed.

The literature indicates that hybrid concrete mixes combining lightweight aggregates (EPS or LECA) with waste iron chips can offset strength loss while maintaining reduced density. However, most existing studies focus on individual materials rather than their combined effects. Identified research gaps include the lack of standardized mix designs, limited long-term durability studies, insufficient large-scale and economic feasibility analyses, and minimal use of predictive modeling techniques.

The aim of the study is to comparatively evaluate the compressive, tensile, and flexural strength of concrete incorporating EPS, LECA, and WIC, either individually or in combination, and to identify optimal mix proportions that balance strength, weight reduction, durability, and sustainability. The research also seeks to assess workability, density, water absorption, and thermal insulation properties to determine the practical applicability of these eco-friendly concrete solutions in modern construction.

Conclusion

From the review of current literature, it is evident that the integration of alternative materials such as EPS beads, LECA, and waste iron chips into concrete can significantly influence its mechanical and durability characteristics. EPS beads are most beneficial for lightweight applications where thermal insulation is a priority, though their lower strength limits structural use. LECA offers a superior balance between weight reduction and mechanical strength, making it a promising substitute for conventional aggregates in both structural and architectural applications. Waste iron chips not only contribute to waste minimization but also enhance strength, particularly in compressive and flexural aspects, though careful mix design is necessary to prevent segregation and corrosion. Comparative studies highlight that hybrid mixes or the combination of these materials may offer optimal performance in terms of both sustainability and structural integrity. Future research should focus on long-term durability studies, corrosion behavior, life cycle assessment, and practical implementation strategies to further explore the feasibility of large-scale adoption. As construction practices shift toward greener technologies, such comparative evaluations serve as a critical foundation for engineering sustainable and high-performance concrete materials.

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Copyright

Copyright © 2026 Ms. Pragati P. Waghamare , Prof. Mayur M. Lohe . 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.