Method for the Mixing Design and Physical Characterization of Air-Foamed Lightweight Clay Concrete: A Response to the Issue of Recycling Dredged Sediments

From both economic and environmental points of view, the reuse of dredged sediments in the direct onsite casting of concrete represents a promising method for replacing sand. The aim of this study was to develop a cementitious material that (i) reuses the thin particles of sediments; (ii) has a low density due to the incorporation of air foam in the material; and (iii) achieves a minimum mechanical strength of 0.5 MPa for embankment applications. This study focused on the characterization of a non-standard “concrete”, which is a mixture of a synthetic soil (80% montmorillonite and 20% calibrated sand) and cement. To reduce its density, air foam was incorporated into the material during the manufacturing process (air-foamed lightweight clay concrete—AFLCC). The study results highlight that a density around 1.2 (unit: g/cm3/1 g/cm3) can be obtained. This density reduction can be obtained with a certain degree of workability when the material is in a fresh state. To obtain this workability, a certain amount of water must be added; however, the addition of water has a significant impact on the compressive strength of the AFLCC. As such, a mathematical equation correlating the compressive strength, the density, and the percentage of cement is proposed in this study. The mechanical strength results of the AFLCC at different times, in conjunction with the Vicat results, show that the porosity created by the air foam has the effect of slowing down the hydration mechanism of the cement. The porosities obtained are consistent with the density results. The characteristic radii indicate large pore sizes for formulations with low fluidity in the fresh state when air bubbles are incorporated.