Master Degree in Structures

High Performance & Self Compacted Concrete

Prepared By: Eng. Albushra Abdel-Bagi &Taha Elnour Isshage

Seminar In

Supervised By: Dr. Nadir M. Hassanain July 2010

3CaO.SiO2 C3S Dicalcium silicate 2CaO.SiO2 C2S Tricalcium aluminate 3CaO.Al2O3 C3A Tetracalcium aluminoferrite 4CaO.Al2O3.Fe2O3 C4AF C3S and C2S are responsible for the strength of hydrated cement paste

Tricalcium silicate

C3A is undesirable
is present in small quantities. Reacts very rapidly with water (flash setting) gypsum retards this provides early strength prone to sulphate attack

C4AF
dark in color with little cementing value forms due to iron oxide, a useful flux during the burning process.

Regular concrete High-strength concrete Stamped concrete High-performance concrete Self-consolidating concretes Vacuum concretes Shotcrete Pervious concrete Cellular concrete, Cork-cement composites Roller-compacted concrete

Glass concrete Asphalt concrete Rapid strength concrete Rubberized concrete Polymer concrete Geopolymer or green concrete Limecrete Refractory Cement Concrete cloth Innovative mixtures Gypsum concrete

It is also known as Reactive Powder Concrete (RPC) It is a high strength, ductile material formulated by combining portland cement, silica fume, quartz flour, fine silica sand, high-range water reducer, water, and steel or organic fibers

Concrete may be regarded as high performance for several different reasons: high strength, high workability high durability and perhaps also improved visual appearance.

How to recognize concrete structure with KALMATRON KFA?

Wash the surface with water and see the difference

Typical shrinkage cracks as a result of retarded structure forming process.

Intact surface of concrete with lowered shrinkage development.

High strength concrete (HSC) might be regarded as concrete with a strength in excess of 70MPa and such concrete can be produced as relatively normal concrete with a higher cement content and a normal waterreducing admixture. However ultra high performance concrete (UHPC) will more usually contain cement replacement materials and a high-range water-reducer (HRWR) or superplasticiser(SP) (different names for the same thing).

How High? Strengths of 150-200MPa were reported in several papers at a recent symposium How is it done? Using only fine sand as an aggregate, a high content of cement and silica fume, a high dosage of HRWR admixture plus steel fibres

In what kind of structures? Thin shell roofing (2cm thick) and bulb double and single tees were reported Both insitu and precast applications Flexural and tensile strengths also high, allowing omission of secondary reinforcement. Concrete in tees was generally selfcompacting

High early strength

High strength High modulus of elasticity High abrasion resistance High durability and long life in severe environments Low permeability and diffusion Resistance to chemical attack

High resistance to frost and deicer scaling damage Toughness and impact resistance Volume stability

Ease of placement
Compaction without segregation Inhibition of bacterial and mold growth

Material Portland cement Blended cement Fly ash / Slag / Silica fume

Primary Contribution/Desired Property Cementing material / Durability

Calcined clay/ Metakaolin

Calcined shale Superplasticizers High-range water reducers Hydration control admix.

Cementing material / Durability / High strength

Flowability Reduce water-cement ratio Control setting

Material Retarders Accelerators Corrosion inhibitors

Primary contribution/Desired property Control setting Accelerate setting Control steel corrosion

Water reducers
Shrinkage reducers ASR inhibitors Optimal graded Aggr.

Reduce cement and water content

Reduce shrinkage Control alkali-silica activity Improve workability/reduce paste

Polymer/latex modifiers

Durability

Property High Strength Comp. Strength Flex. Strength Abrasion Resistance Low Permeability

Test Method ASTM C 39 ASTM C 39 ASTM C 78 ASTM C 944 ASTM C 1202 AASHTO T 259/260 ASTM C 642 ASTM C 469

Criteria that may be specified 70-140 MPa @ 28 to 91 days 20-30 MPa @ 3-12 hrs or 1-3 days 2-4 MPa @ 3-12 hrs or 1-3 days 0-1 mm depth of wear 500 to 2000 coulombs

Chloride Penetration
Low Absorption

Less than 0.07% Cl at 6 months

2% to 5%
More than 40 GPa

High Mode of Elsti.

May be achieved by

Type III or HE high-early-strength cement

High cement content 400 to 600 kg/m3 (675 to 1000 lb/yd3)

Low water-cementing materials ratio (0.20 to 0.45 by mass)

Higher freshly mixed concrete temperature Higher curing temperature

May be achieved by

Chemical admixtures
Silica fume (or other SCM)

Steam or autoclave curing

Insulation to retain heat of hydration

Special rapid hardening cements

90% of ready-mix concrete 20 MPa - 40 MPa (3000 6000 psi) @ 28-d (most 30 MPa 35 MPa)

High-strength concrete by definition 28 day compr. strength 70 MPa (10,000 psi)

Aggregates

9.5 - 12.5 mm (3/8 - 1/2 in.) nominal maximum size gives optimum strength Combining single sizes for required grading allows for closer control and reduced variability in concrete For 70 MPa and greater, the FM of the sand should be 2.8 3.2. (lower may give lower strengths and sticky mixes)

Supplementary Cementing Materials

Fly ash, silica fume, or slag often mandatory Dosage rate 5% to 20% or higher by mass of cementing material.

Admixtures

Use of water reducers, retarders, HRWRs, or superplasticizers mandatory in high-strength concrete Air-entraining admixtures not necessary or desirable in protected high-strength concrete.

Air is mandatory, where durability in a freeze-thaw environment is required (i.e.. bridges, piers, parking structures)

Recent studies:
w/cm 0.30air required w/cm < 0.25no air needed

Placing, Consolidation, and Curing

Delays in delivery and placing must be eliminated Consolidation very important to achieve strength Slump generally 180 to 220 mm (7 to 9 in.) Little if any bleedingfog or evaporation retarders have to be applied immediately after strike off to minimize plastic shrinkage and crusting 7 days moist curing

1970s and 1980s focus on HighStrength HPC Today focus on concretes with high durability in severe environments resulting in structures with long life High-Durability HPC

Durability Issues That HPC Can Address

Abrasion Resistance
Blast Resistance Permeability

Carbonation
Freeze-Thaw Resistance Chemical Attack Alkali-Silica Reactivity Corrosion rates of rebar

Properties of UHPC Compressive strengths up to 200 Mpa Flexural Strengths up to 50 Mpa Modulus of Elasticity 45 to 50 GPa Ductile strong Durable High bending tensile strength Low capillary porosity (high endurance) High resistance to deicing salt Greatly reduced permeability to moisture, chlorides and chemical attack Increased resistance to abrasion, erosion and corrosion

Properties of Concrete Compressive Strength 25 to 35 Mpa Relatively Weak Extremely Brittle Almost no tensile strength High thermal expansion and contraction with temperature fluctuations

Confederation Bridge, Northumberland Strait, Prince Edward Island/New Brunswick, 1997 Cement: 398 kg/m3 (671 lb/yd3) Fly ash: 45 kg/m3 (76 lb/yd3) Silica fume: 32 kg/m3 (72 lb/yd3) w/c: 0.30 Water Red.: 1.7 L/m3 (47 oz/yd3) HRWR: 15.7 L/m3 (83 oz/yd3) Air: 5-8% 91d strength: 60 MPa (8700 psi)

Scraper paths in treatment plants Architecture Bridges Narrow supports Filigree beams Thin or slab-like components Buttresses for high pressures

Self-consolidating concrete (SCC) also known as self-compacting concrete flows and consolidates on its own

developed in 1980s Japan Increased amount of

Fine material (i.e. fly ash or limestone filler)

HRWR/Superplasticizers

Strength and durability same as conventional concrete

Never pre-mix admixtures before adding them to the concrete The order and timing of admixture addition can be critical

When properties cannot be made by varying the composition of basic material To produce desired effects more economically Unlikely to make a poor concrete better Not a substitute for good concrete practice Required dose must be carefully determined and administered

Check job specification Use the correct admixture

never use one from an unmarked container. keep containers closed to avoid accidental contamination.

Add the correct dosage.

avoid adding 'a little bit extra' use a dispenser wash thoroughly at the end the day

Best if added to the mixing water Manufacturer's recommended dosage is usually adequate Trial mixes are important to determine most effective dosage

Self-compactability Avoidance of bleeding and segregation Low shrinkage Low permeability Strength as needed

Less dependent on skill on site Safer, quieter sites (no vibration) Better appearance Better durability Strength as needed

Segregation resistance from mortar viscosity, not aggregate grading Workability through admixtures, not water content

 Higher

cost especially if high strength not needed Plant control has to be better

My guess is that 50% of concrete will be self-compacting within 10 years In USA a very large proportion of precast concrete is already SCC

Paste Viscosity! Attained by one of three means: High cement content High content of Fly Ash, Silica Fume etc Use of Viscosity Modifying Admixture Plus low water content using HRWR

Reduces the total mass of the structures. Ability to have more additional floors. Less sections dimensions. Long Spans can be adopted in buildings. Less deflection can be achieved. High rise building high resistance to earth quake. Overcoming hot weather concreting problems.

Cost of HSC may be almost Doubled compared to Ordinary Strength Concrete. This High cost is offset by high building performance and less durability problems. For High rise building this extra cost accumulates to less than 20% of the skeleton cost. Cost of Quality control inceases to 50% than the usual concrete works.

Measuring spread rather than height plus: Speed of flow outwards Ability to pass through J-ring Observation of edge during flow Interesting to note that it works better with the cone upside down!

Portland cement (Type I)

297 kg/m3

(500 lb/yd3)

Slag cement
Coarse aggregate Fine aggregate Water

128 kg/m3
675 kg/m3

(215 lb/yd3)
(1,137 lb/yd3)

1,026 kg/m3 (1,729 lb/yd3) 170 kg/m3 (286 lb/yd3)

Superplasticizer ASTM C 494, Type F (Polycarboxylatebased) 1.3 L/m3 (35 oz/yd3) AE admixture as needed for 6% 1.5% air content

Properties:
High strength 200 MPa (can be produced to 810 MPa) Very low porosity Properties are achieved by: Max. particle size 300 m Optimized particle packing Low water content Steel fibers Heat-treatment

Property Compressive strength Flexural strength Tensile strength

Unit MPa (psi) MPa (psi) MPa (psi) GPa (psi) 103 J/m2

80 MPa 80 (11,600) 7 (1000)

RPC 200 (29,000) 40 (5800) 8 (1160)

Modulus of Elasticity
Fracture Toughness Freeze-thaw Carbonation Abrasion

40 (5.8 x 106) <1

60 (8.7 x 106) 30

RDF
mm 10-12 m2/s

90
2 275

100
0 1.2

uctal

Raw Material Components

Cement Sand Silica quartz Silica fume Micro-Fibres - metallic or poly-vinyl acetate Mineral fillers - Nano-fibres Superplasticizer Water

uctal

What is the typical Ductal mix ?

Cement

710 kg/m3
230 kg/m3 210 kg/m3

Silica fume
Crushed Quartz Sand Fibres

1020 kg/m3

40 - 160 13 kg/m3 140 kg/m3

kg/m3

Superplasticizer Total water

No aggregates !

uctal

What is the typical Ductal mix ?

Cement

28 - 30%
9 10% 8.5 9%

Silica fume
Crushed Quartz Sand Fibres

42 43%

1.7 6.5% 0.6% 5.5 6%

Superplasticizer Total water

w/c = 0.20

No aggregates !

Use concrete materials and proportions with satisfactory records in hot weather Use cool concrete Use a concrete consistency that permits rapid placement and effective consolidation Transport, place, consolidate, and finish with least delay Protect concrete against moisture loss at all times, during placement and curing period

Special Mixes in Khartoum Al-Riyadh Almashtel and Burri Durrat Alneel

Portland cement (Type I) Slag cement Coarse aggregate Fine aggregate 450 kg/m3 0.00 kg/m3 1050 kg/m3 760 kg/m3

Water

160 kg/m3

Superplasticizer ASTM C 494, Type F (Polycarboxylatebased) 6.0 L/m3

AE admixture as needed for 6% 1.5% air content

W/C = 0.36

Concrete Strength = 56N/mm2

Higher w/c = higher slump, workability