VELAMMAL ENGINEERING COLLEGE, CHENNAI

SPECIAL CONCRETES

DEPARTMENT OF CIVIL ENGINEERING

Paper Presentation on (DEPT.OF CIVIL ENGG)

Presented By,

SIVA KUMAR.R, SHANMUGAM.R,

(B.E-CIVIL ENGG)

PREPARED BY

R.SIVA KUMAR R.SHANMUGAM

VELAMMAL ENGINEERING COLLEGE, CHENNAI

SPECIAL CONCRETES

COLLEGE

VELAMMAL ENGINEERING COLLEGE SURAPET, CHENNAI-66

DEPARTMENT TOPIC EVENT COMPETITION

: : : :

B.E (CIVIL ENGINEERING) SPECIAL CONCRETES PAPER PRESENTATION NATIONAL LEVEL TECHNECAL SYMPOSIUM

Gazebo2k10
DATE OF SUBMISSION: 25-12-2010 PRESENTED BY : SIVA KUMAR.R SHANMUGAM.R

E-MAIL ID

thiaraa@rediffmail.com
trsiva92@gmail.com

CONTACT NO

Mr. Rajarajan, (civil dept lecturer) VELAMMAL ENGG COLLEGE

9884107703

CLASS

CIVIL-B

PREPARED BY

R.SIVA KUMAR R.SHANMUGAM

VELAMMAL ENGINEERING COLLEGE, CHENNAI

SPECIAL CONCRETES

CONCRETE Concrete is a composite construction material composed of cement (commonly Portland cement) and other cementious materials such as fly ash and slag cement, aggregate (generally a coarse aggregate made of gravels or crushed rocks such as limestone, or granite, plus a fine aggregate such as sand), water, and chemical admixtures. Concrete solidifies and hardens after mixing with water and placement due to a chemical process known as hydration. The water reacts with the cement, which bonds the other components together, eventually creating a robust stone-like material. Concrete is used to make pavements, pipe, architectural structures, foundations, motorways/roads, bridges/overpasses, parking structures, brick/block walls and footings for gates, fences and poles. Concrete is used more than any other man-made material in the world. As of 2006, about 7.5 cubic kilometers of concrete are made each yearmore than one cubic meter for every person on Earth.

SPECIAL CONCRETE
Special Concrete means the concrete used or made for special cases, such as:
PREPARED BY R.SIVA KUMAR R.SHANMUGAM

VELAMMAL ENGINEERING COLLEGE, CHENNAI

SPECIAL CONCRETES

Concreting in Hot Weather Concreting in Cold Weather

Frequently, concrete may be used for some special purpose for which special properties are more important than those commonly considered. Sometimes, it may be of great importance to enhance one of the ordinary properties. These special applications often become apparent as new developments using new materials or as improvements using the basic materials. Some utilize special aggregates (lightweight aggregate, steel fiber, plastic fiber, glass fiber, and special heavy aggregate). Some special properties increased compressive and tensile strength, water proofing, and improved chemical resistance are achieved with polymers, either as admixtures or surface treatment of hardened concrete. Admixtures for coloring concrete are available in all colors. The oldest and cheapest is perhaps carbon black. Admixtures causing expansion for use in sealing cracks or under machine bases, etc., include powdered aluminum and finely ground iron. Special admixtures are available for use where the natural aggregate is alkali reactive, to neutralize this reaction. Proprietary admixtures are available that increase the tensile strength or bond strength of concrete. They are useful for making repairs to concrete surfaces.

TYPES OF SPECIAL CONCRETE

There are different types of concrete. This difference is usually as a result of using different methods of preparation. The most common type of concrete is normal concrete. It is widely used Special types of concrete are those with out-of-the-ordinary properties or those produced by unusual techniques. Concrete is by definition a composite material consisting essentially of a binding medium and aggregate particles, and it can take many forms. Self-compacting - This type of concrete is characterized by excessive fluidity Super plasticizers are used to give it this quality. Sprayed - This type of concrete is cast using compressed air. It is in two forms - dry mix and wet mix. Dry mixed concrete is formed by using compressed air to shoot a dry mixture of cement and aggregates through holes. Water for hydration is added at the nozzle. Wet mix concrete is first hydrated then pumped through holes. To reinforce sprayed concrete, fiber is used. Tremmie is the type of concrete used for casting loads, columns and in areas where it is expected to flow into a particular area.

PREPARED BY

R.SIVA KUMAR R.SHANMUGAM

VELAMMAL ENGINEERING COLLEGE, CHENNAI

SPECIAL CONCRETES

Reinforced concrete is wrapped in iron rod mesh. This gives it capability to carry huge loads. It is the most versatile, being used in diverse applications. Chipping is results when concrete is passed between very small spaces to form stones of small sizes. Pump concrete is a special type prepared to be pumped from the roadside to the construction site. The amount of sand used to prepare it is more than that which is used when making normal concrete. It also requires more cement to attain the required strength. To make it smooth and wet, additional water is used.

Mortar - No sand is used when preparing this type of concrete. It is porous and requires water
to ensure that minimum paste stays at the bottom during placing.
Need for the special concrete? Why special concrete may be a needed? Uses and Application of Special Concrete

Special concrete is used in extreme weather. Good cohesiveness or sticky in mixes with very high binder content Some delay in setting times depending on the compatibility of cement, fly ash and chemical admixture Slightly lower but sufficient early strength for most applications Comparable flexural strength and elastic modulus Better drying shrinkage and significantly lower creep Good protection to steel reinforcement in high chloride environment Excellent durability in aggressive sulphate environments Lower heat characteristics Low resistance to de-icing salt scaling
STRUCTURAL LIGHTWEIGHT CONCRETE

Structural lightweight concrete is similar to normal weight concrete except that it has a lower density. It is made with lightweight aggregates or with a combination of lightweight and normal weight aggregates. The term sand lightweight refers to lightweight concrete made with coarse lightweight aggregate and natural sand. Structural lightweight concrete has an air-dry density in the range of 1350 to 1850 kg/m3 and 28-day compressive strength in excess of 17 MPa. Some job specifications allow air-dry densities up to 1920 kg/m3. For comparison, normal-weight concrete containing regular sand, gravel, or crushed stone has a dry density in the range of 2080 to 2480 kg/m3. Structural lightweight concrete is used primarily to reduce the dead-load weight in concrete members, such as floors in high-rise buildings.

PREPARED BY

R.SIVA KUMAR R.SHANMUGAM

VELAMMAL ENGINEERING COLLEGE, CHENNAI

SPECIAL CONCRETES

Structural Lightweight Aggregates

Structural lightweight aggregates are usually classified according to their production process because various processes produce aggregates with somewhat different properties. Processed structural lightweight aggregates should meet the requirement which includes: Rotary kiln expanded clays shales, and slates Sintering grate expanded shales and slates Pelletized or extruded fly ash Expanded slags Structural lightweight aggregates have densities significantly lower than normal-weight aggregates, ranging from 560 to 1120 kg/m3 compared to 1200 to 1760 kg/m3 for normal-weight aggregates.These aggregates may absorb 5% to 20% water by weight of dry material. To control the uniformity of structural lightweight concrete mixtures, the aggregates are prewetted (but not saturated) prior to batching.

Expanded clay

Synthetic lightweight aggregate

Most of normal weight aggregate of normal, weight concrete is natural stone such as limestone and granite. With the amount of concrete used keeps increasing, natural environment and resources are excessively exploited. Synthetic lightweight aggregate produced from environmental waste, like fly ash, is a viable new source of structural aggregate material. The use of lightweight concrete permits greater design flexibility and substantial cost savings, reducing dead load, improved cyclic loading structural response, longer spans, better fire ratings, thinner sections, smaller size structural members, less reinforcing steel, and lower foundation costs. Weight of lightweight concrete is typically 25% to 35% lighter but its strengths is comparable to normal weight concrete.

PREPARED BY

R.SIVA KUMAR R.SHANMUGAM

VELAMMAL ENGINEERING COLLEGE, CHENNAI

SPECIAL CONCRETES

CHARACTERISTICS OF THE AGGREGATE The quality of the green aggregate [in terms of crushing strength] was specified by a crushing strength test. The strength as measured by compressing the aggregate in a steel cylinder through a prescribed distance of 20 mm is 3.8 MPa. Results of the sieve analysis and water absorption of the aggregate at different time are given in Table.

Section of the lightweight aggregate

PREPARED BY

R.SIVA KUMAR R.SHANMUGAM

VELAMMAL ENGINEERING COLLEGE, CHENNAI

SPECIAL CONCRETES

PREFABRICATION USING LIGHTWEIGHT AGGREGATE CONCRETE The structural lightweight aggregate was used to develop pre-cast concrete elements for green construction. The mix proportion used is given in Table. Cement 420 Water 175 Sand 715 AC agg. (pre-wetted) 630 Admixture 1000 ml

Mix proportion of the green lightweight concrete (kg/m3).

Displays that a good workable fresh concrete for concrete casting. The slump of lightweight concrete measured 30 minutes after batching was 50 mm.

Highly workable fresh concrete Shows the protocol of finished lightweight concrete pre-cast faade.

PREPARED BY

R.SIVA KUMAR R.SHANMUGAM

VELAMMAL ENGINEERING COLLEGE, CHENNAI

SPECIAL CONCRETES

It is seen that the gross weight of the lightweight concrete faade achieved only 70% of the density of normal weight concrete with the same compressive strength.Also indicated the bonding between reinforcing steel and lightweight concrete is good. ADVANTAGES The following advantages are concluded for using lightweight concrete in prefabrication in building:           Reduce the dead weight of a faade from 5 tons to about 3.5 tons Reduce craneage load, allow handling, lifting flexibility with lighter weight Good thermal and fire resistance, sound insulation than the traditional granite rock Allow design and construction flexibility for larger prefabrication modules Allow maintenance flexibility with replaceable modules Factory production of module enhances quality of product Enhance speed of construction, shorten overall construction period Enhance green building construction, minimize wet trade on site Improve damping resistance of building Utilization of PFA in aggregate production resolves the waste disposal problems of ash and reduce the production cost of concrete

PREPARED BY

R.SIVA KUMAR R.SHANMUGAM

VELAMMAL ENGINEERING COLLEGE, CHENNAI

SPECIAL CONCRETES

Bonding between the steel bars and the lightweight concrete POLYMER M ODIFIED CONCRETE Portland cement concrete is one of the most versatile and cost-effective construction materials. The relative high cost of monomers had limited the commercial viability of certain polymer-modified concrete. The advancement in chemical admixtures and mineral additives has offered alternative solutions to overcome a range of those limitations. Certain polymer cement concrete and polymer concrete remain relevant. They offer unique solutions to a range of applications. Classifications There are three types of polymer-modified concrete: Polymer-impregnated concrete (PIC) is a hardened cement concrete impregnated with a monomer system that is subsequently polymerized in situ Polymer cement concrete (PCC) is a concrete with polymeric admixtures or a monomer system added to the fresh concrete. The monomer system is subsequently polymerised after the concrete has hardened, whereas the polymeric admixtures cure with the hardening concrete.

Polymer concrete (PC) consists of an aggregate mixed with a monomer or resin that is subsequently polymerized in situ Compressive strength 114 MPa Modulus of elasticity 33 GPa Modulus of rupture 17 MPa Flexural modulus of elasticity 35 GPa Specific gravity 2.40 REACTIVE POWDER CONCRETE A composite material & ultra high strength with mechanical properties. Mixture of fiber reinforced, super plasticized, silica fume, cement & quartz sand with very low water cement ratio. Quartz sand used instead of ordinary aggregate. Therefore increases compressive strength. COMPOSITION
PREPARED BY R.SIVA KUMAR R.SHANMUGAM

VELAMMAL ENGINEERING COLLEGE, CHENNAI

SPECIAL CONCRETES

It is composed of similar modulus of elasticity and size increasing homogeneity reducing differential tensile strain. The material having the largest particle size in RPC is the sand. The higher the density, the greater the strength & lower the permeability. Water cement ratio used in RPC ranges from 0.15 to 0.25 Strength more than 200MPa achieved, cured at 90 degree celsious. COMPONENTS WITH FUNCTIONS PARAMETERS Components Sand Cement Quartz powder Silica fume Steel fibers Superplasticiser

Function parameters Give strength to aggregate Binding material Maximum reactivity during heat-treating Filling the voids Improve ductility Reduce water binding

PROPERTIES OF RPC 1. COMPRESSIVE STRENGTH Higher compressive strength than HPC

PREPARED BY

R.SIVA KUMAR R.SHANMUGAM

VELAMMAL ENGINEERING COLLEGE, CHENNAI

SPECIAL CONCRETES

It is a factor linked with durability of material. Maximum compressive strength of RPC is approximately 200MPa.

2. FLEXTURAL STRENGTH Plane RPC possess high flexural strength than HPC By introducing steel fibers, RPC can achieve high flexural strength. 3. WATER ABSORPTION

4. WATER PERMEABILITY

PREPARED BY

R.SIVA KUMAR R.SHANMUGAM

VELAMMAL ENGINEERING COLLEGE, CHENNAI

SPECIAL CONCRETES

5. RESISTANCE TO CHLORIDE ION PENETRATION Increases when heat curing is done in concrete Heat cured RPC show higher value than normal cured RPC. 6. HOMOGENITY Improved by eliminating all coarse aggregates. Dry components for use in RPC is less than 600 micro meter.

7. COMPACTNESS: Application of pressure before and during concrete setting period. 8. MICROSTRUCTURE: Microstructure of the cement hydrate can be changed by applying heat treatment during curing. 9. MATERIAL DUCTILITY: Material ductility can be improved through the addition of short steel fibres. APPLICATION BENEFITS It has the potential to structurally compete with steel.

PREPARED BY

R.SIVA KUMAR R.SHANMUGAM

VELAMMAL ENGINEERING COLLEGE, CHENNAI

SPECIAL CONCRETES

Superior strength combined with higher shear capacity result in significant dead load reduction. RPC can be used to resist all but direct primary tensile stress. Improved seismic performance by reducing inertia load with lighter member. Low &non-interconnected porosity diminishes mass transfer, making penetration of liquid/gas non-existent. LIMITATIONS OF RPC
Least costly components of conventional concrete are eliminated by more expensive elements.

RPC replace steel in compression members where durability issues risk. So long term properties are not yet known.

PAPERCRETE
PaperCrete is essentially a type of industrial strength paper Mache made with paper and cardboard, sand and Portland cement. There are many varieties of PaperCrete possible. Essentially, the constituents when mixed in different proportions result in PaperCrete of varying properties. The basic constituents of PaperCrete are:
y y y y

Paper: usually waste paper such as used newsprint or cardboard. Aggregate coarse aggregate or fine aggregate such as sand may be used depending in the desired strength of the Paper Crete. Cement: it is used as a binder and used to provide strength and rigidity to the Paper Crete. Water

Pouring the Slurry into a Panel Mould

PREPARED BY

R.SIVA KUMAR R.SHANMUGAM

VELAMMAL ENGINEERING COLLEGE, CHENNAI

SPECIAL CONCRETES

A Mobile Mixer. Adding Cement to Paper and sand.

A tried combination is 60% paper, 20% sand and 20% cement. The method of making PaperCrete is very simple. The dry ingredients are mixed with water in a mixer to form slurry. The slurry is cast into blocks or panels and allowed to dry in the sun. When it hardens up, PaperCrete is lightweight (its 80 percent air), an excellent insulator (R 2.8 per inch), holds its shape even when wet, and is remarkably. And, since it contains paper fibers, it has considerable tensile strength as well as compressive strength. PaperCrete is suitable for making low cost homes with limited longevity and durability. It is also suitable for making community rooms, sale booths, storage rooms and dwellings for livestock. PaperCrete can also be used as a plaster. It can be sprayed on walls to give them good sound and heat insulating properties.

Pros of PaperCrete:
y y y y y y y

Raw materials are very inexpensive and freely available. Equipment used is relatively low-tech and inexpensive. Has high compressive strength. It has excellent heat and sound insulating properties. PaperCrete is light weight and can be used to make inexpensive roofing alternatives. PaperCrete is very workable and can be formed into different shapes such as blocks, panels and sheets with ease. It does not catch fire easily but smolders for hours.

Limitations of PaperCrete:
y y y y y y

Poor moisture resistance Susceptible to termite and mould Disintegrates when exposed to water for prolonged periods of time. Low longevity Expands and contracts frequently leading to cracks and buckling Poor tensile strength.

PREPARED BY

R.SIVA KUMAR R.SHANMUGAM

VELAMMAL ENGINEERING COLLEGE, CHENNAI

SPECIAL CONCRETES

PaperCrete is a recent technology and its use is limited to experimental and recreation use. PaperCrete when used in conjunction with more traditional building techniques has yielded positive and encouraging results.

PaperCrete Wall Panel

CONCLUSION

 It is a recent concrete method. In many countries this type of concrete is adopted in many structures.  It is compared with reinforced concrete or any other concrete method is more advantages and economical.
PREPARED BY R.SIVA KUMAR R.SHANMUGAM

VELAMMAL ENGINEERING COLLEGE, CHENNAI

SPECIAL CONCRETES

 As an engineer which method of constructing are more advantages and fully economic must be selected. And it is the duties for every engineer.

PREPARED BY

R.SIVA KUMAR R.SHANMUGAM