Specialty Concrete High End Value Materials

High-Value Concrete

All concrete is high value!

Cost of material (small) Cost of placement (significant) Cost of Replacement (HIGH)

High-Value Concrete

High-Value Concrete

High value generally associated with High-Performance

What is High-Performance?

High-Early Strength Concrete

High-Strength Concrete High-Durability Concrete Self-Consolidating Concrete Reactive Powder Concrete

High-Value Concrete

Characteristics of HighPerformance Concretes

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-Value Concrete

Characteristics of HighPerformance Concretes

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

High-Value Concrete

Materials Used in HighPerformance Concrete

Material Portland cement Blended cement Fly ash / Slag / Silica fume Calcined clay/ Metakaolin Cementing material / Durability / High strength Flowability Reduce water-cement ratio Primary Contribution/Desired Property Cementing material / Durability

Calcined shale
Superplasticizers High-range water reducers

Hydration control admix.

High-Value Concrete

Control setting

Materials Used in HighPerformance Concrete

Material Retarders Accelerators Corrosion inhibitors Water reducers Shrinkage reducers ASR inhibitors Optimally graded aggr. Primary contribution/Desired property Control setting Accelerate setting Control steel corrosion Reduce cement and water content Reduce shrinkage Control alkali-silica activity Improve workability/reduce paste Durability

Polymer/latex modifiers
High-Value Concrete

Selected Properties of HighPerformance Concrete

Property
High Strength H-E Comp. Strength

Test Method
ASTM C 39 ASTM C 39

Criteria that may be specified

70-140 MPa @ 28 to 91 days 20-30 MPa @ 3-12 hrs or 1-3 days

H-E Flex. Strength

Abrasion Resistance Low Permeability

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

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-Value Concrete

High Mod.of Elast.

High-Early-Strength Concrete

High-early compressive strength

ASTM C 39 (AASHTO T 22) 20 to 28 MPa (3000 to 4000 psi)

at 3 to 12 hours or 1 to 3 days

High-early flexural strength

ASTM C 78 (AASHTO T 97) 2 to 4 MPa (300 to 600 psi) at 3 to 12 hours or 1 to 3 days

High-Value Concrete

High-Early-Strength Concrete
May be achieved by

Type III or HE high-early-strength cement

High-Value Concrete

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

High-Early-Strength Concrete
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

High-Value Concrete

High-Strength Concrete

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)

High-Value Concrete

High-Strength Concrete Materials

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)

High-Value Concrete

High-Strength Concrete Materials

Supplementary Cementing Materials

Fly ash, silica fume, or slag often mandatory

Dosage rate 5% to 20% or higher by mass of cementing material.

High-Value Concrete

High-Strength Concrete Materials

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:

High-Value Concrete

w/cm 0.30air required w/cm < 0.25no air needed

High-Strength Concrete
Placing, Consolidation, and Curing

High-Value Concrete

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

High-Durability Concrete

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

High-Value Concrete

High-Durability Concrete
Durability Issues That HPC Can Address

Abrasion Resistance
Blast Resistance Permeability

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

High-Value Concrete

High-Durability Concrete
Confederation Bridge, Northumberland Strait, Prince Edward Island/New Brunswick, 1997

Cement: Fly ash: Silica fume: w/c: Water Red.: HRWR: Air: 91d strength:

398 kg/m3 45 kg/m3 32 kg/m3 0.30 1.7 L/m3 15.7 L/m3 5-8% 60 MPa

(671 lb/yd3) (76 lb/yd3) (72 lb/yd3) (47 oz/yd3) (83 oz/yd3) (8700 psi)

High-Value Concrete

Self-Consolidating Concrete
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

High-Value Concrete

Strength and durability same as conventional concrete

Self-Consolidating Concrete

High-Value Concrete

SCC for Power Plant in PennsylvaniaMix Proportions

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) (35 oz/yd3)

Superplasticizer ASTM C 494, Type F (Polycarboxylate-based) 1.3 L/m3 High-Value Concrete

AE admixture as needed for 6% 1.5% air content

Reactive-Powder Concrete (RPC)

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

High-Value Concrete

Mechanical Properties of RPC

Property
Compressive strength Flexural strength Tensile strength Modulus of Elasticity Fracture Toughness Freeze-thaw Carbonation Abrasion
High-Value Concrete

Unit
MPa (psi) MPa (psi) MPa (psi)

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

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

GPa (psi) 40 (5.8 x 106) 60 (8.7 x 106) 103 J/m2 <1 30 RDF 90 100 mm 10-12 m2/s 2 275 0 1.2

Reactive Powder Concrete

High-Value Concrete

uctal

Raw Material Components

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

High-Value Concrete

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

High-Value Concrete

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

High-Value Concrete

w/c = 0.20

No aggregates !