2.

13 SPECIAL CONCRETES
Low Cost Light Weight Heavy Weight Underwater Ultra High Strength Ultra Durable Architectural Low Noise Reduced environmental impact Fast setting Placing without formwork Bulk fill Self compacting

Low Cost
Cement replacement with PFA - also helps durability and workability. Cement replacement with GGBS - helps durability but may increase bleeding. Water (and cement) reduction with a water reducer - helps with durability. Cementitious content reduction with CSF do not do it.

2.13 SPECIAL CONCRETES

Low Cost Light Weight Heavy Weight Underwater Ultra High Strength Ultra Durable Architectural Low Noise Reduced environmental impact Fast setting Placing without formwork Bulk fill Self compacting

Light Weight
Light weight aggregate - some strength reduction, good thermal properties. Foamed concrete - very low strength. No-fines concrete Fig.2.13.1 Shows routes to producing light weight concrete and fig.2.13.2 shows the achievable densities.

Foamed concrete

Lightweight aggregates

Lightweight concrete and mortar

2.13 SPECIAL CONCRETES

Low Cost Light Weight Heavy Weight Underwater Ultra High Strength Ultra Durable Architectural Low Noise Reduced environmental impact Fast setting Placing without formwork Bulk fill Self compacting

Heavy weight (for shielding)

Heavy weight aggregate Steel shot - high cost and segregation.

2.13 SPECIAL CONCRETES

Low Cost Light Weight Heavy Weight Underwater Ultra High Strength Ultra Durable Architectural Low Noise Reduced environmental impact Fast setting Placing without formwork Bulk fill Self compacting

Underwater concrete
CSF - OK to use it for this - good cohesive mix. Non dispersal admixtures. Note that any concrete may be placed under water if precautions are used to avoid washout.

2.13 SPECIAL CONCRETES

Low Cost Light Weight Heavy Weight Underwater Ultra High Strength Ultra Durable Architectural Low Noise Reduced environmental impact Fast setting Placing without formwork Bulk fill Self compacting

Ultra high Strength

Superplasticisers (high range reducers) CSF In-situ de-watering (for slabs) Must have strong aggregate water

Ultra high performance concrete

Advantages of High Strength Concrete (HSC)

High durability (e.g. abrasion and carbonation resistance) High strength to weight ratio, particularly for lightweight HSC High early strength allows faster construction and formwork reuse Increased elastic modulus and lower creep Very tall buildings become feasible Lower column costs for concrete and steel Smaller columns allow for more floor space Box girder and solid girder bridge spans may be increased and designs simplified

Disadvantages of HSC
Increased cost per unit volume More stringent quality control of materials and construction needed CSF mixes may self-desiccate giving failure at day joints. Workability difficult to define and often declines rapidly with time after mixing Timing of concrete delivery and addition of admixtures becomes critical. High heat evolution may necessitate use of low heat binders (e.g. PFA) and cooling measures. Stiffness (modulus) does not increase in proportion to strength. More than 28 days may be required to reach specified strength Structural members may exhibit brittle failure. Use of HSC not covered by codes

2.13 SPECIAL CONCRETES

Low Cost Light Weight Heavy Weight Underwater Ultra High Strength Ultra Durable Architectural Low Noise Reduced environmental impact Fast setting Placing without formwork Bulk fill Self compacting

Ultra durable concrete

Ultra high strength with good curing Controlled permeability formwork Coated or stainless rebar Silanes or siloxanes (Glass fibre in surface)

Fragmentation resistance with glass fibre

2.13 SPECIAL CONCRETES

Low Cost Light Weight Heavy Weight Underwater Ultra High Strength Ultra Durable Architectural Low Noise Reduced environmental impact Fast setting Placing without formwork Bulk fill Self compacting

Concrete with good appearance (Architectural concrete)

Avoid plain surfaces Exposed aggregate: Surface retarded, Bush hammered, Worked before final set, Hand placed aggregate Board finish Brush finish Ribbed finish Imprints etc. White cement, pigments etc. Note that a highly textured surface may collect dirt and moss.

Needs a feature to hide colour change

Concrete with good appearance (Architectural concrete)

Avoid plain surfaces Exposed aggregate: Surface retarded, Bush hammered, Worked before final set, Hand placed aggregate Board finish Brush finish Ribbed finish Imprints etc. White cement, pigments etc. Note that a highly textured surface may collect dirt and moss.

Exposed aggregate finish

Concrete with good appearance (Architectural concrete)

Avoid plain surfaces Exposed aggregate: Surface retarded, Bush hammered, Worked before final set, Hand placed aggregate Board finish Brush finish Ribbed finish Imprints etc. White cement, pigments etc. Note that a highly textured surface may collect dirt and moss.

Board finish

Patterned board finish

Concrete with good appearance (Architectural concrete)

Avoid plain surfaces Exposed aggregate: Surface retarded, Bush hammered, Worked before final set, Hand placed aggregate Board finish Brush finish Ribbed finish Imprints etc. White cement, pigments etc. Note that a highly textured surface may collect dirt and moss.

Brush Finish

Concrete with good appearance (Architectural concrete)

Avoid plain surfaces Exposed aggregate: Surface retarded, Bush hammered, Worked before final set, Hand placed aggregate Board finish Brush finish Ribbed finish Imprints etc. White cement, pigments etc. Note that a highly textured surface may collect dirt and moss.

Profiled (ribbed) finish

Profiles to hide day joints

Deep profiles on wall

Ribbed (profiled) finished spoiled by unevenly applied mould release oil.

Concrete with good appearance (Architectural concrete)

Avoid plain surfaces Exposed aggregate: Surface retarded, Bush hammered, Worked before final set, Hand placed aggregate Board finish Brush finish Ribbed finish Imprints etc. White cement, pigments etc. Note that a highly textured surface may collect dirt and moss.

Imprinted concrete

Concrete with good appearance (Architectural concrete)

Avoid plain surfaces Exposed aggregate: Surface retarded, Bush hammered, Worked before final set, Hand placed aggregate Board finish Brush finish Ribbed finish Imprints etc. White cement, pigments etc. Note that a highly textured surface may collect dirt and moss.

White concrete (being cleaned)

Pigmented Concrete

Concrete with good appearance (Architectural concrete)

Avoid plain surfaces Exposed aggregate: Surface retarded, Bush hammered, Worked before final set, Hand placed aggregate Board finish Brush finish Ribbed finish Imprints etc. White cement, pigments etc. Note that a highly textured surface may collect dirt and moss.

2.13 SPECIAL CONCRETES

Low Cost Light Weight Heavy Weight Underwater Ultra High Strength Ultra Durable Architectural Low Noise Reduced environmental impact Fast setting Placing without formwork Bulk fill Self compacting

Low noise concrete for roads

Random grooves Exposed aggregate

2.13 SPECIAL CONCRETES

Low Cost Light Weight Heavy Weight Underwater Ultra High Strength Ultra Durable Architectural Low Noise Reduced environmental impact Fast setting Placing without formwork Bulk fill Self compacting

Concrete with reduced environmental impact

Cement replacements such as PFA or GGBS save 850kg of CO2 for every tonne of portland cement saved No-fines concrete is also known as "pervious" concrete and can reduce or eliminate run-off from roads and prevent flooding and pollution. A bright white concrete surface with GGBS will reduce the "heat island" effect of cities in hot climates. Magnesia or Alumina Cements to replace calcium silicate

Placing pervious concrete

Concrete with reduced environmental impact

Cement replacements such as PFA or GGBS save 850kg of CO2 for every tonne of portland cement saved No-fines concrete is also known as "pervious" concrete and can reduce or eliminate run-off from roads and prevent flooding and pollution. A bright white concrete surface with GGBS will reduce the "heat island" effect of cities in hot climates. Magnesia or Alumina Cements to replace calcium silicate

2.13 SPECIAL CONCRETES

Low Cost Light Weight Heavy Weight Underwater Ultra High Strength Ultra Durable Architectural Low Noise Reduced environmental impact Fast setting Placing without formwork Bulk fill Self compacting

Fast Setting Concrete for Precasting

Superplasticisers to reduce the water content are often as effective as accelerators. High temperature curing - but this can cause delayed ettringite formation Autoclaved concrete (high temperature and pressure) for rapid production but the hydration products are very different.

2.13 SPECIAL CONCRETES

Low Cost Light Weight Heavy Weight Underwater Ultra High Strength Ultra Durable Architectural Low Noise Reduced environmental impact Fast setting Placing without formwork Bulk fill Self compacting

Placing without formwork

Shotcrete Often used with fibres.

2.13 SPECIAL CONCRETES

Low Cost Light Weight Heavy Weight Underwater Ultra High Strength Ultra Durable Architectural Low Noise Reduced environmental impact Fast setting Placing without formwork Bulk fill Self compacting

Bulk Fill
Foamed concrete Controlled Low Strength Material (CLSM) is a flowable fill Below about 1MPa it can be re-excavated with a hydraulic excavator Can be made without cement

CLSM. Waste gypsum and steel slag (no cement)

2.13 SPECIAL CONCRETES

Low Cost Light Weight Heavy Weight Underwater Ultra High Strength Ultra Durable Architectural Low Noise Reduced environmental impact Fast setting Placing without formwork Bulk fill Self compacting

Self Compacting Concrete

Requires viscosity modifier to prevent segregation Reduces labour required Reduces noise Reduces risk of white-finger Costs about 30/m3 more