Module 5 Concrete Technology Dr Suryamani Behera
Concrete Technology
Module 5
Special concretes: Light weight aggregates – Light-weight aggregate concrete - Cellular
concrete - No-fines concrete - High-density concrete – Fibre-reinforced concrete - Polymer
concrete - Types of Polymer concrete - High-performance concrete - Self-compacting
concrete.
Module 5 Concrete Technology Dr Suryamani Behera
Lightweight aggregate concrete
Lightweight aggregate is a coarse aggregate used to make lightweight concrete for structural
as well as non-structural applications.
• The Compressive design strength of normal concrete for cast-in-situ, precast and
prestressed concrete ranges between 20 N/mm2 to 35 N/mm2. On the other hand, the
minimum compressive design strength of concrete which uses lightweight aggregate
will be around 17-18 N/mm2.
• Normal concrete has a density between 2300 and 2500 kg/m3. However, when it
comes to LWC the density ranges between 500 kg/m3 to 1800 kg/m3 depending on the
type of aggregate used.
• Lightweight concrete with densities lower than 17 N/mm2 falls under the category of
LWC. And, those with densities above 17 N/mm2 are referred to as structural
lightweight concrete (SLWC).
• LWC can also be designed for the minimum compressive strength as normal concrete
by varying the proportions of mineral admixtures used.
• SLWC is used for structural applications. They can be used along with reinforcement
steel just like normal concrete.
Features of Lightweight Aggregates
• The lightweight aggregate used in concrete may have any form, including cubical,
rounded, angular, and other shapes. Its workability is directly influenced by its form
and texture.
• These aggregates are known for absorbing little water and maintaining their low
density.
• A high saturation level makes it an attractive option for the internal curing of
concrete.
Module 5 Concrete Technology Dr Suryamani Behera
• LWA can reduce the dead loads on the structure and make it more economical.
• Has relatively low thermal conductivity and is preferred for roof insulations.
• Helps in consuming industrial wastes like blast furnace slag, fly ash, clinkers etc.
• Possess good acoustic properties.
Types of Lightweight Aggregates
Lightweight Aggregates can be divided into three types by their sources:
(1) Industrial waste lightweight aggregate – This is processed by industrial wastes,
such as fly ash, ceramisite, expanded slag ball, cinder and light sand, etc.
(2) Natural lightweight aggregate – This is made from natural porous stone, such as
pumice, volcanic cinder, and light sand, etc.
(3) Artificial lightweight aggregate – This is manufactured from local materials,
such as clay ceramisite, and expanded perlite, etc.
Lightweight Aggregate Concrete Applications
1. Screeds and thickening are made with lightweight aggregates. When the floor or roofs
need thickening or smoothing, it can be used to easily achieve it.
2. Can be applied to screeds and walls where the wood would be nailed together.
3. Casting structural steel in lightweight aggregate concrete can protect it from fire and
corrosion. Also, it can be used to cover architectural needs.
4. Can be used on roofs as a heat insulation material.
5. Used as insulation for water pipes.
6. Used to construct partition walls and panel walls in frame structures.
Difference between lightweight aggregate concrete and conventional concrete
Module 5 Concrete Technology Dr Suryamani Behera
Cellular Concrete
• Cellular concrete is a special engineered concrete manufactured by mixing Portland
cement, sand, fly ash, water and pre-formed foam in varied proportions to form a
hardened material having an oven-dry density of 50 pounds per cubic foot (PCF) or less.
• One of the important characteristics of specially formulated cellular concrete is the self-
compacting property wherein no compaction is required and it steadily flows out of a
pump outlet to fill the mould. Due to this property, it can be pumped over major height
and distances.
• This specially engineered concrete is also known as foam cement, foamed concrete, or
lightweight flow-able fill.
• The main constituent of the raw material of foam that is used in the production of
cellular concrete is Genfil and its organic substance. The size of the bubbles differs from
around 0.1 to 1.5 mm in diameter. The foam generator is employed to produce stable
foam by using an appropriate agent.
Module 5 Concrete Technology Dr Suryamani Behera
Types of Cellular Concrete Based on Density
Cellular concrete is differentiated into 3 types based on the range of density, which is
produced for different purpose.
1. High Density Cellular Concrete
This is a structural grade concrete having a density ranging from 1200kg/m3 to 1800 kg/m3.
It is used in the construction of load-bearing walls, and partition walls and in the production
of pre-cast blocks for load-bearing brickwork.
2. Medium Density Cellular Concrete
The density range of this cellular concrete is 800-1000 kg/m3. The major use of this type of
cellular concrete is found in the manufacturing of pre-cast blocks for non-load-bearing
brickwork.
3. Light Density Cellular Concrete
Light-density cellular concrete has a density in the range of 400 –600 kg/m3. LDCC is ideal
for thermal and sound insulations. They act as a resistance against fire accidents, termites and
moisture absorbent. They have also proved to be a better substitute than glass wool, wood
wool and thermocol.
Advantages of Cellular Concrete
1. Lightweight
The low-weight property of cellular concrete has a great advantage on building dead loads
and craning works.
2. Fire Resistance
The air pockets formed to act as a barrier to fire. The structure made of cellular concrete is
non-combustible and can endure fire breakout for hours.
3. Thermal Insulation
Cellular concrete acts as a perfect thermal insulator.
4. Acoustical Insulation
The low density increases acoustical insulation.
5. Environmental Friendly
Fly-ash-based cellular lightweight concrete is suitable for surrounding because fly-ash is one
of the by-products of industrial waste.
Module 5 Concrete Technology Dr Suryamani Behera
6. Cost-Efficient
Cost of the material used in concrete is reduced as the foam is introduced into the concrete.
Secondly, the use of industrial waste such as fly ash saves a considerable amount of
investment on cement products.
7. Other Advantages
Cellular lightweight concrete is also termite-proof and resistant towards freezing issues.
Applications of Cellular Concrete
1. Cellular lightweight concrete is utilized as thermal insulation in the form of bricks and
blocks over flat roofs or non-loading walls.
2. Bulk filling by applying relatively low-strength material for old sewer pipes, wells,
unused cellars and basements, storage tanks, tunnels and subways.
3. Production of heat-insulated light wall panels.
4. Maintain the Acoustical balance of concrete.
5. Manufacture cement and plaster-based light plate.
6. Production of special light heat-resistant ceramic tiles.
7. For soil water drainage purposes.
8. Application in the bridge to prevent freezing.
9. Utilized for tunnel and shaft filling and lightweight concrete manufacturing.
10. Production of Perlite plaster and Perlite lightweight concrete.
No-Fines Concrete
No-fines concrete is a lightweight concrete made up of only coarse aggregate, cement and
water by omitting fines (sand or fine aggregates) from normal concrete. Very often only
single-sized coarse aggregate, of size passing through 20 mm retained on 10mm is used. No-
fines concrete is becoming popular because of some of the advantages it possesses over
conventional concrete. The single-sized aggregates make good no-fines concrete, which in
addition to having large voids and hence light in weight, also offers an architecturally
attractive look.
Advantages of No-Fines Concrete
1. No fines concrete is a lightweight concrete i.e. density is about 25 to 30% less than
the normal concrete due to no fine aggregates, thus self-weight of structure is less.
2. As it does not have sands or fine aggregates, it has less drying shrinkage compared to
normal concrete
3. It has better thermal insulating characteristics than normal concrete and thus it is
useful for the construction of external wall.
Module 5 Concrete Technology Dr Suryamani Behera
4. As it has no fine aggregates, the surface area required for cement coating is reduced
considerably. So, quantity of cement required gets reduced per cubic meter compared
with normal concrete. So, it is economical.
5. Lightweight concrete has no effect on quality due to the segregation of coarse
aggregates as it has no fine aggregates. Thus, it can be dropped from heights.
6. No fines concrete can be compacted without the need for any types of concrete
vibrator and can be easily done by tamping with rods.
Limitations of No Fines Concrete
1. As there are no fine aggregates to fill the voids in this concrete, it has higher
permeability than normal concrete. Thus, it is not a good idea to construct reinforced
concrete with no fines concrete, as the reinforcement can easily get corroded.
2. To make this concrete impermeable, an extra coat of masonry plaster is required,
which increases the cost.
3. No fines concrete can not be tested for workability by using tests for normal concrete
such as slump or compaction factor tests. Values of workability and its test methods
are unknown.
High-Density Concrete
• High-density concrete is a concrete having a density in the range of 6000 to 6400
kg/cu.m.
• High-density concrete is also known as Heavy weight concrete.
• High-density concrete is mainly used for the purpose of radiation shielding, for
counterweights and other uses where high density is required.
• The high-density concrete has a better-shielding property, so it can protect harmful
radiations like X-rays, gamma rays, and neutrons.
• High-density aggregates are used to achieve heavy-weight concrete. Some of the
high-density aggregates are barite, ferrophosphorus, limonite, hematite, ilmenite,
magnetite, goethite, steel punchings, and steel shots.
Fiber Reinforced Concrete
Fiber Reinforced Concrete is a composite material consisting of fibrous material which
increases its structural integrity. It includes mixtures of cement, mortar or concrete and
discontinuous, discrete, uniformly dispersed suitable fibers. Fibers are usually used in
concrete to control cracking due to plastic shrinkage and drying shrinkage. They also reduce
the permeability of concrete and thus reduce the bleeding of water.
Advantages of Fiber-reinforced concrete
• Fibers reinforced concrete may be useful where high tensile strength and reduced
cracking are desirable or when conventional reinforcement cannot be placed
• It improves the impact strength of concrete, limits the crack growth and leads to a
greater strain capacity of the composite material
• For industrial projects, macro-synthetic fibers are used to improve concrete’s
durability. Made from synthetic materials, these fibers are long and thick in size and
may be used as a replacement for bar or fabric reinforcement
• Adding fibers to the concrete will improve its freeze-thaw resistance and help keep
the concrete strong and attractive for extended periods.
• Improve mix cohesion, improving pumpability over long distances
• Increase resistance to plastic shrinkage during curing
Module 5 Concrete Technology Dr Suryamani Behera
• Minimizes steel reinforcement requirements
• Controls the crack widths tightly, thus improving durability
• Reduces segregation and bleed-water
• FRC, toughness is about 10 to 40 times that of plain concrete
• The addition of fibers increases fatigue strength
• Fibers increase the shear capacity of reinforced concrete beams
Different Types of Fiber Reinforced Concrete
Following are the different type of fibers generally used in the construction industries.
1. Steel Fiber Reinforced Concrete
2. Polypropylene Fiber Reinforced (PFR) cement mortar & concrete
3. Glass Fiber Reinforced Concrete
4. Asbestos Fibers
5. Carbon Fibers
6. Organic Fibers
7. Natural Fibers
Module 5 Concrete Technology Dr Suryamani Behera
8. Cellulose Fibers etc.
Polymer Concrete
➢ Polymer concrete is a type of concrete that replaces cement with polymer as a binder.
Sometimes, the polymer is used in addition to Portland cement to form Polymer cement
concrete (PCC) or Polymer Modified Concrete (PMC).
➢ Polymer concrete composites have a unique combination of properties depending on the
formulation. These include
• rapid curing at ambient temperatures from –18 to +40°C (0 to 104°F);
• high tensile, flexural, and compressive strengths;
• good adhesion to most surfaces;
• good long-term durability with respect to cycles of freezing and thawing;
• low permeability to water and aggressive solutions;
• good chemical resistance; and
• lightweight.
Composition of Polymer Concrete
➢ Thermoplastic polymers are used in polymer concrete but mostly thermosetting resins
are used as the principal polymer component because of their high thermal stability and
resistance to a wide variety of chemicals.
➢ It contains aggregates that include granite, quartz, silica, limestone and other high-
quality materials. The aggregates used must be free from dust, and debris and it is of
good quality and must be dry. If these criteria are not fulfilled, it reduces the bond
strength between the polymer binder and aggregates.
Types of Polymer Concrete
1. Polymer Impregnated Concrete (PIC)
2. Polymer Concrete (PC)
3. Polymer Cement Concrete (PCC)
Polymer Impregnated Concrete (PIC)
Polymer impregnated concrete is mostly used polymer composite. It is a precast conventional
concrete that is cured and dried in an oven or by dielectric heating from which the air in the
open cell is removed by vacuum. Then a low-viscosity monomer is diffused through the open
cell and polymerized by using radiation, heat or chemical initiation.
Polymer Concrete (PC)
In Polymer concrete, aggregate is bound with a polymer binder instead of Portland cement as
in conventional concrete.
The main technique used in Polymer Concrete is to minimize the void volume in the
aggregate mass to reduce the quantity of polymer needed for binding the aggregates. This is
to be done by properly grading and mixing the aggregates to attain the maximum density and
minimum void volume. The graded aggregates are vibrated in a mould. The monomer is then
diffused up through the aggregates and polymerization is initiated by radiation or chemical
means. A Silone coupling agent is combined with the monomer to improve the bond strength
between the polymer and the aggregate.
Polymer Cement Concrete (PCC)
Polymer cement concrete is manufactured by mixing cement, aggregates, water and
monomers. The plastic mixture is then cast in moulds, cured, dried and polymerized.
The monomers that are used in PCC are Polyester-styrene, Epoxy-styrene, Furans,
Vinylidene Chloride, etc.
Properties of Polymer Concrete
Module 5 Concrete Technology Dr Suryamani Behera
1. Rapid curing: Curing effect is rapid at ambient temperature (–18 to +40°C). Polymer
concrete develops 70% strength after one day of curing at room temperature while the
conventional concrete gains only 20% strength of its 28-day strength in one day.
2. Strength: It has high tensile strength, flexural strength, compressive strength and
good abrasion resistance as compared to cement-concrete.
3. Good Adhesion: Good adhesion to most surfaces improves adhesion to the old
surface.
4. Durability: It gives good long-term durability of concrete with respect to cycles of
freezing and thawing action and chemical attack, as it reduces the intrusion of
chlorides and salts.
5. Low Permeability and Water Tightness: It is low permeable to water.
6. Lightweight: It produces lightweight concrete.
Advantages of Polymer Concrete
1. Polymer concrete is highly unaffected by freezing and thawing.
2. It has high compressive strength.
3. It has high impact resistance.
4. It has low permeability.
5. It can be applied in very thin cross-sections.
6. It reduces the intrusion of carbon dioxide, saving concrete from the carbonation and
hence loss of alkalinity.
7. It reduces shrinkage.
Disadvantages of Polymer concrete
1. It is very expensive
2. It requires high skill and precise work while mixing.
3. Chemicals used in polymer concrete can be risky, hence mask and hand gloves must
be used for skin protection.
Uses of Polymer Concrete
1. It is used in road construction.
2. It is used for nuclear power plant construction.
3. Used in kerbstones.
4. Used for prefabricated structural elements.
5. Used in precast slabs for bridge decks.
6. Used for waterproofing of buildings.
7. It is also used in sewage work.
8. It is used for irrigation works.
9. It is used in marine works.
10. It is used for prestressed concrete.
11. Used in electrical and industrial construction
High-performance concrete (HPC)
High-performance concrete (HPC) is concrete that has been designed to be more durable and,
if necessary, stronger than conventional concrete.
HPC mixtures are composed of essentially the same materials as conventional concrete
mixtures, but the proportions are designed, or engineered, to provide the strength and
durability needed for the structural and environmental requirements of the project.
High-strength concrete is defined as having a specified compressive strength of 8000 psi (55
MPa) or greater. The value of 8000 psi (55 MPa) was selected because it represented a
strength level at which special care is required for production and testing of the concrete and
at which special structural design requirements may be needed.
Difference between High-performance and High-strength concrete
Module 5 Concrete Technology Dr Suryamani Behera
Items High-Performance Concrete High-Strength Concrete
High-performance concrete is
defined as concrete meeting special
combinations of performance and
High-strength concrete is defined as
uniformity requirements that cannot
Definition concrete that has a compressive of 55
always be achieved routinely when
MPa or greater.
using conventional constituents and
normal mixing, placing and curing
practices, as per ACI Code.
Chemical resistant concrete, early
High-strength concrete (50 – 100
drying concrete, ultra-water
MPa), ultra-high Strength Concrete
Types resistant concrete, heat resistant
(100 – 150 MPa), especial Concrete (>
concrete, and impact and abrasion
150 MPa)
resistant concrete.
It has high strength but does not
Strength High strength, modulus of elastic, necessarily possess superior
criteria low creep and shrinkage characteristics as high-performance
concrete
Resist scaling, freezing and
Durability of high strength is
Durability thawing, chloride and carbonation,
commonly improved by adding
criteria and prohibit bacterial and mold
pozzolanic materials
growth
Low ductility but can be improved
Ductility It is brittle
by adding steel fibers
Cement, fine aggregate, coarse
aggregate, water, mineral
admixtures; fine filler and/or Cement, fine and coarse aggregate;
pozzolanic supplementary fine aggregates with higher fineness
Compositions
cementation materials, chemical modulus of around 3 is recommended,
admixtures; plasticizers, water, water reducing admixtures
superplasticizers, retarders, air-
entraining agents)
It is sensitive to changes in
constituent material properties,
Degree of High quality control is needed in order
hence great degree of quality
quality control to maintain the special properties
control is required for the successful
requirements desired.
production of high-performance
concrete.
High-performance concrete is High-strength concrete is achieved at
produced by careful selection of low water to cement ratio which is
Production of raw materials such chemical obtained by adding water reducing
concrete admixtures and appropriate mix plasticizer or high range water
design to achieve the desired reducing plasticizer. It is also essential
performance objectives. to select a high-quality Portland
Module 5 Concrete Technology Dr Suryamani Behera
cement, and optimize aggregates, then
optimize the combination of materials
by varying the proportions of cement,
water, aggregates, and admixtures.
Placement and Easy to pour and can be compacted Placement would not be easy unless
compaction without segregation. superplasticizer is used
Self-Compacting concrete
Self-compacting concrete (SCC) can be defined as fresh concrete that flows under its own
weight and does not require external vibration to undergo compaction. It is used in
construction where it is hard to use vibrators for consolidation of concrete. Filling and
passing ability, and segregation resistance are the properties of self-compacting concrete.
SCC possess superior flow ability in its fresh state that performs self-compaction and
material consolidation without segregation issues.
Materials Used for Self Compacting Concrete
Cement, aggregates, water, mineral and chemical admixtures
Tests and Properties of Self-Compacting Concrete
The requirements of the self-compacting concrete are achieved by the properties in its fresh
state. The three main properties of SCC are:
1. Filling Ability: This property of the concrete is the ability to flow under its own
weight without any vibration provided intentionally.
2. Passing Ability: This property is the ability of the concrete to maintain its
homogeneity.
3. Segregation resistance: This is the resistance of the concrete not to undergo
segregation when it flows during the self-compaction process.
Different tests are conducted to determine the above-mentioned properties of Self-
compacting concrete. The tests conducted for Self-compacting concrete can be categorized
into three categories:
1. Filling Ability Tests
2. Passing Ability Tests
3. Segregation Resistance Test
The tests coming under the above-mentioned categories are tabulated below.
Different Tests conducted on Self Compacted Concrete
Filling Ability Tests Passing Ability Tests Segregation Resistance Tests
Slump flow test L-Box Test V- funnel test at T5 minutes
Module 5 Concrete Technology Dr Suryamani Behera
T50cm Slump Flow J- ring test GTM screen stability Tests
Orimet U- Box Test
V-funnel Test Fill – Box Test
Advantages of Self-Compacting Concrete
The main advantages of self-compacting concrete are:
1. The permeability of the concrete structure is decreased
2. SCC enables freedom in designing concrete structures
3. The SCC construction is faster
4. The problems associated with vibration is eliminated
5. The concrete is placed with ease, which results in large cost-saving
6. The quality of the construction is increase
7. The durability and reliability of the concrete structure is high compared to normal
concrete structures
8. Noise from vibration is reduced. This also reduces the hand-arm vibration syndrome
issues
Disadvantages of Self-Compacting Concrete
SCC construction faces the following limitations:
1. There is no globally accepted test standard to undergo SCC mix design
2. The cost of construction is costlier than conventional concrete construction
3. The use of the designed mix will require more trial batches and lab tests
4. The measurement and monitoring must be more precise.
5. The material selection for SCC is more stringent
Applications of Self-Compacting Concrete
The major applications of self-compacting concrete are:
1. Construction of structures with complicated reinforcement
2. SCC is used for repairs, restoration and renewal construction
3. Highly stable and durable retaining walls are constructed with the help of SCC
4. SCC is employed in the construction of raft and pile foundations
