Latest developments

i concrete
in
t admixtures
d i t

29th October 2008

Programme

Intro to concrete admixtures

Self-compacting concrete

History, testing, project references

Latest developments in SCC
Questions
Q

Introduction to
concrete admixtures

29th October 2008

History of admixture developments

Concrete
performance

development of VEA
VEAs
s
Polycarboxylates

Hyperplasticiser

Polyacrylates
Naphthalenesulphonates

Superplasticiser
Plasticiser

Melaminesulphonates
Lignosulphonates
1950
Plastic
concrete

1970

1980
Rheoplastic
concrete

1990
Self compacting
concrete

2008

Admixture performance

Type

Typical dosage %
by weight of cement

% water
reduction

brand
name

Modified
Lignosulfonate (MLS)

0.2 - 0.6

< 10

Pozzolith

Naphthalene
Sulfonate (BNS)

0.8 - 1.5

< 26

Rheobuild

Polycarboxylic ether (PCE)

0.5 - 1.3

> 40

Glenium

Flo
ow [%]

Performance of
plasticising admixtures

100
90
80
70
60
50
40
30
20
10
0

Polycarboxylate

Lignosulphonate
Melaminesulphonate
Naphthalenesulphonate
Polyacrylates

30

60

90
Time [min]

120

150

180

Self-compacting
concrete

29th October 2008

Contents

Why do we need it?

History & Definition of SCC
Testing
g
Opportunities & benefits
Job references / case studies
Next generation SCC

The problem
Inadequate & incomplete compaction dramatically lowers
the quality of concrete:
Greatly reduced strength (1% voids reduces 28 days strength by
more than 5%)
Lack of compaction of surface layer leads to poor durability
performance (durability closely associated with the permeability
of the surface layer of a concrete structure)
Poor appearance ((surface finish))
Cube results not representing actual castings
Inconsistent hardened properties (different permeabilities) in
various locations, enhancing the ingress of aggressive
substances.

FACTS

More than 90% of repair materials go to new construction

sites

Aboutt 100,000
Ab
100 000 tto 200
200,000
000 Dh
Dhs off repair
i materials
t i l are
consumed in a 40 story tower, on vertical elements alone.

On average,
average the cost of repairs (in materials only) adds about
20 to 30 Dhs/ m3 of concrete.

5 Million Dhs were consumed in a single project for repairs.

40% of consultants time and efforts dedicated to inspection of

repairs.
p

End of Service life : When you start making the first repair

The solution

Design the concrete mix so that

NO
external compaction is required !

What is SCC?

Definition:
highly flowable, yet stable concrete that can spread readily
into place and fill the formwork without any consolidation
and without undergoing
g g anyy significant
g
separation.
p
(by Khayat, Hu and Monty: Proc. 1st. Intl. RILEM Symposium, SCC, Stockholm 1999)

Flowing concrete without segregation and bleeding,

bleeding
capable of filling spaces and dense reinforcement or
inaccessible voids without hindrance or blockage.
(by EFNARC, Technical Committee, Self Compacting Concrete, London 2000)

Types of SCC

A. Powder type

Optimising the concrete structure

by increasing the fines (<100 m)
&
addition
of
a
Glenium
hyperplasticiser.

B. Viscosity
y type
y

Addition
of
a
Glenium
hyperplasticiser & a stabiliser VEA
(Viscosity Enhancing Admixture),
RheoMATRIX.

C. Combination type

Combination
of
a
stabilizer
with an increased quantity of fines in
addition to a Glenium hyperplasticiser
& RheoMATRIX.

The European Guidelines for

Self-Compacting Concrete
(Specification, Production & Use)

In order to enhance the acceptance of SCC a joint project group

consisting of :

BIBM (European Precast Concrete Organisation),

CEMBUREAU (European Cement Association),
ERMCO (European Ready
Ready-mix
mix Concrete Organisation),
Organisation)
EFCA (European Federation of Concrete Admixture Association) and
EFNARC (European Federation of Specialist Construction Chemicals
and Concrete Systems)

Published the "European Guidelines for Self-Compacting

Concrete in 2005.

EN206-9 & EN12350-8 to 12

Test Methods

Characteristic

Test method(s)

Flowability and filling ability

Slump-flow test (EN12350-8)

Viscosity

T500 Slump-flow test or V-funnel test

(EN12350 8 or 9)
(EN12350-8
L-box test (EN12350-10)

Passing ability
Segregation

Segregation (sieve) stability test

(EN12350-11)

Consistence classes

Slump-flow
Class

Slump-flow in mm

SF1

550 to 650

SF2

660 to 750

SF3

760 to 850

Viscosity

V-Funnel Time (s)

Class
VF1

<9

VF2

9 to 25

SCC vs. high

g slump
p concrete

Fill Box
Normal Concrete
(high slump, 200 mm+)

Fill Box
B
SCC

Testing SCC

Where can SCC be used?

Piles
Columns
Beams
Slabs
Precast
Rafts
Heavily reinforced elements
Areas of limited access
Anywhere that concrete is required !

SCC Project
j
References

29th October 2008

SCC Project References

1st SCC pour in the

UAE
February 2001

DXB International Airport,

T
Terminal
i l3

Why SCC?

- The main contractor was looking for means to enhance his work
programme and for early completion of the project.
- Reduction in concrete repairs was also another aim.
Cylinder strength
45/20
60/10
80/20

No. of columns
180
62
78

Volume
2,500
2
500 m3
3
2,000 m3
2 500 m3
2,500
7,000 m3

Advantages Offered:

Speed of construction: The use of SCC reduced the columns

casting
ti cycle
l from
f
7 days
d
(original
( i i l design
d i
to
t castt in
i 3 layers),
l
)
to one day.

No remedial works required, therefore additional savings in

manpower and materials.

The client was sure of the high quality and durability of the
columns.

Marina Heights Tower-Dubai

Basement walls

Consultant:

RMJM

Contractor:

Dutco Const.Co.

Grosvenor House Hotel

Transfer beams (heavily reinforced)

C
Consultant:
lt t

A h
Archon

Contractor:

Nasa Multiplex

Sewage Treatment Plant

Emirates Hills

Pump inlet

Palm Jumeirah
Sewage Treatment Works

Consultant:

Ace Consultants

Contractor:

Target Engg.

SCC pumped from the side walls and flowing

upwards.
upwards

Consultants: De Leuw Cather Intl

Int l
Contractor: Al Muheiry

SCC raft

12,500m3 (3 pours of 2,300m3 + 1 pour of 5,600m3)

Current status

SCC raft pour

Value EngineeringEngineering
Summary:
To RMC

To Contractors

To Clients/Engineers

Efficient Fleet Utilisation.

Speed of construction

Early completion.

Less wear & tear on

equipment.
q p
(concrete pumps)

Less wear & tear on

Equipment.
q p

Enhanced durability,
extended service life.

Optimisation & reduction of

manpower

Design benefits
(on elements sizes).

Savings in repair costs

Noise reduction &

Market Differentiation.

environmental benefits
benefits.
Savings in vibrators
cost

The next g
generation of
self-compacting concrete

29th October 2008

Smart Dynamic Concrete (SDC)

For a new generation of highly fluid concretes

Solving the dilemma

Cost
effectiveness

Objective
Obj
ti off the
th project
j t
was to develop SCC
mixes with cement
contents of 350- 400 kg/m3
so as to be used in normal
ready mixed concrete
concrete.

Selfcompaction

SelfCompacting
Concrete (SCC)

Traditionally
Vibrated
Concrete (TVC)
Robust mix
Low stickiness
Good price

Robustness

No vibration

SDC

High speed
Great surface

Fields of Application
Made for day-to-day use

Applications for
for:

TVC

SDC

SCC

fits
fits to the following applications

vertical: walls & columns (W)

Special
20%

Application type

W
C

horizontal: floors (C) and

SDC
80%
F

driver: surface quality

foundations (F)
driver: labour productivity

100-125

Slump

150-175

Use SDC to convert high slump to true self-compacting concrete

Construction Benefits
Adding value to concrete

B
Benefits
fit

M lti i situation
Multi-win
it ti

Economical
Savings in cement
Up
U tto 40% ffaster
t placing
l i
Up to 5x higher labour productivity
Easy to produce

Specifier + general contractor

Contractor
Ready-mix producer

Ecological
Less cement, less CO2
Higher
g e du
durability
ab ty

Specifier + general contractor

Ergonomic
No vibration
No noise
Low stickiness

Contractor

Features & Costs

Material cost in % per m3 concrete

Features

Fines: Cement content >350 kg

150%

134%

Slump flow: 60-70 cm

Strength: C35 C50
Robust mix-design with
day-to-day raw material

Self-compacting

125%
100%

100%

108%

75%
50%
25%

M
Material
i l cost analysis
l i

TVC: reference
SDC: 8% higher
SCC: 34% higher

0%
TVC

SDC
SDC

Fi
Fines
& Ad
Admixtures
i t

SCC
A
Aggregates
t

Cost savings
g

29th October 2008

Smart Dynamic Construction

Full cost analysis

Approach
Stop-watch all activities
Full cost analysis

5 process steps
1. Outside formwork
2 Reinforcement
2.
3. Inside formwork
4. Concrete placing
5 Remove formwork
5.

Target
Material cost impact (incl
(incl. equipment cost)
Labour cost impact

Process Step 1
Placing outside formwork

T
V
C

Difference between TVC and SDC

Formwork savings (less wear and tear)

Re-use of shutters increased by 5x

S
D
C

Process Step 2
Reinforcement

T
V
C

Difference between TVC and SDC

Same activities
Same materials

Impact on total wall cost

Material cost: 0 Dhs

S
D
C

Labour cost: 0 Dhs

Process Step 3
Placing inside formwork

T
V
C

Difference
e e ce be
between
ee TVC
Ca
and
dS
SDC
C
Formwork savings (less wear and tear)
Re-use of shutters increased by 5x

S
D
C

Process Step 5
Removing formwork

T
V
C

Difference between TVC and SDC

Less cleaning with SDC
Much higher surface quality with SDC
For fair faced concrete: remedial work
savings of 25-75%
25 75%

Impact on total wall cost

S
D
C

Reduced labour (no. & time)

Reduced repairs (material & time)

Full Cost Analysis Summary

TVC SDC

300

Labour cost impact:

p
-6%

250
200

Material cost impact: -6%

- 3%

150

Plus:
0%

Improved surface quality

+ 8%

Higher safety

100

- 43%

Faster construction
constr ction

50
Formwork

Reinforcement

Concrete

Placing

In horizontal applications, the benefits of SDC pay off even better!

Smart Dynamic Concrete

Summary

Technology

Features

Benefits in the field of

Robust mix design

Fines < 400 kg

Economics

Tailor-made superplast.

60-70cm slump flow

Ecology

Exclusive VMA

Self-compacting

Ergonomics

Smart

Dynamic

Construction

New:
SDC makes unique mix-design optimization possible
SDC combines the advantages of both, TVC and SCC
RheoMATRIX is the key to solve paradox requirements: robustness (stability) + fluidity
SDC is cost effective: it saves labour and material costs

Summary
y

Development of admixtures
The
Th need
d for
f SCC
Testing
est g o
of SCC
SCC in use
SDC and RheoMATRIX

Ultimate labour saving

Chemistry-based
Thank youinnovations
for
f the
for
thyour
construction
t ti industry
i d t
attention!