SPECIAL

CONCRETES
[PART 03]
Fahim Al-Neshawy & Esko Sistonen
20.11.2015

HPC &
Normal HSC
concrete
SCC

Underwater
Fast drying
concrete concrete

Fiber
Shotcrete Concrete reinforced
types concrete

Self-
Healing Lightweight
concrete concrete

Mass Colored
concrete concrete
Polymer
concrete
 MASS CONCRETE

Definition
Mass concrete – is defined as

“Any volume of concrete with dimensions

large enough to require that measures be
taken to cope with (resist) the generation of
heat from hydration of cement and attendant
volume change to minimize cracking.”
Why study of mass concrete?

Why study of mass concrete?

generation of heat from hydration of cement

 Why study of mass concrete?

• When the temperature in the core of the concrete increases, the surface of
concrete is cooled in comparison with the core, due to thermal expansion
• The respective volume changes in the concrete causes compressive forces to
develop in the core, and tension forces to develop at the surface

Factors affecting temperature rise

1. Geometry
− Pours (cast) with a large volume: surface area
ratio are more susceptible to thermal cracking!
− Research has been performed to produce more
accurate dimensions for when temperature rise
should be considered.
2. Cement Composition
− Cements used for Mass Concrete should have a
low C3S and C3A content to reduce excessive
heat during hydration.
− Most Mass Concrete structure do not require early
strength, so slower hydration is usually not
harmful to construction.
Factors affecting temperature rise
3. Cement Fineness
− Cement with a lower fineness with slow hydration,
and reduce temperature rise.
4. Cement Content
− Mass Concrete mixtures should contain as low of
a cement content as possible to achieve the
desired strength.
− This lowers the heat of hydration and subsequent
temperature rise.
− Can be as low as 100 kg/m³

Factors affecting temperature rise

5. Aggregate Content
− Coarse Aggregate should be have an MSA (max.
size of agg.) of 15 cm if possible.
− A higher coarse aggregate content (70-85%) can
be used to lower the cement content, reducing
temperature rise.
Factors affecting temperature rise
5. Coarse Aggregate Coefficient of Thermal Expansion
− The CTE of the coarse aggregate is the main
influence on the CTE of the concrete.
− Choosing an aggregate with a low CTE can cut
thermal stresses in half.

Factors affecting temperature rise

6. Supplementary Cementitious Materials (SCMs)
− SCMs such as Fly Ash, and Slag can greatly reduce the heat of
hydration.
− Pozzolans such as FA (class F is best > slower hydration) and
Slag will produce between 15-50% of the heat of normal
Portland Cement.
− Highly reactive SCMs such as Silica Fume and Metakaolin do
not substantially lower the heat of hydration.
Factors affecting temperature rise
6. Supplementary Cementitious Materials (SCMs)
− Use of SCMs such as FA and GGBFS is commonly up to 60-
75% cement replacement.

Factors affecting temperature rise

7. Placement Temperature
− Casting at lower temperatures will reduce the thermal stresses;
o Slows hydration > lowers heat of hydration
o Lowers temperature differential between the core and the
outer surface
Factors affecting temperature rise
8. Water cement ratio
− W/C has a large effect on temperature rise
− W/C = 0.25-0.4 is common
9. Workability
o Most Mass Concrete mixtures have a ~0-60 mm slump
o Water reducer WRs or Superplasticizers may have to be
used to retain workability

Materials and Mix Proportions

• The heat of hydration of a cement is a function
of its compound composition and fineness
− cement contents as low as 100 kg/m3
o substitution of 20 percent pozzolan
− 4 to 8% entrained air
− water-reducing admixtures
− the extent of reduction in water content by
the use of entrained air and the largest
possible size of aggregate
o At a given water-cement ratio and consistency,
as the maximum aggregate size is increased,
both the water and the cement contents are
reduced.
Applications

SELF-HEALING
CONCRETE
 Self healing (bacterial) concrete
• What is S.H.B.C?
− A new concrete technology that autonomously repairs
cracks.
• How does it work?
− Alkaliphilic bacteria added to concrete matrix.
− Bacteria react to the water and metabolize crystals, which
close the crack and protect the steel within.

Self healing bacterial concrete

Bacterias used

Bacillus cohnii Bacillus filla Bacillus parturii

• Cement and water have a pH value of up to 13 when mixed together, usually a

hostile environment for life, most organisms die in an environment with a pH
value of 10 or above.
• Microbes that survive in alkaline environments can be found in natural
environments, for example:
o alkali lakes in Russia,
o carbonate-rich soils in desert areas of Spain
o soda lakes in Egypt.
Preperation of bacterial concrete
Self healing bacterial concrete can be prepared in two
ways.
− By direct application
− By encapsulation in light weight concrete.

• By the method of direct application

− bacterial spores and calcium lactate are added
directly while making the concrete and mixed.
− Here when the crack occurs in the concrete
bacterial spores broke and bacteria comes to life
and feed on the calcium lactate and limestone is
produced which fill the cracks.

Preperation of bacterial concrete

• By encapsulation method
− the bacteria and its food, calcium lactate, are placed inside
treated clay pellets and concrete is made
− About 6% of the clay pellets are added for making bacterial
concrete
− When concrete structures are made with bacterial concrete,
when the crack occurs in the structure and clay pellets are
broken and bacterial treatment occurs and hence the concrete
is healed.
− Minor cracks about 0.5mm width can be treated by using
bacterial concrete

• Among theses two methods encapsulation method is

commonly used, even though it’s costlier than direct
application. Bacillus bacteria are harmless to human life
and hence it can be used effectively.
 What is happening inside bio concrete
(mechanism)
1. The cracks are formed on the surface of concrete due
to many reasons like shrinkage, Inadequate water for
hydration …etc.

2. The water is deliberately forced into the crack and the

precursor is activated

What is happening inside bio concrete

(mechanism)

Ca(C3H5O2)2 + 7O2 → CaCO3 + 5CO2 + 5H2O

CO2 + Ca(OH)2 → CaCO3 + H2O

(carbonation)

3. The activated precursor intern induces the bacteria to react

with that precursor and form a base of calcium carbonate
called as limestone, the chemical equation is given above.
BEFORE HEALING AFTER HRALING

20x
 40x

Advantages
• The self healing bacterial concrete helps in reduced
maintenance and repair costs of steel reinforced concrete
structures.
• Oxygen is an agent that can induce corrosion, as bacteria
feeds on oxygen tendency for the corrosion of
reinforcement can be reduced.
• Self healing bacteria can be used in places where humans
find it difficult to reach for the maintenance of the
structures.
− Hence it reduces risking of human life in dangerous
areas and also increases the durability of the structure.
• Formation of crack will be healed in the initial stage itself
thereby increasing the service life of the structure than
expected life.
Disadvantages
• If the volume of self healing agents (bacteria
and calcium lactate) mixed becomes greater
than 20%, the strength of the concrete is
reduced.

• Preparation of self healing concrete needs

bacteria and calcium lactate.
− Preparation of calcium lactate from milk is
costlier.
− Hence preparation of self healing concrete
costs double than conventional concrete.

Applications
Self healing bacterial concrete can be used for
sectors such as
− tunnel-lining,
− structural basement walls,
− highway bridges,
− concrete floors
− marine structures.

Tunnel lining
Marine structure
Applications

Concrete flooring

Underground
retaining walls

Highway bridge

SHOTCRETE
• A concrete placing process
where concrete mixtures are
conveyed through a hose
then - with the help of
pressure - projected at high
velocity onto a surface to
achieve high quality in-place
compaction.
• It produces high quality
dense concrete, with a low
w/cm ratio, low permeability,
and a high cementitious
material content.

Ø Shotcrete is today a term that describes spraying

concrete or mortar with either a dry or wet mix
process.

Ø Gunite is a trademarked name that is incorrectly

used to describe the dry-mix shotcrete process

Ø Shotcrete emerged as the only acceptable

industry term to correctly describe "pneumatically
applied concrete“.
 Shotcrete, high performance product
consisting of …

Cement + aggregates + water + admixture

+
non-alkaline accelerator

Ø was invented in the early

1900s by American
taxidermist Carl Akeley.
Ø used to fill plaster models
of animals.
Ø In 1911, he was granted a
patent.
Ø Until the 1950’s, the wet-
mix process was devised,
only the dry-mix process
was used.
Ø Sprayed concrete is
reinforced by conventional
steel rods, steel mesh,
and/or fibers.

Ø Fiber reinforcement (steel

or synthetic) is also used
for stabilization in
applications such as slopes
or tunneling.
Ø conventional concrete is first placed and then
compacted in the second operation.
Ø shotcrete undergoes placement and compaction at the
same time.
Ø Shotcrete is more dense, homogeneous, strong, and
waterproof .
Ø It can be impacted onto any type or shape of surface,
including vertical or overhead areas

1. Dry process 2. Wet process

1. Dry process:
Ø Step1: Pre blended, dry or semi-dampened
materials are placed into shotcrete equipment and
metered into a hose.
Ø Step2: Compressed air conveys materials at high
velocity to the nozzle where the water is added.
Ø Step3: Then the material is consolidated on
receiving surface by high impact velocity.
Advantages of Dry process:
Ø Easy start up, shutdown and clean up.
Ø Control of materials is on site.
Ø Nozzle can be up to:
• 300 m horizontally or
• 150 mm vertically from the gun.

Wet process:
Ø Step 1: All ingredients, including water, are
thoroughly mixed and introduced into the shotcrete
equipment.
Ø Step 2: Wet material is pumped to the nozzle
where compressed air is introduced
Ø Step 3: Mostly wet-process shotcreting is done
with premixed mortar or small aggregate
concrete.
Wet process:

Advantages of Wet process:

Ø Little or no formwork is required.

Ø Cost effective method for placing concrete.
Ø Ideal for irregular surface applications
Ø Allows for easier material handling in areas with
difficult access
 Rehabilitation
of subway
tunnels

construction of domed roofs

Swimming pool construction

lining construction

UNDERWATER
CONCRETE - UWC
Introduction
There are often situations such as :
− Port and harbor installations
− Bridge piers in rivers
− Water industry structures
− Metro systems
− Deep shafts in unstable ground
, in which concrete is to be placed
underwater.

ž Performance requirements for UWC

— Workability & self compaction
— Cohesion against washout & segregation
— Low heat of hydration
— Controlled set time
— Compressive strength
— Adequate bond

ž Problems faced
— Segregation of fine aggregates from coarse
aggregates
— Water pollution
— Increased w/c ratio
— washout
 Materials used :
Composition (Example 0 – 32 mm aggregate):
• Aggregate
− Use an aggregate suitable for pumped mixes
− Fines including cement > 400 kg/m³
• Cement and Powder Additives
− Minimum cement content 350 kg/m³
− Limestone can be added to the fines content in the mix
design
• Admixtures
− Superplasticizer for the reduction of free water in the mix
− Mix stabilizer to minimize washout effect of fines and
cement (especially in running water conditions)

Materials used :
Components Description Example formula
Any quality aggregates
Aggregates All aggregate sizes are possible
possible
Target cement paste volume
Any cement meeting local
Cement according pumping concrete
standards
recommendations: > 350 kg/m³

Sufficient fines content by

Powder Limestone, fly ash or ground
adjustment of the binder content:
additives granulated blast furnace slag
Fines including cement > 400 kg/m³

Fresh water and recycling

w/c-ratio according to standards
Water content water with requirements
with regard to exposure class: < 0.48
regarding fines content
 Materials used :
Components Description Example formula

• Superplasticizer
Type dependent on Superplasticizer 0.60 - 1.50% *
Concrete placement and early Cement
admixtures strength requirements
• Stabilizer for stagnant water Stabilizer: 0.20 - 2.00% * Cement
Stabilizer for running water

Most often used today is pumping a suitably modified mix through

Installation
a standard concrete pump. The end of the delivery pipe must be
requirements
kept deep enough in the fresh concrete.

Concrete laying techniques

• Tremie method

• Bucket Placing

• Pump method
Tremie method

— A Tremie is a watertight pipe

— Generally 250mm in dia.

— Funnel shaped hopper at its

upper end and a loose plug
at the bottom.
— It is supported on a working
platform above water level.

Tremie method
Specifications of concrete to be used in Tremie method:
• Coarse Aggregate:
− Gravel of 20 mm max. size.
− Use 50-55 % of the total aggregate by weight.
• Sand, 45-50% of the total aggregate by weight
• Water/Cement Ratio: 0.42 (0.45 Maximum).
• Water-Reducing Admixture (preferably it is also plasticizer):
− Do not use super plasticizers.
• Air-Entrainment Admixtures:
− To give 6% total air.
• Retarding Admixture:
− To increase setting time to 4-24 hours, as required.
• Slump: 160 mm ± 25 mm
• This mix will develop compressive strength in the range of 40
– 50 MPa at 28 days.

Bucket placing
• The buckets used for underwater placement of
freshly mixed concrete should have drop-bottom
or roller- gate openings.
• The gates should be able to be opened from above
water.
• If air is used to open the bucket, the air should
discharge through a line to the surface to prevent
water disturbance.
• The top of the bucket must be covered to prevent
water from washing the surface of the freshly
mixed concrete.
 Bucket placing

drop-bottom opening roller- gate opening

Pump method:
Ø Pumping concrete directly
into its final position,
involving both horizontal
and vertical delivery of
concrete.
Ø Pumping concrete has the
advantage of operational
Pump method of laying
efficiency with potential concrete
savings of time and labour.
 References
1. ACI 207.1R-96 (1996). “Mass Concrete” Reported by ACI Committee 207

2. S. B. Abdul Wahab, (2014). Self healing bacterial concrete. Online at:

http://www.slideshare.net/neenavahab/self-healing-bacterial-concrete

3. Jürg Schlumpf and Jürgen Höfler (2006). Shotcrete in Tunnel

Construction - Introduction to the basic technology of sprayed concrete.
Online at: https://www.sika.com/dms/getdocument.get/7850f7a9-8547-
3441-bf68-599a2734334e/Fact%202_shotcrete%20handbook.pdf

4. Underwater concrete - mix design and construction practices

ftp://dfi.org/OneMine/Marine%20Foundations%20Book%20-
%20individual%20papers/29-5.4%20Underwater%20Concrete%20-
%20Mix%20Design%20and%20Construction%20Practices.pdf

Next lecture: Mon. 23.11.2015

• Permeability of concrete:
− Permeation defines the ease with which
fluids, both liquids and gases, can enter
into, or move through concrete.

• Durability of concrete:
− Is the ability to resist
o weathering action,
o chemical attack,
o abrasion,
o or any process of deterioration.