Modern construction materials Module-i

High-Strength and High- Performance Concrete It is important to note the high-strength and highperformance concrete are not synonymous. Concrete is defined as high-strength concrete solely on the basis of its compressive strength measured at a given age. In the 1970s, any concrete mixtures that showed 40 Mpa or more compressive strength at 28-days were designed as highstrength concrete. Later, 60-100 MPa concrete mixtures were commercially developed and used in the construction of high-rise buildings and long-span bridges in many parts of the world.

Definitions
The definition of high-performance concrete is more controversial. Mehta and Aitcin[1] used the term, high-performance concrete (HPC) for concrete mixtures possessing high workability, high durability and high ultimate strength. ACI defined high-performance concrete as a concrete meeting special combinations of performance and uniformity requirements that cannot always be achieved routinely using conventional constituents and normal mixing, placing, and curing practice.

TYPICAL CLASSIFICATION

Normal Strength
High Strength Ultra High Strength Especial

20-50 Mpa
50-100 MPa 100-150 MPa > 150 MPa

Microstructure

 From the general principles behind the design of high-strength concrete mixtures, it is apparent that high strengths are made possible by reducing porosity, in homogeneity, and micro cracks in the hydrated cement paste and the transition zone.

The utilization of fine pozzolanic materials in high strength concrete leads to a reduction of the size of the crystalline compounds, particularly, calcium hydroxide. Consequently, there is a reduction of the thickness of the interfacial transition zone in high-strength concrete.
The densification of the interfacial transition zone allows for efficient load transfer between the cement mortar and the coarse aggregate, contributing to the strength of the concrete. For very high-strength concrete where the matrix is extremely dense, a weak aggregate may become the weak link in concrete strength.

Materials Cement
Almost any ASTM portland cement type can be used to obtain concrete with adequate rheology and with compressive strength up to 60 MPa.

In order to obtain higher strength mixtures while maintaining good workability, it is necessary to study carefully the cement composition and finenesses and its compatibility with the chemical admixtures. Experience has shown that low-C3A cements generally produce concrete with improved rheology.

Materials Aggregate
In high-strength concrete, the aggregate plays an important role on the strength of concrete. The low-water to cement ratio used in high strength concrete causes densification in both the matrix and interfacial transition zone, and the aggregate may become the weak link in the development of the mechanical strength. Extreme care is necessary, therefore, in the selection of aggregate to be used in very high strength concrete

Materials Aggregate
The particle size distribution of fine aggregate that meets the ASTM specifications is adequate for high-strength concrete mixtures.

If possible, Aitcin recommends using fine aggregates with higher fineness modulus (around 3.0). His reasoning is as follows:
a) high-strength concrete mixtures already have large amounts of small particles of cement and pozzolan, therefore fine particles of aggregate will not improve the workability of the mix; b) the use of coarser fine aggregates requires less water to obtain the same workability; and c) during the mixing process, the coarser fine aggregates will generate higher shearing stresses that can help prevent flocculation of the cement paste.

Guidelines for the selection of Materials

The higher the targeted compressive strength, the smaller the maximum size of coarse aggregate.
Up to 70 MPa compressive strength can be produced with a good coarse aggregate of a maximum size ranging from 20 to 28 mm. To produce 100 MPa compressive strength aggregate with a maximum size of 10 to 20 mm should be used. To date, concretes with compressive strengths of over 125 MPa have been produced, with 10 to 14 mm maximum size coarse aggregate.

 Using supplementary cementitious materials, such as blast furnace slag, fly ash and natural pozzolans, not only reduces the production cost of concrete, but also addresses the slump loss problem. The optimum substitution level is often determined by the loss in 12- or 24-hour strength that is considered acceptable, given climatic conditions or the minimum strength required. While silica fume is usually not really necessary for compressive strengths under 70 MPa, most concrete mixtures contain it when higher strengths are specified.

Differences Between NSC and HSC

In normal strength concrete, the micro cracks form when the compressive stress reaches ~ 40% of the strength. The cracks interconnect when the stress reaches 80-90% of the strength For HSC, Iravani and MacGregor reported linearity of the stress-strain diagram at 65 to 70, 75 to 80 and above 85% of the peak load for concrete with compressive strengths of 65, 95, and105 MPa. The fracture surface in NSC is rough. The fracture develops along the transition zone between the matrix and aggregates. Fewer aggregate particles are broken. The fracture surface in HSC is smooth. The cracks move without discontinuities between the matrix and aggregates.

Mechanical Behavior
Stress-strain curve is more linear The strain corresponding to the maximum stress increases with strength

The post-peak domain gets steeper

The ultimate deformation decreases with the increasing strength

Examples of application
The bridge constructed in Joigny used concrete with 60 MPa instead of concrete with 35 MPa. The volume of concrete reduced 30%
Prof. Zia has shown that for 29-m spans with 80 MPa concrete instead of 40 MPa allow a 17% increase in span. Jobse has demonstrated that by increasing the compressive strength of concrete from 40 MPa to 70 MPa the number of supports could be reduced from nine to four

TYPES OF MATERIAL

Ferrous metals: Carbon-, Alloy-, Stainless-, Tool-and-die steels

Non-ferrous metals: Aluminum, Magnesium, Copper, Nickel, Titanium, Superalloys, Refractory metals, Beryllium, Zirconium, Low-melting alloys, Gold, Silver, Platinum, Plastics: Thermoplastics (Acrylic, Nylon, Polyethylene, ABS,) Thermosets (Epoxies, Polymides, Phenolics, ) Elastomers (Rubbers, Silicones, Polyurethanes, ) Ceramics, Glasses, Graphite, Diamond, Cubic Boron Nitride Composites: Reinforced Plastics, Metal-, Ceramic Matrix Composites Nanomaterials, shape-memory alloys, superconductors,

PROPERTIES OF MATERIALS
Mechanical properties of materials Strength, Toughness, Hardness, Ductility, Elasticity, Fatigue and Creep Physical properties Density, Specific heat, Melting and boiling point, Thermal expansion and conductivity, Electrical and magnetic properties

Chemical properties Oxidation, Corrosion, Flammability, Toxicity,

General Properties and Applications of Ferrous Alloys

Ferrous alloys are useful metals in terms of mechanical, physical and chemical properties. Alloys contain iron as their base metal. Carbon steels are least expensive of all metals while stainless steels is costly.

Carbon steels
1. 2. 3. Classified as low, medium and high: Low-carbon steel or mild steel, < 0.3%C, bolts, nuts and sheet plates. Medium-carbon steel, 0.3% ~ 0.6%C, machinery, automotive and agricultural equipment. High-carbon steel, > 0.60% C, springs, cutlery, cable.

Carbon and alloy steels Alloy steels

Steels containing significant amounts of alloying elements.

Structural-grade alloy steels used for construction industries due to high strength.
Other alloy steels are used for its strength, hardness, resistance to creep and fatigue, and toughness. It may heat treated to obtain the desired properties.

High-strength low-alloy steels

Improved strength-to-weight ratio. Used in automobile bodies to reduce weight and in agricultural equipment. Some examples are: Dual-phase steels Micro alloyed steels Nano-alloyed steels

1. 2. 3.

STAINLESS STEELS
Characterized by their corrosion resistance, high strength and ductility, and high chromium content.
Stainless as a film of chromium oxide protects the metal from corrosion.

What is Stainless Steel

Any steel with 11% or more chromium

Five General Categories of Stainless Steel

Ferritic Martensitic Precipitation-Hardening Austenitic Duplex

Ferritic
Wholly Ferritic Structure-Balance of Chemistry Wrought Designation-Type 442 Low Impact Properties Replaced by 300 Series Can not be hardened

Martensitic
12% Chrome Steels (No nickel) 400 Series Wrought-410, 416, 440 Cast CA-15, CA-120, CA6-NM Tough w/Hardness to500 HB Applications Pump Components [Shafts and Sleeves] Hydraulic Cylinders Wear Rings Used in API Pumps not CPI

Precipitation-Hardening
Chrome-Nickel Steel Martensitic Structure Contains Copper-Precipitates Designation 17-4PH and 15-5PH [Wrought] CB7Cu [Cast] High Strength 80,00 psi Tensile Solution Condition 120,000 psi Aged Condition Corrosion Resistance-Between 300 & 400 SS

Austenitic 300 Series

Most Prevalent in the CPI Nickel >8%-Structure Austenitic 18-8 SS (304) original 316- Cast-CF8M [18% Cr-9%Ni-2.5%Mo] 316-Greater Pitting Resistance Alloy 20- Cast CN7M [18% Cr-30% Ni-2% Mo]

Austenitic Super alloys

Nickel Based Nickel-Chromium-Molybdenum Alloys Hastelloy C-276 [Cast CW-12MW] Hastelloy C-22 [Cast CX-2MW ] Inconel 625 [Cast CW-6MC] Nickel-Molybdenum Alloys Hastelloy B [Cast N7M]

Aluminium and aluminium alloys

1. 2. 3. 4. 5. Factors for selecting are: High strength to weight ratio Resistance to corrosion High thermal and electrical conductivity Ease of machinability Non-magnetic

Magnesium and magnesium alloys

Magnesium (Mg) is the lightest metal. Alloys are used in structural and non-structural applications. Typical uses of magnesium alloys are aircraft and missile components. Also has good vibration-damping characteristics.

Copper and copper alloys

Copper alloys have electrical and mechanical properties, corrosion resistance, thermal conductivity and wear resistance.

Applications are exchangers.

electronic

components, springs

and

heat

Brass is an alloy of copper and zinc. Bronze is an alloy of copper and tin.

Nickel and nickel alloys

Nickel (Ni) has strength, toughness, and corrosion resistance to metals. Used in stainless steels and nickel-base alloys. Alloys are used for high temperature applications, such as jetengine components and rockets.

Superalloys
Superalloys are high-temperature alloys use in jet engines, gas turbines and reciprocating engines.

Titanium and titanium alloys

Titanium (Ti) is expensive, has high strength-to-weight ratio and corrosion resistance. Used as components for aircrafts, jet-engines, racing-cars and marine crafts. Refractory metals have a high melting point and retain their strength at elevated temperatures. Applications are electronics, nuclear power and chemical industries. Molybdenum, columbium, tungsten, and tantalum are referred to as refractory metal.

Refractory metals

Other nonferrous metals

1. 2. 3. Beryllium Zirconium Low-melting-point metals: - Lead - Zinc - Tin Precious metals: - Gold - Silver - Platinum

4.

Special metals and alloys

1. 2. 3. 4. Shape-memory alloys (i.e. eyeglass frame, helical spring) Amorphous alloys (Metallic Glass) Nanomaterials Metal foams

A shining example

All about Recycling Aluminium

Recycling aluminium is one of the best things we can do for the environment

Recycled

aluminium

only

uses

5%
of the energy need to make new material, and can be recycled indefinitely without loss of quality.

Almost all councils recycle aluminium cans

and many recycle kitchen foil and food trays

The UK has a 'closed-loop' aluminium drinks can recycling plant

It turns used cans into slabs of aluminium which are perfect to make new cans

First, the cans are shredded and have their colour removed

The shreds are then melted in a huge furnace

They are then turned into ingots

Each ingot can make 15,00,000 cans

Aluminium foil is a different alloy

and is usually recycled with other aluminium scraps to make cast items

Recycling 1kg of aluminium saves

6kg of bauxite 4kg of chemical products 14kWh of electricity

Aluminium is the most cost-effective material to recycle, because of the huge energy savings - up to 95%

Recycling is part of the normal lifecycle for large industrial aluminium products.
Around 75 per cent of all the aluminium ever made is still in circulation!

Aluminium after recycling

An aluminium can could be back in your fridge in six weeks

Foil and other aluminium scrap can be made into a whole range of other products

like engine components

making vehicles lighter and more fuel-efficient

Window frames

Buildings

Greenhouses

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