ADVANCED CONCRETE TECHNOLOGY

ASSIGNMENT 2
D.Kavya
GTE-04

1 .GEOPOLYMER CONCRETE

Geopolymer cement concrete is made from utilization of waste

materials such as fly ash and ground granulated blast furnace slag (GGBS). Fly ash
is the waste product generated from thermal power plant and ground granulate
blast furnace slag is generated as waste material in steel plant.The main
constituent of geopolymers source of silicon and aluminium which are provided
by thermally activated natural materials (e.g. kaolinite) or industrial byproducts
(e.g. fly ash or slab) and an alkaline activating solution which polymerizes these
materials into molecular chains and networks to create hardened binder. It is also
called as alkali-activated cement or inorganic polymer cement.
METHOD OF PREPARATION:
Following materials are required to produce this concrete:
 Fly ash – A byproduct of thermal power plant.
 GGBS – A byproduct of steel plant.
 Fine aggregates and coarse aggregates as required for normal
concrete.

 Alkaline activator solution for GPCC as explained above. Catalytic liquid

system is used as alkaline activator solution. It is a combination of solutions
of alkali silicates and hydroxides, besides distilled water.

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  The role of alkaline activator solution is to activate the geopolymeric
source materials
PROPERTIES:
 The drying shrinkage of is much less compared to cement concrete. This
makes it well suited for thick and heavily restrained concrete structural
members.

 It has low heat of hydration in comparison with cement concrete.

 The fire resistance is considerably better than OPC.
 This concrete possess very high acid resistance when tested under
exposure to 2% and 10% sulfuric acids.
APPLICATIONS:
 The applications are same as cement concrete. However, this material has
not yet been popularly used for various applications.

 This concrete has been used for construction of pavements, retaining

walls, water tanks, precast bridge decks.

2 .SELF COMPACTING CONCRETE (SCC):

The consistence of the concrete is specified and measured as a flow rate rather
than the normal slump test SCC provides

 Low cost(no vibration equipment required)

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  Faster construction times.
 Increased workability and ease of flow around heavy reinforcement.
 Excellent durability.

PROPERTIES OF SCC :
 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:
 Filling Ability Tests
 Passing Ability Tests
 Segregation Resistance Test

Advantages of Self Compacting Concrete :

The main advantages of self-compacting concrete are:
 The permeability of the concrete structure is decreased
 SCC enables freedom in designing concrete structures
 The SCC construction is faster
 The problems associated with vibration is eliminated
 The concrete is placed with ease, which results in large cost saving
 The quality of the construction is increase
 The durability and reliability of the concrete structure is high compared to
normal concrete structures
 Noise from vibration is reduced. This also reduce the hand arm vibration
syndrome issues

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 Disadvantages of Self Compacting Concrete:
 SCC construction faces the following limitations: The measurement and
monitoring must be more precise.
 The material selection for SCC is more stringent
 The use of designed mix will require more trial batches and lab tests
 There is no globally accepted test standard to undergo SCC mix design
 The cost of construction is costlier than the conventional concrete construction

Applications of Self Compacting Concrete :

 Construction of structures with complicated reinforcement
 SCC is used for repairs, restoration and renewal construction
 Highly stable and durable retaining walls are constructed with the help of SCC
 SCC is employed in the construction of raft and pile foundations

Materials Used for Self-Compacting Concrete :

1. Cement:
Ordinary Portland cement either 43 or 53 grade cement can be used.
2. Aggregates:
The size of the aggregates used for SCC design is limited to 20mm. If the
reinforcement employed for the structure is congested, the aggregate size used
can be in the range 10 to 12mm. Well graded aggregates either round or cubical
shape are a best choice. The fine aggregates used in SCC can be either natural
aggregates or manufactured aggregates (M- Sand) with a uniform grade. The fine
aggregates with particle size less than 0.125mm are generally employed.

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3. Water:
The quality of water used is same that followed for reinforced concrete and
prestressed concrete construction.

4. Mineral Admixtures:
The mineral admixtures used can vary based on the mix design and properties
required. Mentioned below are the different mineral admixtures that can be used
and their respective properties they provide...
APPLICATIONS:
 Construction of structures with complicated reinforcement
 Used for repairs, restoration and renewal construction.
 Employed in the construction of raft and pile foundations.
 Highly stable and durable retaining walls are constructed.

3 .SLURRY INFILTRATED CONCRETE

Slurry infiltrated concrete is considered as a special type of high
strength high-performance fiber reinforced concrete, extremely strong, and ductile.
steel fibered is prepared first and cement slurry is infiltrated this is called slurry
infiltrated fiber concrete (SIFCON). With this technique macro fiber contents about
20% by volume can be achieved. It increases both flexural loads carrying capacity
and toughness. A very high compressive strength is also achieved.

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Another form of slurry infiltrated mat concrete (SIMCON) has been developed.
SIMCON is made by infiltrating continuous steel fiber mats with a specially
designed cement based slurry. Instead of reinforcing concrete with steel bars, it
is reinforced with a mixture of cement, aggregates and water, called slurry.

Tests for SIFCON:

 Test for compressive strength.
 Split tensile strength test.
 Impact test
 Flexural strength test.

MATERIALS:
• OPC 53 grade
• Coiled steel fibre(0.2-0.5)
• Super plasticizer
• Ordinary sand
Tests are conducted for alternate wetting and drying for 3 days.
PROPERTIES:
• Contains 5-20% volume fraction of steel fibre.
• Unit weight=1900-3200 kg/m3
• Compressive strength=60-210 MPa
• Tensile strength=4-14 MPa
• Ductility ca reach value of 1000 times that of the plain matrix.

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APPLICATIONS:
SIMCON:
• Fibre mats are shaped and wrapped around existing columns and beams
injected with concrete.
• The concrete slurry for repairing (or) strengthening existing structures.
The mats are made of recycled stainless steel fibres.
• In this slurry infiltrated concrete fibres and it does not collapse instead of
large chunks breaking and falling from a structure the materials crumbles
into small harmless flakes which pose damage to people (or) property.

SIFCON:
• Pavement rehabilitation and precast concrete products
• Overlays, bridge decks and protective revetments
• Seismic and explosive resistant structures
• Safety vaults
• Saddle piers.
• High thermal resistance
• Resistance to seismic hazards.

4.FERROCEMENT
Ferrocement is a new material consisting of wire meshes and cement mortar.it
consist of closely spaced wire meshes which are impregnated with rich cement
mortar mix. The wire mesh is usually of 0.5 to 1.0 mm dia wire at 5mm to 10 mm

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spacing and cement mortar is of cement sand ratio of 1:2 or 1:3 with
water/cement ratio of 0.4 to 0.45.The ferrocement elements are
usually of the order of 2 to 3 cm in thickness with 2 to 3mm external
cover to the reinforcement. The steel content varies between 300kg
to 500 kg per cubic meter of mortar.This material is more suitable to
special structures like shells which have strength through forms and
structures like roofs, silos, water tanks and pipelines. Because of its
easy adaptability to prefabrication and lesser dead weight of the
units cast this is highly suitable material for precast products.

CASTING TECHNIQUES:
1. Hand plastering (without using any formwork)
2. Semi-mechanized process (using hand plastering)
3. Centrifuging and
4. Geniting.
APPLICATIONS:
• Domestic over-head water tanks.
• For building boats.
• Ferrocement manhole cover.
• Prefabricated roof units.
• Pressure pipes.
• Curved benches for parks, garden and open air cinema theatre.
• Tree guards.

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ADVANTAGES:
• Simplicity of construction.
• Lesser dead weight of the elements due to their small thickness.
• High tensile strength.
• Less crack width compared to conventional concrete.
• Easy repairability.
• Noncorrosive nature and
• Easier mouldability to any shape required.

DISADVANTAGES:
• Can be punctured by collision with pointed objects.
• Corrosion of the reinforcing materials due to the incomplete coverage of
metal by mortar.
• It is difficult to fasten to ferrocement with bolts, screws, welding and etc.
• Large number of labour required.
• Tying rods and mesh together is especially tedious and time consuming.

5 .ROLLER COMPACTED CONCRETE

Roller-compacted concrete has the same basic ingredient as
conventional concrete: cement, water, and aggregates, such as gravel or
crushed stone.But unlike conventional concrete, it's a drier mix—stiff
enough to be compacted by vibratory rollers.

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Application
1. Dam construction
2. Rehabilitation of existing dams
3. Road construction
4. Air field pavements and Airports
5. Power plants and other industrial facilities
6. Reservoir lines
7. Ports
Properties
1. Modulus of elasticity: Modulus of elasticity of Roller Compacted Concrete is
similar or slightly higher than the conventional concrete
2. Compressive Strength: The compressive strength is higher than that of the
conventional concrete since the low w/c of roller compacted concrete produce
low porosity cement matrix which contributes to the high strength.
3. Flexural Strength: Flexure strength is directly related to the density and
compressive strength. Flexure strength is more compared to the conventional
concrete.
4. Permeability: The low w/c of roller compacted concrete produce low porosity
cement matrix which makes the concrete less permeable.
5. Freezing and Thawing: Freeze and thawing durability can be attributed by its
low moisture content and high density.

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Method of preparation
Materials: Fly Ash, cement, coarse aggregate, fine aggregate, water, Chemical
admixtures.
Roller compacted concrete has the same basic ingredients as that of the
conventional concrete but it is a stiff mix. This type concrete mix requires
different mixing process. Central mix plants have been successfully produce RCC
mixes, most consistent results have been obtained using continuous mixing plant
known as pug mills. These pug mills have the mixing efficiency to evenly disperse
the small amount of water used in the mix.

5.Recycled aggregate concrete

Properties:
1. Flexural and Tensile Strength
ACI 55.1R reported that, flexural and tensile strength of concrete made from
recycled coarse aggregates is less than conventional concrete by 10%, and this
reduction increases to 20% in worst case scenario. However, concrete produced
from coarse recycled aggregate and natural sand provide approximately the same
flexural and tensile strength as concrete made from natural aggregate.
The standard size of beams for flexural tests according to (BS 1881) is 150mm x
150mmx700mm.
However, according to the American society for testing materials (ASTM C790)
the size of flexural test specimen is 3.2mm x 12.7mm x 125mm.
2. Modulus of Elasticity
Modulus of elasticity of concrete made with recycled coarse and fine aggregate is
lower than that of concrete made with recycled coarse aggregate only.
3. Creep
Creep of concrete produced from recycled concrete aggregate is higher than
concrete made using natural aggregate by 30 to 60%.
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4. Drying Shrinkage
Drying shrinkage of concrete made from recycled aggregate is usually greater
than concrete made using natural aggregate. the percentage of drying shrinkage
soar if it is produced from recycled coarse and fine aggregate.
5. Permeability
Permeability of concrete made from recycled aggregate is greater than that of
concrete produced with natural aggregate.
6. Freezing and Thawing Resistance
It is proven that freezing and thawing resistance of concrete made with crushed
concrete aggregate is the same as concrete produced with natural aggregate.
7. Carbonation, Chloride Penetration, and Reinforcement Corrosion
Generally, carbonation of concrete made with crushed concrete aggregate is
higher than concrete with natural aggregate, especially if the recycled aggregate
suffered carbonation previously.Similarly, rate of reinforcement corrosion in
concrete produced using recycled aggregate is greater than conventional
concrete.
8. Shear Strength
Shear strength of recycled aggregate concrete is lesser than of normal concrete.
This is because the recycled aggregate from field-demolished concrete for
example can be relatively weaker than a typical natural aggregate. In general,
there is a 10% decrease in strength when recycled coarse aggregates are used.
Applications:
1. Uses of Crushed Concrete (Unprocessed)
In general, applications without any processing include:
• Many types of general bulk fills
• bank protection
• base or fill for drainage structures

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• road construction
• noise barriers and embankments
2. Uses of Processed Crushed Concrete (Crushed Concrete Aggregate)
After processing crushed concrete aggregate can be used in the following
projects:
• bridge foundations
• structural grade concrete
• lean-concrete
• bituminous concrete
• soil-cement pavement bases
• Freeways
• Airport runways
• Oil & gas civil construction projects.
• pavements
• shoulders
• median barriers
• sidewalks
• curbs and gutters
Preparation:
The two different mix proportions of characteristic strength of 20 N/ mm2 (M 20)
and 25 N/mm2 (M 25) commonly used in construction of low-rise buildings are
obtained as per IS 10262 – 1982 or both recycled aggregate concrete and natural
aggregate concrete. Due to the higher water absorption capacity of RCA as
compared to natural aggregate, both the aggregates are maintained at saturated
surface dry (SSD) conditions before mixing operations. The proportions of the
ingredients constituting the concrete mixes

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are 1:1.5:2.9 and 1:1.2:2.4 with water cement ratio 0.50 & 0.45 respectively for
M-20 & M-25 grade concrete. The ordinary Portland cement of 43 grade and
natural fine
aggregates (Haldwani sand) are used throughout the casting work. The maximum
size of coarse aggregate used was 20 mm in both recycled and natural aggregate
concrete.
The total two mixes were cast using natural aggregate and eight mixes were cast
using four type of recycled aggregate concrete for M-20 & M-25. The
development of compressive strength is monitored by testing the 150-mm cubes
at 1, 3, 7, 14, 28, 56 and 90 days. In one set 39 cubes were cast for each mix. The
cylinder strength and corresponding strain & modulus of elasticity were measured
in standard cylinder of 150x300 mm size at the age of 28 days. The prism of size
150x150x700 mm and cylinder of size 150x300mm were cast from the same
batches to measure Flexural strength and splitting tensile strength respectively.
This paper reports the results of

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