www.LC3.

ch

Strength and Durability of

Concrete with LC3

Manu Santhanam
Professor, Civil Engineering, IIT Madras

Workshop on Limestone Calcined Clay Cement, Sep 4, 2017 1

 www.LC3.ch

Part 1: Mix Design and

Mechanical Performance of
3
LC Concrete

2
Mixture variables

» Materials used
» Limestone Calcined Clay Cement (LC3)
» OPC 53 grade cement
» Fly ash – Class F

» Design Mixes
» Grades M30 and M50
» Common mix with w/b - 0.45 and total binder - 360 kg/m3

» Target slump: 80-120 mm

Concrete Mix Design
Fly Water Fine Coarse SP
Sl. Cement
Mix I.D. w/b ash content aggregate aggregate dosage
No (% wt. of
kg/m3 cement
1 OPC-M30 0.50 310 0 155 695 496 744 0.02
2 FA30-M30 0.45 217 93 140 723 491 737 0.65
3 LC3-M30 0.50 310 0 155 708 491 736 1.00
4 OPC-M50 0.40 360 0 144 703 477 716 0.65
5 FA30-M50 0.35 266 114 133 699 475 713 0.60
6 LC3-M50 0.40 340 0 136 704 488 732 0.85
7 OPC-C 360 0 162 721 463 694 0.10
8 FA30-C 0.45 252 108 162 721 463 694 0.23
9 LC3-C 360 0 162 721 463 694 0.36
Conventional methods of mix design can be followed for concretes with LC3
Binder requirement was lower and strengths of specific grades could be achieved
at higher water contents for LC3 concretes, as compared to fly ash based
concrete
Evolution of compressive strength of concrete

LC3-50(56)(2:1)1B

Strength development characteristics for LC3 concretes matched

with OPC concrete, and were better than fly ash based concrete in
the early ages
Elastic modulus of concrete

Elastic moduli of concretes with all three binder systems

were similar
Shrinkage of concrete

M30
Shrinkage of concrete

M50
Shrinkage of concrete

C-Mix
 Shrinkage of concrete
M30 M50 C-Mix
Concrete Grade
OPC FA30 LC3 OPC FA30 LC3 OPC FA30 LC3

Measured total
450 430 490 450 330 520 390 380 430
shrinkage strain

410 370 410 390 380 360 430 410 430

B4
shrinkage strain
Predicted total

(-40) (-60) (-80) (-60) (+50) (-160) (+40) (+30) (0)

440 440 430 450 480 470 450 450 470
ACI

(-10) (+10) (-60) (0) (+150) (- 50) (+60) (+70) (+40)

CEB

471 520 490 450 440 450 480 490 460

fib

(+20) (+90) (0) (0) (+110) (-70) (+90) (+110) (+30)

Shrinkage performance of concretes with different binders was

dependent on the water content of the specific mixes. Concretes
with similar mixture proportion (binder content and w/b) had
similar shrinkage irrespective of the binder
 www.LC3.ch

Part 2: Durability
3
Performance of LC Systems

11
Framework for assessment of transport
properties Assessment of
transport
properties

Concrete at equivalent
strength grade and
equivalent binder-w/c
ratio

Porosity and
Chloride ingress Moisture ingress Gas Ingress pore structure of
binder ACMT, NT build 492

Performance of
1.1) RCPT Water Sorptivity Oxygen concrete with LC3
2.2) Chloride test permeability test binder against
Migration test different transport
3.3) Bulk diffusion mechanisms
test
Resistivity measurement

Oxygen permeability Water Sorptivity

RCPT, ASTM C1202 test, DI manual, SA
12
test, DI manual, SA
 Surface resistivity

Resistivity of LC3 concretes was an order of magnitude higher than OPC (and also
significantly higher than PPC) which suggests better resistance to corrosion
13
propagation.
Chloride penetrability by RCPT (ASTM C1202)
Red- 28 days Blue- 90 days

• There is a marked
improvement of the
chloride resistance at
an early age
irrespective of the
different grades of
concrete, unlike fly ash
based PPC system
which requires
additional curing at
higher water-binder
ratios.

14
Chloride penetrability by Migration test (NT 492)
Red- 28 days Blue- 90 days

• There is a marked
improvement of the
chloride resistance
at an early age
irrespective of the
different grades of
concrete, unlike fly
ash based PPC
system which
requires additional
curing at higher
water-binder ratios.

15
Oxygen permeability test (Durability Index
Manual, South Africa)

• All concretes in the

‘Excellent’
category as per
South African
criteria
• Gas penetration
resistance higher
for higher grade
concretes

16
Sorptivity Index (Durability Index Manual, South
Africa)

• Tortuous pore
structure has
reduced sorptivity in
the LC3 system;
FA30 system also
has a relatively
lower sorptivity
compared to the
OPC mix

17
 Chloride profile in M30 and M50 grade of concrete (56 days
Chloride exposure) – Bulk Diffusion test (ASTM C1556)

Chloride concentration ( % mass of concrete)

1.6
Chloride concentration ( % mass of concrete)

1.6
OPC M30 OPC M50
FA30 M30 1.4 FA30 M50
1.4 LC3 M30 LC3 M50
1.2
1.2

1.0
1.0

0.8
0.8

0.6 0.6

0.4 0.4

0.2 0.2

0.0 0.0
0 5 10 15 20 25 0 5 10 15 20 25
Mid-depth (mm) Mid-depth (mm)

• Higher resistance to ingress of chloride was seen in LC3 and FA30.

• At equivalent strength, performance is better is OPC and comparable with FA30 (since
FA30 had lower w/b ratio to produce equivalent strength of concrete)
• Lower variability in chloride profiles of LC3 can be due to better quality of concrete (i.e.,
homogeneity) with LC3 binder
18
Chloride profile in concrete with Common mix (56 days Chloride
exposure)
Chloride concentration ( % mass of concrete) 1.6

OPC C-Mix
1.4 FA30 C-Mix
LC3 C-Mix
1.2

1.0

0.8

0.6

0.4

0.2

0.0
0 5 10 15 20 25
Mid-depth (mm)
• With similar binder content and w/b ratio, the performance of LC3 is better than
OPC and FA30
• Increased binding of chlorides due to additional AFm and Al in CSH from
Calcined clay – Better resistance to Chloride ingress 19
Service Mechanisms Strength
Durability Parameters (28 days)
conditions (MPa)
Total charge passed from
Wenner Resistivity (Kohm.cm) Sorptivity (mm/sq.hr)
RCPT (Coulombs)
Exposed to
airborne salt but Diffusion, sorption,
in direct contact physical 40 50-100 <2000 6 to 10
with sea water degradation

XS1 OPC FA30 LC3 OPC FA30 LC3 OPC FA30 LC3
M30 Mix-1 11.1 16.4 227.5 2635 1356 123 9.6 7.6 8.4
• ConcreteM50
made with LC3 can meet16.4the durability
Mix-2 19.0 indices
298.6 requirements
2040 1000 98 for different
7.9 8.0 7.6
exposureC-Mix
class in chloride
Mix-3laden environment
12.6 15.7 at260.4
28 days;
2314unlike
1666FA30
99 which requires
10.1 9.6 5.4
extended period of curing.
Permanently
Diffusion,
submerged in
Permeation
35 50-100 <2000 -
sea water
XS2 Mix-1 11.1 16.4 227.5 2635 1356 123 9.6 7.6 8.4
Mix-2 16.4 19.0 298.6 2040 1000 98 7.9 8.0 7.6
Mix-3 12.6 15.7 260.4 2314 1666 99 10.1 9.6 5.4
Tidal, Splash and
Spray zones Diffusion, sorption,
Wick action,
Permeation, Physical 50 >100 <1000 <6
degradation

XS3 Mix-1 11.1 16.4 227.5 2635 1356 123 9.6 7.6 8.4
Mix-2 16.4 19.0 298.6 2040 1000 98 7.9 8.0 7.6
Mix-3 12.6 15.7 260.4 2314 1666 99 10.1 9.6 20
5.4
 Pore structure evolution in
LC3
250 250
OPC- C 3 DAYS FA30 C-3 DAYS

Cummulated pore volume (mm3 / g)

OPC- S 3 DAYS FA30 S -3 DAYS
Cummulated pore volume (mm /g)

OPC- C 7 DAYS FA30 C-7 DAYS

3

200 200
OPC- S 7 DAYS FA30 S-7 DAYS
OPC- C 28 DAYS FA30 C-28 DAYS
OPC- S 28 DAYS FA30 S-28 DAYS

150 150

100
100

50
50

0
0 0.00 0.01 0.10 1.00 10.00 100.00
0.00 0.01 0.10 1.00 10.00 100.00
Pore Diameter ( m)
Pore Diameter ( m) Cummulated Pore Volume Vs Pore diameter of FA30 (w/c: 0.4)
Cummulated Pore Volume Vs Pore diameter of OPC (w/c: 0.4)
250
LC3 C- 3 DAYS
LC3 S- 3 DAYS

Cummulated pore volume (mm /g)

LC3 C- 7 DAYS
3
200
LC3 S- 7 DAYS
• LC3 shows lowered threshold diameter LC3
LC3
C-
S-
28 DAYS
28 DAYS

even as early as at 3 days 150

• Refined pore structure major factor for

100
better durability performance at early
ages 50

0
0.00 0.01 0.10 1.00 10.00 100.00

Pore Diameter ( m)
Cummulated Pore Volume Vs Pore diameter of LC3 (w/c: 0.4)
21
Comparative pore size distribution by MIP – OPC,
FA30 and LC3

• There is a shift in the pore sizes to the lower pore size (0.1-0.01 microns) at an early
age with LC3 – results in better durability parameter in concrete at an early age

22
Carbonation study
»Binder type
»OPC, FA30, LC3
»Concrete grade (binder content, w/b)
»M30 (310 kg/m3, 0.5),
»M50 (340 kg/m3, 0.4),
»Common mix (360 kg/m3, 0.45)
»CO2 concentration Carbonation depth
»Natural carbonation
»Accelerated carbonation (1 and 3%)
»Exposure conditions
»Sheltered
»Unsheltered
Methodology
Carbonation
induced
corrosion

Objective 1 Objective 2
Carbonation Service life
resistance Estimation

Natural Accelerated
carbonation carbonation
test test

24
Accelerated carbonation

»Specimen size = 100 × 100 × 500

mm
»Curing duration = 28 days
»Pre-conditioning = 65% RH (14 days)
»Accelerated carbonation test
»Concentration of CO2 = 1% and 3%
»Temperature = 20oC
»Relative humidity = 65%
»Testing days = 28, 90, 120, 150

25
Evolution of carbonation depth in accelerated carbonation
with respect to time in concrete grade M30 and M50

1 % CO2 3 % CO2

• Concrete elements cast with LC3 show lower carbonation resistance at similar
strength grade in comparison with concretes made with OPC and FA30.

• Reason for lower carbonation resistance can be attributed to the lowered buffer
capacity of calcium bearing hydrated compounds 26
Evolution of carbonation depth in concrete mixes with
similar binder content (360 kg/m3, w/b : 0.45)

1 % CO2 3 % CO2

• Under lesser Carbon dioxide partial pressure both fly ash and LC3
system with similar binder content and w/b ratio show similar
carbonation resistance 27
Natural Carbonation Test
• Climatic zone : Tropical wet and dry climate (Chennai)
• Average concentration of CO2 : 0.04%
• Type of exposure : Sheltered and Unsheltered
• Testing period : 1, 2, 3 and 5 years
• Carbonation depth Measurement: Phenolphthalein indicator

28
Natural Carbonation Results – Unsheltered exposure

• After two years of exposure concrete specimens cast with LC3 showed
higher carbonation than other cementitious systems at similar strength 29
grades
Natural Carbonation Results – Sheltered exposure

• Carbonation depth in sheltered exposure is greater than unsheltered

exposure due to relatively lesser micro climate variation 30
What does this mean for corrosion?

Corrosion Initiation
• Better chloride binding  lesser risk of chloride induced corrosion
initiation
• Greater rate of carbonation  greater risk of corrosion initiation

Corrosion propagation
• Higher resistivity  reduced ionic conductivity, therefore reduced
rate of corrosion propagation
• Better microstructure development  reduced moisture availability,
therefore reduced rate of corrosion propagation

31
Chloride-induced corrosion performance of
steel-cementitious system with OPC, FA30, and
LC3 cements
»Short-term Testing
»Impressed Current Corrosion (ICC) Test
»Wet–Dry Corrosion (WDC) Test

»Long term Testing

»ASTM G109 test

32
 ICC test method - To assess resistance against
corrosion-induced cracking of concrete cover
»Test Parameters
• Concrete: M30 and M50 (15 V)

• Cement: OPC, FA30, and LC3

• 100 mm long TMT bar; 50 mm end
cover
• Applied voltage : 15 V
• Exposure Solution: Simulated pore 100 mm
solution with 3.5% NaCl
(H2O- 966.08 g/l; NaOH-10.4 g/l;
KOH-23.23 g/l; Ca(OH)2-0.3 g/l)
• Duration of testing : Visible crack or
500 hours of voltage application
whichever is earlier

33
ICC test method – Typical results

Test results from Impressed Current Tests

Total Current Vs Exposure Time
6000 0.25
Applied Voltage 15 V OPC M50 500 hours of applied voltage (15V) / till crack opening

(Mass loss %/hour)

Cumulative Current (mA)

5000 Testing Duration 500Hrs 0.2

FA30 M50 Rate of mass loss
     
LC3 M50
4000
0.15 COV COV COV COV COV COV
C
3000 C
0.1
2000
C C
0.05
1000 C

0
0
LC3100system 200 0has300 higher400
Total Time of Exposure (Hours)
resistance
500 600 against
OPC impressed
FA30 LC3current
OPC corrosion
FA30 LC3
compared
Note: Specimens marked with 'C' were cracked to OPC and FA30M30
and testing discontinued systems M45
34
LC3- 50(56)(2:1) IB
WDC test method - Determination of chloride threshold
in steel-cementitious system

Mortar

70mm length
Plastic mould and steel Lollipop Specimen Steel
steel with 4mm
fully threaded SS inside before casting rod
rod

35
Chloride threshold in steel-cementitious system
»Test Variables
»OPC ,FA30, LC3 Cementitious System; Mortar 1:2.75
»QST Steel (8 mm dia)
»Prestressing steel- king wire (5.2 mm dia)
»
3

µ - 1.45 1.22 1.08 1.06 0.55 0.56

Chloride threshold (%bwoc)

COV - 32.15 12.45 38.83 18.39 42.71 34.40

2.5
2
1.5
1
0.5

Lollipop
Test Specimen
0

TMT -OPC PS -OPC TMT-FA30 PS -FA30 TMT -LC3 PS -LC3

LC3 system has less chloride threshold when compared to OPC and
FA30 systems.
36
LC3- 50(56)(2:1) IB
 ASTM G109 - To evaluate long term performance
OPC, FA30 and LC3 steel-cementitious system
Anode
Electroplaters tape
19

65 25
350
Front View Side View All dimensions are in mm
Test Variables
250
»OPC ,FA30, LC3 Note: All dimensions are in mm.
ASTM G109
Cumulative Current (Coulombs)

»QST Steel (16 mm dia) 200

»M30
»Calcium Nitrite based 150
Failure Criteria >150C

Inhibitor Recommended Dosage of the Inhibtor (5l/m )

3

100

OPC and FA30 systems without inhibitors showed some corrosion activity.
50
OPC,FA30 systems with inhibitors and LC3 system with and without inhibitors did
not show any0 corrosion activity
OPC FA30 LC3 OPC FA30 LC3
Without Inhbitor With Inhbitor 37
LC3- 50(56)(2:1) IB
Conclusions from corrosion studies

»LC3 system has higher resistance against impressed

current corrosion compared to OPC and FA30 systems.

»LC3 has lower chloride threshold compared to OPC and

FA30.

»ASTM G109 showed less macrocell corrosion in LC3

compared to OPC and FA30 specimens without
inhibitors. None of the inhibitor specimens have
corrosion activity.
Sulphate Attack Study

»To evaluate the performance of LC3 binder system in: (i)

Sodium Sulphate immersion, and (ii) Magnesium
Sulphate immersion tests
»Compare performance with OPC and FA30 mortars
»Length and mass change measurements
»Evaluation of alteration in hydrated phases by X-ray
diffraction

Mortar Mixture: 0.485 : 1 : 2.75 (Water: Cement : Standard Sand)

PCE based SP was added to LC3 mix to attain workability
Continuous immersion in 33800 ppm sulphate solution

39
Results of length change LC3-50(56)(2:1) IB

T0 = Day 7

Sodium sulphate solution Magnesium sulphate solution

No expansion in LC3 and FA30 mortars even after more than 70 weeks of
exposure; OPC mortars show very high expansion 40
Summary
Limestone-calcined clay ternary systems show good
strength development at early ages, and result in
superior pore structure characteristics.

Resistance to chloride penetration is much better with LC3

concretes as opposed to OPC – at long term, fly ash
concretes and LC3 concretes are similar

Carbonation of LC3 is higher than fly ash concrete, but this

is mainly because of higher replacement levels of the
cement

41