EPFL Lectures, 10 November 2014

Concretes of XXI Century: Achievements and

Challenges

Roberto Torrent
Civil Eng., PhD

Materials Advanced Services Ltd.

1425 Buenos Aires, Argentina
6877 Coldrerio, Switzerland
torrent.concrete@gmail.com
www.m-a-s.com.ar
Content

Part I: Special Concretes y Applications*

o Present the available tools to develop and produce a
wide range of special concretes
o Show emblematic examples of such concretes
o A glance at the future
Part II: The Durability Challenge

* Not just a mere listing, but explaining the reason of the

versatility of concrete and developing some examples in
more detail

2
Versatility Tools

We have a limited, yet powerful, tool-box to engineer the

properties of concrete.

Basically, we can act on four fronts:

Rheology of fresh concrete

Pore structure
Chemical processes
Fracture mechanics

3
What is Rheology?
Rheology is the science dealing with the deformation
and flow of matter. Some well known branches of
rheology are:
Elasticity
Plasticity
Fluid Mechanics

Here we will concentrate on the rheology of

fresh concrete

4
Rheological Behavior of Newtonian Liquids

g Viscosity
V

5
What is Fresh Concrete: Liquid or Solid?

6
 Fresh Concrete behaves like Bingham (solid) Body

Water, WR

o = Yield Stress
= Plastic Viscosity
7
Fresh Concrete and Toothpaste show similar
rheological behavior

8
SCC and Honey have similar rheological behavior

9
 Factors Affecting the Rheological Parameters

The rheological behavior of fresh concrete

corresponds to the Bingham Model, and is
characterized by the yield stress o (resistance to
flow) and the plastic viscosity . These parameters
can be varied by appropriate changes in:
Water content of the mix
Type and content of very fine particles
Use of different chemical admixtures
Grading of the aggregate

10
Rheological Behavior of Different Concretes

Shear Stress Rigid

Plastic

Soft

Shear Rate

11
Flowing concrete (D=710 mm) SCC . Segregable!

12
Slump flow (D= 650 mm) of a true SCC

13
Advantages of SCC
1) Placing rate, 3 to 15 times higher than conventional
concrete, f(type of element)
2) Less manpower for placing/consolidation of concrete

3) Better working conditions (vibration creates health

problems of workers)
4) Less noise (neighbours complaints, night work, precast
more attractive to qualified workers)
5) Achievement of shapes unthinkable with conventional
concrete
6) Better finishing (less cosmetic work)

14
Shortcomings of SCC
1) Requires strong (> P) and watertight formwork
2) Costs more (~30%)
3) Requires more attention and controls in the Ready-
Mixed Concrete operations
4) Competent, conscious and motivated personnel
5) More responsibility for the producer (SCC?)

15
SCC: Complex or unthinkable shapes

16
Conclusions
Fresh concrete behaves like a Bingham solid
Varying the rheological parameters of fresh concrete it
is possible to produce a wide range of concretes..

Workability and Mobility are not synonymous

17
Concrete that:
Can be demolded immediately after compaction

18
Concrete that:
Withstands heavy loads in the fresh state
(RCC: Roller Compacted Concrete)

19
Concrete that:
Can be raised and placed with conveyor belts

20
 Concrete that:

Can be slipformed along inclined slopes

21
Concrete that:

Can be pumped at long distances and heights

22
Concrete that:

Can be pneumatically sprayed

23
Concrete that:
Can flow freely down along chutes
Flow like liquids without segregation (SCC)

24
Versatility Tools

We have a limited, yet powerful, tool-box to engineer the

properties of concrete.

Basically, we can act on four fronts:

Rheology of fresh concrete

Chemical processes
Pore structure
Fracture mechanics

25
Chemical Processes

Both the intensity and the kinetics of the chemical

reactions taking place within the 'concrete' system can be
controlled, mainly through:

Cement composition and fineness

Use of mineral components or SCM
Cement content in the mix
Use of chemical admixtures
Thermal treatment

26
Chemical Processes

By controlling the chemical processes it is possible to

produce concretes that:

Set almost instantaneously

Remain days without setting
Develop high early strength (fast-track)
Develop low heat of hydration (massive)
Generate controlled expansions that
compensate the drying shrinkage (shrinkage
compensating)

27
High Early Strength: Fast-Track Concrete
20 MPa in 24 hours 20 MPa in 5 hours

Replacement of road and

airport slabs

Industrialized construction
systems (e.g. Outinord)
18-23% fc at 14-18 h
28
Substitution of Airport concrete slabs
London Heathrow

29
Thermal treatment
Insulating mats to retain heat of hydration and accelerate
strength development

30
Mass Concrete: Definition ACI 207
Any volume of concrete with dimensions large enough to
require that measures be taken to cope with generation of
heat from hydration of the cement and attendant volume
change to minimize cracking.
For conventional concretes it refers to structures with
smaller dimension 1 m (dams, locks, large foundations,
etc.)
For high strength concrete, with high cement contents, the
problem may arise for smaller dimensions < 1 m.

31
 Thermal evolution of Mass Concrete

Tmax

Placing T
Ambient T
T rise T drop

Heat of hydration = Dissipation of heat to the environment =

f (binder type and content, f (dimensions, construction process,
dimensions) ambient conditions)

32
From T to to crack: external restraint concept

a) To

Lo

b) To - T

Lo L
c) To - T

Lo
d) if > ft
L
33
Key is to reduce the T drop
Achieved by:

1. Reducing cement content as much as possible

2. Low heat binder

3. Lowering placing temperature (pre-cooling)

4. Removing heat from concrete mass (post-cooling)

34
 Ta = f (Cement Content) for various dams

45
Slope = 0.15 C/(kg/m)
40

35
Ta (C)

30

25
Itaipu (BR)
20 Tucurui (BR)
Various (BR)
15
P.del A. (AR)
10
Record Cmin: 50 100 150 200 250 300
Urugua- (AR):
RCC with 60 kg/m Cement Content (kg/m)
35
 Larger aggregate Dmax, less paste content

Conventional concrete

Mass concrete

100 mm

For dams, Dmax reaches 75 and even 150 mm

36
 Large aggregates create some problems....

300x300x1200 mm

450x900 mm 150x300 mm

300x600 mm Young RT testing E modulus of

dam concrete

37
 Effect of Pre-cooling

Peak
Temperatura T

Months,
Years

Mean Annual
Temperature

~3 days Time
Pre-cooling of materials: aggregates and water (ice), liquid N2
38
Post-cooling of Xiluodu Dam, China

Pipes to
circulate cool water

39
Examples of massive Structures

40
New Panama Canal
Main shortcomings of conventional concrete floors
a) Slabs dimensions limited by the need
of contraction joints (5 a 7 m),
necessary to avoid cracks
b) Water evaporation from upper face
generates moisture gradients through
the slab thickness and differential
shrinkage. This creates curling of the
slab, rising the edges and corners
with loss of flatness of the floor and
bending fractures due to lack of
support

41
Demands of modern industrial floors

Lifting vehicles work with

heavy loads at high altitudes

42
Demands of modern industrial floors
High flatness to avoid dangerous swinging of the vehicles
Departure from verticality interferes with the bar codes
reading of products and the automation of the storage system

43
Demands of modern industrial floors

Joints are the weak point of the floor, reduce the service
life of vulnerable wheels of the vehicles (e.g. Nylon wheels)
and interfere in the correct operation of vehicles
44
 Number of joints must be minimized
55 mm 30 m
30 m

90 m

90 m
90 m 90 m

90 m
90 m
90
90 mm

3.060 m of joints 360 m of joints

Less damage to wheels

Less No. of joints = Less damage to joints = Less costs!
Less maintenance
45
Behaviour of ShCC

Expansion

Shrinkage-
Compensating
Concrete

1 7 14 28 56 90 180 360
Shrinkage

Age (days)

Conventional
Concrete

Moist Dry

46
Shrinkage Compensating Concrete (ShCC)
ShCC is a concrete that generates an early controlled
expansion which, if properly restrained by steel
reinforcement or other means, compensates the expected
drying shrinkage. Due to the restraint, during the
expansive phase, concrete will undergo a controlled
precompression which will be relieved during the
subsequent shrinkage phase.

As a result, in its final hygral equilibrium state, concrete

will reach a zero stress condition or a slight residual
compressive state, that minimizes the risk of cracking.
ShCC floors do not curl.

47
 Concepto bsico del CRC
Steel bar (upper 1/3) Concrete
Slab
Original Length

T T
C
Initial expansion puts the steel in tension,
precompressing the concrete

T T
C
During the shrinkage phase there is a loss of srtess due to
shrinkage and creep. The bar remains under slight tension and the
concrete under slight compression.
Null final deformation or slight residual expansion
48
> 1 million m of ShCC floors in Argentina

49
Concrete International, May 2003
Versatility Tools

We have a limited, yet powerful, tool-box to engineer the

properties of concrete.

Basically, we can act on four fronts:

Rheology of fresh concrete

Chemical processes
Pore structure
Fracture mechanics

50
Range of Pores and Voids in Hardened Concrete

Entrapped
Air

Entrained
Capillary Pores Air

Gel Pores

0.001 0.01 0.1 1 10 100 1000 10000

Pore size (m) 1 10 mm

51
Pore Structure
The main tools available to modify the pore structure of
concrete are:
w/c ratio (volume and size of capillary pores)
cement content (volume of gel and capillary pores)
use of active MIC or SCM (e.g. pozzolans)
use of micro-fillers (e.g. silica fume)
use of pore blockers/sealers (e.g. polymers)
use of air / gas entrainers (volume and size of micro-
bubbles)
use of porous aggregates
use of special grading of aggregates ("no-fines"
concrete)
52
Pore Structure

Varying the pore structure of concrete it is possible to

obtain:
A wide range of lightweight concretes
Porous, draining, yet strong concretes
Frost-resistant concretes
Controlled-low strength materials (e.g. flowable fill)
High-strength concretes (up to 150 MPa)
Highly impermeable and durable concretes

53
Pore Structure: Lightweight Concretes

54
Pore Structure: Features of Cellular Concrete

55
Pore Structure: Pervious/Draining Concrete

Strength in the range 10 30 MPa

58
Pore Structure: High-Strength Concrete
Petronas Towers (Kuala Lumpur), 452 m (88 stories)

59
 High Strength Concrete and SP

480 m

No SP With SP 420
Burj
Eiffel Khalifa
311 South Tower 360
Wacker Drive
Water Tower 300
Place 80
MPa
Lake Point 240
Tower
60
MPa 180
Executive 89
House MPa 120
80
60 MPa

0
Chicago Chicago Chicago Chicago Kuala Lumpur Paris Dubai
1959 1968 1975 1989 1996 1889 2010
113 m 197 m 262 m 295 m 452 m 300 m 828 m

SP = Superplastizicer = HRWR 60
 Pore Structure: Effect on Properties

Property Typical values Concrete type

200 - 800 Lightweight (insulating)
800 - 1400 Lightweight (insulating and structural)
Density (kg/m) 1400 - 2000 Lightweight (structural)
2000 - 2600 Normal weight
2600 - 5000 Heavyweight (radiation shield)
0.5 - 2.0 Flowable fills
Compressive 0.4 - 30 Lightweight
Strength (MPa) 15 - 60 Normal strength
60 - 150 High-strength
Modulus of 2 - 15 Lightweight
15 - 35 Normal strength
Elasticity (GPa)
30 - 50 High-strength
Thermal Conductivity 0.1 - 1.0 Lightweight
(W/m.K) 1.0 - 2.5 Normal weight
<0.1 High-strength (>65 MPa)
0.1 - 0.5 Good quality
Permeability to Air 0.5 - 2.5 Medium quality
(10-16 m) 2.5 - 12.5 Poor quality
>12.5 Very poor quality
Draining, aerated

61
Pore Structure: High-Strength Concrete

62
Versatility Tools

We have a limited, yet powerful, tool-box to engineer the

properties of concrete.

Basically, we can act on four fronts:

Rheology of fresh concrete

Chemical processes
Pore structure
Fracture mechanics

63
Fracture Mechanics

Although the intrinsic weaknesses of concrete as structural

material (brittleness and low tensile strength) have been
successful overcome through the composite reinforced
concrete, there is still scope for improvements.
The use of fibers (metallic, synthetic, carbon, glass,
vegetable, etc.) has not yet been sufficiently explored and
exploited. This is an area where developments can be
expected to improve the ductility of concrete and its
cracking susceptibility.

64
Fibers in Concrete
Fiber Types
Steel
Polypropylene
Polyvinyl Acetate
Cellulose
Glass (Alkali-Resistant)
Carbon
Asbestos (health!!)

Used in:
Ready-Mixed Concrete
Shotcrete (tunnels)
Precast Concrete

65
 Fibers in Concrete: Hybrid Fibers Systems

35
5% Glass 40:20:40
30 G:PP:PVA
Flexural Stress (MPa)

5%
25

20 2% PVA

15

10
5% PP
5

0
0 1 2 3 4
Deflection (mm)
PVA: polyvinyl alcohol PP: Polypropylene 66
Future challenges
High-Perforance Concretes
(especially linked to durability aspects)
Concretes with nanotechnology
Self-Compacting Concrete
Concrete reinforced with different fibers types
Non-metallic / non-corroding reinforcement (FRP)
Green Concretes (made partly or entirely from
recycled materials)
Self-healing concretes
Ultra-high strength concretes
Service Life Design

67
 Nanotecnology in Concrete
Aerogel: gel of matter in air instead of liquid,
Silica Aerogel: = 80 99.8 %; = 2 250 kg/m

Aerogel

Lightweight
aggregate

68
Nanotecnology in Concrete

Experiment to measure fire protection

Exposed side
(T~ 950C)
400x400x50 mm plate of
Aerogel Concrete
( = 580 kg/m

Opposite side
(T~ 63C)
69
Self-healing of Concrete with bacteria

Ice

Bacilla Levan
glue

Water Aggressive
ions

filaments calcite

70
A cement spring?, yes, D. Birchall made it long ago

71
Frontiers of the Imagination: UHS Concrete

Ultra High-Strength Concretes Characteristics:

Compressive Strength: 150 800 MPa
Bending Strength: 10 400 MPa
Virtually impermeable (unlimited durability)

72
UHPFRC mechanical properties
tensile behaviour :
UHPFRC CC

Compress.
[MPa] 160-250 ~ 40
strength

E modulus [GPa] 48-60 ~ 35

Tensile
[MPa] 9-20 ~3
strength

Strain
[%] 0.05 - 0.2 0
hardening

First crack
[MPa] 7-16 ~3
strength

Shrinkage: 0.6 to 1.0 %o

73
 UHS Concrete: Applications

Pedestrian Bridge in
Sherbrooke (CND)

fc: 200 MPa (350 MPa confined)

ft: 7 MPa
fb: 40 MPa
E: 50 GPa

74
UHS Concrete: Applications
SHAWNESSY LIGHT RAIL TRANSIT
STATION
Calgary, AB, Canada

75
UHS in Costa Rica

76
UHS in Costa Rica

77
UHS in Costa Rica

78
UHS in Costa Rica

79
UHS in Costa Rica

80
UHS in Costa Rica

First Stage:
Compressive strength: 170 MPa.
Flexural Strength: 23 MPa.
No rebar, no steel bars/wires.

Steam curing

81
Expo-Construccin 2006, Costa Rica

fc: 150 MPa

Thickness: 4 cm.

82
UHSC Costa Rica

83
Expo-Construccin 2006, Costa Rica

Thickness = 25 mm
84
Concrete: Special Applications

86
Concrete: Special Applications

87
Concrete: Special Applications

88
Concrete: Special Applications

89
Concrete: Special Applications

90
Concrete: Special Applications

91
Concrete: Special Applications

Translucent Concrete

LiTraCon

Light-transmitting glass optical

fibres cast into concrete

92
Concrete: Special Applications

LiTraCon

93
Frontiers of the Imagination: Lunar Concrete

Will concrete play a

role in Space
Conquest?

94
Frontiers of the Imagination: Lunar Concrete

Yes,
concrete may have a role
in Space Conquest

95
Back to Earth: Prospects of Concrete

Concrete will continue to be the preferred building

material of this century, although with fierce competition
from different flanks
More attention will be paid to the design of concrete
structures for durability, to improve the life cycle of
sustainable constructions
Through the increased usage of recycled waste as raw
materials, concrete will turn into eco-concrete

96