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Technical Report Documentation Page

1. Report No. 2. Government Accession No. 3. Recipient's Catalog No.
ICAR 103
4. Title and Subtitle 5. Report Date
USE OF HIGH FINES CONCRETE (HFC) IN INSULATED September 2001
CONCRETE FORM (ICF) CONSTRUCTION 6. Performing Organization Code

7. Author(s) 8. Performing Organization Report No.

Dan G. Zollinger Research Report ICAR 103
9. Performing Organization Name and Address 10. Work Unit No. (TRAIS)
Texas Transportation Institute
11. Contract or Grant No.
Texas Texas A&M University System
College Station, Texas 77843-3135 Project No. ICAR 103
12. Sponsoring Agency Name and Address 13. Type of Report and Period Covered
Aggregates Foundation for Technology, Research and Education Research: August 20 1998 -
2101 Wilson Blvd, Ste 100 October 31 1999
Arlington, Virginia 22201-3062 14. Sponsoring Agency Code

15. Supplementary Notes

Research performed in cooperation with the International Center for Aggregate Research and Aggregates
Foundation for Technology, Research and Education
Research Project Title: Development of a Controlled Low Strength Material for Use in Residential Concrete
Building Systems
16. Abstract

This project work consisted of developing technical data to justify, from the standpoint of material
properties (of aggregate fines and HFC), construction efficiency, cost competitiveness, and energy
performance, a basis for the use of high-fines concrete (HFC) inside ICF wall systems. Although several
aspects of the study are listed above, the report primarily concentrates on the material aspects of a limited
number of aggregate fines sources and their use in HFC relative to strength development and placeability.
Originally, emphasis was planned to be placed upon the use of a controlled low strength material (CLSM)
but due to strength requirements currently in force for ICF construction, it was determined that greater
benefit would be derived from highlighting the advantages of using aggregate fines in ICF concrete. A
framework for developing suitable HFC mixture designs for different ICF wall systems relative to placement
and strength characteristics is discussed. These guidelines were based upon results from the construction to
two residential structures using HFC and the placement of 4 trial wall systems. One of the structures
consisted of a Atest model@ that was used to investigate methods of construction and the energy efficiency of
an ICF wall system.

17. Key Words 18. Distribution Statement

Concrete, Fines, Sand, Aggregate, Workability, No restrictions. This document is available to the
Pumping, Mixture Design, Insulated Concrete Form public through NTIS:
National Technical Information Service
5285 Port Royal Road
Springfield, Virginia 22161
19. Security Classif.(of this report) 20. Security Classif.(of this page) 21. No. of Pages 22. Price
Unclassified Unclassified 126
Form DOT F 1700.7 (8-72) Reproduction of completed page authorized
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Use of High Fines Concrete (HFC) in Insulated

Concrete Form (ICF) Construction:

by

Dan G. Zollinger
Associate Research Engineer
Texas Transportation Institute

Report ICAR 103

Project Number 103
Research Project Title: Development of a Controlled Low Strength Material
for Use in Residential Concrete Building Systems

Sponsored by the

The International Center for Aggregate Research

September 2001

TEXAS TRANSPORTATION INSTITUTE

The Texas A&M University System
College Station, Texas 77843-3135
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DISCLAIMER

The contents of this report reflect the views of the authors, who are responsible for
the facts and the accuracy of the data presented herein. The contents do not necessarily
reflect the official view or policies of the International Center for Aggregate Research or
AAB Building Systems. The report does not constitute a standard, specification, or
regulation, nor is it intended for construction, bidding, or permit purposes. The engineer in
charge of this project was Dan G. Zollinger, P.E. #67129.

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ACKNOWLEDGMENTS

Research findings presented in this report are a result of a project carried out at the
Texas Transportation Institute (TTI), Texas A&M University. The authors would like to
thank the staff of the International Center for Aggregate Research or AAB Building
Systems for their support throughout this research project. The authors would also like to
recognize significant contributions made by the following organizations and individuals:

Texas Transportation Institute

_Texas Industries
_Pioneer Concrete
_Dr. Roger Gold
_Chemlink
_Tenneco Building Products
_Flexible Products
_Thermothru Doors
_Holnam Cement
_ACME Brick

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TABLE OF CONTENTS
Page
List of Figures ........................................................................................................................ ix
List of Tables .......................................................................................................................xiii
Chapter 1 Use of Concrete in Residential Construction ...................................................... 1.1
Scope of Work ............................................................................................................... 1.4
Objectives ................................................................................................................ 1.4
Beneficial Aspects of ICF Construction ........................................................................ 1.5
Economical Considerations of ICF Construction ........................................................ 1.11
ICF Construction Practices .......................................................................................... 1.13
Chapter 2 Considerations for the Use of Fines in Concrete ............................................... 2.1
Research on Fines in Concrete....................................................................................... 2.1
Use of Fines in Concrete................................................................................................ 2.1
Implications of the Literature Review ........................................................................... 2.6
Testing Protocol Considerations.............................................................................. 2.7
Protocol for Testing Relevant to HFC ........................................................................... 2.7
Fines Classification for Use in HFC .............................................................................. 2.9
HFC Performance Considerations ......................................................................... 2.14
Application of Classification System .................................................................... 2.19
Conclusions.................................................................................................................. 2.29
Chapter 3 Properties of HFC Relative to ICF Construction ............................................... 3.1
Laboratory Test Program ............................................................................................... 3.1
Module Construction ............................................................................................... 3.7
Chapter 4 Case Study in ICF Construction.......................................................................... 4.1
Introduction.................................................................................................................... 4.1
General Features ............................................................................................................ 4.1
Specific Construction Details ........................................................................................ 4.3
Concrete Factors ...................................................................................................... 4.4
Interior Finishing ..................................................................................................... 4.5
Construction Costs ......................................................................................................... 4.9

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TABLE OF CONTENTS (Continued)

Chapter 5 ICF Construction and Energy Test Module ........................................................ 5.1

Test Module Temperature Instrumentation ................................................................... 5.2
Heat Transfer Considerations ........................................................................................ 5.3
Boundary Conditions of Heat Transfer.................................................................... 5.6
Heat Transfer Analysis ............................................................................................ 5.7
Chapter 6 Summary and Conclusions.................................................................................. 6.1
References........................................................................................................................... R.1
Appendix A ICF Wall Configurations................................................................................ A.1
Appendix B Micrographs of Aggregate Fines .................................................................... B.1
Appendix C X-Ray Diffraction Patterns of Aggregate Fines ............................................. C.1
Appendix D Laboratory Test Results ................................................................................. D.1
Appendix E Laboratory Cracking Results ...........................................................................E.1
Appendix F HFC Performance Rating.................................................................................F.1

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LIST OF FIGURES
Figure Page
1.1 ARXX=s Building Products Concrete Wall Form.............................................. 1.2
1.2 Residential Concrete Building Systems. Left to Right: Hebel
Block Rasta, ICF, and Polystyrene ICFs .......................................................... 1.3
1.3 Construction of the Thomas A. Edison Home [Collins, 1959].......................... 1.6
1.4 Completed Home of Thomas A. Edison [Collins, 1959]................................... 1.7
1.5 (a) Panel System; (b) Plank System; (c) Block System
[VanderWerf et al., 1997] ................................................................................ 1.15
1.6 (a) Flat System; (b) Grid System; (c) Post-and-Beam System
[VanderWerf et al., 1997] ................................................................................ 1.16
1.7 Examples of House Footprint Irregularities; Curved Walls, Non-90°
Angles, and Frequent Corners [VanderWerf et al., 1997] ............................... 1.17
1.8 Examples of Forming Curved Walls by Bending ICF Panels (top)
and Blocks (bottom) [VanderWerf et al., 1997] .............................................. 1.17
1.9 Curved Walls Formed by Bending the Face Shells of Units Assembled
in the Field [VanderWerf et al., 1997]............................................................. 1.18
1.10 Curved Wall Formed by Cutting the Ends of the Units at Angles
[VanderWerf et al., 1997] ................................................................................ 1.18
1.11 Placement of Opening in ICF Wall Section [VanderWerf et al., 1997] .......... 1.19
2.1 Water Demand of Reference Concrete, and Concretes Containing
10 Percent Fines............................................................................................... 2.26
2.2 Compressive Strength at 7 and 28 Days Note: LS-Limestone N-Natural ....... 2.26
2.3 Porosity of Reference Concrete, and Concretes Containing 10, 20,
and 30 Percent Siliceous Fines ........................................................................ 2.27
2.4 Porosity of Reference Concrete and Concretes Containing 10, 20,
and 30 Percent Limestone Fines ...................................................................... 2.27
2.5 Shrinkage vs. Time for Concrete Samples Containing
Limestone Fines ............................................................................................... 2.28
3.1 Aggregate Grading............................................................................................. 3.2

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LIST OF FIGURES (Continued)

Figure Page
3.2 Ring Test Specimen ........................................................................................... 3.5
3.3 Compressive Strengths for Mixture Combination # 1 ....................................... 3.6
3.4 Shrinkage and Creep Strain Comparisons for Mixture
Combination # 1................................................................................................. 3.6
3.5 Forms Provided by AAB Building Systems ...................................................... 3.7
3.6 Test Module Fin Construction ........................................................................... 3.8
3.7 Fin and Slab Placement...................................................................................... 3.8
3.8 Test Module HFC Placement............................................................................. 3.9
3.9 Placement of Test Module Concrete.................................................................. 3.9
3.10 Green Roof System of TTI Test Module ........................................................... 3.9
3.11 Finished Test Module ...................................................................................... 3.10
4.1 Preformed Aluminum Archway in Background; Braces for
Wall Blowouts in Foreground............................................................................ 4.2
4.2 Floor Plan of Gold Home................................................................................... 4.3
4.3 ICF Units with Spanners.................................................................................... 4.4
4.4 Gold Home in Rockport, Texas ......................................................................... 4.6
4.5 Rear View, Showing Second Floor.................................................................... 4.7
5.1 Basic Layout of ICF Test Module ..................................................................... 5.1
5.2 Layout of Test Module Temperature Instrumentation....................................... 5.3
5.3 Test Module Mapping Scheme .......................................................................... 5.3
5.4 Test Module Thermo-Couple Temperatures...................................................... 5.5
5.5 Average Test Module Temperatures.................................................................. 5.6
5.6 Heat Transfer Analysis of Typical ICF Wall Section........................................ 5.8
A.1 (a) Flat Panel System Wall; (b) Grid (Interrupted) Panel
System Wall ...................................................................................................... A.3
A.2 (a) Post-and-Beam Panel System Wall; (b) Flat Block
System Wall ...................................................................................................... A.3
A.3 (a) Flat Plank System Wall; (b) Grid (Interrupted) Block
System Wall ...................................................................................................... A.3

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LIST OF FIGURES (Continued)

Figure Page

A.4 Post-and-Beam Block System Wall.................................................................. A.4

B.1 Showing the Distribution of Fine and Coarse (A) Particles
(Source Number 1)............................................................................................ B.3
B.2 Subrounded and Subangular Morphology of Grains
(Source Number 1)............................................................................................ B.3
B.3 An Elongated Particle (A) with a High Aspect Ratio of 8:1
(Source Number 1)............................................................................................ B.4
B.4 Distribution of Dolomite Rhombs (A) and Subrounded Calcite
Crystals (B) (Source Number 1) ....................................................................... B.4
B.5 Distribution of Elongated (A) and Coarse (B) Particles
(Source Number 2)............................................................................................ B.5
B.6 Quartz (A) and Calcite (B) Grains in the Sample (Source Number 2) ............. B.5
B.7 Overall Particle Size Distribution is Finer than that of Source
Number 1 Shown in Figure B.1 ........................................................................ B.6
B.8 Particle Size Distribution of Source Number 1 ................................................ B.6
C.1 X-ray Diffraction Pattern of Fines from Source Number 1 (Limestone).......... C.3
C.2 X-ray Diffraction Pattern of Fines from Source Number 2 (Siliceous)............ C.4
D.1 Strength Data for 400-lb HFC Mixture............................................................. D.3
D.2 Bleeding Data for 400-lb HFC Mixture............................................................ D.3
D.3 Shrinkage Data for 400-lb HFC Mixture .......................................................... D.3
D.4 Strength Data for Lightweight Aggregate HFC Mixture.................................. D.4
D.5 Bleeding Data for Lightweight Aggregate HFC Mixture................................. D.4
D.6 Shrinkage Data for Lightweight Aggregate HFC Mixture ............................... D.4
D.7 Strength Data for HFC Mixture Containing 100 Percent Fines........................ D.5
D.8 Bleeding Data for HFC Mixture Containing 100 Percent Fines....................... D.5
D.9 Shrinkage Data for HFC Mixture Containing 100 Percent Fines..................... D.5
D.10 Strength Data for Control Mixtures ................................................................. D.6

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LIST OF FIGURES (Continued)

Figure Page
D.11 Bleeding Data for Control Mixtures ................................................................ D.6
D.12 Shrinkage Data for Control Mixtures ............................................................... D.6
E.1 Concrete Strength at Cracking...........................................................................E.3
E.2 Total Creep Strain ..............................................................................................E.3

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LIST OF TABLES

Table Page
1.1 Sample Costs of ICF Wall Construction [VanderWerf et al., 1997] ............... 1.13
2.1 Substitution of Limestone Fines in Malhotra and Carrette Study ..................... 2.2
2.2 Influence of Aggregate Fines-Related Material Properties on
HFC Performance ........................................................................................ 2.8
2.3 Parameters to Classify Fines............................................................................ 2.10
2.4 Sand Equivalent Results .................................................................................. 2.20
2.5 Classification of Particles in Fines................................................................... 2.21
2.6 Elemental Composition (Percent by Mass) of Aggregate Fines...................... 2.24
2.7 Mixture Design for Limestone Fines Concrete................................................ 2.25
3.1 HFC Mixture Factors ......................................................................................... 3.1
3.2 Typical HFC Mix Design Material Properties................................................... 3.2
3.3 Specific Mixture Combinations ......................................................................... 3.3
3.4 W/CM vs. W/S for 400-lb HFC......................................................................... 3.4
3.5 HFC Mixture Proportions .................................................................................. 3.5
5.1 Cross Section Thermal Properties....................................................................... 54
F.1 HFC Performance Rating...................................................................................F.3

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