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Underwater Concreting by Using Two-Stage (Pre-placed Aggregate) Concrete”

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 Proceedings of the 1st International Conference on Concrete Technology, Tabriz, Iran, 6-7 November 2009

Paper Code. No. . CT0001

UNDERWATER CONCRETING BY USING TWO-STAGE

(PREPLACED AGGREGATE) CONCRETE

M. F. NAJJAR 1 , H. S. ABDELGADER 2
Civil engineering Department, AL-Fateh University, Libya,
1 engmnajjar@yahoo.com
2 hakimsa@poczta.onet.pl

H. S. ABDELGADER
Civil engineering Department, AL-Fateh University, Libya,
hakimsa@poczta.onet.pl

ABSTRACT
The pouring of underwater concrete is considered as challenge for engineers even during the design or during
implementation and supervision, due to the fact that many precautions must be taken for the success of casting process.
The most important precaution is to protect the fresh concrete during the casting process from the water until the
completion of the pouring of concrete and the concrete harden, so as to avoid the risk of washout of cement past and
segregation of aggregates. Concrete can be placed underwater successfully though good design of concrete mix, and
through choosing the most suitable method for placing of concrete underwater. There are wide ranges of methods for
underwater concreting including traditional methods such as tremie method and pumping method, there are also some
new and non common methods such as grouted aggregate which is known as two-stage concrete method. Two-stage
concrete is considered as one of modern techniques in the concreting industry. The two-stage concrete or pre-placed
aggregate method, as the name implies, consists of filling a form with aggregate and then injecting a grout to fill the
voids through pumping tubes extended to the bottom of the form. The main objective of the research is to present a
study for the capability of preparation and execution of pouring the concrete underwater by using two-stage concrete
method.

Key Words: Underwater concrete, Two stage concrete, Grout, Coarse aggregate.

1 INTRODUCTION

Pouring of concrete underwater is necessary in the implementation process of most inshore

structures such as ports and oil refineries as well as some offshore structures that is near the
seacoast or at the case that the level of ground water table is high and near the ground surfaces.
Underwater concreting is considered as challenge for engineers even during the design or during
implementation and supervision, due to the fact that many precautions must be taken for the success
of casting process. This process can be successfully carried out and good quality concrete produced
if sufficient attention is paid to the concrete mix itself and the methods of construction employed.
Most underwater concrete is mixed on the surface in the conventional manner and then
placed by one of a variety of methods. In many respects the rules and recommendations for
underwater concrete are the same as those for conventional concrete placed in the dry, chief of
which is that air is not required for the setting and hardening of concrete, it sets and hardens just as
well and often even better under water. Thus the aim, when placing concrete underwater, should be
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to keep as much as possible of the concrete out of contact with the water and to avoid any rapid
movement or agitation at the exposed surfaces [1].
The aggregate and laitance which may accumulate as a result of this washing-out has no
structural value and it must not be trapped in the heart of the work by new concrete deposited on
top. It is not normal practice to vibrate concrete underwater, consequently an exceptionally high
degree of workability is required so that the concrete will flow and self compact. Concrete can be
placed in slowly flowing water but where the flow is fast enough to wash the cement from the mix,
the surface of the concrete should be protected or the flow diverted. Sometimes, more concrete is
placed than is theoretically required on the premise that the potentially weaker outer layers of
concrete can be ignored structurally.
The method of placing concrete will be governed to a great extent by the location and the
volume of material to be placed [2]. There are wide ranges of methods for underwater concreting,
this paper presents a study about using two stage concrete for underwater concreting.

2 METHOD OF PLACING CONCRERTE UNDERWATER

When devising a technique of placing concrete under water, the quality of the concrete must be
ensured. However, the critical factors in concrete placing underwater are avoiding segregation and
minimizing the contact between the surface of the concrete and the water:

2.1 Bagwork

Bagwork is probably one of the oldest and simplest techniques of placing concrete underwater; a
common application of bagwork is the construction of retaining walls to act as formwork to mass
concrete pours. The type of bags used here is normally made from an open-weave material such as
hessian. They should be half- filled with plastic concrete, sealed and then taken under water and
placed by a diver. Partial filling allows them to be molded into shape and gives them good contact
areas with adjacent bags. Grout from the mix seeps through the open textured material allowing
bond to be established with adjacent bags. For additional stability the bags can be spiked together
with small-diameter reinforcing bars.

2.2 Skips

Skips are more suitable for thin pours, although it is possible to bury the mouth of the skip in
previously poured concrete to produce deeper pours (Fig.1). The skip should be fully charged in the
dry and covered with a pair of flexible and overlapping covers; these prevent washout during
lowering and also during discharge because they stay in contact with the top surface of the concrete
as it flows out of the bottom [2].

2.3 Tremie

The tremie is one of the traditional techniques used for the placing of concrete underwater, the
tremie consists of a steel pipe mounted vertically in the water (Fig.2). To the top of the pipe is fixed
a hopper, to receive the concrete; it also acts as a reservoir for the supply of fresh concrete. Tremies
are best used for thick pours of any area. For large area pours, multiple tremies are used, spaced at
about 4–6 m apart, depending on the flatness required for the top level [3].

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Paper Code. No. . CT0001

Figure 1: Skip

Figure 2: Schematic of A tremie

2.4 Pumping

The principal advantage of pumping is that concrete can be delivered to the pour site quickly and
virtually continuously. Using static pipe runs, concrete can be pumped over distances of up to 1000
m and the hydraulic boom on most mobile units permits great versatility in placing. The placement
of concrete can be carried out using either a tremie or direct pumping to the underwater site. A
pump pipeline is normally at an angle when used under water and is therefore not as controllable as
a tremie tube; preventing it moving sideways is essential in preventing washout.

2.5 Two stage (Preplaced aggregate) concrete

The two stage concrete method, also known as preplaced aggregate method, is suitable for
underwater work. The technique is particularly applicable in conditions where there is limited
access to the work, in situations where high water velocities exist or where the site is subjected to
wave action, which would normally prohibit the use of conventional placement methods. The two
stage concrete method consists of filling a form with aggregate and then injecting a grout to fill the
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Paper Code. No. . CT0001

voids, as shown in (Fig. 3). We will present study about this method and the advantages of two-
stage concrete.

Figure 3: Two Stage Concrete

3 PERFORMANCE REQUIREMENTS FOR UNDERWATER CONCRETE

Underwater concreting needs special requirements in order to avoid any problems that may be
resulted from the direct contact of fresh concrete and water such as the washout of cement paste,
aggregate separation, and formation of cold joints during the casting process. The properties needed
for underwater concrete are directly related to the method of placement, some of the requirements
of underwater concrete are given as following:

- Flow ability and Self-Compaction

- Workability Retention
- Cohesion Against Washout, Segregation, and Laitance Formation
- Low Bleeding
- Low Heat of Hydration
- Controlled Set Time
- Compressive Strength Adequate
- Durability.

4 TWO STAG CONCRETE

Two-stage concrete (TSC) is considered as one of modern techniques in the concreting industry.
The two-stage concrete or pre-placed aggregate method, as the name implies, placing the coarse
aggregate in the place of destination then grouting the cavities (voids) of the coarse aggregate with a
special mixture (grout) under pumping tubes extended to the bottom of the form, to fill the voids
between aggregate particles. The technology of concretes made by the two-stage method is quite
different from normal traditional concrete, not only in the method of placement but also in that it
contains a higher proportion of stone aggregate; consequently, the properties of the coarse aggregate
appear to have a greater effect on the properties of the concrete than on the cement mortar. In the
case of using two-stage concrete method for underwater concreting, the water and air being
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Paper Code. No. . CT0001

displaced upward by the rising grout front. Injection is continued until a free washout of grout is
emitted from the top of the pour and the voids between the aggregate is completely filed by the
cement grout.

4.1 Properties of coarse aggregate

The choice of stone aggregate is of great importance with respect to the two-stage concrete
method; the aggregate that is used in (TSC) should be washed, free of surface dust and fines. The
void content of the aggregate should be as low as possible and is usually attained when the coarse
aggregate is graded uniformly from the smallest allowable particle size to the largest size [4]. It is
typically 40mm or larger; if aggregates smaller than 20 mm are used then the injected grout tends to
bridge the interstices, thereby impeding grout flow. The mechanics the two-stage concrete depended
on mechanical properties of coarse aggregate, because of the point-to-point contact of the stone
aggregate, the stresses are properties of The characteristic mechanical properties of transferred first
to the stone aggregate and then, after deformations of grains, to the hardened grout.

4.2 Properties of grout

The grout that is used in (TSC) normally consists of ordinary Portland cement and well graded
sand. The flow of the grout around the aggregate is essential, therefore some admixtures are
normally recommended to improve the flow of the grout, improve penetrability, and control the
potential for both shrinkage and bleeding.

4.3 Propagation of mixture in coarse aggregate

The problem of flow and curve of mixture propagation in coarse aggregate is a special
important economic question. Mathematically the description of propagation is very difficult. The
shape of the curve (Fig.4 ) depends on many factors such as: mixture density, intensity of mixing,
hydraulic pressure, shape and size of grains and pores………..etc.

y=f(x)
Y(m)

(0,0)
X(m)

Figure 4 : Propgation Curve of mixture in stone

General empirical equation of propagation curve has been derived [5], and described in Eq.(1)
as follows:
a (1)
y=
g 1
( bx 2 + 1) - +1
t b
Where:
α = thickness of stone layer (m).
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Paper Code. No. . CT0001

β = (a×b×f)
a = parameter dependent of mixture fluidity.
b = parameter dependent of stone : shape, size, kind of grain, surface , number and relation
of fraction.
f = Environment of construction.
γ = (c×d×e)
c=parameter dependent of efficiency of flushing pipe(m3 /min.).
d=parameter dependent of perforation.
e= parameter dependent on the kind of excavation bottom.
t = time (min.)
x = distance from flushing pipe(m),
y = level of mixture mirror in stone (m).
4.4 Grouting systems

The injection is achieved by pumping the grout through vertically mounted pipes which project
almost to the bottom of the section to be cast. These pipes are rigid, normally 20mm in diameter and
placed at 1.5m centers [4]. As the grout is pumped into the form the injection pipes are slowly
raised. Injection of grout into small units can be achieved by pumping into the bottom of the form.

5 ADVANTAGES OF USING (TSC) FOR UNDERWATER CONCRETING

The two-stage concrete completely differs from the normal concrete in the placement and
implementation method. Some of the advantages of two-stage concrete are given as following:

5.1 Economics

The cost of two stage concrete is less than the cost of normal concrete by nearly 40 %. This is
related to the reduction of cement content by 30 % and there is no need for compaction or vibrating
of concrete [5]. In the case of using (TSC) method for underwater concreting, the cost of water-
tight forms and dewatering may be eliminated and preparatory work can be done under water.

5.2 The modulus of elasticity

The modulus of elasticity of two stage concrete is slightly higher than that of conventional
concrete, because of point-to-point contact of the coarse aggregate and it is mainly affected by the
mechanical properties of stone aggregate. Extensive laboratory tests of the two-stage concrete
using three different types of coarse aggregate (rounded, crushed, and mixed) and three different
grout proportions (w/c = 0.45, 0.50, and 0.55; c/s = 1/1.5, 1/1, and 1/0.8) were performed to
describe the concrete mechanical properties [6]. The obtained results and their statistical analysis
allow for formulating the following remarks.
The linear part of the stress-strain curve may reach as much as 40–60% of the compressive
strength of the specimens as shown in (Fig. 5).

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Paper Code. No. . CT0001

Figure 5: Graphical Presentation Of Estimating Two-Stage Concrete Modulus Of Elasticity

The static modulus of elasticity as a function of the compressive strength of the two-stage
concrete is derived. See Eq. (2).

For rounded aggregate:

(2a)
For crushed aggregate:

(2b)
For mixed aggregate:

(2c)

The strength limit values in Eq. (2) are

The two-stage concrete static modulus of elasticity, for the examined types of aggregates and
grout proportions, is mainly influenced by the mechanical characteristics of the aggregates—i.e., the
compressive cylindrical strength, surface texture, and grading. The type of grout has a meaningful
effect. The characteristic mechanical properties of the two-stage concrete can be explained by the
specific stress distributions, which occur mainly through the particles of coarse aggregate (skeleton
of the aggregate).

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Paper Code. No. . CT0001

Figure 6: Relationships Between Modulus Of Elasticity of Two-Stage Concrete And Its

Compressive Cube Strength
5.3 Shrinkage

The drying shrinkage of two stage concrete is lower than that of ordinary concrete about 50%,
due to the contact between the large aggregate particles. This contact restrains the amount of
shrinkage that can take place.

5.4 Segregation of the aggregate

Avoiding the risk of segregation of the aggregate because of the separated statue of the coarse
aggregates and fine aggregates, and also especially for heavy weight aggregate. In the case of using
two-stage concrete method for underwater concreting, the dense grout displaces upwards the water
present between aggregate particles, producing a high aggregate/cement ratio concrete with point-
to-point aggregate contact. This has the advantage of no segregation and low settlement.

5.5 The cold joints

In the case of normal concrete, the cold joints should be executed in specific location, but in the
case of two-stage concrete can be executed in any location, because the coarse aggregate pieces
cross this joint, bond and shear in most cases will be adequate

5.6 Compressive and tensile strength of (TSC)

There is a good correlation between the compressive strength and tensile strength of (TSC). The
compressive strength and the tensile strength of (TSC) were investigated at 28 days for all grout
proportions. On the basis of these results a relationship between tensile and compressive strength of
TSC has been statistically derived. (See Eq. 3)

(3)

Where is tensile strength and is compressive strength. (Table 1) shows the values of the
regression coefficients [7]. The measured tensile strength of TSC is in fact higher than that
predicted by the ACI equation for conventional concrete. The greater mechanical interlocking
among the particles could be responsible for this high tensile strength.

Table 1 Regression Coefficients of Equation (3)

Type of grout A B C D Correlation coefficient
Without admixture -49.67 -0.44 38.63 0.150 0.724

Superplasticizer 39.97 0.36 -32.28 0.100 0.800

Expanding admixture -4.30 -0.30 1.82 0.658 0.721

Combination of
Superplasticizer and 162.65 1.15 132.28 0.108 0.680
Expanding admixture

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Paper Code. No. . CT0001

6 CONCLUSIONS

- The placing of concrete under water is a specialist operation, often working in remote and
difficult conditions and in an unusual environment. If it is incorrectly carried out the
consequences can be undetected and serious; it is therefore essential to pre-plan and to use
personnel experienced in this particular field.
- As it results from previous building investigations. Two stage concrete is the cheapest
method of underwater concreting.
- The quality of two stage concrete is not significantly reduced by placement under water
because the grout is not significantly diluted by the water it displaces from the voids in the
aggregate preplaced in the forms. Therefore, the cost of water-tight forms and dewatering
may be eliminated and preparatory work can be done under water.
- The stress-strain relations as a function of water/cement and cement/sand ratios were
obtained. The linear part of the stress-strain curve may reach as much as 40% to 60% of the
compressive strength of the specimens.
- The initial tangent modulus of elasticity as a function of compressive strength of the two-
stage concrete is derived. The obtained equations allow engineers to improve the design of
the two-stage concrete according to the algorithm presented by [8].
- The two-stage concrete elastic modulus of elasticity is mainly influenced by the mechanical
characteristics of the aggregates, i.e. the compressive cylindrical strength. The type of grout
has meaningful effect. It can be concluded that for the examined types of aggregate and the
grout proportions, the initial tangent modulus of elasticity of two-stage concrete can be
approximated by constant values.
- The relationship between tensile and compressive strength suggests that the tensile strength
of TSC increase with an increase in compressive strength.
- Two stage concrete is suitable for use in effecting repairs and making additions to concrete
structures under water, because of the bond between preplaced aggregate concrete and a
roughened existing concrete is excellent [9].

REFERENCES

[1] CS-TR-35, [2008], Underwater Concreting : Concrete Society, 10 pages.

[2] McLeish, A. and Advisor, E., [1992], Underwater Concreting and Repair, First Edition.

[3] Newman, J. and Seng, B. C., [2003], Advanced Concrete Technology, First Edition , pp.244-
255.

[4] ACI 304R-05, [2005], Guide for Measuring, Mixing, Transporting, and Placing Concrete :
American Concrete Institute, 15 pages.

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[5] Abdelgader, H. S. , [1995] , Polcrete Economical Method For Dams, Proceeding of The MWA
International Conference on Dam Engineering, Vol.1, pp.1-4, Kuala Lumpur, Malaysia, 1-2
August.

[6] Abdelgader, H. S. and Górski, J.[2003], “Stress-strain relations and modulus of elasticity of
two-stage concrete ” Journal of Materials in Civil Engineering ASCE, Vol. 15, No. 4, pp. 329-
334.

[7] Abdelgader, H. S. and Elgalhud, A. A. [ 2008] “ Effect of grout proportions on strength of two-
stage concrete ” Structural Concrete, Vol.9, No.3, pp.163-170.

[8] Abdelgader, H. S. [1999], How to design concrete produced by a two-stage concreting method ”
Cement and Concrete Research, Vol. 29, No.3, pp. 331-337.

[9] ACI 546.2R-98, [1998],Guide to Underwater Repair of Concrete: American Concrete Institute,
10 pages.

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