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Super Performing Construction Materials

Article · January 2014

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 Super Performing Construction Materials
A. Choudhary*, N. Dogne*, R. K. Pandit**
Abstract
This article deals with an introduction and implementation of super
performing building materials and techniques in reference to energy saving
efficiency of the material, cost efficiency, application feasibility, availability,
vernacular characteristics, life span, etc. Materials are considered super
performing when they contribute something to upgrade the quality of
building. With all advancements in construction techniques and also with the
demand of end users for smart buildings, we as constructors and designers
ought to introduce something new and smart to fulfill their demands and
needs. Smart structures and material technologies are a tool for sharing the
knowledge of how various building materials can significantly increase
production and profit using advanced communication, collaboration and
management technologies. This article provides an overview of the types of
materials available giving a new insight into innovative methods and
techniques that will be available, and opens new doors for advancement and
improvement in the construction industry. The new materials discussed in this
article present a small fraction of the options that are available for use by
industry.

Keywords: Smart materials, Advanced concrete, Energy efficient, Cost

Cutting, Time saving, Safety purposed construction material, Repurposed,
Hyper- Performance.

Literature Study
Concrete is a composite material composed
mainly of water, aggregate, and cement. Usually
there are additives and reinforcements included to
achieve the desired physical properties of the
finished material. When these ingredients are
mixed together, they form a fluid mass that is
easily molded into shape. Over time, the cement
forms a hard matrix which binds the rest of the
ingredients together into a durable stone- like
material with many uses. 1 The Colosseum in
Rome was built largely of concrete, and the
concrete dome of the Pantheon is the world's
largest unreinforced concrete dome. 2, 3Mineral
admixtures and blended cements contain Ground
granulated blast furnace slag (GGBFS or GGBS):
A by- product of steel production used to partially
replace Portland cement (by up to 80% by mass).
It has latent hydraulic properties. 4 Silica fume: A
byproduct of the production of silicon
and ferrosilicon alloys. Silica fume is similar to fly
ash, but has a particle size 100 times smaller. This
results in a higher surface- to- volume ratio and a
much faster pozzolanic reaction. Silica fume is
used to increase strength and durability of
concrete, but generally requires the use of super
plasticizers for workability. 5
Plastic is the generic name for a family of
synthetic materials derived from petrochemicals. It
is often the product of two or more components. 6
There are many families of plastics and polymers
being used in construction industry. Examples of
plastics used in buildings are Acrylic Composites,
Expanded Polystyrene, Polycarbonate,
Polyethylene, Polypropylene and Polyvinyl
Chloride. Examples of Products of Plastics usedin
the Construction industry are as follows:
 Pipes: Electrical Conduits, Rain Water &
Sewage pipes, Plumbing, Gas Distributions.

*Student, Deptt of Arch, MITS Gwalior 474005

**Professor& Head, Deptt of Arch, MITS Gwalior 474005.
Correspondence to: Mr. A. Choudhary, Deptt of Arch, MITS Gwalior 474005.
E- mail: choudharyashish30@yahoo.com

© ADR Journals 2014. All Rights Reserved.

11
 Cables: PVC Insulation on cables, Insulation
Tapes.
 Floorings: Flooring tiles & Rolls.
 Domes / sky lights: Opaque as well as
transparent.
 Roofing: Colored or double skinned for
insulation.
 Windows & doors: Extruded sections for
Door and windows and panels.
 Storage tanks: Storage tanks.
 Hardware accessories: Washers, Nut bolts,
Sleeves, Anchoring wires.
 Temporary structures: Guard cabins, tents.
 Insulation materials: PVC sheets, insulating
membranes.
Metal foam is a cellular structure consisting of a
solid metal, frequently aluminum, as well as a
large volume fraction of gas- filled pores. The
pores can be sealed (closed- cell foam), or they
can form an interconnected network (open- cell
foam). The defining characteristic of metal foams
is a very high porosity: typically 75–95% of the
volume consists of void spaces, making these ultra
light materials. The strength of foamed metal
possesses a power law relationship to its density;
i.e., a 20% dense material is more than twice as
strong as a 10% dense material. 7
Steel is an alloy of iron and carbon that is widely
used in construction and other applications
because of its hardness and tensile strength.
Carbon, other elements, and inclusions within iron
act as hardening agents that prevent the movement
of dislocations that naturally exist in the iron
atom crystal lattices. The carbon in typical steel
alloys may contribute up to 2.1% of its weight.
Varying the amount of alloying elements, their
formation in the steel either as solute elements, or
as precipitated phases, retards the movement of
those dislocations that make iron so ductile and
weak, and thus control qualities such as
hardness, ductility, and tensile strength of the
resulting steel. Steel's strength compared to pure
iron is only possible at the expense of ductility, of
which iron has an excess. 8
Super Performance is, introducing these
materials in such a way that they perform more
efficiently than their conventional style of use.
That can be done by alterations in their
manufacturing processes or inculcating some other
material with them to get best of both of them.
J. Adv. Res. Const. Arch. Engi. 2014; 1(3&4): 10- 19.
Choudhary A et al.
Introduction
To understand all how and about of super
performing construction materials, we must study
materials according to their use from the very root
to the tip. Then, we can easily conclude and infer
about the application, implementation and
feasibility of that particular construction material.
Elements of construction where these smart
materials and techniques shall be implemented
are:
 Foundation
 Plinth
 Beam
 Column
 Wall
 Sill
 Window
 Door
 Roof
 Parapet
 Skylights
 Finishing Works
Construction materials are said to be super
performing when they-
 Save overall building energy
 Make building esthetically pleasing
 Cut cost of construction
 Easily available
 Increase life span of building
 Upgrade building quality
 Make the building safe for living
Super Performing Materials
1. High Performance Concrete
Lafarge has developed a whole new family of concretes
called Ductal. These concretes have high compressive
and flexural strength, and their special characteristics
enable the achievement of outstanding architectural
feats. Ductal concrete incorporates strengthening fibers
and opens the horizon to ultra-high performance due to
its special composition which provides it with
outstanding strength, six to eight times greater than
traditional concrete (under compression).“Fiber-
reinforced” means that it contains metal fibers which
make it a ductile material. Highly resistant to bending,
its great flexural strength means it can withstand
significant transformations without breaking. 9 Ductal
also comes with organic fibers for applications with less
load, and for advanced architectural applications.
Choudhary A et al.
Super- Performance
 Ultra- high performance with ductility:
strength, ductility, durability
 Easy to use & highly moldable: flow-
able, dry- cast, form replication
 Superior esthetics & quality surface
aspect: colors, textures, surface
 Compressive Strength: 150 MPa to 200
MPa
Figure 1.Stress- Strain Ration Comparison in Ductal
and Concrete
2. Light Transmitting Concrete
The days of dull, grey concrete could be about to
end. A Hungarian architect has combined the
world’s most popular building material with
optical fiber from Schott to create a new type of
concrete that transmits light. A wall made of
“LitraCon” allegedly has the strength of traditional
concrete but thanks to an embedded array of glass
fibers can display a view of the outside world,
such as the silhouette of a tree. “Thousands of
optical glass fibers form a matrix and run parallel
to each other between the two main surfaces of
every block,” explained its inventor Áron
Losonczi. 11 Shadows on the lighter side will
appear with sharp outlines on the darker one. Even
the colors remain the same. This special effect
creates the general impression that the thickness
and weight of a concrete wall will disappear. 11
The hope is that the new material will transform
the interior appearance of concrete buildings by
making them feel light and airy rather than dark
and heavy.
Advantages and Disadvantages
 The main advantage of these products is
J. Adv. Res. Const. Arch. Engi. 2014; 1(3&4): 10- 19.
12
 Flexural Strength: 20 MPa to 50 MPa
 Ductility: Greater capacity to deform and
support flexural and tensile loads, even
after initial cracking
 Abrasion Resistance: Similar to natural
rock
 Impermeability: Almost no carbonation
or penetration of chlorides
Figure 2.Ductal in use
that on large scale objects the texture is still
visible - while the texture of finer
translucent concrete becomes indistinct at
distance.
 When a solid wall is imbued with the ability
to transmit light, it means that a home can
use fewer lights in their house during
daylight hours.
 It has very good architectural properties for
giving good aesthetical view to the
building.
 Transparent concrete can be used at the
place where light is not able to come
properly.
 Energy saving can be done by utilization of
transparent concrete in building.
 Totally environment friendly because of its
light transmitting characteristics, so energy
consumption can be reduced.
 The main disadvantage is that this concrete
is very costly because of the optical fibers.
 Casting of transparent concrete block is
difficult for the labor so special skilled
person is required.
13 Choudhary A et al.

Product LitraCon Light transmitting

Concrete
Form Prefabricated blocks
Ingredients 96% concrete, 4% optical fiber
Density 2100-2400 Kg/m2
Block size 600mm x 300mm
Thickness 25-500mm
Color White, Grey or Black
Fiber distribution Organic
Finished Polished
Compressive strength 50 N/mm2 Figure 2. Light transmitting Concrete
Bending Tensile 7 N/mm2
strength

3. Pervious Concrete flow- through ratio inspired the phrase “the

Pervious pavement is a cement- based concrete
product that has a porous structure which allows
rainwater to pass directly through the pavement
and into the soil naturally. This porosity is
achieved without compromising the strength,
durability, or integrity of the concrete structure
itself. The pavement is comprised of a special
blend of Portland cement, coarse aggregate rock,
and water. 12 Once dried, the pavement has a
porous texture that allows water to drain through it
at the rate of 8 to 12 gallons per minute per square
foot. Tests conclude that a square foot of Bahia
sod drains at the rate of 2.5 to 3 gallons per
minute. According to the manufacturer, this rapid
pavement that drinks water.”
Super Performance`
 Reduce storm water runoff from paved area.
 Eliminate the need for detention ponds and
other costly rain water management practices.
 Replenish water tables and aquifers.
 Allow more efficient land development.
 Minimize flash flooding and standing water.
 Prevent warm and polluted water to enter our
stream.
 Mitigate surface pollution.

Figure 3.Pervious Concrete

4. Aerated Concrete
It was discovered in 1914 in Sweden that adding
aluminum powder to cement, lime, water, and
finely ground sand caused the mixture to expand
dramatically. The Swedes allowed this “foamed”
concrete to harden in a mold, and then they cured
it in a pressurized steam chamber-- an autoclave.
13 Autoclaved aerated concrete is produced by
about 200 plants in 35 countries and is used
extensively in residential, commercial, and
industrial buildings. At a density of roughly one-
fifth that of conventional concrete and a
compressive strength of about one- tenth, AAC is
used in load- bearing walls only in low- rise
buildings. In high- rises, AAC is used in partition
and curtain walls. 14

J. Adv. Res. Const. Arch. Engi. 2014; 1(3&4): 10- 19.

Choudhary A et al.
Super Performance
 Reduces Additional Material Use and
Minimizes Waste and Pollution
The ability of a product to reduce material use,
utilize recycled products, and avoid toxic
emissions are key criteria in determining whether
a product qualifies as “green” or can be used in a
sustainable manner. First, AAC consumes a
relatively small amount of raw material relative to
the amount of finished product produced. Because
AAC is approximately 80% air, the finished
product is up to 5 times the volume of the raw
material consumed in its production. Additionally,
the raw materials that are consumed are generally
abundant and found in most geographic regions,
allowing them to be locally sourced. Furthermore,
much of the raw materials used in AAC
production may consist of recycled materials,
including copper mine tailings and fly ash, a
byproduct of coal- fired power plants.
Second, with respect to embodied energy, AAC
consumes approximately 50% and 20% lesser
energy than that needed to produce concrete and
CMUs, respectively.
 Has High Thermal Efficiency
Autoclaved aerated concrete is further considered
a sustainable building product because of its
excellent insulating qualities resulting in increased
energy efficiency. AAC’s thermal efficiency stems
from three factors. First, AAC structures result in
solid wall construction with integrated insulation.
Entire wall coverage prevents the thermal bridging
associated with conventional stud- framed walls,
which essentially leave cold gaps around every
stud and header.
Second, the solid wall construction of AAC
structures creates an airtight building envelope,
minimizing uncontrolled air changes while helping
maintain desired indoor temperatures and
maximizing the efficiency of HVAC equipment.
Third, AAC structures benefit from the added
value of thermal mass and low thermal
conductivity. Though an eight inch AAC wall has
a steady state R- value of approximately 8.4, here
in Sacramento, the same wall has an “effective” or
“mass- enhanced” R- value of about 21.8. The
benefits of thermal mass, however, vary by
14
location, and are greatest in regions where the
outdoor temperature fluctuates above and below
the desired indoor temperature over a 24- hour
period.
 Reduces Noise Pollution and
Improves Indoor Air Quality
An additional quality contributing to the
sustainability of a building product is its ability to
reduce and absorb noise or to improve or maintain
indoor air quality. Due to its millions of
independent air cells, which dampen sound
transmission, AAC has excellent sound insulation
and absorption qualities. Because of this benefit;
many of the first applications of AAC in the
United States have been the construction of hotels
and freeway sound walls.
Moreover, because AAC construction has very
low air infiltration and is mould resistant, indoor
air quality of AAC structures is improved relative
to competitors. AAC’s performance both as a
structural and insulation material also eliminates
the need for other materials (like fiberglass
insulation) that may contribute to poor indoor air
quality.
 Structures Well- Suited to Withstand
Fires, Earthquakes, and Other
Natural Disasters
AAC is inorganic, non- combustible, and virtually
fireproof. It receives a 4 hour UL fire rating and
has a melting point of over 2900 degrees
Fahrenheit. As a result, the use of AAC eliminates
the need for additional fireproofing materials.
Moreover, because AAC is completely inert, it
does not emit toxic gases even when exposed to
fire.
AAC buildings can be engineered for earthquake
and hurricane prone areas, and such buildings
have performed well to date. For example, the vast
majority of AAC homes in the 1995 Kobe, Japan
earthquake survived substantially undamaged.
They were also immune from fires started during
the earthquake and even acted as firebreaks. The
ability of AAC structures to withstand fires and
natural disasters minimizes waste, contamination
to the surrounding environment, and the need for
repair materials, while also lowering insurance
costs.
J. Adv. Res. Const. Arch. Engi. 2014; 1(3&4): 10- 19.
15
Figure 4.Light weight AAC
5. Foamed Aluminum
“Light- as- air, stronger- than- steel materials are
just beginning to shape our world. Foamed
aluminum first emerged from the lab in the form
of a 1998 Karman concept car. Ten times stronger
than traditional aluminum at just one tenth the
weight, the material allows a more fuel- efficient
vehicle. Its isotropic cellular structure helps the
frame absorb shock and serves as an insulating
firewall between the engine and the rest of the car.
Figure 5.Processes in Foaming of Aluminum
Properties of aluminum foams
Aluminum foams are isotropic porous materials
with several unusual properties that make them
especially suited for some applications. Due to
their low densities between 0.3 g/cm3 and 0.8
g/cm3, the foams can float in water (in case of
closed porosity). Foams exhibit a reduced
conductivity for both heat and electricity. 15
J. Adv. Res. Const. Arch. Engi. 2014; 1(3&4): 10- 19.
Choudhary A et al.
The foaming process can also be applied to steel,
lead, tin, and zinc.” The product is a high strength,
extremely light weight material that possesses
high durability, excellent finish and lasting value.
The foam comes in an assortment of densities and
sizes up to five feet wide and up to fifty feet long.
It has numerous applications including
architectural, automotive, marine, military,
aviation, transportation, electronics, appliances,
and signage.
The strength is lower than conventional dense
aluminum and declines with decreasing
density. Foams are stable at temperatures up to
the melting point. They are incombustible and
non- toxic. In most foam production
technologies, the properties can be varied over
a wide range by controlling the production
parameters.
Choudhary A et al.
Figure 6.Products of Foamed aluminum
Super Performance
 Efficient energy absorption
 Excellent stiffness- to- weight ratio
 Nearly isotropic – Multi- axial loading
 Low thermal conductivity
 Fire resistant
 Shock wave attenuation
 Sound and vibration damping and
absorption
 Flexible density and properties
 Recyclable
6. Aerogel
Aerogel or “Air glass” is a transparent material
that looks like glass, insulates better than mineral
wool and is more heat resistant than aluminum.
The material has many interesting properties and
possible applications such as insulation in
windows and solar collectors, windows in
firewalls, a component in air- conditioning
equipment, etc. Aerogel is molded, giving the
possibility of getting different shapes: cylinders,
cubes, plates of varying thickness etc. Chemically,
Aerogel is composed of quartz and a great deal of
air, making it fragile. The grains of quartz are
small compared to the wavelength of light, giving
Aerogel good transparency properties. At around
750°C (1380°F), it starts to shrink and slowly
Properties
Density 50-200 kg/m3
Refractive Index 1.02-1.05
Heat Transfer Coefficient 0.021 W/m 0C At 20 0C rising to 0.2 W/m 0C At 300 0C
Non Deforming Up to 750 0C
Chemical Composition 99.99 % SiO2
Grain Size 10-30 nm ᴓ
16
collapses to a piece of ordinary quartz. Aerogel
can be cut with a band saw and holes can be
drilled with a metal drill. It should be noted that
Aerogel is non- flammable and non- toxic, on
basis of manufacturing process. Some of its types
are classified as TEOS, Ti02, NaWG.
Super Performance
 It is strong enough to support a weight 1600
times its own weight.
 It has capacity to absorb impact so it can be
used as bomb proof materials.
 It has large sound absorption - low sound
velocity, damping > 50 dB, v1 ≈ 100 m/s. It
can be used as acoustic material.
 It can be manufactured as transparent or
opaque or even colored with variable
refractive index (1,001 to 2, 1).
Aerogel Tiles
 Manufacturing Company : Airglass
(Sweden)
 Material : Silica (precursor TMOS:
Methanol)
 Hydrophilic
 Drying is made super critically (methanol)
J. Adv. Res. Const. Arch. Engi. 2014; 1(3&4): 10- 19.
17
Figure 7.Aerogel
7. Laminated Thermo Plastic Panels
A thermoplastic, also called a thermo-
softening plastic is a plastic which becomes
pliable or moldable above a specific
temperature and returns to a solid state upon
cooling. Most thermoplastics have a
high molecular weight. The poly- molecules
chains associate through intermolecular forces,
which permit thermoplastics to be remolded
because the intermolecular interactions
increase upon cooling and restore the bulk
properties. In this way, thermoplastics differ
from thermosetting polymers, which form
irreversible chemical bonds during the curing
process. Thermo- sets often do not melt, but
break down and do not reform upon cooling.
Blizzard Composite GmbH manufactures high-
tech plastic composites for the architectural
field as well as the trucking industry. Their
core expanding machinery heats up and
vertically expands solid thermoplastic sheets,
which are then processed into sandwich panels
by lamination equipment. Due to the unique
geometry of the Pep Core, the panels are of low
weight and provide an excellent combination of
high stiffness and compressive strength.
Thermoplastics: Advantages
Disadvantages
Advantages
• The softening or melting by heating allows
welding and thermoforming.
• The processing cycles are very short because
of the absence of the chemical reaction of cross
linking.
J. Adv. Res. Const. Arch. Engi. 2014; 1(3&4): 10- 19.
Choudhary A et al.
• Processing is easier to monitor, because there
is only a physical transformation.
• Thermoplastics don’t release gases or water
vapor if they are correctly dried before
processing.
• The wastes are partially reusable as virgin
matter because of the reversibility of the
physical softening or melting.
Disadvantages
• When the temperature rises, the modulus
retention decreases, due to the absence of
chemical links between macromolecules.
• For the same reason, the creep and relaxation
behaviors are not as good as for the thermoses.
• During a fire, fusibility favors dripping and
annihilates final residual physical cohesion.
Super Performance
 Better dimensional stability – reduction in
warping shrinkage and creep.
 Low co- efficient of thermal expansion.
 Retention of mechanical properties over a
much wider temperature range.
 Low co- efficient of friction and therefore
/ improvement in wear resistant property.
 Higher stiffness and rigidity.
 Higher impact strength at higher & lower
temperatures.
 Improvement in flexural strength and
modulus.
 Higher heat distortion temperature.
 Imparting electrical and thermal
conductivity.
Choudhary A et al.
Figure 8.Thermoplastic panels in use
8. High Volume Slag Cement Concrete
Slag is the glass- like by- product left over after
a desired metal has been separated
(i.e., smelted) from its raw ore. Slag is usually
a mixture of metal oxides and silicon dioxide.
However, slag can contain metal sulfides and
elemental metals. While slag is generally used
to remove waste in metal smelting, they can
also serve other purposes, such as assisting in
the temperature control of the smelting, and
minimizing any re- oxidation of the final liquid
metal product before the molten metal is
removed from the furnace and used to make
solid metal.
Ground- granulated blast- furnace
slag (GGBS or GGBFS) is obtained by
quenching molten iron slag (a by- product of
iron and steel- making) from a blast furnace in
water or steam, to produce a glassy, granular
product that is then dried and ground into a
fine powder. Further, this fine powder is mixed
with Portland cement as per requirement of
properties.
HVSC is cement in which amount of slag is
slightly more than that of fly ash in fly ash
cement.
Figure 9.Setting time graph of different types of slag cement
J. Adv. Res. Const. Arch. Engi. 2014; 1(3&4): 10- 19.
18
Super- Performance
 Fresh HVSC Properties
Normally, the paste volume in slag cement
concrete is higher than in Portland cement
concrete for the same cement content (in mass)
due to the relatively lower density of slag
(about 2.9g/cm3) than that of clinker (about
3.15 g/cm3). The increased paste volume can
normally improve the workability of concrete
with low paste content or lack of fine particles
in aggregate.
 Strength
High fineness of slag cement increases the
compressive strength, but the enhancement is
much less prominent at early ages than that for
Portland cement. The compressive strength
increases with increasing glass content in the
slag as well, especially with regard to the later
ages. However, slag with completely vitreous
glass does not always lead to the highest
strength. A low percentage of crystallization
(3–5 percent in mass) was found to be
beneficial to the compressive strength
development.
 19 Choudhary A et al.

Conclusion
After the brief study on performance of these to understand the materials around us and their
materials, it can be concluded that today, the most efficient properties that can be useful in
promising technologies for life time efficiency and construction industry for better results. It is must
improved reliability for lifespan include the use of to develop new materials from conventional
smart materials and structure. It is very important materials to enhance their performance and make
them fit for use in future.
S. No. Material Base Material(s) Applications Benefits
1. High Performance Concrete, For Long span structures Strength, Durability
Concrete Steel Fiber
2. Light transmitting Concrete, For capture maximum Energy Saving
Concrete Optical Fiber Day Light
3. Pervious Concrete Concrete Pavements Saves water run off
4. AAC Concrete Light weight Structure Cost Effective, Durable
Construction
5. Foamed Aluminum Multiple Strength, Durability,
Aluminum Heat Resistance
6. Aerogel Silica Skylights, Partition walls Heat insulation, Sound
Insulation, Energy saving
7. Thermoplastic Many Plastics Skylights, Partition walls Heat insulation, Sound
Insulation, Energy saving
8. Slag Cement Slag, Portland Cement Substitute Strength, Waste
Cement management,
Cost effective
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J. Adv. Res. Const. Arch. Engi. 2014; 1(3&4): 10- 19.

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