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1. No-fines concrete
It is a kind of concrete in which the fine aggregate fraction has been omitted. This concrete is made
up of only coarse aggregate, cement and water. Very often only single sized coarse aggregate of
size passing through 20mm and retained on 10mm is used.
No-fines concrete can be defined as a lightweight concrete composed of cement and tine
aggregate. Uniformly distributed voids are formed throughout its mass. The main characteristics of
this type of lightweight concrete is it maintains its large, voids and not forming laitance layers or
cement film when placed on the wall.
No fines concrete usually used for both load bearing and non-load bearing for external walls and
partitions. The strength of no-fines concrete increases as the cement content is increased.
However, it is sensitive to the water composition. Insufficient water can cause lack of cohesion
between the particles and therefore, subsequent loss in strength of the concrete. Likewise too
much water can cause cement film to run off the aggregate to form laitance layers, leaving the bulk
of the concrete deficient in cement and thus weakens the strength.
3. Aerated concrete
Aerated concrete does not contain coarse aggregate, and can be regarded as anaerated mortar.
Typically, aerated concrete is made by introducing air or other gas into a cement slurry and fine
sand. In commercial practice, the sand is replaced by pulverized fuel ash or other siliceous material,
and lime maybe used instead of cement.
There are two methods to prepare the aerated concrete. The first method is to inject the gas into
the mixing during its plastic condition by means of a chemical reaction.
The second method, air is introduced either by mixing-in stable foam or by whipping in air, using an
air-entraining agent. The first method is usually used in precast concrete factories where the
precast units are subsequently autoclaved in order to produce concrete with a reasonable high
strength and low drying shrinkage. The second method is mainly used for in-situ concrete, suitable
for insulation roof screeds or pipe lagging.
The properties of light weight concrete can be categorized into two types
Functional properties.
Structural properties
Functional properties
Thermal Insulation- Lightweight aggregate concrete has excellent insulating properties. The Co-
efficient of thermal expansion of light aggregate concrete is less than that of normal weight
concrete and is primarily a function of the component materials. Thermal Conductivity is a measure
of the rate at which heat energy passes through a unit area of material of unit thickness per degree
temperature gradient.
Density and Strength- The most obvious characteristic of light weight concrete is its density, which
at times could be only being a fraction of that of ordinary concrete. Light weight concrete brings in
a distinct advantage of having appreciable reduction of dead loads, lower haulage and handling
costs. Based on density and strength following are types of light weight concrete;
Light weight concrete of low strength and exceptionally good thermal insulation having
densities 1n the range of 250 to 800 kg/m3.
Light weight concrete of medium strength and adequate thermal insulating properties
having densities range of 800 to 1400 kg/m3.
Light weight concrete of structural strength (not less than 17.5 M pa) and limited thermal
insulating property having density in the range of 1400 to 2100 kg/m3.
Acoustic Properties- Noise nuisance may be avoided by suppression of the sound as its source or by
isolating it from the zone where it is generated. Light weight concrete has not been considered to
have any special sound insulating value. Compared to slightly higher sound insulation than might be
expected from mass law, light weight concrete: show moderately good built in sound absorption
coefficients of value ranging from 0.2 to 125 cps to 0.5 at 4000 cps frequencies.
Water Absorption- Lightweight concretes particularly those used in blocks, being porous in nature,
have a higher tendency to absorb water than dense concrete. Since light weight concretes in
practice are not generally used without water proofing to prevent rain penetration, this is not
considered to be of significance in practice.
Fire protection- More effective the protection than compared to conventional concrete.
Structural properties
Structural light weight concretes have come of age as an important and versatile material in
modern construction.
It has many and varied applications such as multistory buildings frames and floors curtain
walls, shell roofs, folded plates bridges, pre-stresses or precast elements of all types.
High quality structural light weight concrete can safely be used in reinforced concrete
columns, including ultra-high rise buildings.
The low density of cellular concrete makes it suitable for precast floor and roofing units
which are easy to handle and transport from the factory to the sites.
As load bearing masonry walls using cellular concrete blocks.
As precast floor and roof panels in all types of buildings.
As a filler wall in the form of precast reinforced wall panels in multistoried buildings
As partition wall in the residential, institutional and industrial buildings
As in situ composite roof and floor slabs with reinforced concrete grid beams.
As precast composite wall or floor panels
An insulation cladding to exterior walls of all types of buildings particularly in office and
industrial buildings.
In high rise building can save money and manpower considerably. In addition to the reduced
dead weight the lower modulus of elasticity and adequate ductility of light weight concrete
may be advantageous in the seismic design of structures.
Other inherent advantages of the material are its greater fire resistance, low thermal
conductivity, low co-efficient of thermal expansion, and lower erection and transport costs
for pre-fabrication members.
For pre-fabricated structures a smaller crane is required or the same crane can handle large
unit due to reduction in dead weight.
For cast in-situ structures, its smaller dead weight makes foundation less expensive.
Disadvantages of Light Weight Concrete
Suitability of pumice, scoria and saw dust as light aggregates for making light weight concrete
Pumice
These are rocks of volcanic origin which occur in many parts of the world. They are light enough and
yet strong enough to be used as light weight aggregate. Their lightness is due to the escaping of gas
from the molten lava when erupted from deep beneath the earth’s crest. Pumice is usually light
colored or nearly white and has a fairly even texture of interconnected cells.
Scoria
Scoria is also lightweight aggregate of volcanic origin which is usually dark in color and contains
large and irregularly shaped cells unconnected with each other. Therefore, it is slightly weaker than
pumice.
Saw dust
Sometimes saw dust is used as a light weight aggregate in flooring and in the manufacture of
precast products. A few difficulties have been experienced for its wide-spread use. Saw dust affect
adversely the setting and hardening of Portland cement owing to the content of tannins and soluble
carbohydrates. With saw dust manufactured from soft wood, the addition of lime to the mix in an
amount equal to about 1/3 to 1/2 the volume of cement will counteract this.
Concrete is said to be high density concrete its unit weight ranges from 3360 t0 3850 kg/m3, which
is about 50% higher than unit weight of conventional concrete.
High density concrete is used in the construction of radiation shields to prevent hazards effect of
radiation.
Concrete is an excellent material for radiation shielding material that possesses need characteristics
for both gamma ray and neutron attenuation has satisfactory mechanical properties and has a
relatively low initial maintenance cost. Also the ease of construction makes concrete a specially
suitable material for radiation shielding.
There are many aggregates whose specific gravity is more than 3.5 for making heavy concrete out
of these commercially employed aggregates are barite, magnetite, limonite, hematite etc. are used
also available materials are steel, and iron aggregates in the form of shots, punching scraps for use
of heavy weight aggregates since the capacity of various heavy weight aggregates to absorb gamma
rays is directly proportional to their density, also the heavier elements are more effective in
absorbing fast neutrons by inelastic collision than the higher ones, as heavy aggregates as possible
should be used for this purpose.
However, density is not the only factor to be considered in the selection of an aggregate for
neutron shielding. The desired increase in hydrogen content, required to slow down fast neutrons
can be accomplished by the use of hydrogen’s ores. These materials contain a high percentage of
water for hydration. On heating the concrete, some of this fixed water in the aggregate may be lost.
Limonite and goethite are reliable sources of hydrogen as long as shield temperature does not
exceed 200°C. Whereas serpentine is good up to about 400°C.
How do you increase the density of concrete required for radiation shielding? What are the
Problems encountered in the preparation of high density concrete?
The density of concrete can be increased by using the aggregate of high density.
There are many aggregates which have specific gravity more than 3.5 for making high
density concrete out of these; the commercially employed aggregates are BARITE,
MAGNATITE, ILMENITE, LIMONITE, HEMATITE etc...
Also available are steel and iron aggregates in the form of SHOTS, PUNCHING SCRAPS etc.
For heavy weight concrete aggregate used must be Clean, strong, inert, and relatively free
from deleterious materials which might impair the strength in concrete.
The problems that may be encountered during the preparation of high density concrete are:
As the cement content is high, concrete may exhibit increased creep and shrinkage.
By the use of high density aggregate, there will be tendency of segregation.
Good quality control has to be followed while preparing high density concrete.
Radiation Shielding is necessary due to following reasons
1. To thermalize the fast moving neutrons by using hydrogen ions.
2. To capture thermal Neutrons by adding Boron or Cadmium into the concrete.
3. To produce secondary particles this can be shielded easily.
4. To effectively shield against secondary particles produced
5. To minimize the built up of long lived activity.
Why high density concrete is the preferred material for biological Shielding?
Concrete is commonly used for biological shielding in nuclear power plants, medical units and
atomic research and testing facilities other materials can be employed for this purpose but concrete
is usually the most economical and has several concrete are being used for shielding purpose.
However where usable space is limited the reduction in the thickness of the shielding is
accomplished by the use of heavy weight concrete heavy weight concrete are produce generally by
using natural heavy weight aggregates the concrete unit weight are in the range 210 to 240 lb/ft³,
which is about 50 percent higher than the unit weight of concrete containing normal weight
aggregate. Two types of radiation have to be considered in the design of biological shield. First are
X-rays and Gamma rays which having a high power, of penetration but can be absorbed adequately
by an appropriate mass of any material most material attenuate these high energy, high frequency
electromagnetic waves primarily according to the Compton .scattering effect. The attenuation
efficiency being approximately proportional to the mass of the material, different materials of the
sane mass have the ability to offer equal protection against x rays and Gamma rays. The second
type of radiation involves neutrons, which are heavy particles of atomic nuclei and do not carry an
electrical charge. Thus neutrons are not affected by the electric field of the surroundings and
therefore slow down only on collision with atomic nuclei.
Materials
Cement- In addition to use Portland cement special cements such as magnesium oxy chloride
cements have been used mainly to realize as residual water content as feasible. This is intended to
satisfy the desirable features of hydrogen and oxygen in neutron shielding.
Aggregates:
Since over 73% of concrete is made up of coarse aggregates it is logical to expect that choice of
aggregate having higher specific gravity enables in an appreciable measure to realize high densities.
Naturally occurring aggregates include material such as magnetite, barites and limonite steel
shots, sheared bars, scrap iron, steel punching and leg fall under man made aggregates.
Steel should be preferably degreased prior to use to promote rusting. sometimes both natural and
manmade aggregate are used in combination .while specific gravity of natural aggregates may vary
only in the range of 3.6-4.7 , for steel shot punching it is in the range of 7.5-7.74. Some of the values
of specific gravities of natural aggregates noted in some of the investigation are 3.61 to 3.7 for
limonite and geolite, 4.23-4.67 for magnetite and 4.1 for barite. Barite is known to occur as a
natural rock with a purity of 95% the aggregate tends to break up; hence care must be taken in
handling and processing and over mixing should be avoided. Iron ore in the form of magnetite,
limonite and goethite have been used for aggregate and limonite has also been fused as fine
aggregates.
Barites
Composed of Barium Sulphate
Optimum sizes are between 10-20 mm for concrete production
Density in around 2600 kg/m3
Lower and of high density concrete can be produced
Magnetite
Form of Iron Oxide (Fe2 O4)
Ideal Sizes 10 to 20 mm for coarse grain and 6 mm for fine grain.
Relative density around 3000 kg/m3.
Medium range high density concrete can be produced.
Haematite
Form of Iron Oxide (Fe2O3)
Contains 70% Iron of total Composition
Size of 20 mm is ideal as coarse grain aggregate
Relative density is around 2900 kg/m3.
Uneven and sub-concoidal fracture
Limonite
Another type of Iron Ore used in high density concrete
60% of Fe
Relative Density is 2300 kg/m3
Hardness: 4-5.5
Uneven Fracture
Water content:
One of the objectives in designing a neutron shield is to provide sufficient water and other
light elements so not to impair its effectiveness foe slowing down fast neutrons. Witter content of
hardened concrete below 4% by weight causes marked reduction in shield efficiency, the fixed
water content concrete can be increased by using aggregates such as limonite which contain
crystallized water.
At higher temperature working conditions beyond 2000 C the amount of free evaporable
water contained in the shield can be increased by using porous aggregate sulphadite keeping
concrete cool and sealing the surface of concrete with impermeable membrane or replenishing nee
water.
Admixture:
Water reducing admixture is used Consists Lignosulfonic acid, carboxylic acids. Uses of
Water reducing admixture in high density concrete are
Increase workability
Conventional method
This method is cheaper and can be adopted when
Steel pieces are not used as coarse aggregates.
When natural heavy weight aggregates are used.
When forms are relatively free of embedded items.
Following precautions are to be taken when conventional method is adopted.
1. Prevention of overloading of the mixer and segregation
2. Use of vibrator during placement with discretion
Pre-packed method
To avoid the possibility of segregation this method is used. In this method coarse aggregate are
placed in the forms and the inter void. Spaces later filled with rich cement mortar grout. Pre-
packed method assures uniform distribution of heavy aggregate throughout the Shield.
The specific advantages of this method over conventional method are
1. Segregation of coarse aggregates particularly that of steel punching can be minimized.
2. Concrete of uniform density composition can be laced more easily in confined areas and around
embedded items.
3. Several types of aggregates in combined can be used.
4. There is flexibility of varying the type of aggregate of one zone to another.
Puddling method
This method of placements consists of spreading several cms of mortar in the form and the inter-
void spaces later filled with rich cement mortar front pre-packed method assumes uniform
distribution of heavy aggregates throughout the shield.
The specific advantage of this ova conventional method is that it avoids the segregation 0f coarse
aggregates.
Discuss the properties of high density concrete in fresh state and hardened state.
Structural requirements of concrete shields are used quite low due to large thickness adopted.
Properties such as specific heat and thermal conductivity are important where thermal stress
problems are encountered. Based on test results of heavy steel aggregate concretes, we conclude
that the strength of concrete is proportional to its density. Properties of high density concrete
made with iron aggregate have been studied. Differences in the properties of conventionally placed
and repacked with high dense concrete, it was possible to have aggregate graded from course and
fine.
With respect to bond strength repacked concrete exhibits equal to or slightly greater than
those of conventionally placed specimens. In general, the physical and structural properties of
concrete made with iron bearing aggregate are found to be reasonable. It was also found that
magnetic concrete exhibited good structural characteristics.
Applications
High Density Concrete pre-engineered designs to meet your radiation and non-radiation
applications:
High density radiation shielding.
Linear accelerator vaults and treatment rooms.
High dose rate HDR rooms.
Mass concrete projects.
High density concrete applications columns.
Gravity seawall, coastal protection & breakwater structures.
Bridge counterweights.
Ballast for ocean vessels and off shore platforms.
Noise and vibration dampening.
Nuclear Industries
Dense biological shielding is required.
Necessary to avoid every kind of radiation including beta and gamma.
Density required is highly unpredicted.
Used in medical institutes to avoid X-ray exposure.
Counterweights
High density concrete is used to manufacture counterweights.
If weight is greater than 5 tonnes.
Low cement requirement and hence reduced cost.
Offshore Concreting
To cover underwater pipes.
Magnetite aggregate is used to manufacture concrete.
Important Questions
1. Explain the classification of lightweight concrete.
2. Explain the different types of lightweight concrete.
3. Explain the functional and structural properties.
4. Discuss the suitability of pumice, scoria and saw dust as light aggregates for making light weight
concrete
5. What are the situations under which light weight concrete is used?
6. How do you increase the density of concrete required for radiation shielding? What are the
Problems encountered in the preparation of high density concrete?
7. Why high density concrete is the preferred material for biological Shielding?
8. Explain Different methods of placement of high density concrete
9. Discuss the properties of high density concrete in fresh state and hardened state.
10. Problems on LIGHTWEIGHT CONCRETE.