SPECIAL CONCRETE

The Maharaja Sayajirao University of Baroda

Faculty Of Technology
 SPECIAL CONCRETE

 Light weight concrete

 Plum concrete
 Fibre reinforced concrete
 Polymer concrete
 High density concrete
 No fines concrete
 Ferro cement
 Self compacted concrete
 Ready mix concrete
 Lightweight concrete

 Lightweight concretes can either be lightweight aggregate

concrete, foamed concrete or autoclaved aerated concrete (AAC).
 Such lightweight concrete blocks are often used in house
construction.
 Light weight concrete - or foamed concrete - is a versatile material
which consists primarily of a cement based mortar mixed with at
least 20% of volume air.
 The material is now being used in an ever increasing number of
applications, ranging from one step house casting to low density
void fills.
 Lightweight concrete

 Normal concrete has a density of 2,400 kg/m3 while densities

range from 1,800, 1,700, 1,600 down to 300 kg/m3.
 Compressive strengths range from up to 40 MPa down to almost
zero for the really low densities.
 Generally it has more than excellent thermal and sound insulating
properties, a good fire rating, is non combustible and features cost
savings through construction speed and ease of handling.
 The adoption of light-weight concrete gives an outlet for industrial
wastes such as clinker, fly ash, slag.
 Lightweight concrete create by by three different ways.
 ( a ) By replacing the usual mineral aggregate by cellular
porous or light-weight aggregate.
 ( b ) By introducing gas or air bubbles in mortar. This is
known as aerated concrete.
 ( c ) By omitting sand fraction from the aggregate. This
is called ‘no-fines’ concrete.
 Out of the three main groups of light-weight concrete,
the light-weight aggregate concrete and aerated
concrete are more often used than the ‘no-fines’
concrete.
Group of Light weight concrete
Light Weight Aggregates
 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 coloured or nearly white and has a
fairly even texture of interconnected cells.
 Diatomites :-
 This is a hydrated amorphous silica derived from the
remains of microscopic aquatic plants called diatoms. It is
also known a Kieselguhr. The deposits of this aquatic
plants are formed beneath the deep ocean bed.
Subsequently when the ocean bed is raised and becomes
continent, the diatomaceous earth become available on
land. In pure form diatomite has an average weight of 450
kg/m3
Light weight concrete
 High Density Concrete
 Density of normal concrete is in the order of about
2400 kg. per cubic metre.
 The density of light-weight concrete will be less than
about density 1900 kg per cubic metre.
 High density concrete, it must have unit weight
ranging from about 3360 kg per cubic metre to 3840
kg per cubic metre, which is about 50% higher than
the unit weight of conventional concrete.
 However be produced with the densities upto about
5280 kg per cubic metre using iron as both fine and
coarse aggregate. The high density concrete is used in
the construction of radiation shields.
light weight conrete
 Plum concrete

 The original idea of the use of aggregate as an inert filler can be

extended to the inclusion of large stones up to 300 mm size in a
normal concrete; thus the apparent yield of concrete for a given
amount is increased. The resulting concrete is called Plum
Concrete.
 It is a fluid, concrete can be pumped to where it is needed.
 Here, a concrete transport truck is feeding concrete to a concrete
pumper, which is pumping it to where a slab is being poured
Plum concrete
 Fibre reinforced concrete

 Fibre reinforced concrete can be defined as a composite material

consisting of mixtures of cement, mortar or concrete and discontinuous,
discrete, uniformly dispersed suitable fibres. Continuous meshes, woven
fabrics and long wires or rods are not considered to be discrete fibres.

 Concrete made with Portland cement has certain characteristics: it is

relatively strong in compression but weak in tension and tends to be
brittle.
 The weakness in tension can be overcome by the use of conventional rod
reinforcement and to some extent by the inclusion of a sufficient volume
of certain fibres.
 The use of fibres also alters the behaviour of the fibre-matrix composite
after it has cracked, thereby improving its toughness
 Fibre is a small piece of reinforcing material
possessing certain characteristic properties. They can
be circular or flat. The fibre is often described by a
convenient parameter called “aspect ratio”. The
aspect ratio of the fibre is the ratio of its length to its
diameter. Typical aspect ratio ranges from 30 to 150.
Fibre reinforced concrete
Fibre reinforced concrete
 The use of fibres

 For the effective use of fibres in hardened concrete fibres should be

significantly stiffer than the matrix.
 Fibre content by volume must be adequate.
 There must be a good fibre-matrix bond.
 Fibre length must be sufficient.
 Fibres must have a high aspect ratio, i.e. they must be long relative
to their diameters of elasticity than the matrix
 Types of fibre

 Glass
 Steel
 Synthetic fibres
 Carbon
 Nylon
 Polyester
 Types of fibre

1. Glass
 Glass-fibre products exposed to outdoor environment have shown
a loss of strength and ductility.
 The reasons for this are not clear and it is speculated that alkali
attack are possible causes.
 Because of the lack of data on long-term durability, GRC has been
confined to non-structural uses where it has wide applications.
 Glass fibre is available in continuous or chopped lengths. Fibre
lengths of up to 35-mm are used in spray applications and 25-mm
lengths are used in premix applications.
 Types of fibre

2. Steel
 Steel fibres have been used in concrete since the early 1900s. The
early fibres were round and smooth and the wire was cut or
chopped to the required lengths.
 The use of straight, smooth fibres has largely disappeared and
modern fibres have either rough surfaces, hooked ends or are
crimped or undulated through their length.
 Modern commercially available steel fibres are manufactured from
drawn steel wire, from slit sheet steel that have a crescent-shaped
cross section.
 Typically steel fibres have equivalent diameters (based on cross
sectional area) of from 0,15 mm to 2 mm and lengths from 7 to 75
mm.
 Types of fibre

3. Synthetic fibres
 Synthetic fibres are man-made fibres resulting from research and
development in the petrochemical and textile industries.
 There are two different physical fibre forms: monofilament fibres,
and fibres produced from fibrillated tape
 Types of fibre

4. Carbon
 Carbon fibre is substantially more expensive than other fibre types.
For this reason its commercial use has been limited.
 Carbon fibres are manufactured by carbonizing suitable organic
materials in fibrous forms at high temperatures and then aligning
the resultant graphite crystallites by hot-stretching.
 The fibres are manufactured as either Type I (high modulus) or
Type II (high strength) and are dependent upon material source and
extent of hot stretching for their physical properties.
 Types of fibre

5. Nylon
 Nylon is a generic name that identifies a family of polymers.
 Nylon fibre’s properties are imparted by the base polymer type,
addition of different levels of additive, manufacturing conditions
and fibre dimensions.
 Currently only two types of nylon fibre are marketed for concrete.
Nylon is heat stable, hydrophilic, relatively inert and resistant to a
wide variety of materials
 Types of fibre

6. Polyester
 Polyester fibres are available in monofilament form and belong to
the thermoplastic polyester group.
 They are temperature sensitive and above normal service
temperatures their properties may be altered. Polyester fibres are
somewhat hydrophobic.
 Polyester fibres have been used at low contents (0,1% by volume)
to control plastic-shrinkage cracking in concrete
 POLYMER CONCRETE

 Low component weight, high strength, smooth surfaces and

extremely high resistance are four reasons why polymer concrete
is the ideal material for professional drainage channels.
 It is made from natural minerals such as quartz, basalt and
granite which are mixed with a polymer binder. MEA polymer
concrete is the basis for highly resilient, heavy-duty drainage
channels. The high resistance of MEA polymer concrete to most
chemical liquids is beneficial for the environment.
 POLYMER CONCRETE

 Polymer concrete uses a polymer binder in place of Portland

cement.
 Potassium silicate polymer concretes are more like Portland
cement concrete in that they achieve compressive strengths in the
3,500-4,500 psi range and have a certain degree of absorption.
 Unlike Portland cement concrete, potassium silicate concrete
offersexceptional resistance to non-fluoride acids including nitric,
hydrochloric, sulfuric, and phosphoric.
POLYMER CONCRETE
 No fines concrete

 No-fines concrete (NFC) consists of coarse aggregate and cement

paste. In the hardened state, aggregate particles are covered by a
thin layer of cement paste and are in point-to-point contact with
each other. At each contact point the paste forms a small fillet;
these fillets hold the particles together and give strength to the
concrete.
 No-fines concrete can be defined as a lightweight concrete
composed of cement and fine aggregate. Uniformly distributed
voids are formed throughout its mass. No-fines concrete usually
used for both load bearing and non-load bearing for external walls
and partitions.
No fines concrete
No fines concrete
 Mass Concrete

 Concrete in a massive structure, e.g., a beam, columns, pier, lock,

or dam where its volume is of such magnitude as to require
special means of coping with the generation of heat and
subsequent volume change.
 The concrete is placed in large open forms.
 The mix is relatively harsh and dry and requires power vibrators
of the immersion type for compaction.
Mass Concrete
 Ferro cement

 Ferro cement is a type of thin wall reinforced concrete, commonly

constructed of hydraulic cement mortar, reinforced with closely
spaced layers of continuous and relatively small size wire mesh.
 The mesh may be made of metallic or other suitable materials”
 The term Ferro cement is most commonly applied to a mixture of
Portland cement and sand applied over layers of woven or
expanded steel mesh and closely spaced small-diameter steel rods
rebar.
 It can be used to form relatively thin, compound curved sheets to
make hulls for boats, shell roofs, water tanks, etc.
 It has been used in a wide range of other applications including
sculpture and prefabricated building components.
 Ferro cement

 Ferro cement has a very high tensile strength-to-weight ratio and

superior cracking behaviour in comparison to reinforced concrete.
This means that Ferro cement structures can be relatively thin, light
and water-tight.
 In India, ferro concrete is used often because the constructions
made from it are more resistant to earthquakes.
 Earthquake resistance is dependent on good construction technique
and additional reinforcement of the concrete.
Ferro cement
Ferro cement
 High density concrete

 High density or heavyweight concrete is concrete with a density

greater than 2600kg/m3.
 Its primary use is in radiation shielding, either in nuclear power
plants or in radiation therapy units.
 It can also be used as ballast in offshore locations such as
pipelines.
High density concrete
 High Performance Concrete

 Concrete may be regarded as high performance for several

different reasons:
• high strength,
• high workability
• high durability
and perhaps also improved visual appearance.
 High Performance Concrete

 High strength concrete (HSC) might be regarded as concrete with

a strength in excess of 60MPa and such concrete can be produced
as relatively normal concrete with a higher cement content and a
normal water-reducing admixture.
 However ultra high performance concrete (UHPC) will more
usually contain cement replacement materials and a high-range
water-reducer (HRWR) or super plasticiser(SP) (different names
for the same thing).
 Self-Compacting Concrete

 Self-compacting concrete (SCC) is an innovative concrete that does not

require vibration for placing and compaction.
 It is able to flow under its own weight, completely filling formwork and
achieving full compaction, even in the presence of congested
reinforcement.
 Concrete that requires little vibration or compaction has been used in
Europe since the early 1970s but self-compacting concrete was not
developed until the late 1980’s in Japan.
 In Europe it was probably first used in civil works for transportation
networks in Sweden in the mid1990’s.
 The EC funded a multi-national, industry lead project “SCC” 1997-
2000 and since then SCC has found increasing use in all European
countries.
 Self-Compacting Concrete

 Self-compacting concrete offers a rapid rate of concrete

placement, with faster construction times and ease of flow around
congested reinforcement.
 The fluidity and segregation resistance of SCC ensures a high
level of homogeneity, minimal concrete voids and uniform
concrete strength, providing the potential for a superior level of
finish and durability to the structure.
 SCC is often produced with low water-cement ratio providing the
potential for high early strength, earlier demoulding and faster use
of elements and structures.
 Self-Compacting Concrete

The Benefits
 Less dependent on skill on site
 Safer, quieter sites (no vibration)
 Better appearance
 Better durability
 Strength as needed
 Self-Compacting Concrete

The Important Properties:

 Self-compactiability
 Avoidance of bleeding and segregation
 Low shrinkage
 Low permeability
 Strength as needed
Self-Compacting Concrete
 RMC

 Ready mix concrete that is manufactured in a factory or batching

plant, according to a set recipe, and then delivered to a worksite,
by truck mounted transit mixers .
 This results in a precise mixture, allowing specialty concrete
mixtures to be developed and implemented on construction sites.
 It is popularly called as RMC, specially manufactured for delivery
to the customers construction site in a freshly mixed and plastic or
unhardened state.
 It is sold by volume expressed in cubic meters.
 RMC

ADVANTAGES:
 A centralized concrete batching plant can serve a wide area.
 The plants are located in areas zoned for industrial use, and yet
the delivery trucks can service residential districts or inner cities.
 Better quality concrete is produced.
 Elimination of storage space for basic materials at site.
 Elimination of hiring of plant and machinery.
 Wastage of basic materials is avoided.
 Labours associated with production of concrete is eliminated.
 Time required is greatly reduced.
 Noise and dust pollution at site is reduced.
RMC
RMC
RMC
Rmc plant
Rmc plant (silo – 1 for fly ash and 2
for cement)
Rmc plant (silo – 1 for fly ash and 2
for cement)
Rmc plant (hopper for coarse and
fine aggregate)
Filling of cement in silo using
compressor
Loose cement bunker
Rmc plant control panel
Display of control panel
Coarse aggregate & fine aggregate
weighing hopper
Coarse aggregate weighing hopper &
conveyor belt
Transit mixer (TM)
Cement weighing hopper
THANK YOU