Mizan-Tepi University

College of Engineering & Technology

Department of Construction Technology and
Management
.
CHAPTER 5

SPECIAL CONCRETES
 SPECIAL CONCRETES
WHAT IS SPECIAL CONCRETE?
Special concrete is defined as “concrete which meets
special performance and uniformity requirements
that cannot always be achieved routinely by using
only conventional materials and normal mixing, plac-
ing and curing practices”.

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I. LARGE VOLUME POURS OF CONCRETE
Defn:- Any concrete member of such dimension that the
thermal behaviour may lead to cracking unless
appropriate measures are taken.
- Crucial feature of mass concrete is its thermal
behaviour.

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• In mass concrete, temperature rise results
from the heat of hydration of cementitious mate-
rials.

•As the interior concrete increases in temperature

and expands, the surface concrete may be cool-
ing and contracting.

•This causes tensile stresses that may result in

thermal cracks at the surface if the temperature
differential between the surface and center is too
great.

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- There are two categories of restraints:
i. Internal Restraints
- arises when the surface of concrete loses heat
to the atmosphere  develops a temperature
differential between the cool exterior and the hot
core of the concrete element  free thermal
expansion is unequal in the various parts of the
concrete element  stress development,
compressive in one part of the element and
tensile in the other  surface cracks develop.

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- Internal restraint can also occur when concrete is
placed against a surface at a much lower
temperature (cold ground, uninsulated formwork in
cold weather).
- Experience indicated that cracking will occur when
temperature difference exceeds 200C. (Fitz Gibbon).

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- From the stand point of the development of a
temperature differential, it is not only the total heat
of hydration but also its rate of heat development
that are relevant.

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- Remedial measures:
a. Choose a Portland cement with a chemical
composition which leads to a low rate of heat
development.
b. A higher fineness of cement leads to a more
rapid hydration, so that it might be desirable to
avoid cements with a high specific surface.
c. Lower the cement content as much as possible
since it largely governs the heat generated.
d. Use blended cements  chemical reaction
of pozzolans is slow  rate of heat generation
will be lowered.
e. Low content of cement + high proportion of
pozzolans  the maximum temperature rise
can be reduced and even occurrence can be
delayed  less prone to cracking. 8
f. cooling the fresh concrete below the ambient
temperature and placing it at a low temperature
reduces the rate of generation of heat difference
between the maximum temperature of the concrete
and the final ambient temperature is reduced.
g. In large plain concrete structures, use large size
aggregate as much as possible  allows a
reduction in water content of the mix for a given
workability  at a fixed w/c ratio, cement can be
reduced.
h. In structures, like large gravity dams, the strength of
concrete is of little importance  w/c ratio could be
increased (up to 0.72)  prevents cracking  but
durability will be critical.

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i. Prevent the heat loss at the surface by using proper
insulators  formwork and the top surface of the
structure must be adequately insulated  controls
loss of heat by evaporation.
- insulator must be maintained until the temperature
differential is reduced to about 100C.

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ii. External Restraints
- Results in cracking of reinforced concrete
members, even when thin.

Typical shrinkage cracks in a slab on ground.

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II. Ready-mix Concrete

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- Concrete mix originating from a central plant.

- Particularly useful on congested sites or in road

construction where little space for mixing plant and
for extensive aggregate stockpiles is available.

- Advantageous since it is made under better

conditions of control than are normally possible on
any but large construction sites

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- Also advantageous when only small quantities
of concrete are required or when concrete
requirement is only at intervals.

- Proper care during transportation of the concrete

is ensured by use of agitator trucks.

- Placing and compaction remain the responsibility

of the personnel on the site.

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Ready-mixed concrete can be manufactured by
any of the following methods:

i. Central-mixed concrete
- Mixing is done at a central plant transported
usually in an agitator truck which revolves slowly
to avoid segregation and undue stiffening of the
mix.

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ii. Shrink-mixed concrete

•Mixed partially in a stationary mixer and completed

in a truck mixer.

III. Truck-mixed concrete

•mixed completely in a truck mixer

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- Agitating speed is between 2 – 6 rev/min and
mixing speed is between 4 – 16 rev/min.

- Mixing at high speeds for long periods of time,

about 1 or more hours, can result in concrete strength
loss, temperature rise, excessive loss of entrained air,
and accelerated slump loss.

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- Major problem in production of ready-mixed
concrete is maintaining the workability of the mix
right up to the time of placing  stiffening
aggravated by prolonged mixing and by a high
temperature.
- ASTM C94-94  Max. Time allowed for
cement and moist aggregate to remain in
contact = 90 min.
- BS 5328:Part 3:1990 allows 2hrs.
- Use of retarders allow the time limit to be extended
to 3 - 4 hrs. provided the concrete temperature at
delivery is below 320C.

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III. Pumped Concrete

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1. Concrete Pumps
- System consists of hopper into which concrete is
discharged from the mixer, a concrete pump and
pipes through which the concrete is pumped.
- Pumps are designed so as to permit always the
passage of the largest particles of aggregate being
used.
- Squeez pumps move concrete for distances up to
90 m horizontally or 30 m vertically while piston
pumps move concrete up to 1000 m horizontally or
120 m vertically.

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- Various pipe diameter available but, the side to be
chosen should be at least 3 times the maximum
aggregate size.
- Oversize in coarse aggregate should not be
permitted so as to avoid blockage at bends. 22
 2. Use of Pumping
- Economical if used without interruption.
• At the beginning of each period of pumping,
pipes have to be lubricated by mortar
- Considerable effort is required to clean the
pipes at the end of operation.
- Aluminum pipes must not be used since alkalis
react with aluminum in cement and might introduce
voids in hardened concrete resulting in a loss of strength.

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- Main advantages of pumping concrete:
i. Can be delivered to points over a wide area
otherwise not easily accessible.
ii. Concrete is delivered direct from the mixer to the
form and so avoids double handling.
iii. Placing can proceed at the rate of the output of
the mixer, or of several mixers, independent of
transporting and placing equipment.
iv. A high proportion of ready-mixed concrete is
nowadays pumped.

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3. Requirements for pumped concrete
- Concrete must be well mixed before feeding into
the pump.
- Sometimes remixing in the hopper by means of a
stirrer is a requirement.
- Mix must not be harsh or sticky, too dry or too wet
 Consistency is very critical.
- A slump between 50 and 150 mm in general is
recommended.

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 - ACI 304.2R recommends,
for aggregate with a maximum size of 20 mm (
- the bulk volume of dry-rodded coarse aggregate
of 0.56 – 0.66  the fineness modulous of sand to
be used is about 2.4.
- the bulk volume of dry-rodded coarse aggregate
of 0.50 – 0.60  the fineness modulous of sand to
be used is about 3.0.
- Shape of aggregate influences the optimum mix
proportions for good pumpability but, angular
coarse aggregate requires a higher volume of
mortar in the mix.

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IV. LIGHTWEIGHT CONCRETE

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1. Introduction
- Normal-weight concrete  2200 - 2600 kg/m3 
self-weight of concrete elements represent a large
proportion of the load on the structure.
- Use of concrete with a lower density can result in
significant benefits in load-bearing elements 
reduction in size of structural elements.
- Lighter concrete  formwork withstands a lower
pressure than would be the case with normal-
weight concrete.
- Lightweight concrete, on the other hand,
requires a higher cement content than normal-
weight concrete  incurs additional cost.

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2. Classification of Lightweight Concrete
- Density can be reduced by replacing some of the
solid material in the mix by air voids.
- There are three possible locations of the air:
i. In the aggregate particles  lightweight
aggregate.

ii. In the cement paste by entering foam or air

bubbles (Cellular concrete.)
iii. Between the coarse aggregate particles (fine
aggregate being omitted)  Usually called no-fines
concrete.
- Practical range of lightweight concrete  300 -
1850 kg/m3.
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V. Roller-Compacted
Concrete (RCC)
 Lean
 No-slump

 Almost dry

 Compacted in place
by vibratory roller or
plate compaction
equipment

Special Types of Con-

crete
 RCC is a mixture of well-graded aggregates,
cementitious materials, and water.
 Cementitious contents range from 60 to 360 kg per
cubic meter depending on the application.
Mixing is done with conventional batch mixers, contin-
uous mixers, or in some instances tilting-drum truck
mixers.
Applications for RCC fall into two distinct categories-–
water control structures (dams) and pavements..

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RCC—Water Control Structures

Special Types of Con-

crete
RCC—Pavements

Special Types of Con-

crete
 VI. Soil-Cement
 Soil-cement is a mixture of pulverized soil or granular
material, cement, and water.
 The mixture is compacted to a high density, and as the
cement hydrates the material becomes hard and
durable.
 Soil-cement can be mixed in place using onsite materi-
als or mixed in a central plant using selected materials.
 Primarily used as pavement base course for roads,
streets, airports, and parking areas.
 Soil-cement is also used as slope protection for earth
dams and embankments, reservoir and ditch linings,
deep-soil mixing, and foundation stabilization.

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 Soil-Cement
Four steps of soil cement construction:
1. Spreading cement

2. Mixing

3. Compaction

4. Curing

Special Types of Con-

crete
VII. Shotcrete
n Used for: Concrete to be placed
in difficult locations, thin sec-
tions, and large areas.

n Advantages: Placing concrete

in freeform shapes, repairing
structures, thin linings, etc.

n Watch for: Quality of work

depends on skill of those
using equipment.

Special Types of Con-

crete
 Self-Consolidating Concrete
Self-consolidating concrete (SCC) also
known as self-compacting concrete —
flows and consolidates on its own
 developed in 1980s — Japan
 Increased amount of

– Fine material
(i.e. fly ash or limestone filler)
– HRWR/Superplasticizers
 Strength and durability same as conven-

tional concrete
High-Performance Con-
crete
Self-Consolidating Concrete(SCC)

 SCC is very exceptionally flowable concrete that never

needs to be consolidated to fill forms or flow.
 Good SCC has:
 High flowability — It flows easily into the finest details
of formwork or molds and around reinforcing under its
own weight.
 Passing ability—The ability to flow through tight spaces,
like congested steel reinforcing bars or narrow spots
in the formwork.
 Stability —Stability implies that even at very high
slumps (or slump flows), the concrete doesn't segre-
gate; it remains homogenous and there is no separa-
tion of the aggregate from the cement paste.
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 TESTING SELF-CONSOLIDATING CON-
CRETE
 The primary test used in the field for SCC is slump flow,
although there are other field tests currently in
use.
 J-ring-The J-Ring is a measure of the concrete's passing
ability-how easily it flows through obstructions and rein-
forcing.
 The J-Ring test is standardized as ASTM C 1621, "Pass-
ing Ability of Self-Consolidating Concrete by J-Ring." The
J-Ring is a cage of rebar that is set up around the slump
cone..
 T50 test-This is a measure of the concrete's viscosity
and is measured as the amount of time it takes for con-
crete in the slump flow test to reach a diameter of 50
centimeters.
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The J-Ring test measures the passing ability of
the SCC through a rebar cage.

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 The T50 test measures vis-
A slump flow test is of- cosity by timing how many
ten performed with the seconds it takes for the con-
slum cone upside down crete to spread to 50 cen-
timeter in diameter.
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Reactive-Powder Concrete (RPC)
 Properties:
– High strength — 200 MPa
– (can be produced to 810 MPa
– Very low porosity
 Properties are achieved
by:
– Max. particles size  300 m
– Optimized particle packing
– Low water content
– Steel fibers

High-Performance Con-
crete
 Mechanical Properties of RPC
Property Unit 80 MPa RPC
Compressive
strength MPa (psi) 80 (11,600) 200 (29,000)

Flexural strength MPa (psi) 7 (1000) 40 (5800)

Tensile strength MPa (psi) 8 (1160)
Modulus of Elasticity GPa (psi) 40 (5.8 x 106) 60 (8.7 x 106)
Fracture Toughness 103 J/m2 <1 30
Freeze-thaw RDF 90 100
Carbonation mm 2 0
Abrasion 10-12 m2/s 275 1.2

High-Performance Con-
crete
Reactive Powder
Concrete

High-Performance Con-
crete
THE END

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