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HIGH PERFORMANCE CONCRETE

CONCRETE TECHNOLOGY

BEM 1, SCHOOL OF PLANNING AND ARCHITECTURE

MANGALA MAHANTHAN J

BEM1

OCTOBER 2010
HIGH PERFORMANCE CONCRETE:

In recent years, the terminology "High-Performance Concrete" has been introduced into the
construction industry. This edition of Technical Talk explains high-performance concrete and
how it differs from conventional concrete.
The American Concrete Institute (ACI) defines high-performance concrete as concrete
meeting special combinations of performance and uniformity requirements that cannot
always be achieved routinely when using conventional constituents and normal mixing,
placing and curing practices. A commentary to the definition states that a high-performance
concrete is one in which certain characteristics are developed for a particular application and
environment.

"High Performance Concrete is a concrete: made with appropriate materials combined

according to a selected mix design; properly mixed, transported, placed, consolidated and
cured so that the resulting concrete will give excellent performance in the structure in which
it is placed, in the environment to which it is exposed and with the loads to which it will be
subject for its design life."

HPC - What is it?

The concept of HPC has certainly evolved with time. What exactly is "high-performance?"
Various parameters have been attached to HPC, with high strength being a popular
descriptor. While equating HPC with high strength certainly has some merit, it doesn't
present a complete or, in some cases, accurate picture. Other properties of the concrete must
also be considered, and may even override the strength issue. How should high performance
concrete be defined? Three influences must be considered: the structure in which the concrete
will be used, including support; the environment in which the structure will be placed; and
the type and number of loads to which the structure will be subjected. Let's look at these
considerations in more detail, before finalizing our definition of HPC.
Because many characteristics of high-performance concrete are interrelated, a change in one
usually results in changes in one or more of the other characteristics. Consequently, if several
characteristics have to be taken into account in producing a concrete for the intended
application, each must be clearly specified in the contract documents.
A high-performance concrete is something more than is achieved on a routine basis and
involves a specification that often requires the concrete to meet several criteria. A high-
strength concrete is always a high-performance concrete, but a high-performance concrete is
not always a high-strength concrete. ACI defines a high-strength concrete as concrete that has
a specified compressive strength for design of 6,000 psi (41 MPa) or greater. Some countries
use a higher compressive strength in their definitions of high-strength concrete with 7,000 psi
(48 MPa) minimum. Some other countries also specify a maximum compressive strength,
whereas the ACI definition is open-ended.
The specification of high-strength concrete generally results in a true performance
specification in which the performance is specified for the intended application, and the
performance can be measured using a well-accepted standard test procedure. The same is not
always true for a concrete whose primary requirement is durability.
Durable concrete Specifying a high-strength concrete does not ensure that a durable concrete
will be achieved. In addition to requiring a minimum strength, concrete that needs to be
durable must have other characteristics specified to ensure durability. In the past, durable
concrete was obtained by specifying air content, minimum cement content and maximum
water-cement ratio. Today, performance characteristics may include permeability, deicer
scaling resistance, freeze-thaw resistance, abrasion resistance or any combination of these
characteristics. Given that the required durability characteristics are more difficult to define
than strength characteristics, specifications often use a combination of performance and
prescriptive requirements, such as permeability and a maximum water-cementitious material
ratio to achieve a durable concrete. The end result may be a high-strength concrete, but this
only comes as a by-product of requiring a durable concrete.
Examples of characteristics that may be considered critical for an application are:
* Ease of placement
* Compaction without segregation
* Early age strength
* Long-term mechanical properties
* Permeability
* Density
* Heat of hydration
* Toughness
* Volume stability
* Long life in severe environments
Concrete materials Most high-performance concretes produced today contain materials in
addition to portland cement to help achieve the compressive strength or durability
performance. These materials include fly ash, silica fume and ground-granulated blast
furnace slag used separately or in combination. At the same time, chemical admixtures such
as high-range water-reducers are needed to ensure that the concrete is easy to transport, place
and finish. For high-strength concretes, a combination of mineral and chemical admixtures is
nearly always essential to ensure achievement of the required strength.
Most high-performance concretes have a high cementitious content and a water-cementitious
material ratio of 0.40 or less. However, the proportions of the individual constituents vary
depending on local preferences and local materials. Mix proportions developed in one part of
the country do not necessarily work in a different location. Many trial batches are usually
necessary before a successful mix is developed.
High-performance concretes are also more sensitive to changes in constituent material
properties than conventional concretes. Variations in the chemical and physical properties of
the cementitious materials and chemical admixtures need to be carefully monitored.
Substitutions of alternate materials can result in changes in the performance characteristics
that may not be acceptable for high-performance concrete. This means that a greater degree
of quality control is required for the successful production of high-performance concrete.
HIGH-PERFORMANCE CONCRETE MIX PROPORTIONS
Mix proportions for high-performance concrete (HPC) are influenced by many factors,
including specified performance properties, locally available materials, local experience,
personal preferences, and cost. With today's technology, there are many products available
for use in concrete to enhance its properties. Consequently, there are many alternatives for
mix proportions that will result in concrete with the desired properties. Here, Technical Talk
briefly addresses selection of mix proportions for high-strength and low permeability
concretes.
High-strength concrete is defined by the American Concrete Institute (ACI) as concrete with
a specified compressive strength of 6,000 psi (41 MPa) or greater. Although concretes with
compressive strengths greater than 6,000 psi (41 MPa) can be produced using only cement as
the binding material, it is likely that these concretes will also contain a mineral admixture
such as fly ash, silica fume, or ground granulated blast furnace slag (GGBFS). At the present
time, guides are in preparation for high-strength concretes containing silica fume or GGBFS.
However, many of the guidelines that apply to concrete containing fly ash also apply to
concrete containing silica fume or GGBFS. Some of these are summarized below:
Testing age. Concrete tested at an age of 56 or 90 days generally has a higher compressive
strength than concrete tested at 28 days. This is more noticeable with concrete containing fly
ash and less noticeable with concrete containing silica fume. The use of a later age makes it
easier and more economical to achieve the higher strengths. Proportions of cementitious
materials are usually selected to produce the desired strength at the selected test age.
Water-cementitious materials ratio. According to ACI 211.4R,(1) many researchers have
concluded that the most important variable in achieving high-strength concrete is the water-
cement ratio. However, most high-strength concretes contain binding materials other than
cement. Consequently, the water-cementitious materials ratio must be considered instead of
the water-cement ratio where the cementitious materials include cement, fly ash, silica fume,
and GGBFS as appropriate. In general, as the water-cementitious materials ratio decreases,
the concrete compressive strength increases.
Portland cement. Proper selection of the type and source of cement is one of the most
important steps in the production of high-strength concrete. Variation in the chemical
composition and physical properties of the cement affect the concrete compressive strength
more than variations in any other single material. There is also an optimum cement content
beyond which little or no additional increase in strength is achieved by increasing the cement
content.(1) To achieve higher strengths, it is necessary to include other materials such as fly
ash, silica fume, GGBFS, or combinations of these materials
Coarse aggregate. For each concrete strength level, there is an optimum size for the coarse
aggregate that will yield the greatest compressive strength per unit mass of cement. In
general, a smaller size aggregate will result in a higher compressive strength concrete. On the
other hand, the use of the largest possible coarse aggregate size is important in increasing the
modulus of elasticity or reducing creep and shrinkage
Fine aggregate. According to ACI 211.4R,(1) fine aggregates with a fineness modulus in the
range of 2.5 to 3.2 are preferable for high-strength concrete. Concretes with a fineness
modulus less than 2.5 may be sticky and result in poor workability and high water
requirement.
Chemical admixtures. Water-reducers or high-range water-reducers are essential in high-
strength concrete to ensure adequate workability while achieving a low water-cementitious
materials ratio. Retarding admixtures may also be used. The optimum dosage of an admixture
or combination of admixtures should be determined by trial mixtures using varying amounts
of each additive. It is also important to be sure that admixtures are compatible when used in
combination.
There is no standard mix to produce a high-strength concrete. Trial mixes are needed to
obtain the optimum use of each locally available constituent material.
Low permeability concrete Whereas guidelines are available for mix proportions of high-
strength concrete, the same is not true for low permeability concretes. Most specifications
address the requirements for low permeability by specifying a maximum water-cementitious
materials ratio of 0.40 and a maximum permeability per ASTM C 1202.(4)
According to the Portland Cement Association publication EB001,(5) fly ash and GGBFS
generally reduce the permeability of concrete even when the cement content is relatively low,
and silica fume is especially effective in this regard. Tests show that the permeability of
concrete decreases as the quantity of hydrated cementitious materials increases and the water-
cementitious materials ratio decreases. Values of permeability less than 2,000 coulombs may
be achieved with concretes containing fly ash, silica fume, or GGBFS. Values of permeability
less than 1,000 coulombs may require the use of silica fume.
Conclusions For HPC, mix proportions must be selected to meet the specified performance
criteria at a reasonable cost while using locally available materials.

Considerations for HPC

Structure: What are we building? A plain (unreinforced) floor slab-on-grade will require
vastly different strength properties than a bridge deck; or a bridge structural member; or a
slip-formed building or cooling tower. And yet, for each respective application, these greatly
different strength ranges can certainly result in a HPC. Other concrete properties which the
type of structure may dictate include allowable heat generation during curing; volume
stability; creep; crack susceptibility/brittleness; bond to reinforcing; workability;
pumpability; and the list goes on and on. Basically, the structural and construction
requirements of the structure must be met by the concrete to be used.
Environment: What conditions (exclusive of loading as used here) will the structure be
exposed to? Under this factor consideration must be given to climatic conditions, i.e. heating
and cooling, wetting and drying, and freezing and thawing, and the requirements they place
on the concrete. Further, potential chemical attack must also be considered for those
structures in contact with the ground, exposed to chemicals in the air or exposed to
chemicals because of the end use. In short, the concrete must be resistant to the environment
in which it is placed. As with the structural requirements, the environmental requirements
can vary widely: a concrete pavement built on a sulfate rich subgrade and subject to deicing
chemicals in a freeze/thaw climatic zone will certainly have different requirements to
achieve long term durability than a second story interior floor slab in a climatically
controlled high rise building.
Expected Loads: Depending on the breadth of the definitions, either structural or
environmental considerations could easily include the loads to which a structure will be
subject, and I would not argue with either interpretation. Because of its importance,
however, I have chosen to break loading out separately for clarity in discussion. As with the
two previous factors, the influence, or impact of load on performance can vary widely.
Because I most often deal with pavements in my position, I tend to think of loads in terms of
vehicular traffic, such as ADT (Average Daily Traffic) or ESALs (Equivalent Single Axle
Loads (of 8165 kg each)). However, for buildings the engineer must consider much different
loads, including those from wind or earthquakes. Marine structures present still another set
of conditions and requirements. The loads may be compressive, flexural or tensile, or
include multiple types. In short, the type, magnitude and number of expected loads must be
carefully considered.
Other Factors: Beyond the three basic influences discussed above, additional factors must
also be considered. First, no matter how good the potential of our mix design or "lab-crete"
is for meeting the three influences, in order to be practical the concrete must be
"constructable." That is, while in the plastic state the concrete must be workable, pumpable
(as required) and easily consolidated within the confines of any form-work or reinforcing. It
must maintain this plasticity for the time period necessary to transport, place and consolidate
the concrete. Any desired concrete properties, such as the entrained air void system, must
not be adversely affected by transport, placement or consolidation. A wide range of specific
materials requirements may be placed on the mix components, depending on the
environmental exposure and type of structure in which the concrete is placed, and the
concrete must meet these requirements while still remaining "construction-friendly."
Secondly, good practices must be followed during construction. The base or form-work must
be well prepared; adequate coverage must be provided for reinforcing; placement techniques
must be such as to avoid segregation of the concrete components; consolidation techniques
must be adequate to attain target densities, but not so great as to adversely affect the air void
system or produce segregation; and finishing and curing techniques must be properly timed
and adequate for environmental conditions.
Thirdly, the interaction of the concrete at an early age with the environment and any loads
must be considered. Heat generated during hydration must be estimated and combined with
the effects of expected environmental conditions. Hot weather concreting requires special
considerations, and changes in mix proportions may become necessary to prevent excessive
internal temperatures, thermal gradients and thermal stresses. Similar concerns must be
addressed for cold weather, or where large swings in ambient temperature are expected in
short periods of time. These factors, and others which may influence the maturity of the
concrete, must be considered when determining the allowable load for the concrete at any
given age. The load may be (for instance) construction traffic, for pavements, or the mass of
movable form-work in the case of some structures. Without paying attention to these and
other factors during the early life of the concrete, damage may occur which will prevent the
concrete from attaining the design properties or design life which were intended.

Fig. 1. Factors to be considered for high-performance concrete.

The benefits of 

high-performance concrete

 Cost-effective to construct ...

 Easy to maintain ... 
 Competitive in value ...
 Innovative in aesthetics.

A Span of Concrete Advantages

More than 70% of of the bridges in the U.S. are constructed of concrete. Bridge construction
with high-performance concrete offers many long-term benefits. Click on title for more info.
 Admixture for High Performance
Concrete - Super Pozzo

SuperPozzo is a new generation specially engineered material (high reactivity pozzolan) that
reacts with free lime as soon as it is available in the concrete / plaster matrix.
 
This prevents lime leach and also forms additional C-S-H gel thereby improving the
performance of concrete, reducing porosity, improves water resistance, enhancing early
setting and making the concrete "brighter".
 
As such this can be added also to architectural applications where white cement is used.  
 
SuperPozzo is typically added @ 5-10% by weight of cement and results in “buttery” or
“cheesy” finish to the concretes and plasters.
 
Applications:
 
SuperPozzo can be used in any concrete and plaster application where performance
enhancement is desired. It can also be used in:

 Water resistant areas e.g. swimming pools, water tanks

 Wet slabs such as roof slabs, toilet & utilities areas slabs
 Waterproof plasters
 External plasters
 Marine application areas (jetties, coastal applications, water intake wells)
 High performance concrete applications (With mix designs tested in appropriate
laboratory to suit the end use)
 Areas where quick setting of concrete & plaster is desired
 Architectural applications using white cement

 
Usage and method of application:
 
SuperPozzo can be added to the concrete mixer or plaster immediately after addition of
cement. However, due to its highly reactive nature, if external RMC is used.
SuperPozzo should be added to the transit mixer after it reaches the site.

For high performance / specific concrete applications, the mix designs should be prepared
and tested in laboratories to confirm suitability.