Chapter 2
Chapter 2
2.1 Concrete
Concrete and steel are the two most commonly used structural materials. They sometimes
complement one another, and sometimes compete with another so that the structures of
similar type and function can be built in either of these materials. Concrete is made from
cement, aggregate and water with the occasional addition of admixtures. Concrete has a
proven track record as a successful material in the construction of highest towers, the
longest tunnels, the deepest shafts and the largest man made structures, and in conditions
as extreme as the Arctic tundra and Middle Eastern desert (Masterton et al; 1997).
The invention to overcome the problem of the low tensile strength of concrete by
providing steel reinforcement was the starting point for concrete to become the leading
construction material in this century. It was realized that steel will not corrode, even in out
Different concrete mixes such as designed mixes, prescribed mixes (done as weigh
batching), nominal mixes (mostly done as volume batching) are used to meet the needs of
construction work. In particular the concrete should have the following (Schacklock, 1974).
1. Comply with the specification requirement for structural strength which is usually
stated in terms o f the compressive strength of standard test specimens
Following the practice first established many years ago. concrete mixes are still sometimes
coarse aggregate are in terms of the bulk volumes of the individual materials, (i.e. for grade
20 concrete 1:2:4, for grade 25 concrete 1:1.5:3 and for grade 30 concrete 1:1:2).
According to the ICTAD specifications (1988), the minimum cement contents for the Grade
3
20, 25 and 30 concrete are 320 kg, 405 kg and 552 kg per m of volume batched concrete
respectively. (These values are taking into account the cement bulking as well). Volume
batching is difficult to control and nominal mix specifications provide no control over water
content, so this type of specification should not be used unless site condition make it
Expeiience also showed that allowance had to be made for the bulking which occurs with
fine aggregates when they are damp. It is generally accepted that most concreting sands
will bulk on average by about 25%. However, coarse aggregate do not bulk to any
significant extent. The allowance can be increased for finer sands and decreased if the
Shacklock (1974) also mentioned that the quantity of water in the nominal mixes are judged
so as to give a concrete of suitable workability for the work in hand. The fact that the
required amount of water affects the final properties o f the concrete very considerably, and
that the quantity varies with both the selected workability of the concrete and the maximum
size o f the aggregate, shows the extreme weakness and the imprecision of this type of
specifications.
In practice, nominal volumetric mix proportions are often associated with a particular,
concrete strength which is checked by the taking of test specimens. This association of the
7
2.2.2 Specified mixes
B S 5328: Part 2: 1991, recognizes four methods of specifying concrete mixes. A designed
mix is specified by the designer principally in terms of strength, cement content and water
cement ratio; compliance relies on strength testing. A prescribed mix is specified by the
designer in terms of nature and proportion of mix ingredients; the concrete producer simply
makes the concrete 'to order'. The assessment of mix proportions is used for compliance
purposes, strength testing rot being routinely used. The use of prescribed mix is
advantageous when particular properties of concrete; for instance with respect to its finish
or abrasion resistance, are required. However, a prescribed mix should be specified only
when there are sound reasons for assuming that it will have the required workability,
A standard mix is based on ingredients and proportion fully listed in B 3 5328: part 2:
1991 for several values of compressive strength up to 25 MPa, measured on cubes. The
fourth type of mix is the designated mix, for which the concrete producer selects the water
cement ratio and the minimum cement content, using a table of structural applications
coupled with standard mixes. This approach can be used only if the concrete producer
holds a special certificate of product conformity based on product testing and surveillance,
Standard mixes are used only in minor construction such as housing. Designated mixes,
although they can be used for strengths up to 50 MPa, are limited in application to routine
constiuction. It is therefore, only in the selection o f designated and prescribed mixes that a
Strength of concrete is commonly considered its most valuable property, although, in many
practical cases, other characteristics, such as durability and permeability, may in fact be
more important. Nevertheless, strength usually gives an overall picture of the quality of
concrete because strength is directly related to the structure of the hydrated cement paste.
Moreover, the strength of concrete is almost invariably a vital element o f structural design
8
The properties of in situ concrete are subject to considerable variability, because it is not a
factory produced construction material such as steel, for example. The principal factors that
affect the properties o f concrete are mix proportions (especially the cement content), slump
achieved (primarily depend on the water content) compaction during placing and curing
after casting. The first two factors represent concrete mix constituents, and taken together
will be characterized by the water / cement ratio, which is by far the greatest single
influence on concrete production. However, this composite index is separated into mix and
slump because the latter have more practical significance for concrete production and
The characteristic strength of the concrete should be specified at one age only. Unless
specified otherwise, the strength test should be carried out at an age of 28 days for concrete
made with a Portland-type cement (Barnbrook et al; 1976). Under normal conditions
adopted in Sri Lanka, a standard deviation of about 8 is usually used for concrete mixes.
2
This gives a current margin of about 13 N / m m . This means, when Grade 20 concrete is
2
needed, under laboratory conditions, a strength o f about 33 N / m m should be obtained as
the mean strength. However, it is stated that this current margin could be reduced by about
2
3.5 N / m m when nine cubes were tested (Barnbrook et el. (1975)). Thus, the current
2
margin required could be considered as 10 N / m m when 9 cubes were tested. The current
2
margin of 10 N / m m is also confirmed by Dias (1991) as well
One o f the major problem in making specifications for Sri Lankan practice will be to
answer the question as to whether Grade 20 concrete, which is the most widely used grade
in Sri Lanka, is permissible or not. Most modern codes o f practice specify a minimum
strength. However, recent specifications drawn up for Sri Lankan practice - ie the Model
Code and the ICTAD specifications have continued the use of Grade 20 concrete, probably
basing their recommendations on the now outdated CP114 and CP 110 respectively
(Dias, 1991).
On the other hand, the use of Grade 20 concrete can not be rejected outright, because
environmental conditions in Sri Lanka are probably less harsh uVn those in the UK or
Australia, for example. Furthermore, most concrete surface in Sri Lanka receive a mortar
rendering, which provide additional protection. Finally, structures built out of Grade 20
concrete have not performed too badly. Hence, it may be permissible to continue the use of
Grade 20 concrete, especially if it is shown that this does not violate the spirit of BS 8110
which is the code used for the design of concrete structures in Sri Lanka (Dias, 1991).
Concrete is made from cement, aggregate and water with the occasional addition of an
admixtures. There is some variety in the properties of cements, even between cements of
the same type but made from different raw materials and the variation in properties possible
heterogeneous material with variable properties. The section outlines the typical properties
2.3.1.1 Cement
In Sri Lanka, Portland cement manufactured by cement corporation is mostly used for
allowed to be imported which again should be complied with B S 12(1). Hence one can
assure that the strength and workability of concrete related to water / cement ratio and
aggregate / cement ratio as in mix design charts are acceptable as for as local cement is
Ordinary Portland Cement (OPC) and Rapid Hardening Cement satisfying BS 12 and
ASTM C I 5 0 (Specification for Portland cement) can be used for producing high strength
concrete. However, different brands of OPC will have different strength development
fineness within certain limits. Also the performance of chemical and mineral admixtures
cement for use in high strength concrete, it is important to examine carefully its fineness &
10
2.3.1.2 Aggregate
The teiiri aggregate is used to describe the gravels, crushed stones and other materials which
are mix with cement and water to make concrete. A s aggregate form bulk of the volume o f
Of the materials in concrete, aggregate is the most variable. The overall grading of the
aggregate affects the amount of water that must be added because 'fine' grading require
more water than 'coarse' grading to obtain the same degree o f workability. Aggregate
particles which have sharp edges or rough surface, such as crushed stones, need more water
than smooth and rounded particles to produce concrete o f the same workability. It may be
necessary to increase the cement content of a mix made with crushed aggregates or irregular
shaped gravels to allow water to be added in order to make the concrete sufficiently
workable without reducing the strength below the required level. However, due to interlock
between aggregate particles, a crushed aggregate concrete may have higher strength than a
smooth or rounded aggregate concrete with the same water / cement ratio, and this extra
As the maximum size o f the aggregate is reduced, the cement content o f the mix will need
to be increased to give the same workability with the same water / cement ratio. This is
because the surface area of aggregate to be wetted is greater with the smaller aggregate size.
The fine and coarse aggregates should be proportioned to obtain the required workability
with the minimum amount of water. Badly proportioned constituents require an excessive
amount of water to give adequate workability, and this will result in concrete o f low
strength and poor durability. Moreover, aggregates should be hard, durable, firm,
appropriately cleaned and suitably graded. The presence of harmful substances such as
dust, mud, organic imparities, chlorides or any other harmful substance should not be in-
2.3.1.3 Water
Mixing water for concrete is usually required to be fit for drinking, or to be taken from an
approved source. This is to ensure that the water is reasonably free from such impurities as
11
suspended solids, organic matter and dissolved salts, which are frequently contained in
natural water and which may adversely affect the properties of concrete.
Water is the most consistent of the constituents of the concrete but water quantity, and in
particular the water / cement ratio, is most important for the production of concrete of
consistent strength. The amount of water used should be the minimum necessary to give
sufficient workability for full compaction of the concrete. When deciding how much water
to use, allowance must be made for absorption by dry or porous aggregates and for the free
2.3.2 Curing
The setting and hardening of cement depend on the presence of water. Drying out, if
allowed to take place too soon, results in low strength and porous concrete. At the time the
concrete is placed, there is normally an adequate quantity of water present for full
hydration, but it is necessary to ensure that this water is retained so that the chemical
reaction continues until the concrete has thoroughly hardened. If curing is efficient, the
strength of the concrete increases with age; this increase is rapid at early ages and then
continues more slowly for an indefinite period. Correct curing increases the impermeability
and durability of the concrete, which is particularly important when it will be subject to
increases resistance to abrasion; effective curing is thus most necessary for floors and other
surfaces subject to wear. Continuous curing from the time the concrete is placed helps to
ensure a hard, dense surface and to reduce the risk of crazing and dusting (Barnbrook et al;
1976).
More specifically, the object of curing is keep concrete saturated, or as nearly saturated as
possible, until the originally water filled space in the fresh cement paste has been filled to
the desired extent by the products of hydration of cement. In the case of site concrete,
active curing stops nearly always long before the maximum possible hydration has take
Powers in 1947 showed that hydration is greatly reduced when the relative humidity within
the capillary pores drops below 80 percent. This was confirmed by Patel et al in 1988.
12
Meyer in 1987 has clearly established that the effect of curing on strength is a function of
specimen size. Dias in 1994 has recommended that the curing is very significant main
1989 indicate that inadequate curing has a more dramatic effect than inadequate compaction
on the time required to initiate corrosion and on the severity of sulphate attack. Dias (1994)
has recommended that minimum of 7 days of moist curing is essential for concreting in hot
climates.
Duff A Abram's water/cement ratio law, which states that fundamentally the strength of
concrete is governed by the ratio of the weight of water to the weight of cement in a mix
provided that it is plastic and workable, fully compacted and adequately cured (Taylor,
1977).
To eliminate excessive porosity, a minimum amount of water should be used. The volume
of the products of hydration is nearly twice that of unliydrated cement (Powers, 1958). At
water / cement ratio grater than 0.38, even if 100% hydration to occur, the products of
hydration can not fill the entire volume of water filled spaces. The obvious conclusion is
that the higher the water / cement ratio, the higher the porosity and the lower the strength
(layathilaka, 1995).
However, the accurate measurement of water / cement ratio on site is difficult, due paitly to
quantity of water in fresh concrete under most practical conditions. However, for a given
maximum size and type o f aggregate ana a given workability of concrete, the quantity o f
water per unit volume of compacted concrete is reasonably constant over a wide range of
cement contents. Therefore, it is reasonable, in practice, to ensure that the cement content
used exceed a particular minimum value which has been determined in such a way that the
maximum water cement ratio is unlikely to exceed the value which it has been found
13
There is a very significant influence of curing on sorptivity but that its effect on strength is
minimal especially if the size of concrete elements are around 150 mm or greater (Dias,
1994).
Given that sorptivity is a measures of the quality of cover zone concrete and the fact that
this zone plays a crucial barrier functior in concrete durability ie in the protection of
concrete (especially reinforced concrete) over time it is possible to say that curing is very
Ben - Bassat et al, in 1990 have shown that w/c ratio and curing significantly affect the
depth of carbonation, drying shrinkage, initial surface absorption, total absorption and
oxygen permeability. However, the importance of curing was reduced as the water / cement
ratio decreased.
Ho and Lewis (1988) showed that water / cement ratio is the decisive parameter governing
carbonation depth, as opposed to water binder ratio, where blended cements are concerned.
The aim of the concreting process is to achieve a homogeneous mass flee from voids, and
the planner must ensure that the concrete mix and compaction method are selected giving
14
Chandrakeerthy et al. (1986) has recommended that the concrete should be compacted with
either immersion or shutter vibrators. Compaction is very important for concrete with a
slump of 10 - 15mm, while it is of a lesser importance for a concrete with a slump of 125 -
150mm.
compaction has also been found by Chandrakeerthy et al, (1986). For 1:2:4 concrete, the
2
properly vibrated concrete yielded a mean equivalent cube strength of 21.6 N / m m and
incompletely vibrated concrete one of 13.9 N/mm . This is also confirmed by Dias in 1994.
2.4.1 General
Microsilica consisting of more than 90% of amoiphous Silicon Dioxide has a quite high
pozzolanic potential. This was first tested in 1947 in Norway and the large scale production
was started in 1970s. The present use of concrete containing microsilica is over 5 milion
3
m /year (Lewis, 2001). The term generally used for Microsilica in the concrete industry is
silica fume. Microsilica concrete has been used in major projects either to produce high
strength concrete or when enhanced durability was required (Lewis and Hasbi, 2001).
Microsilica concrete has proved particularly beneficial in areas where the structures are
(Sulphate and Chloride attack), moisture exposure or physical degradation such as abrasion
and erosion (Keck, 2001). The countries extensively use silica fume include United States
of America, United Kingdom, countries in the Middle East, Hong Kong, Norway, Sweden,
Denmark etc. Recently, India also started using silica fume in many large construction
projects upon the realization of the advantages that silica fume could offer with enhanced
durability.
15
2.4.2 The function and benefits of silica fumes
Silica fume is amorphous silicon dioxide. It is quite similar to silica dust (ground Si02), but
only in appearance. When available in concrete, silica fume will combine with calcium
hydroxide that is released by the hydration of cement, and produce more calcium silicate
hydrates. This is the pozzlanic reaction that gives higher strength and impermeability. Due
to the lack of free Ca(OH)2, it could improve the abrasion resistance in both wet and dry
conditions. Silica fume is a much finer material than cement particles. Therefore, it can
spread well into the mix and hence enhance the cohesive nature o f concrete thus improving
workability while reducing the segregation and bleeding. Since silica fumes are very fine
spherical particles, those can act as a lubricant to enhance the pumpability of concrete
(Lewis et al; 2001).
Since silica fume could enhance both durability and strength, it has been used in many large
scale projects in the world. Few of these are given in Table 1 obtained from Lewis and
16
Abu Dhabi Baynnuah Tower 80 Mpa concrete To improve the durability
(building) of 156 in with 10% silica and Chloride, Sulphate
height in 1992. fumes resistance in harsh
environment of the Gulf
region.
Hong Kong Tsing Ma bridge, a High strength To produce high strength
suspension bridge with concrete with 25% concrete to suit stringent and
200m tall towers and flyash and 5% silica comprehensive performance
2,167m length. fumes criteria.
India Bandra - Worli sea link 60 MPa concrete To reduce shrinkage cracking
of length 5.86Km. with 10% silica associated with high cement
fumes content and also to improve
durability.
India Viaduct in Mumbai. 75 MPa concrete To ensure long term
with 10% silica durability o f the structure.
fumes. This concrete has also given
an excellent finish for the
i
insitu and precast products.
Table 2.1: Application of concrete containing silica fume in many parts o f the world
The details given in Table 1 indicate that silica fume has been used for both durability and
high strength. Generally, silica fumes are added as an additional cementitious material as a
percentage of the original cement content. When the silica fume content is 10%, it means
3
that the weight of silica fume will be 40 kg/m in a concrete containing 400 kg of cement
!
per m . The details given in Table 1 indicates that in the above projects, silica fume were
used from 2%-10% by weight. The guidelines given in Table 2 are suggested by Lewis
Strength 7-15
Table 2.2: The contents of silica fumes suggested for different applications
17
It was shown by Keck (2001) that about 7.5% silica fume by weight could reduce the
chloride permeability by about 95% and could be used in the marine structures quite
effectively. Silica fume (5% by cement weight) was used for reducing the drying shrinkage
of bridge deck concrete in U S A (Ramey & Cope, 2001). In Norway, 5% silica fume
concrete was used to ensure good compaction of concrete, high chloride resistance and high
strength (Fidjestol, 1993). Silica fume was found to be an excellent material to reduce the
rebound of shotcrete in addition to improved durability. The silica fume content was about
8 % (Fidjestol, 1993)
Although silica fume has all these advantages, it is suggested by Neville (2001) that if it is
is permitted and if permitted, where and how to use it. This is because, it is generally
considered as a costly material and hence the benefits should outweigh the extra cost
(Neville, 2001).
2.5 Durability
During the third quarter of the last century, a tremendous boom in construction activities
occurred in the Western World, pushing the development of building materials and
optimization of load design and load bearing capacity, and did net take into account that at
least some of these developments had negative effect on robustness, sensitivity to bad
execution and duration of concrete structures (eg: pure strength oriented development of
Although the initial concern about the concrete properties was regarding strength, there is
now much concern about concrete durability. Here, too, the principal worldwide focus
most concrete) from corrosion, although there is also some attention given to the protection
of concrete itself (from phenomena such as sulphate attack and alkali aggregate reactions).
18
''.iJ'MftTiS!'-- •—
A durable concrete is one that performs satisfactorily in the working environment during its
anticipated service life. The materials and mix proportions specified and used should be
such as to maintain its integrity and, if applicable, to protect embedded steel from corrosion.
To achieve this, it is necessary to consider many interrelated factors at various stages in the
design and construction process. Thus, the cover to steel is considered at the structural
influencing the durability include its permeability and resistance to the ingress of the
which can enter concrete: water pure or carrying aggressive ions, carbon dioxide and
oxygen. They can move through the concrete in different ways, but all transport depends
primarily on the structure of the hydrated cement paste. Durability of concrete largely
depends on the case with which fluids, both liquids and gases, can enter into, and move
Permeability refers to flow through a porous medium. N o w , the movement of various fluids
through concrete take place not only by flow through the porous system but also by
diffusion and sorption, so that our concern in really with penetrability of concrete.
procedure used in making the concrete. A suitably low permeability is achieved by having
an adequate cement content, a sufficiently low free water cement ratio, by ensuring
complete compaction of concrete and by sufficient hydration of the cement through proper
curing method.
It is unfortunate that the concrete has to be reinforced with embedded metal when used to
resist tension or flexural loading. It is the potential corrosion of this embedded metal that is
the prime cause of the majority of the structural concrete deterioration that is now becoming
evident. Indeed, it has been estimated that in 1998, the value of building and civil
engineering repairs and maintenance carried out in the UK was o f the order o f £ 15 billion
of this approximately £ 500 million per annum is spent on concrete repair (Mays, 1999).
With such vast sums of money involved, it is important that the construction industry
recognizes the unwitting errors of the past and puts to good effort the lessons that have been
77714
19
2.5.1 Sorptivity testing of concrete
Durability however is a long term property. Hence, appropriate indices have to be chosen
for characterizing it. One such index that is gaining increasing acceptability is sorptivity
(Hail, 1989), especially since it is concerned with the surface areas o f concrete which
protect the steel reinforcement, and also because sorptivity testing reflects to a reasonable
extent some of the process by which actual deterioration of concrete will take place on site.
Dias (1994) obtained the volumes of water (from measured masses) absorbed per unit
surface area, after various durations up to 49 hours, by cylinders coated on their curved
surface and absorbing water through one flat face. A linear relationship can be obtained
when plotting volume absorbed per unit surface area against the square root of time. The
slope of this line is defined as the sorptivity of the specimen. Although, sorptivity is
results can be obtained even if preconditioning, varies to some extent. (Dias, 1994). The
quality of concrete in the cover region is quite important to enhance the durability. It is
generally accepted that the sorptivity of concrete could give a very good indication of the
concrete's ability to transport water (or oxygen and carbon dioxide), more precisely there
are two mechanisms controlling the uptake and transport of water. Permeability, which is a
measure of the flow of water under pressure in a saturated porous medium, and sorptivity,
which characterizes the materials ability to absorb and transmit water through it by capillary
more important parameter (which is directly related to durability) for above ground
structures is sorptivity.
Hence, sorptivity may be more convenient index of durability than is air peimeability. It
has also being argued that sorptivity, being sensitive to changes in mix constituents and
20
2.6 Summary
In BS 8110: Part 1: 1985, the enhancement of durability was achieved by using higher
strength concrete. In obtaining higher strength with adequate quality controlling measures,
weigh batching of constituent materials should be adopted. With this it is possible to use
design mixes since any cement to aggregate ratio is achievable with weigh batching.
In Sri Lanka, still volume batching is often used due to non availability of weigh batching
equipments with many small scale contractors. One nominal mix that is often used is 1: 2: 4
cement, sand and 20mm coarse aggregates. However this may give only a strength of about
2
20N/mm . However the minimum grade recommended in BS 8110: Parti: 1985 is Grade
25.
The mix of 1:1.5:3 of cement sand and 20 mm coarse aggregates is also not often adopted
since is considered as an expensive mix. Therefore, there is an urgent need to develop cost
effective mixes that could be practically used for Grades 25 and 30 concretes. This could
be considered as a short term solution until weigh batching could be adopted in majority of
Durability of concrete was improved by using other product like silica fume in many other
parts of the world. However, this is not used very much in Sri Lanka. Therefore, it is
useful to determine the possibility of using silica fume with locally available aggregates.
Therefore, in this research study, the development of economical nominal concrete mixes
and the use of silica fume for enhancing the durability and t i e concrete strength was
determined.
21