Concrete Technology 18CV44

Module – 5
Contents:-

5.1 Ready mix concrete

5.1.1 Introduction
5.1.2 Advantages
5.1.3 Disadvantages

Special concrete

5.2 Light weight concrete

5.2.1 Introduction
5.2.2 Classification of light weight aggregates
5.2.3 Types of light weight aggregates
5.2.4 Properties of light weight aggregate
5.2.5 Structural applications of light weight aggregate
5.2.6 Advantages of light weight aggregate
5.2.7 Disadvantages of light weight aggregate
5.3 Fiber reinforced concrete
5.3.1 Introduction
5.3.2 Types of fibers
5.3.3 Factors affecting the properties of fibers
5.3.4 Mechanical properties of FRC
5.3.5 Advantages of fiber reinforced concrete
5.3.6 Applications of FRC
5.4 Self compacting concrete
5.4.1 Introduction
5.4.2 Materials for SCC
5.4.3 Advantages of SCC
5.4.4 Fresh properties of SCC
5.4.5 Tests for determining the fresh properties
5.4.6 Applications

Department of Civil Engineering, GMIT Page 1

Concrete Technology 18CV44

Ready mixed concrete

5.1.1 Introduction

A concrete whose constituents are weighed according to the proportion at a central

batching plant, mixed either at the plant itself or in truck mixers and then transported to the
construction site and delivered in a condition ready to use, is termed as Ready Mixed Concrete.

The concrete delivered at site or into purchaser vehicle in plastic condition. It requires no
further treatments before being in position in which it as to set and harden is called Ready
Mixed Concrete.

Objective

To know about RMC (Ready Mix Concrete)

Problems involved in site mixed concrete are

It requires large space to stack materials.

It requires large labour force.
Work output is low.
Quality is not uniform.
No control on water –cement ratio.
Variation of mixing time.
Dust pollution and noise etc
These problems can be rectified by RMC because of the following reasons

Production by weigh batch.

Controlled mixing.
Water cement can be controlled easily.
Lower labour force and less maintenance cost.
No need of ordering cement and aggregate.
Reduces inventory expenses.
Multi transporting of materials is eliminated.
Assured uniform quality of concrete.

Department of Civil Engineering, GMIT Page 2

Concrete Technology 18CV44

Pollution free environment.

5.1.2 Advantages of RMC

Production is by weigh batching: In this type of batching the properties can be

controlled same for successive mixing.
Controlled mixing: In plant we can control the mixing without leading it to
segregation.
Water/cement ratio can be controlled easily.
Lower labour force and less supervisory cost.
No need of ordering cement and aggregate:since concrete is directly available for the
placing where it is necessary.
Reduces inventory expenses.
Multi transporting of material is eliminated
Assured uniform quality of concrete.
Pollution free environment.
Time is very much saved than other modes of concreting.
5.1.3 Disadvantages of RMC

Installation of plant has got high expenses when compared to other modes of
concreting. This is one of the major disadvantage of the RMC
There may be legal complications near the location of the plant.
It is not suitable for small quantity of concrete.

Department of Civil Engineering, GMIT Page 3

Concrete Technology 18CV44

Special Concrete

Light weight concrete

5.2.1 Introduction

Lightweight concrete can be defined as a type of concrete which includes an expanding agent in
that it increases the volume of the mixture while giving additional qualities such as durability
and lessened the dead weight.

It is lighter than the conventional concrete with a dry density of 300 kg/m3 up to 1840 kg/m3
and 87 to 23% lighter. It was first introduced by the Romans in the second century where „The
Pantheon‟ has been constructed using pumice, the most common type of aggregate used in that
particular year. From there on, the use of lightweight concrete has been widely spread across
other countries such as USA, United Kingdom and Sweden.

The main specialties of lightweight concrete are its low density and thermal conductivity. Its
advantages are that there is a reduction of dead load, faster building rates in construction and
lower haulage and handling costs. The building of „The Pantheon‟ of lightweight concrete
material is still standing eminently in Rome until now for about 18 centuries. It shows that the
lighter materials can be used in concrete construction and has an economical advantage.

Lightweight concrete performance after producing of artificial lightweight aggregates in early

20th century moved to a new phase, so that the use of lightweight concrete in deck slabs of High
Rise Buildings, bridge decks and other similar cases such as special application of lightweight
concrete in oil extraction deck and oil-drilling basements.

Wide range of lightweight aggregates is used for producing concrete. Using appropriate
materials and methods lead to achieve concrete unit weigh of 300 to 1850 kg/m3 and its
corresponding strength about 3 MPa and in some cases upon to 60 MPa.

Lightweight concrete may be made by using lightweight aggregates, or by using of foaming

agents, such as aluminum powder, which generates gas while the concrete is still plastic. Natural
lightweight aggregates include pumice, scoria, volcanic cinders, tuff, and diatomite. Lightweight
aggregate can also be produced by heating clay, shale, slate, diatomaceous shale, perlite,
obsidian, and vermiculite. Industrial cinders and blast-furnace slag that has been specially cooled
can also be used.

Pumice and scoria are the most widely used of the natural lightweight aggregates. They are
porous, froth-like volcanic glass which come in various colors and are found in the Western

Department of Civil Engineering, GMIT Page 4

Concrete Technology 18CV44

United States. Concrete made with pumice and scoria aggregate weighs from 90 to 100 pounds
per cubic foot.

Objective
To know about lightweight concrete.

5.2.2 Classification of Light Weight Concrete

The RILEM classification of light weight concrete is as given below

1. Lightweight aggregate concrete

a. Fully compacted concrete
b. Partially compacted concrete
2. No fines concrete
3. Aerated concrete
a. Aerated concrete by chemical processes [gas concrete]
b. Aerated concrete by physical processes [foam concrete]
4. Micro cellular concrete

The other modes of classification is based on either type of binder [cement, lime, Gypsum
etc] or type of aggregates [natural, processed natural by products, Unprocessed].

Classification based on density and strength

1] Light weight concrete of low strength and exceptionally good thermal Insulating properties
having densities in the range of 250 to 800 kg/m3.

2] Light weight concrete of medium strength and adequate thermal insulating Properties having
density range of 800 to 1400 kg/m3.

3] Light weight concrete of structural strength and limited thermal insulating properties having
density in the range of 1400 to 2100 kg/m3.

5.2.3 Types of lightweight concrete

Lightweight concrete can be prepared either by injecting air in its composition or it can
be achieved by omitting the finer sizes of the aggregate or even replacing them by a hollow,
cellular or porous aggregate.
Particularly, lightweight concrete can be categorized into three groups
i) No-fines concrete
ii) Lightweight aggregate concrete
iii) Aerated/Foamed concrete

Department of Civil Engineering, GMIT Page 5

 Concrete Technology 18CV44

i) 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

coarse 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.
Properties of No fines concrete

I. Density: The density of no fines concrete may be around 360kg per cubic meter.
II. Compressive strength: The compressive strength of no fines concrete may vary from 1.4 MPa
to 14 MPa.
III. Bond Strength: The bond strength of no fines concrete is very low.
IV. Drying Shrinkage: The drying shrinkage of no fines concrete is considerably lower than that
of conventional concrete.
V. Thermal conductivity: The value of coefficient of thermal conductivity of no fines concrete is
much less than that of conventional concrete.

ii) Lightweight aggregate concrete

Porous lightweight aggregate of low specific gravity is used in this light weight concrete
instead of ordinary concrete. The lightweight aggregate can be natural aggregate such as pumice,
scoria and all of those of volcanic origin and the artificial aggregate such as expanded blast-
furnace slag, vermiculite and clinker aggregate. The main characteristic of this lightweight
aggregate is its high porosity which results in a low specific gravity.
The lightweight aggregate concrete can be divided into two types according to its
application. One is partially compacted lightweight aggregate concrete and the other is the
structural lightweight aggregate concrete. The partially compacted lightweight aggregate
concrete is mainly used for two purposes that is for precast concrete blocks or panels and cast in-
situ roofs and walls. The main requirement for this type of concrete is that it should have
adequate strength and a low density to obtain the best thermal insulation and a low drying
shrinkage to avoid cracking.
Structurally lightweight aggregate concrete is fully compacted similar to that of the
normal reinforced concrete of dense aggregate. It can be used with steel reinforcement as to have

Department of Civil Engineering, GMIT Page 6

Concrete Technology 18CV44

a good bond between the steel and the concrete. The concrete should provide adequate protection
against the corrosion of the steel. The shape and the texture of the aggregate particles and the
coarse nature of the fine aggregate tend to produce harsh concrete mixes. Only the denser
varieties of lightweight aggregate are suitable for use in structural concrete.
Lightweight aggregate concrete can be produced using a variety of lightweight
aggregates. Lightweight aggregates originate from either:

Natural materials, like volcanic pumice.

The thermal treatment of natural raw materials like clay, slate or shale i.e. Leca.
Manufacture from industrial by-products such as fly ash, i.e. Lytag.
Processing of industrial by-products like FBA or slag.

iii) Aerated concrete

Aerated concrete does not contain coarse aggregate, and can be regarded as an aerated
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-
inair, 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.

5.2.4 properties of light weight concrete

The properties of light weight concrete can be categorized into two types

i. Functional properties.
ii. 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

Department of Civil Engineering, GMIT Page 7

Concrete Technology 18CV44

The most obvious characteristic of light weight concrete is its density, which at times
could be only be a fraction of that of ordinary concrete. Light weight concrete brings in a distinct
advantage of having appreciable reduction of dead loads, lo9wer 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 in 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 have 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 concretes 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

Light weight 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 fire protection than compared to conventional concrete.

Durability
It posses good resistance to exposed environmental pollutants.

Structural property

Tensile strength
It increases with the aging of concrete

Modulus of elasticity
It is usually one half to three fourth that of the reference concrete.

Fatigue strength
It is similar to that of normal concrete.

Department of Civil Engineering, GMIT Page 8

Concrete Technology 18CV44

Creep
Creep is higher than that of normal aggregate concrete.

Shrinkage
The shrinkage is assumed to be twice that of conventional concrete

Bond strength
The bond strength of structurally light weight concrete is normally high and as such at
equal compressive strengths, comparable bond strength can be expected although the bond
strength for horizontal bars are lower.

Shear strength
Shear strength is lower compared to that of conventional concrete

5.2.5 Structural applications of light weight concrete

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, priestesses 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.

5.2.6 Advantages of Light Weight Concrete

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.

Department of Civil Engineering, GMIT Page 9

Concrete Technology 18CV44

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.

5.2.7 Disadvantages of Light Weight Concrete

Very sensitive with water content in the mixtures
Difficult to place and finish because of the porosity and angularity of the aggregate. In
some mixes the cement mortar may separate the aggregate and float towards the surface
Mixing time is longer than conventional concrete to assure proper mixing

Discuss the suitability of (a) pumice (b) scoria (c)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. there fore ,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 ½ the volume of cement will counteract
this.

What are the situations under which light weight concrete is used?

Light weight aggregate is relatively new material. For the same crushing strength, the
density of concrete made with such an aggregate can be as much as 35% lower than the normal
weight concrete. In addition to the reduced dead weight, the lower modules of elasticity and
adequate ductility of light weight concrete may be advantageous in the seismic design of
structure. Other inherent advantages of material are its greater fire resistance, low thermal

Department of Civil Engineering, GMIT Page 10

Concrete Technology 18CV44

conductivity, low co-efficient of thermal expansions, and low eructation and transport cause for
pre fabricated member.

The light weight concrete is used as

(i) Load bearing masonry walls using cellular concrete blocks.

(ii) Pre-cast floor and roof panels in all types of building.
(iii) A filler wall in the form of pre cast reinforced wall panels in multistoried building.
(iv) Partition walls in residential, institutional and industrial buildings.
(v) In-situ composite roof and floor slabs with reinforced concrete grid beams.
(vi) Pre- cast composite wall or floor panel.
(vii) Insulation cladding to exterior walls of all types of building, particularly in Office and
industrial buildings.

Department of Civil Engineering, GMIT Page 11

Concrete Technology 18CV44

Fiber reinforced concrete

5.3.1 Introduction

Fiber reinforced concrete can be defined as a composite material consisting of cement

mortar or concrete and discontinuous, discrete, uniformly dispersed fibers. The continuous
meshes, woven fabrics and long wires or rods are not considered to be discrete fibers.(or)

Addition of small closely spaced and uniformly dispersed fibers to concrete would act as
crack arrester which improves its static and dynamic properties. This type of concrete is known
as Fiber reinforced concrete.

A fiber is a small discrete reinforcing material produced from steel, plastic, glass, carbon
and natural materials in various shapes and sizes. A numerical parameter describing a fiber as its
Aspect ratio which is defined as the fiber length divided by an equivalent fiber diameter.
Typical aspect ratio range from 30 to 150 for length dimensions of 0.1 to 7.62 cm. Typical fiber
diameters are 0.25 to 0.76 mm for steel and 0.02 to 0.5 mm for plastic.

Objective

To know about Fibre reinforced concrete

Role of Fibers

When the loads imposed on concrete approach that for failure, cracks will propagate,
sometimes rapidly; fibers in concrete provide a means of arresting the crack growth. Reinforcing
steel bars in concrete have: the same beneficial effect because they act as long continuous fibers.
Short discontinuous fibers have the advantage, however, of being uniformly mixed and dispersed
throughout the concrete. Fibers are added to a concrete mix which normally contains cement,
water and fine and coarse aggregate. Among the more common fibers used are steel, glass,
asbestos and polypropylene.

5.3.2 Types of Fibers

Steel Fibers

It is one of the most commonly used fibre. Generally, round fibres in cross-
sections are used. The diameter may vary from 0.25mm to 0.75mm. The steel fibre is likely to
get rusted and loose some of its strength. But investigations have shown that the rusting of the
fibres takes place only at the surface. Use of steel fibres makes significant improvements in
flexural, impact and fatigue strength of conrete.

Steel fibers have been extensively used in overlays of roads, pavements, airfields, bridge
decks and floorings subjected to wear and tear and chemical attack. The main problem

Department of Civil Engineering, GMIT Page 12

Concrete Technology 18CV44

encountered in the use of steel fibers is the tendency of the fibers to ball or cling together during
mixing. This leads to non-uniform dispersion of fibers. Incorporation of steel fibers also
decreases workability of concrete.

Fig 1 : Different shapes of steel fibers

Advantages

The following advantages can be obtained for SFRC Structural Components:

Increased flexural, shear, torsion strength and freezing-thawing resistances, Increased

durability, fatigue strength, cracking and thermal resistance and reduce shrinkage.

Uses

SFRC elements are suitable to use in the following areas:

1. Slabs and Bridge Decks, Airport Pavements, Parking areas, Fence Posts.

2 .Embankment protection, Machine foundation, Manhole covers and Dams.

3. Storage tanks, Precast Concrete Members, Slab- Column connections, shot creting

4. Repair of cavitations.

Glass Fibers

It is a recent introduction in making fibre concrete. It has very high tensile

strength 1020 to 4080 N/mm2. Glass fibres which is originally used in conjunction with cement
was found to be effected by alkaline condition of cement. Therefore, alkali-resistant glass gibre
by trade name „CEM-FIL‟ has been developed and used. The use of this fibre results in
improvements of impact and flexural strength of concrete.

Department of Civil Engineering, GMIT Page 13

Concrete Technology 18CV44

These are produced in three basic forms (a) rovings (b) strands (c) woven or chopped
strand mats. Major problem in their use are breakage of fibers and the surface degradation of
glass by high alkalinity of the hydrated cement paste. However, alkali resistant glass fibers have
been developed now. Glass fiber reinforced concrete (GFRC) is mostly used for decorative
applications rather than structural purposes.

They are classified as

• A-glass (soda lime silica glass)

• E-glass (borosilicate glass)

• A-R glass (alkaline resistant glass, ph>12.5)

Plastic Fibres or Polymeric fibers

Property A-Glass E-Glass AR-Glass

SpecificGravity 2.46 2.54 2.7

Tensile strength(MPa) 3030 3450 2480

Modulus
64800 71700 80000
ofElasticity(MPa)

Strain at ultimate(%) 4.7 4.8 3.6

Fibers such an Acrylic, Aramid, Nylon, Polyproplylene and Polyethylene have high
tensile strength but low Young‟s Modulus thus sharing inability to produce reinforcing effect.
However, due to their high ultimate elongation, their addition to concrete have shown better
resistance to cracking, reduced crack size and higher impact strength. Their use in concrete is
gaining popularity due to numerous advantages.

Fiber Effective Specific Tensile Elastic Ultimate

Type Diameter x103 gravity Strength(MPa) Modulus(GPa) Elongation(%)

Acrylic 13-104 1.17 207-1000 14.6-19.6 7.5-50.0

Aramid 10 1.44 3620 117 2.5

Nylon - 1.16 9.65 5.17 20

Department of Civil Engineering, GMIT Page 14

Concrete Technology 18CV44

Polyeste
- 1.34-1.39 896-1100 17.5 -
r

Polyeth
25-1020 0.96 200-300 5.0 3.0
ylene

Polypro
- 0.9-0.91 310-760 3.5-4.9 15
pylene

Carbon Fibres

Carbon fibres perhaps posses very high tensile strength 2110 to 2815 N/mm 2. It has been
reported that cement composite made with carbon fibre as reinforcement will have high modulus
of elasticity and flexural strength. The use of carbon fibres for structures like clading, panels and
shells will have promising future. The most important characteristic of the carbon fibre is that it
is stable at high temperature.

These fibers posses high Young‟s Modulus. The modulus of rupture of an aligned carbon
fiber reinforced cement composite with 8 % fiber volume can be as high as 1623 kg/cm². The
composite also possesses high fatigure resistance. The use of carbon fibers in concrete is
promising but it is costly and availability of carbon fibers in India is very limited.

Advantages

High strength lightweight concrete can be achieved.

More durable in hot weather & less shrinkage value.
Increased freezing - thawing resistances.

Uses

The uses of CFRC are in different fields where the lightweight concreting is required.
Precast thin sections with lightweight concreting (up to Specific Gravity 1.0).
Suitable for high temperature and low humidity areas

Asbestos fibre

It is mineral fibre and has proved to be most successful of all fibres as it can be fixed with
Portland cement. Tensile strength of asbestos varies between 560 N/mm2 to 980 N/mm2. The
composite product called asbestos cement has considerably higher flexural strength than the

Department of Civil Engineering, GMIT Page 15

Concrete Technology 18CV44

Portland cement paste.The maximum length of asbestos fiber is 10 mm but generally fibers are
shorter than this.

Natural fibers

These are naturally obtaining fibers extracted from plants in cement based composites.
The unique aspect of these fibers is low energy needed for their extraction.

Types of natural fibers

1. Wood fibre Ex: bamboo

2. Leaf fiber Ex: sisal

3. Fruit fiber Ex: coir

4. Stem fiber Ex: jute

Aspect ratio
It is the ratio of length of the fibre and equivalent diameter. In case of non circular cross
sections of the fibre equivalent diameter is found by equating area of the fibre to equivalent
circle.

5.3.3 Factors affecting properties of fiber reinforced concrete

Relative fiber matrix stiffness.

Modulus of elasticity of matrix must be much lower than that of fiber for efficient stress
transfer.

Volume of fiber.

Strength of composite largely depends on the quantity of fiber. It is found that increase in
the volume of fiber, increases approximately linearly, the tensile strength and toughness of the
composite.

Aspect ratio of fiber.

It has been reported that upto aspect ratio of 75, increase in the aspect ratio increase the
ultimate strength of the concrete linearly. Beyond 75, relative strength and toughness reduced.

Orientation of fiber.

Department of Civil Engineering, GMIT Page 16

Concrete Technology 18CV44

One of the important factor which influence the properties and behaviour of the composite
is the orientation of fiber. It was observed that the fiber aligned parallel to applied load offered
more tensile strength and toughness than randomly distributed or perpendicular fiber.

Workability and compaction of concrete.

Incorporation of fiber decreases the workability considerably.

Even prolonged vibration fails to compact the concrete.

The fiber volume at which this situation reached depends on the length and diameter of the
fiber.

Another consequence of poor workability is non uniform distribution of the fibers.

Size of coarse aggregate.

Maximum size of aggregate restricted to 10mm, to avoid appreciable reduction in the

strength.

Mixing

Mixing of FRC needs careful condition to avoid balling of fibers and Segregation. Increase
in the aspect ratio and volume of fiber intensify the difficulties and balling tendencies. A steel
fiber content in excess of 2% by volume and aspect ratio of more than 100 are difficult to mix.

5.3.4 Mechanical Properties of FRC

Addition of fibers to concrete influences its mechanical properties which significantly

depend on the type and percentage of fiber. Fibers with end anchorage and high aspect ratio were
found to have improved effectiveness. It was shown that for the same length and diameter,
crimped-end fibers can achieve the same properties as straight fibers using 40 percent less fibers.
In determining the mechanical properties of FRC, the same equipment and procedure as used for
conventional concrete can also be used.

Compressive Strength
The presence of fibers may alter the failure mode of cylinders, but the fiber effect will be
minor on the improvement of compressive strength values (0 to 15 percent).

Modulus of Elasticity
Modulus of elasticity of FRC increases slightly with an increase in the fibers content. It
was found that for each 1 percent increase in fiber content by volume there is an increase of 3
percent in the modulus of elasticity.

Department of Civil Engineering, GMIT Page 17

Concrete Technology 18CV44

Flexure
The flexural strength was reported[2j to be increased by 2.5 times using 4 percent fibers.

Toughness
For FRC, toughness is about 10 to 40 times that of plain concrete.

Splitting Tensile Strength

The presence of 3 percent fiber by volume was reported to increase the splitting tensile
strength of mortar about 2.5 times that of the unreinforced one.

Fatigue Strength
The addition of fibers increases fatigue strength of about 90 percent and 70 percent of the
static strength at 2 x 106 cycles for non-reverse and full reversal of loading, respectively.

Impact Resistance
The impact strength for fibrous concrete is generally 5 to 10 times that of plain concrete
depending on the volume of fiber used.

Corrosion of Steel Fibers

A 10 year exposure of steel fibrous mortar to outdoor weathering in an industrial
atmosphere showed no adverse effect on the strength properties. Corrosion was found to be
confined only to fibers actually exposed on the surface. Steel fibrous mortar continuously
immerse in seawater for10 years exhibited a 15 percent less compared to 40 percent strength
decrease of plain mortar.

5.3.5 Advantages of Fibre Reinforced Concrete

Reduction in shrinkage and cracking

Research has shown that high fiber count (number of fibers per unit volume), reduces the
effects of restrained and drying shrinkage cracking. The addition of polypropylene fiber
also reduces crack width significantly. After cracking, the fibers transfer tensile stress across
cracks and act to confine crack tip extension so that many fine (hair line) cracks occur
instead of fewer larger cracks.

Improved Bond Strength

The fibers exhibit improved mechanical bonding as a direct result of cement matrix
penetrating the fibers network. This feature is called pegging. Mechanical bond or
adhesion of fibers with calcium silicate hydrate has also been reported.

Department of Civil Engineering, GMIT Page 18

Concrete Technology 18CV44

Fatigue strength and endurance limit

One of the important attributes of FRC is the enhancement of fatigue strength as compared
to plain concrete. The addition of polypropylene fibers, even in small amount has increased
the flexural fatigue strength. An increase of 15 % to 18 % has been reported.

Better Toughness

Addition of fibers improve post-crack behavior and energy absorbing capacity of concrete.
The ability to absorb elastic and plastic strain energy and to conduct tensile stresses across
cracks is an important performance factor for serviceability of concrete. Fibers have
significant influence on post-crack load carrying capacity of concrete.

5.3.6 Applications

The uniform dispersion of fibers throughout the concrete mix provides isotropic
properties not common to conventionally reinforced concrete. The applications of fibers in
concrete industries depend on the designer and builder in taking advantage of the static and
dynamic characteristics of this new material. The main area of FRC applications are:

Runway, Aircraft Parking, and Pavements

For the same wheel load FRC slabs could be about one half the thickness of plain
concrete slab. Compared to a 375mm thickness' of conventionally reinforced concrete slab, a
150mm thick crimped-end FRC slab was used to overlay an existing as Properties and
Applications of Fiber Reinforced Concrete 53phaltic-paved aircraft parking area. FRC
pavements are now in service in severe and mild environments.

Tunnel Lining and Slope Stabilization

Steel fiber reinforced shortcrete (SFRS) are being used to line underground opening sand
rock slope stabilization. It eliminates the need for mesh reinforcement and scaffolding.

Blast Resistant Structures

When plain concrete slabs are reinforced conventionally, tests showed that there is no
reduction of fragment velocities or number of fragments under blast and shock waves. Similarly,
reinforced slabs of fibrous concrete, however, showed 20percent reduction in velocities, and over
80 percent in fragmentations.

Thin Shell, Walls, Pipes, and Manholes

Fibrous concrete permits the use of thinner flat and curved structural elements. Steel
fibrous shortcrete is used in the construction of hemispherical domes using the inflated
membrane process. Glass fiber reinforced cement or concrete (GFRC) ,made by the spray-up

Department of Civil Engineering, GMIT Page 19

Concrete Technology 18CV44

process, have been used to construct wall panels. Steel and glass fibers addition in concrete pipes
and manholes improves strength, reduces thickness, and diminishes handling damages.

Dams and Hydraulic Structure

FRC is being used for the construction and repair of dams and other hydraulicstructures
to provide resistance to cavitation and severe errosion caused by the impactof large waterboro
debris.

Fiber shot Crete:

Fiber short Crete has been used in rock stabilization, tunnel lining and bridge repair.
Fiber short Crete can be used in the protection of structural steel work particularly in the
support structure.

Other Applications
These include machine tool frames, lighting poles, water and oil tanks and concreterepairs.

Merits

There is an increase in tensile and flexural strength.

There is an improvement in ductility and toughness.
Improvement in blast resistance and impact resistance
Fibres act as crack arrestors, thus control cracking and mode of failure by means of post cracking
ductility.
One major draw-back of high strength concrete is that it is brittle. The failure will be sudden and
catastrophic, particularly in structures subjected to earthquake, blasts or suddenly applied loads.
This serious disadvantage of high strength concrete is overcome by addition of fibres which
makes it ductile.

De-merits

If there is non-uniform distribution of fibres it leads to poor workability.

Conventional mixing techniques and mix proportions usually lead to fibre balling,
improper dispersion and hence quality control should be maintained.

Department of Civil Engineering, GMIT Page 20

Concrete Technology 18CV44

While mixing small quantities of fibre reinforced concrete by hand, there is a possibility
of steel fibres shooting up and hitting the eyes of worker or even pricking the hand.

Typical proportion for FRC is given below.

Cement - 325 to 550kg/m3

W/C ratio- 0.4 to 0.6.

% of sand to total aggregate- 50 to100%.

Max size of aggregate- 10mm.

Air content- 6 to 9 percent.

Fiber content- 0.5 to 2.5 % by volume of mix.

Steel-1% 78kg/m3.

Glass-1% 25kg/m3.

Nylon-1% 11kg/m3

SELF COMPACTING CONCRETE

5.4.1 Introduction

Department of Civil Engineering, GMIT Page 21

Concrete Technology 18CV44

“Self Compacting Concrete is defined as a concrete mixture that can be placed purely by
means of its own weight with little or no vibration”. Or

“Concrete that is able to flow and consolidate under its own weight, completely fill the
formwork of any shape, even in the presence of dense reinforcement, while maintaining
homogeneity and without the need for any additional compaction”

Objective
To know about fiber reinforced concrete.
5.4.2 Materials
• SCC has more powder content and less coarse aggregate
• Fillers used can be flyash, ground granulated blast furnace slag, condensed silica fume,
ricehusk ash, lime powder, chalk powder & quarry dust
• SCC incorporates high range water reducers (HRWR, Super plasticizers) & frequently,
viscosity modifying agent in small amount.
These are some general parameters of mixes that our experience shows are required to produce
trial mixes for quality SCC:
Coarse aggregate content: For normal-density aggregates this typically results in a specific
volume that is 28%–32% of the concrete volume, with the balance (68–72%) being mortar.
Paste fraction: Approximately 35%–37% of the mix. For rounded well-graded fine aggregate
this will be lower, for poor grades or manufactured fine aggregate this will be higher
Powder (cement, supplementary cementitious materials and inert powder materials with
particle sizes passing the 150 mm sieve: Powder contents will generally be in the 295–365
kg/m3 range.
Fine aggregate: Some people track fine aggregate to total aggregate ratio – which usually turns
out to be approximately 45%–55%, with 50% being typical.
Water content: For first mix, as needed to get 25–75 mm slump in concrete without SCC
admixtures. This would include water-reducing admixture or retarders for set control.
W/C ratio: As needed for durability. Generally, powder content requirements for SCC
properties will mean that W/C is low enough, and resultant strength high enough for most
applications; however this must be confirmed.

Department of Civil Engineering, GMIT Page 22

Concrete Technology 18CV44

Air: Air content should be as needed for durability. Air can improve the viscosity of a mix and
increase the paste volume, but may adversely affect paste density. There are many industry
organizations at work developing specifications, test methods, and practices for SCC. As new
information becomes available, this document will be updated accordingly.

5.4.3 Advantages of SCC:

Reduction of labor cost (as much as 50% - 80%), machinery, energy

Increases in early (initial set) and ultimate (in-place) strength
Improved surface finish (virtually eliminates bug holes)
Less efflorescence
Covers reinforcement effectively
Reduction of repairs due to inadequate compaction
Saving in initial cost of form work and more usage
Reduction of energy costs and noise levels (little or no vibration required)
Suitable for slim and complicated moulds.

Some of the important points to be noted are

SCC can improve product quality.

SCC can reduce the product cost.
SCC can be disaster if your quality control is lacking, but a success if your standards are
good.

An SCC mix has the following characteristics:

Non-Segregating: The aggregate will stay in suspension in the mix as it flows into the
form,

Non-Bleeding: Water will not rise to the top of the mix or be observed on the outer edges
of a flow test.

Vibration: No vibration is required during placement. SCC will flow around rebar and
other inclusions in the form under its own weight,

Department of Civil Engineering, GMIT Page 23

Concrete Technology 18CV44

Flow spreads: Flow spreads of 18-inch diameter or greater are obtainable.

Set time: The initial set time in many SCC mixes will increase upwards of 90 minutes,
depending on the admixtures used and water content of the mix. This may be a desirable
trait for many concreting operations in the drilled shaft industry.
Cement cannot be the only finer/filler material.
Mineral admixtures are used to enhance the deformability & stability of concrete.
Chemical admixtures are a must for achieving excellent flow at low water content. VMA
reduces bleeding & improves the stability of the concrete mixture

5.4.4 Fresh SCC Properties

Filling ability
“The ability of SCC to flow into and fill completely all spaces within the formwork, under its
own weight.”
Passing ability
“The ability of SCC to flow through tight openings such as spaces between steel reinforcing bars
without segregation or blocking.”
Segregation resistance
“The ability of SCC to remain homogeneous in composition during transport and placing.”

5.4.5 Test methods for determining fresh SCC properties

Filling ability: Slump flow & T50CM slump flow and V- Funnel test
Passing ability: L-Box, U-box, J-ring, Fill Box
Segregation resistance: V-Funnel at T5 Minutes, GTM Screen stability test
1. Slump flow test and T50cm test
The slump flow is used to assess the horizontal free flow of SCC in the absence of
obstructions.

Department of Civil Engineering, GMIT Page 24

Concrete Technology 18CV44

Equipment:
The apparatus is shown in figure
mould in the shape of a truncated cone with the internal dimensions 200 mm diameter at
the base, 100 mm diameter at the top and a height of 300 mm, conforming to EN 12350-2
base plate of a stiff non absorbing material, at least 700mm square, marked with a circle
marking the central location for the slump cone, and a further concentric circle of 500mm
diameter
trowel, scoop, ruler and stopwatch (optional)
Procedure:
1. About 6 litre of concrete is needed to perform the test, sampled normally. Moisten the
base plate and inside of slump cone,
2. Place base plate on level stable ground and the slump cone centrally on the base plate and
hold down firmly.
3. Fill the cone with the scoop. Do not tamp, simply strike off the concrete level with the
top of the cone with the trowel.
4. Remove any surplus concrete from around the base of the cone.
5. Raise the cone vertically and allow the concrete to flow out freely.
6. Simultaneously, start the stopwatch and record the time taken for the concrete to reach
the 500mm spread circle. (This is the T50 time).
7. Measure the final diameter of the concrete in two perpendicular directions.
8. Calculate the average of the two measured diameters. (This is the slump flow in mm).
Note any border of mortar or cement paste without coarse aggregate at the edge of the
pool of concrete.

Department of Civil Engineering, GMIT Page 25

Concrete Technology 18CV44

2. J Ring test

Fig: J-Ring test

Equipment
Mould, WITHOUT foot pieces, in the shape of a truncated cone with the internal
dimensions 200 mm diameter at the base, 100 mm diameter at the top and a height of 300
mm.
base plate of a stiff non absorbing material, at least 700mm square, marked with a circle
showing the central location for the slump cone, and a further concentric circle of 500mm
diameter
trowel, scoop and ruler
J-Ring a rectangular section (30mm x 25mm) open steel ring, drilled vertically with
holes. In the holes can be screwed threaded sections of reinforcement bar (length 100mm,
diameter 10mm, spacing 48 +/- 2mm)
Procedure:
1. About 6 litre of concrete is needed to perform the test, sampled normally.
2. Moisten the base plate and inside of slump cone,
3. Place base-plate on level stable ground.
4. Place the JRing centrally on the base-plate and the and the slump-cone centrally inside it
and hold down firmly.
5. Fill the cone with the scoop. Do not tamp, simply strike off the concrete level with the
top of the cone with the trowel.
6. Remove any surplus concrete from around the base of the cone.

Department of Civil Engineering, GMIT Page 26

Concrete Technology 18CV44

7. Raise the cone vertically and allow the concrete to flow out freely.
8. Measure the final diameter of the concrete in two perpendicular directions.
9. Calculate the average of the two measured diameters. (In mm).
10. Measure the difference in height between the concrete just inside the bars and that just
outside the bars.
11. Calculate the average of the difference in height at four locations (in mm).
12. Note any border of mortar or cement paste without coarse aggregate at the edge of the
pool of concrete.

3. V funnel test and V funnel test at T 5minutes

Fig: V-Funnel
Equipment:
V-funnel, bucket ( ±12 litre ), trowel, scoop and stopwatch
Procedure flow time:
1. About 12 litre of concrete is needed to perform the test, sampled normally.
2. Set the V-funnel on firm ground.
3. Moisten the inside surfaces of the funnel.
4. Keep the trap door open to allow any surplus water to drain.
5. Close the trap door and place a bucket underneath.
6. Fill the apparatus completely with concrete without compacting or tamping, simply strike
off the concrete
7. Level with the top with the trowel.
8. Open within 10 sec after filling the trap door and allow the concrete to flow out under
gravity.

Department of Civil Engineering, GMIT Page 27

Concrete Technology 18CV44

9. Start the stopwatch when the trap door is opened, and record the time for the discharge to
complete (the flow time). This is taken to be when light is seen from above through the
funnel.
10. The whole test has to be performed within 5 minutes.
Procedure flow time at T 5 minutes:
1. Do NOT clean or moisten the inside surfaces of the funnel again.
2. Close the trap door and refill the V-funnel immediately after measuring the flow time.
3. Place a bucket underneath.
4. Fill the apparatus completely with concrete without compacting or tapping, simply strike
off the concrete
5. Level with the top with the trowel.
6. Open the trap door 5 minutes after the second fill of the funnel and allow the concrete to
flow out under gravity.
7. Simultaneously start the stopwatch when the trap door is opened, and record the time for
the discharge to complete (the flow time at T 5 minutes). This is taken to be when light
is seen from above through the funnel.

4. L-box test method

Equipment:
L box of a stiff non absorbing material see figure
Trowel, scoop and stopwatch

Department of Civil Engineering, GMIT Page 28

Concrete Technology 18CV44

Procedure:
1. About 14 litre of concrete is needed to perform the test, sampled normally.
2. Set the apparatus level on firm ground, ensure that the sliding gate can open freely and
then close it.
3. Moisten the inside surfaces of the apparatus, remove any surplus water
4. Fill the vertical section of the apparatus with the concrete sample.
5. Leave it to stand for 1 minute.
6. Lift the sliding gate and allow the concrete to flow out into the horizontal section.
7. Simultaneously, start the stopwatch and record the times taken for the concrete to reach
the 200 and 400 mm marks.
8. When the concrete stops flowing, the distances “H1” and “H2” are measured.
9. Calculate H2/H1, the blocking ratio.
10. The whole test has to be performed within 5 minutes.

5. U box test method

Fig: U-Box
Equipment
U box of a stiff non absorbing material see figure D.7.1.
Trowel, scoop and stopwatch
Procedure:
1. About 20 litre of concrete is needed to perform the test, sampled normally.
2. Set the apparatus level on firm ground, ensure that the sliding gate can open freely and
then close it.
3. Moisten the inside surfaces of the apparatus, remove any surplus water.

Department of Civil Engineering, GMIT Page 29

Concrete Technology 18CV44

4. Fill the one compartment of the apparatus with the concrete sample.
5. Leave it to stand for 1 minute.
6. Lift the sliding gate and allow the concrete to flow out into the other compartment.
7. After the concrete has come to rest, measure the height of the concrete in the
compartment that has been filled, in two places and calculate the mean (H1). Measure
also the height in the other compartment (H2).
8. Calculate H1 - H2, the filling height.
9. The whole test has to be performed within 5 minutes.

5.4.6 Applications of self compacting concrete

Osaka Gas Station: First Application of SCC (1997-1998)
Akashi-Kaikyo (Straits) Bridge: Longest suspension bridge Length 3911m and central
span of 1991m, 240,000 m3 of SCC
RCC girders
Bangalore International Airport

How is SCC different from conventional slump concrete?

SCC must be highly workable so that it can move under the force of gravity without
vibration, during mixing, transportation, handling, and placement. It is so highly flowable that
the conventional slump test cannot distinguish between different levels of SCC flowability – all
would be 280 mm+ (11 in. +) in slump. However, SCC must also be viscous enough so that the
mortar suspends and carries coarse aggregate, maintaining a homogenous, stable mixture,
resistant to segregation, bleeding, excessive air migration, or paste separation. It must have
dynamic stability during mixing, transportation, handling and placement, and static stability
during protection and curing. SCC‟s workability is a function of its rheology. Conventional
concrete brought to 280 mm+ (11 in. +) slump does not have this stability.

Characteristics of SCC in Hardened state

Table 1.0: Typical Properties of hardened SCC

Item SCC

Department of Civil Engineering, GMIT Page 30

Concrete Technology 18CV44

Water-binder ratio (%) 25 to 40

Compressive strength (age: 28 days) (MPa) 40 to 80
Compressive strength (age:91 days) (MPa) 55 to 100
Splitting tensile strength (age: 28 days) (MPa) 2.4 to 4.8
Elastic modulus (GPa) 30 to 36
Shrinkage strain (x10-6) 600 to 800

Summary
• One of the outcomes of using High Strength Concrete is slender members andconsequently,
very dense reinforcement. Normal methods of vibration are not effective –Hence, SCC.
• SCC has various other applications. It is especially suited to pre-cast/prefab products. InJapan,
they now use for casting composite columns, steel tubes with shear lugs inside filledwith SCC
and no other reinforcement. Very tall columns have been made.
• Very few national standards exist as of now for SCC (Japan, Europe, Italy etc.)
• SCC mixes are very sensitive to variation in water.
• Water curing is absolutely necessary for 3 to 7 days.
• SCC should be treated as high quality concrete and not meant for low strength applications
• SCC can be advantageously used for all types of work with proper understanding of its
behavior
• It is a matter of time SCC replacing Normal Concrete even in INDIA
Assignment Questions

1. Define RMC and give out the advantages and disadvantages of RMC.
2. Define light weight concrete.
3. What are the types of light weight concrete?
4. Explain the properties of light weight concrete.
5. What are the applications of light weight concrete?
6. Define Self compacting concrete.
7. What are the materials required for manufacturing SCC?
8. Write a note on properties of SCC.
9. Explain the tests performed for determining the fresh properties of SCC.
10. What are the applications of SCC?
11. Define Fiber reinforced concrete.
12. What are the types of fibers? Explain their properties.
13. What are the factors affecting the properties of fiber

Department of Civil Engineering, GMIT Page 31

Concrete Technology 18CV44

14. What are the applications of FRC

Outcome

Gives knowledge about RMC, lightweight concrete, Self compacting concrete and fiber
reinforced concrete.

Future scope

By studying this one can design Light weight, self compacting and fiber reinforced concrete
mixes.

Department of Civil Engineering, GMIT Page 32