Elemix® Concrete Additive TECHNICAL GUIDE

TABLE OF CONTENTS
January 2011

Elemix® Concrete Additive

TABLE OF CONTENTS……………………………………………………………………………..PAGE

I. Elemix Concrete Additive Introduction…………………………………………………………………4

i. Definition
ii. Basic benefits of concrete made with Elemix additive
iii. Addition to concrete

II. Design Recommendations………………………………………………………………………………5

i. Typical ranges of ingredients for structural mixes

ii. Proportioning recommendations (ready mix and precast)
iii. Typical ranges of density
iv. Mix design recommendations for concrete masonry units
v. Use of admixtures
vi. Handling & finishing
vii. Pumping
viii. Coloring

III. Technical Properties…………………………………………………………………………………...12

i. Physical Properties
 Performance tables

ii. Mechanical Properties

 ASTM C39 Compressive Strength of Cylindrical Concrete Specimens
 ASTM C496 Splitting Tensile Strength
 ASTM C78 Flexural Strength
 ASTM C469 Static Modulus of Elasticity

iii. Durability in Freezing and Thawing

 ASTM C666 Resistance of Concrete to Rapid Freezing and Thawing
 ASTM C672 Scaling Resistance of Concrete Surfaces Exposed to Deicing
Chemicals

iv. Fire Performance

 ASTM E119 (UL263) Fire Tests of Building Construction and Materials
 ASTM E119 Fire performance of concrete containing Elemix additive
o
 ASTM E136 Behavior of Materials in a Vertical Tube Furnace, 750 C

v. Thermal Properties
 ASTM C177 Thermal Transmission Properties

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IV. Collaborative University Studies……………………………………………………………………..19

i. NCSU: Beam Shear Behavior and Development Length of Reinforcement

ii. Purdue University: Plastic and Restrained Shrinkage Cracking
iii. University of New Brunswick: Durability in Laboratory and Natural Exposure Conditions

V. Code Compliance and Specifications…………………………………………………………….....21

i. ICC-ES Acceptance Criteria and Evaluation Service Report

ii. Engineering Specification

VI. Patent / Intellectual Property Information…………………………………………………………..22

VII. List of Technical Documents………………………………………………………………………..22

VIII. Contact Information………………………………………………………………………………....23

IX. References Cited…..…………………………………………………………………………………23

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I. INTRODUCTION

Definition
®
Elemix concrete additive is comprised of innovative
polymeric spheres that have been specially formulated for
use in concrete.

The customized size and density of Elemix concrete

additive allows it to distribute uniformly in concrete and stay
suspended in the matrix. This results in reduced weight or
lightweight products at structural strengths providing the
key benefits of:

• Reduced density (unit weight)

• Consistent product performance
• Durable concrete produced
• Improved pumping performance
• Improved cracking performance
• Improved thermal performance

Elemix concrete additive is introduced towards the end of the batching process and distributes uniformly
with regular mixing.

Concrete made with Elemix additive meets the requirements for many concrete applications. Our product
has been used successfully in various structural applications such as: ready mix, precast and concrete
masonry units, as well as non-structural applications such as: stone veneer, roof tiles and ornamental
pieces.

Basic Benefits of Concrete made with Elemix Additive

Elemix concrete additive has several properties that are advantageous to use in
concrete, including:

 Reduces Concrete Weight

o Delivers targeted densities while achieving structural compressive strength
o Reduced concrete weight can contribute to overall reduction of building costs or for
manufactured products contributes to reduced transportation costs
o Enables concrete to be used in new design opportunities

 Product / Performance Consistency

o Elemix additive is manufactured under tight tolerances resulting in consistent
performance properties, therefore reducing the overall variability in concrete mixtures

 Durability
o Good durability increases the life of the concrete structure reducing long-term costs
o Elemix concrete additive has been shown to impart freeze-thaw resistance with durability
factors ≥ 80% without the use of air-entraining admixtures
o Studies of concrete containing Elemix additive have generated concrete with low to very
low chloride ion penetrability

 Ease and Efficiency of Placement

o Concrete made with Elemix additive pumps, places and finishes easily by traditional
methods. The non-abrasive nature of the product contributes to less wear on equipment.

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  Cracking Performance
o Studies at Purdue University reveal that the use of Elemix additive in concrete gave crack
reduction ratios, associated with plastic shrinkage cracking, of up to 85% versus a
control. Improved cracking performance was also evident in restrained shrinkage
cracking tests where the addition of Elemix additive increased the time to cracking or in
some cases enabled samples to not crack.

 Thermal Performance
o Concrete made with Elemix additive will improve thermal resistance based on the
reduced unit weight.

Addition to Concrete

Elemix concrete additive is supplied to concrete batches by weight or volume. Elemix additive is easily
added manually to batching equipment or directly to mixers. Additionally, SYNTHEON Inc. has several
equipment options, which may be specified depending upon concrete production requirements.

If you have questions concerning dispensing equipment or other general inquiries, please contact us at
412-490-4397, or via email at elemix@syntheoninc.com .

II. DESIGN RECOMMENDATIONS

Typical Ranges of Ingredients for Structural Mixes

Elemix additive is used as a partial replacement for conventional fine or coarse aggregate. The current
available grades are Elemix XE concrete additive and Elemix Grey XE concrete additive. In a concrete
mixture, optimized strengths are achieved by replacing about half of the typical volume of coarse
aggregate with Elemix additive. Replacement values vary depending on whether the coarse aggregate is
normal weight or lightweight. The following sections give general ranges of ingredients as well as specific
examples of commercial mixtures described by application:

Table 1. Typical Ranges for Ready Mix and

Typical
PrecastRanges for Ready Mix and Precast Designs
Designs

3
Lbs/yd3 Kg/m
Cement* 525 - 800 311 - 475
SCM** 0 - 225 0 - 133
Fine Aggregate 950 - 1700 564 - 1008
Coarse Aggregate 225 - 1000 133 - 593
Water 250 - 420 148 - 249
Elemix concrete additive 1 - 13 0.6 - 7.7
Admixtures As directed by manufacturer

*recommended minimum total cementitious level 640 lb/yd 3 (380 kg/m3 )

**SCM supplementary cementitious material

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Proportioning Recommendations

Establishing the Mix Design

The specific gravity of Elemix additive is 0.042. Elemix additive has a unique weight to volume ratio
3 3
compared to conventional raw materials. One pound of Elemix additive occupies about 0.40 ft (0.011 m )
volume. The product is hydrophobic with negligible moisture absorbance. The material is batched dry
without the need to measure moisture content or account for absorbance. Typical water to cementitious
ratios for mixtures using Elemix additive are 0.34 to 0.42. Because the product is spherical and flows
easily, a 4-inch slump containing Elemix additive tends to be more workable than a conventional mix at
the same slump. This also allows lower w/cm ranges in designs containing Elemix additive. Preferred
top size of coarse aggregate to be used with mixtures containing Elemix additive is ⅜-inch up to ¾-inch
(0.953 cm to 1.905 cm). The suggested range of sand to total aggregate for concrete containing Elemix
additive is 0.55 to 0.62.

It should be noted that the w/cm is not always the primary factor in estimating the strength of concrete
mixtures containing Elemix additive. The compressive strength of concrete containing Elemix additive
correlates more closely with the concrete unit weight and percent loading of Elemix additive. Structural
3 3
concrete can be produced in the range of 90 pcf to 130 pcf (1442 kg/m to 2028 kg/m ) with compressive
strengths ranging from 3000 psi to 7000 psi (20.7 MPa to 48.3 MPa). Aggregates having low specific
gravities require smaller loadings of Elemix additive in order to decrease density. Smaller loadings of
Elemix additive offer higher ranges of obtainable strength.

Mixtures containing Elemix additive generally contain 1.5% to 2% entrapped air, as well as a small
quantity of entrained air. It is recommended to set the mix design air content to 3%. Adjustments can
easily be made with a particular design by comparing fresh air contents versus design air as well as
targeted yields in laboratory test batches. An adjustment of +/- 0.5% may be necessary to fine tune the
air content. If the admixtures being used tend to entrain air, then this percentage may need to be added
on to the 3% target. Elemix additive does compress during the ASTM C231 air test using the pressure
meter adding to the meter reading. Elemix additive technical bulletin #001 titled „Suggested Modifications
to ASTM C231‟ can be referred to for explanation of the correction factor needed for Elemix additive when
using the pressure meter. A full list of Elemix concrete additive Technical Bulletins is referred at the end
of this document and can be accessed through the Elemix concrete additive website at www.elemix.com .

Batching the concrete

It is recommended to add Elemix additive towards the end of the batching process. It should not be
added before the aggregates. The following mix order works well for most designs: coarse aggregate
fine aggregate ½ water cementitious Elemix concrete additive remaining water admixtures.
For lab trials where weighing small quantities of Elemix additive (2 lbs (0.907 kg) or less) is required, use
a scale that measures within +/- 0.1 grams. A typical scale for measuring cements and aggregates will not
be precise enough for metering out the Elemix additive. For commercial applications Elemix additive can
come pre-weighed or can be metered by dosing equipment.
3
It should be noted that when designing very low density non-structural mixes (70 pcf (1121 kg/m ) or less)
with 800-900 psi compressive strength (5.5-6.2 MPa), coarse and fine aggregates must be completely
removed.

Clean up of Elemix additive in a laboratory setting is best achieved using a vacuum hose.

The following pages outline some examples of several standard mix designs used with specified
aggregate types.

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Example Mix 1: Ready mix design (normal weight aggregate)
3 3
Materials lb/yd kg/m
Type I cement 700 415
Class C fly ash 150 89
ASTM C33 sand 1327 787
Elemix additive 10.7 6.4
67 limestone 800 475
w/cm 0.36
HRWR 4 oz/cwt 260 ml/100kg

3
Fresh Density 120 pcf 1954 kg/m
3
Equilibrium Dry Density 117 pcf 1922 kg/m
Slump 8 in 20 cm
Pressure Meter Air Reading, % 5.2%
Total Air, % 3.7%
7-day Compressive Strength 4010 psi 28 MPa
28-day Compressive Strength 4860 psi 33 MPa

Example Mix 2: Ready mix design (lightweight aggregate)

3 3
Materials lb/yd kg/m
Type I cement 650 386
Slag grade 100 150 89
ASTM C33 sand 1044 620
Elemix additive 5.6 3.3
¾” expanded slate 800 475
w/cm 0.40
HRWR 4 oz/cwt 260 ml/100kg

3
Fresh Density 110 pcf 1762 kg/m
3
Equilibrium Dry Density 102 pcf 1634 kg/m
Slump 8 in 20 cm
Pressure Meter Air Reading, % 5.5%
Total Air, % 4.6%
7-day Compressive Strength 3320 psi 23 MPa
28-day Compressive Strength 4910 psi 34 MPa

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Example Mix 3: Ready mix design (blended aggregates)
3 3
Materials lb/yd kg/m
Type I cement 600 356
Class C fly ash 100 59
ASTM C33 sand 1335 792
Elemix additive 7.1 4.2
67 limestone 450 267
¾” expanded shale 400 237
w/cm 0.42
HRWR 4 oz/cwt 260 ml/100kg

3
Fresh Density 118 pcf 1890 kg/m
3
Equilibrium Dry Density 113 pcf 1810 kg/m
Slump 7 in 18 cm
Pressure Meter Air Reading, % 7.3%
Total Air, % 6.2%
7-day Compressive Strength 3700 psi 26 MPa
28-day Compressive Strength 4530 psi 31 MPa

Example Mix 4: Precast (lightweight aggregate)

3 3
Materials lb/yd kg/m
Type III cement 752 446
ASTM C33 sand 1187 704
Elemix additive 4.3 2.6
3/8” expanded slate 900 534
w/cm 0.38
HRWR 10 oz/cwt 650 ml/100kg

3
Fresh Density 116 pcf 1858 kg/m
3
Equilibrium Dry Density 110 pcf 1762 kg/m
Slump Flow 25 in 64 cm
Pressure Meter Air Reading, % 4%
Total Air, % 3.3%
18-hr Compressive Strength 3340 psi 23 MPa
28-day Compressive Strength 4700 psi 32 MPa

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Example Mix 5: Self Consolidating Concrete Design
3 3
Materials lb/yd kg/m
Type III cement 576 342
Slag grade 100 244 145
ASTM C33 sand 1378 817
Elemix additive 3.6 2.2
67 limestone 300 178
3/8” expanded slate 550 326
w/cm 0.36
HRWR 10 oz/cwt 650 ml/100kg

3
Fresh Density 124 pcf 1985 kg/m
3
Equilibrium Dry Density 120 pcf 1922 kg/m
Slump Flow 24 in 60 cm
Pressure Meter Air Reading, % 5.8%
Total Air, % 5.2%
7-day Compressive Strength 5910 psi 41 MPa
28-day Compressive Strength 7100 psi 49 MPa

Example Mix 6: Nonstructural grout (no coarse aggregate)

3 3
Materials lb/yd kg/m
Type I cement 750 445
Class C Fly Ash 250 148
Mason sand (FM = 1.74 ) 500 296
Elemix additive 29.78 17.66
w/cm 0.44 0.36
HRWR 4 oz/cwt 261 ml/100kg

3
Fresh Density 70 pcf 1121 kg/m
3
Equilibrium Dry Density 68 pcf 1089 kg/m
Flow 18 in 457 mm
Pressure Meter Air Reading, % 8.3%
Total Air, % 8.27%
7-day Compressive Strength 1040 psi 7 MPa
28-day Compressive Strength 1500 psi 10 MPa

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Typical Ranges of Density (Unit Weight) – Structural and Non Structural

Mixes can be proportioned to achieve a range of densities. Figure 1 illustrates typical wet concrete
densities that can be attained using Elemix additive at given dosages. Figure 2 shows typical
compressive strengths achieved using Elemix additive with lightweight aggregates and Elemix additive
with normal weight aggregates.

Figure 1. Typical Ranges of Density

Elem ix Concrete Additive Dosage (kg/m 3)

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
150 2400
145 2300
140
2200
135

Wet Density (kg/m 3)

2100
Wet Density (lb/ft3)

130
125 2000
120 1900
115
1800
110
105 1700
100 1600
95 1500
90
1400
85
80 1300
75 1200
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Elem ix Concrete Additive Dosage (lb/yd 3)

Figure 2. Typical Compressive Strength at 28 days

(Elemix additive with normal weight and with lightweight aggregates)

Equilibrium Concrete Density (kg/m3)

1280 1360 1440 1520 1600 1680 1760 1840 1920
8000 60
Elemix additive + lightweight aggregate

7000
50

6000

Compressive Stregth (MPa)

40
Compressive Strength (psi)

5000

4000 30

3000
20

2000

10
1000

0 0
80 85 90 95 100 105 110 115 120 125 130 135
Equilibrium Concrete Density (pcf)

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Mix Design Recommendations for Concrete Masonry Units

Elemix additive has also been used in concrete masonry units to produce medium weight and lightweight
blocks.

Table 2. Typical composition by volume for medium or lightweight units

Cement 10-14%
Fine Aggregate 45-65%
Coarse Aggregate 18-26%
Elemix concrete additive 10-12%

Use of Admixtures

Several classes of admixtures have been used in conjunction with Elemix additive. Admixtures should be
used according to manufacturer‟s specifications.

It should be noted that although air-entraining admixtures have been used with concrete containing
Elemix additives, mixes batched with Elemix additive alone have passed ASTM C666 and ASTM C672
freezing and thawing durability tests. Please refer to testing section for additional details.

Some of the typical admixtures that have been utilized with Elemix additive include water reducers,
accelerators, retarders, and viscosity modifiers. These admixtures do not impact the performance of
Elemix concrete additive.

Handling & Finishing

Elemix concrete additive disperses readily throughout a concrete matrix. Placement is easy and vibration
techniques employed during placement do not cause floating of the beads. Elemix additive is very
compatible with water based adhesives, paints and glues ; however, solvent based coatings are not
recommended. The workability of concrete is enhanced at lower slumps with the addition of Elemix
additive. Finishing may be accomplished with standard techniques such as broom, bull float, trowel and
machine finishes, and the surfaces stamped, colored, painted or stained as preferred.

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Pumping

Pumping concrete containing Elemix concrete additive offers many benefits. Some of the advantages
include consistent flow, no line clogging, and decreased pump pressures. One reason pumping improves
is due to the spherical geometry of the product. The Elemix additive particles provide less friction,
allowing the concrete mixture to flow more freely and minimize the clogging issues that can occur with
other aggregates. Data collected from commercial jobs, customer trials, and controlled pumping studies
show little to no slump loss, no excessive bleed water, and no significant fluctuations in air content. In
some cases, the use of Elemix additive has reduced pump pressures by 20-50%, resulting in a far more
efficient and safer working environment. In a recent trial, the use of Elemix additive reduced pump
pressures by 32% compared to traditional lightweight concrete at the same slump. Additionally, no air
loss was observed while pumping, and less overall variability in the air was noticed than in traditional
lightweight concrete containing air entraining admixtures. Density was therefore more consistent,
improving yield accuracy and eliminating the need to over-batch. Elemix additive technical bulletin #010
has been published on the Elemix additive website with more information on this study, titled „Improved
Pumping with Elemix Additive‟.

Coloring

Elemix concrete additive is available in white or grey colors. Applications requiring a visually pleasing
effect can utilize the Elemix Grey additive to blend into the concrete substrate displaying a monotone
color. Elemix additive can also be used in concrete coloring applications. Elemix concrete additive has
been used successfully in flooring applications where the surface was first polished and then an oxidizing
colorant applied. Elemix additive is inert to mild-to-medium acids and bases.

III. TECHNICAL PROPERTIES

Elemix concrete additive has been evaluated for performance in structural concrete in accordance with
the following ASTM tests: ASTM C39, ASTM C78, ASTM C157, ASTM C177, ASTM C234, ASTM C457,
ASTM C469, ASTM C512, ASTM C642, ASTM C666, ASTM C672, ASTM C856, ASTM C1262, ASTM
C1363, ASTM C1524, ASTM C1581, ASTM E90, ASTM E119, ASTM E136, ASTM F1869, and ASTM
F2170. Specific properties of Elemix additive in concrete have been studied in-depth in collaboration with
several leading universities. In addition, the product has an ICC-ES evaluation service report and a
®
MasterSpec specification available for use in cast-in-place construction projects. The ICC-ES evaluation
report and MasterSpec document are available through the Elemix Concrete Additive website:
www.elemix.com

Physical Properties

Performance Tables
The following tables outline typical performance characteristics of various mixtures that contain Elemix
additive. „NW‟ is used to designate normal weight aggregates while „LW‟ designates concrete made with
traditional lightweight aggregates and Elemix additive. Measured values are compared against
established concrete relationships based on compressive strength. Comparisons to ICC-ES requirements
‟
as set forth in Acceptance Criteria 408 are also shown. Realizing that ACI 318 has defined the term f c as
the specified compressive strength, for convenience in the tables below we have used fc to represent the
measured or tested value of compressive strength.

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Table 3. Typical performance of concrete containing Elemix additive

Flexural Strength ASTM C78

Norm al range is 10-20% of f c / ICC-ES requirement is 7.5 ?f c

Coarse 28-day fc psi Flex psi AC-408 requirement, psi

Run # Aggregate (MPa) (MPa) (MPa) Normal range, psi (MPa)
1 NW 3470 (23.9) 555 (3.8) 442 (3.0) 350 – 690 (2.4 - 4.8)
2 NW 3670 (25.3) 515 (3.6) 454 (3.1) 370 – 730 (2.6 – 5.0)
3 NW 3720 (25.6) 564 (3.9) 457 (3.2) 370 – 740 (2.6 – 5.1)
4 LW 4390 (30.2) 601 (4.1) 497 (3.4) 440 – 880 (3.0 – 6.1)
5 LW 4900 (33.8) 610 (4.2) 525 (3.6) 490 – 980 (3.4 – 6.8)

Splitting Tensile Strength ASTM C496

Norm al range is 8–14% of f c / ICC-ES requirement 6.7?f c
Coarse 28-day fc psi Tensile Strength AC-408 requirement, psi
Run # Aggregate (MPa) psi (MPa) (MPa) normal range, psi (MPa)
1 NW 3600 (24.8) 400 (2.8) 400 (2.8) 290 - 500 (2.0 - 3.4)
2 NW 3600(24.8) 420 (2.9) 400 (2.8) 290 - 500 (2.0 - 3.4)
3 NW 3620 (25.0) 410 (2.8) 400 (2.8) 290 - 507 (2.0 - 3.5)
4 LW 4520 (31.1) 510 (3.5) 450 (3.1) 362 - 630 (2.5 - 4.3)
5 LW 4450 (30.7) 560 (3.9) 450 (3.1) 360 - 620 (2.5 - 4.3)

Modulus of Elasticity (tested at CTLGroup, Skokie, IL) ASTM C469

Measured values typically 80-120% of specified value / ICC-ES requirement w 1.5
c 33?fc

Coarse 28-day fc psi Ec ksi

AC-408 requirement, ksi (MPa)
Run # Aggregate (MPa) (metric) typical performance, ksi (MPa)
1 NW 3470 (23.9) 2800 2400 (16,547) 1920 - 2880 (13,238 - 19,857)
2 NW 3740 (25.8) 2750 2600 (17,926) 2080 - 3120 (14,341 - 21,512)
3 NW 3850 (26.5) 2600 2600 (17,926) 2080 - 3120 (14,341 - 21,512)
4 LW 4820 (33.2) 2400 2500 (17,237) 2000 - 3000 (13,790 - 20,684)
5 LW 4700 (32.4) 2500 2500 (17,237) 2000 - 3000 (13,790 - 20,684)

Mechanical Properties

ASTM C39 Compressive Strength of Cylindrical Concrete Specimens

Results of compressive strength testing are used to determine compliance with specifications and are
affected by the mixture design details and Elemix concrete additive loadings. The graphs below depict a
range of compressive strengths that can be achieved using both normal weight aggregates and traditional
lightweight aggregates with Elemix additive.

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Figure 3. Typical Ranges of Compressive Strength using Elemix XE Additive with Normal
Weight Aggregates

Figure 4. Typical Ranges of Compressive Strength using Elemix XE Additive with

Lightweight Aggregates

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ASTM C496 Splitting Tensile Strength
Currently no standardized test procedures exist to determine the direct tensile strength of concrete.
Tensile properties are important as they give an indication of the resistance of the concrete to cracking.
One common indirect test method is ASTM C496 Splitting Tensile Test. As can be seen in Table 3
above, measured values for splitting tensile strength corresponded well to the established ACI equations
based on the measured compressive strength of the concrete.*
*Sources:
(Steven H. Kosmatka, Design and Control of Concrete Mixtures, 2008)
(ASTM International, 2006)

ASTM C78 Flexural Strength

Flexural Strength is the ability of a beam or slab to resist failure in bending, expressed as Modulus of
Rupture (MOR) in psi (MPa)*. Flexural strength is about 12-20 percent of compressive strength* by
industry standards and laboratory tests on concrete containing Elemix additive demonstrate this
correlation. The flexural performance of concrete mixes containing Elemix additive meets the
requirements of ACI, as demonstrated in Table 3.
*Source:
(NRMCA, 2000)

ASTM C469 Modulus of Elasticity

Modulus of Elasticity or Young‟s Modulus (E c ) is a measure of the stiffness of the concrete. It can be
approximated (under small strains) as the slope of the stress strain curve.

The American Concrete Institute (ACI 318) estimates Young‟s Modulus for concrete between 90pcf and
1.5 1.5
155pcf as E c = wc *33*√fc ′ in psi. (E c = wc *0.043*√fc′ in MPa for concrete between 1500 and 2500
3
kg/m )

Typical values are E c = 1000ksi - 2500ksi (7-17 GPa) for structural lightweight concrete*. Table 3 shows
that concrete made with Elemix additive achieves predicted Modulus of Elasticity.

*Source:
(Steven H. Kosmatka, Design and Control of Concrete Mixtures, 2008)

Durability in Freezing and Thawing

ASTM C666 Resistance of Concrete to Rapid Freezing and Thawing

Several batches of concrete containing Elemix additive were prepared for two different freeze-thaw
testing procedures: Procedure A, rapid freezing in water and thawing in water; and Procedure B, rapid
freezing in air and thawing in water.

The samples tested had various levels of w/c, Elemix additive, and coarse aggregate. After 14-day water
bath curing, samples were analyzed at external laboratories by method ASTM C666, procedures A and B.

Among the various mixes tested, concrete containing Elemix additive without traditional
air-entraining admixtures had durability factors of 80% or better. The trend line in Figure 5 below
indicates the 80%, or passing, mark.

The following results were obtained:

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 Figure 5. Durability Factor Results of ASTM C666 Procedures A and B
100%

95%
Durability Factor (%)

90%

85%

80%

75%

70%
Mix

Procedure A 120lb/ft3 (1920kg/m3) Procedure A 130lb/ft3 (2080kg/m3) Procedure B 130lb/ft3 (2080kg/m3)

Note: No traditional air entrained admixture was used in any of the samples shown in Figure #6

ASTM C672 Scaling Resistance of Concrete Surfaces Exposed to Deicing Chemicals

In initial studies, duplicate pavers were prepared and sent to external laboratories for testing. For one set
of tests a sealer was applied as noted below at 21 days. None of the mixes contained air-entraining
admixtures. Both sets of samples, sealed and unsealed gave a rating of near 2, which is indicative of
slight to moderate scaling. Results are shown in figure 6.
Figure 6. Surface Ratings for Scaling Resistance
3
Test 1 Test 2-sealer applied
2.5

2
Surface Rating

1.5

0.5

0
120lb/ft3 (1920kg/m3)

Summary of Surface Ratings

0 = no scaling 2 = slight to moderate scaling 5 = severe scaling

Salt scaling studies on concrete with Elemix additive were conducted as part of a larger study by the
University of New Brunswick. The studies included samples of non-air entrained and air entrained
concrete with a normal weight control of 145 pcf and normal weight concrete containing various levels of
Elemix additive. The study concluded that in general, as the level of Elemix additive in concrete
- 16 –
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increases, the mass of scaled material decreases. In other words, the addition of Elemix additive to
concrete significantly increases concrete‟s resistance to scaling.

Fire Performance

ASTM E119 Fire Tests of Building Construction and Materials

Ready mix concrete containing Elemix additive has passed the ASTM E119 (UL263 / CAN-ULC® S101)
fire test for concrete on metal deck composite assembly.
® ®
Under UL Design D974 and ULC Design F915, the assembly achieved the following:
3
 Elemix additive with normal weight aggregate, no air, 4.5” above deck, 114-120 pcf (1826 kg/m –
3
1922 kg/m ) equilibrium density
 1, 2, 3 hour restrained assembly ratings
 1, 1.5 hour unrestrained assembly and unrestrained beam ratings
 Load restriction for Canada (73%)
3 3
 Maximum dosage of Elemix additive = 13.0 lb/yd (7.71 kg/m )
® ®
Under UL Design D976 and ULC Design F916, the assembly achieved the following:
3
 Elemix additive with normal weight aggregate, no air, 3.5” above deck, 111-117 pcf (1778 kg/m –
3
1874 kg/m ) equilibrium density
 1, 2 hour restrained and unrestrained assembly ratings
 1, 2 hour unrestrained beam ratings
 Load restriction for Canada (74%)
3 3
 Maximum dosage of Elemix additive = 11.7 lb/yd (6.94 kg/m )
® ®
Under UL Design D977 and ULC Design F917, the assembly achieved the following:
 Elemix additive with normal weight and lightweight aggregate, no air, 3.5” above deck, 106.5-
3 3
112.5 pcf (1706 kg/m – 1802 kg/m ) equilibrium density
 1,2 hour restrained assembly ratings
 1, 1.5 hour unrestrained assembly and unrestrained beam rating
 Load restriction for Canada (74%)
3 3
 Maximum dosage of Elemix additive = 7.1 lb/yd (4.21 kg/m )

Fire resistance testing was also performed on a concrete masonry wall made with Elemix additive. UL
Design U936 and ULC Design U914 achieved a rating of 2 hours.

Elemix additive is registered as a „Classified‟ material in the Underwriters Laboratory (UL) fire directory
and is registered as „Listed‟ in the ULC directory. UL chose to categorize our product as a “concrete
additive” and place it in the section which also covers fibers. None of the designs described above use
fibers nor are they required.

The UL website should be referenced for design details and current results at www.ul.com under the
„Certifications‟ option using the keyword ‟Elemix‟ for the UL certifications; and under Links of Interest
using „ULC Online Directories‟ and keyword „Elemix‟ for the ULC certifications . More information can also
be obtained through our Elemix additive technical bulletins #3 through #6.

Please Note: The UL website should always be referenced for the most current designs and details.

ASTM E119 Fire Performance of Concrete Containing Elemix Additive

A modified small-scale fire test was performed on 4-inch thick slabs of ready mix and precast concrete
with and without Elemix additive. Tests were conducted for a period of 120 minutes. Results showed
that the addition of Elemix additive into the concrete mix did not affect the thermal transmission
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performance of the concrete during the ASTM E119 fire exposures. This report concludes that concrete
made with Elemix additive should provide equal thermal performance as concrete designed without at the
same thickness. This trend has been true of Elemix additive with lightweight aggregate in full scale
testing. For concrete containing Elemix additive and normal weight aggregates a slight improvement in
thermal performance has been seen in full scale tests.

ASTM E136 Behavior of Materials in a Vertical Tube Furnace, 750 C

Concrete containing Elemix additive was tested for small-scale combustibility in a vertical tube furnace
3 3
according to ASTM E136 at a temperature of 750°C. Samples ranging from 3lb/yd to 23lb/yd of Elemix
additive loadings passed this test, indicating that it is not a significant contributor to an ambient fire.

Thermal Properties

ASTM C177 Thermal Transmission Properties

In a concrete wall, heat transfer through the interior of the wall is due mainly to solid conduction.
Reducing solid conduction reduces heat transfer and improves the overall thermal performance. This
graph compares thermal resistance to concrete density when Elemix additive is used. Testing in
accordance with ASTM C177 reveals that concrete with Elemix additive when used to reduce its density
3 3
from 150 pounds per cubic foot (2350 kg/m ) to 120 pounds per cubic foot (1920 kg/m ) , also improves
concrete thermal resistance by nearly 50% - or roughly 0.08 to 0.12. Reference Elemix additive technical
bulletin #007 titled „Thermal Performance‟ for more information.

Figure 7. Thermal resistance of concrete containing varying amounts of Elemix additive

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IV. COLLABORATIVE UNIVERSITY STUDIES

North Carolina State University: Beam Shear Behavior and Development Length
of Reinforcement

A study by the North Carolina State University investigated the beam shear behavior of reinforced
concrete members containing Elemix additive. The study tested concrete samples at 120 pcf and 130 pcf
made with normal weight aggregates only. Results concluded that 120-130 pcf concrete made with
Elemix additive and normal weight aggregate achieves generally the same compressive strength values
as that used commonly in structural applications. In addition, the following data was confirmed:
 concrete made with Elemix additive is flowable and easy to work with
 load deflection and crack patterns are similar to that of beams made with normal weight concrete
 crack section predictive analysis for regular concrete can be used on Elemix additive concrete
 ACI 318-08 equations can be used for design of tension splice
 analysis of bond specimens accurately predicted measured behavior of all beams tested and
bond strength conforms to requirements of ACI 318-08
 measured shear values of concrete made with Elemix additive conform to the shear
requirements of ACI 318-08
The use of the lambda factor commonly associated with lightweight aggregate concrete was not used in
this study and found to not be needed for these factors (concrete of 120pcf or greater and Elemix additive
plus normal weight coarse aggregate).

Purdue University

Plastic Shrinkage Cracking

A study with Purdue University investigated the behavior of concrete with Elemix additive in regard to
plastic shrinkage cracking (ASTM C1579). The analysis revealed that of four types of mixtures with
lightweight synthetic particles used, the mix containing Elemix XE concrete additive achieved the highest
crack reduction ratio (CRR) of 85%. No visible cracking was observed in two of the three sampels cast
for both the 10% and 16% Elemix additive volume loadings. Figure 8 illustrates these results.

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Figure 8. As the volume % replacement with Elemix additive increases in a mixture, the
average age of cracking is increased.

Restrained Shrinkage Cracking

An additional study at Purdue University investigated how the use of Elemix additive improves the
restrained shrinkage cracking behavior of mortar mixtures. Testing was conducted according to ASTM
C1581, Standard Test Method for Determining Age at Cracking and Induced Tensile Stress
Characteristiecs of Mortar and Concree under Restrained Shrinkage. The study found that with the
increased addition of Elemix XE additive, the time to cracking was increased, resulting in a positive
contribution to the overall concrete durability.

Table 4. Increased dosages of Elemix additive increases the time to cracking

Elemix XE Additive Elemix XE Additive Time to Crack Time to Crack
Loading, lbs/yd3 (% Volume) (hours) (days)
(kg/m3)
0 (0) 0 97.7 4.1
9 (144) 13 135.0 5.6
13 (208) 18 132.7 5.5

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Universtiy of New Brunswick: Durability in Laboratory and Natural Exposure
Conditions

A study by the University of New Brunswick investigated the performance of Elemix XE additive in
chloride resistance (ASTM C1202), deicer salt scaling (ASTM C672), chloride diffusion (ASTM C1556)
and freeze thaw (ASTM C666) tests and the mechanism for satisfactory performance of those specimens
in non-air entrained concrete. This study also continues to evaluate the performance of concrete with
Elemix additive under harsh natural exposure conditions including Treat Island and UNB exposure sites.
Testing reveals that the use of Elemix additive imparts freeze thaw resistance in the concrete for test
ASTM C666 with a trend to slightly increasing durability factor (DF) proportional to increasing Elemix
additive volume in the mix. All specimens containing Elemix additive remained in good condition through
600 cycles (beyone the required 300 for ASTM C666 testing), with durability factors in excess of 100.
Cyclic freeze thaw testing is still in progress. Mass loss in the ASTM C672 scaling test reveals that in
general, increasing the volume % of Elemix additive in a mix decreases the amount of scaling mass loss
in the concrete. ASTM C1202 chloride permeability testing rated „low‟ to „very low‟ in samples containing
Elemix additive.

Full reports can be requested for each of the university studies at:
www.elemix.com/technical.aspx

V. CODE COMPLIANCE

ICC-ES

A new acceptance criteria for lightweight synthetic particles was approved in February of 2009 by ICC-
ES. AC-408 Acceptance Criteria for Structural Concrete with Lightweight Synthetic Particles establishes
the requirements for structural concrete to be recognized in an ICC-ES evaluation report. The criteria
was developed since the codes do not provide requirements for evaluation of such products in structural
concrete.
3 3
A maximum loading of 12.7 lbs/yd (7.5 kg/m ) of Elemix XE concrete additive and Elemix Grey XE
concrete additive was validated by AC-408 and is listed in ICC-ES evaluation report ESR-2574.
Compliance is based on the following codes:
®
 2009 International Building Code
®
 2009 International Residential Code
®
 2006 International Building Code
®
 2006 International Residential Code
 ACI 318-05 Building Code Requirements for Structural Concrete

Elemix XE and Grey XE concrete additive has been approved for use as a replacement for fine or coarse
aggregate to the maximum amounts mentioned above. ESR-2574 is a dual report of ICC-ES and UL.
The UL link located in the top left corner of the report accesses the current concrete assemblies tested for
fire resistance by UL. The UL fire resistance designs may also be accessed directly at www.ul.com. The
current version of our report should be referenced for design and installation details as well as conditions
of use. ESR-2574 is available at www.icc-es.org searching by the term “Elemix” or the report number.

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 Engineering Specification
®
A product MASTERSPEC specification for Elemix additive in concrete has been created in partnership
with licensor ARCOM, designed for ease of use to the engineer to allow for a singl e concrete specification
to be used in all applications, including beams, decks, sidewalks, and Elemix additive. The specification
applies to cast-in-place concrete.

VI. PATENTS / INTELLECTUAL PROPERTIES

The following United States patents have been issued to NOVA Chemicals Inc. covering various aspects
of the Elemix Concrete Additive technology:

US Patent No. 7,820,094 Lightweight Concrete Compositions 10.26.2010

US Patent No. 7,790,302 Lightweight Composition and Articles Containing Such 09.07.2010
US Patent No. 7,744,692 Lightweight Concrete Compositions (joint patent) 06.29.2010
US Patent No. 7,699,929 Lightweight Concrete Compositions 04.20.2010
US Patent No. 7,666,258 Lightweight Compositions and Articles Containing Such 02.23.2010
US Patent No. 7,658,797 Lightweight Concrete Compositions 02.09.2010
US Patent No. 7,648,574 Lightweight Concrete Compositions 01.19.2010
US Patent No. 7,644,548 Lightweight Concrete Compositions 01.12.2010
US Patent No. 7,632,348 Lightweight Concrete Compositions Containing 12.15.2009
Antimicrobial Agent

VII. LIST OF TECHNICAL DOCUMENTS

(Please contact us for copies of full test reports)

 Ready Mix Product Data Sheet (English, Spanish and Portugese versions available)
 Testing Summary
 Product MASTERSPEC Short Form
 Product MASTERSPEC Long Form
 Engineering Reports Summary
 MSDS Elemix Additive Aged (English and Spanish versions available)
 MSDS Elemix Grey Additive Aged (English and Spanish versions available)
 Bulletin #001 Suggested Modifications to ASTM C231
 Bulletin #002 Volumetric Air
 Bulletin #003 ULC Floor Structures
 Bulletin #004 UL Floor Structures
 Bulletin #005 UL Masonry Units
 Bulletin #006 ULC Masonry Units
 Bulletin #007 Thermal Performance
 Bulletin #008 Development Length
 Bulletin #009 Beam Shear Behavior
 Bulletin #010 Improved Pumping Performance
 Bulletin #011 Plastic Shrinkage Cracking
 Bulletin #012 Restrained Shrinkage Cracking

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VIII. CONTACT INFORMATION
Please visit us online at www.elemix.com

General inquiries may be directed to our global headquarters:

SYNTHEON, Inc.
1555 Coraopolis Heights Road
Moon Township, PA 15108
Ph. 412-490-4397 or via email: elemix@syntheoninc.com

IX. References Cited

ASTM International. (2006). Significance of Tests and Properties of Concrete and Concrete-Mak ing
Materials (Vol. STP 169D). (J. H. Joseph F. Lamond, Ed.) West Conshohocken, PA, USA: ASTM
International.
NRMCA. (2000). CIP 16-Flexural Strength in Concrete. Retrieved January 4, 2011, from National Ready
Mixed Concrete Association: http://www.nrmca.org/aboutconcrete/cips/default.asp
Steven H. Kosmatka, B. K. (2008). Design and Control of Concrete Mixtures (14 ed.). Skokie, IL, USA:
Portland Cement Association.
Steven H. Kosmatka, B. K. (2008). Design and Control of Concrete Mixtures (14 ed.). Skokie, IL, USA:
Portland Cement Association.

SYNTHEON Inc.
1555 Coraopolis Heights Road | Moon Township, PA 15108
SY NTHEON INC. is not and cannot be a certif ied testing laboratory . All inf ormation is f urnished in good f aith, without warranty , represent ation,
inducement or a license of any kind. No guarantee is giv en that SY NTHEON INC‟S products will be suitable in purchaser‟s f ormulations or processes
f or any particular end use. Materials not manuf actured or supplied by SY NTHEON INC. may present hazards in handling and use.

THE ELEMIX® CONCRETE ADDITIVE MIX DESIGN PROVIDED HEREIN SHOULD NOT BE CONSTRUED AS ENGINEERING ADVICE. WHILE
INFORMATION CONTAINED IN THIS MIX DESIGN IS ACCURATE TO THE BEST OF OUR KNOWLEDGE , SY NTHEON INC. DOES NOT
WARRANT ITS ACCURACY OR COMPLETENESS. THE ULTIMATE CUSTOMER AND USER OF THE ELEMIX CONCRETE ADDITIVE SHOULD
ASSUME SOLE RESPONSIBILITY FOR THE FINAL DETERMINATION OF THE SUITABILITY OF THE INFORMATION AND FOR THE
CONTEMPLATED AND ACTUAL USE OF ELEMIX CONCRETE ADDITIVE. THE ONLY WARRANTY MADE BY SY NTHEON INC. FOR ITS ELEMIX
CONCRETE ADDITIVE IS SET FORTH IN OUR ELEMIX CONCRETE ADDITIVE DATA SHEETS, OR SUCH OTHER WRITTEN WARRANTY AS
MAY BE AGREED BY SY NTHEON INC. AND INDIVIDUAL CUSTOMERS. SY NTHEON INC. SPECIFICALLY DISCLAIMS ALL OTHER
WARRANTIES, EXPRESS OR IMPLED, INCLUDING WITHOUT LIMITATION, WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE, OR ARISING FROM PROVIISION OF SAMPLES, A COURSE OF DEALING OR USAGE OF TRADE.

Elemix ® is a registered trademark and the Elemix logo is a trademark of SYNTHEON Inc.
SYNTHEON is a w holly-owned subsidiary of NOVA Chemicals Inc.

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