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Hakim S Abdelgader
University of Tripoli
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ABSTRACT: Two-stage (Pre-placed aggregate) concrete is produced by placing coarse aggregate in a form and
later injecting a cement-sand grout, to fill the voids between aggregate particles. For economical and technical rea-
sons two-stage concrete is particularly used for construction and repair of mass structures, especially foundations,
underwater constructions, and in all kinds of construction with closely spaced reinforcement. This paper presents
some implementations of using such concrete in repair works, some formulae and guidelines which describe the
mechanical parameters of this concrete such as modulus of elasticity, tensile strength and drying shrinkage.
869
of grout around the end of the pipe. Because the coarse
aggregate pieces cross this joint, bond and shear in most
cases will be adequate. However, if the grout bleeds
excessively, some laitance may collect on the grout sur-
face portion of the joint and weaken the bond [3].
1.1.1 Jackets and collars As it is mentioned before, this study is a result of ana-
Description – Jacketing is the process whereby a sec- lyzing many experimental data in order to obtain better
tion of an existing structural member is restored to orig- understanding for the behavior of TSC as supplemen-
inal dimensions or increased in size by encasement in tary method instead of NC for production of construc-
new Portland cement or polymer-modified Portland tion and repair material. Therefore, the following
cement concrete. A steel reinforcement cage is con- properties of TSC are presented:
structed around the damaged section into which shot-
crete or cast-in-place concrete is placed [3].
Collars are jackets, which surround only a part of a 3.1 Drying shrinkage of TSC
column or pier and typically are used to provide TSC differs from conventional concrete in that it con-
increased support to the slab or beam at the top of the tains a higher percentage of coarse aggregate [4].
column. Because of the point-to-point contact of the coarse
The form for the jacket may be temporary or per- aggregate Figure 3, drying shrinkage of TSC is about
manent and may consist of timber, corrugated metal, one-half that of conventional concrete. Since the aggre-
pre-cast concrete, rubber, fiberglass, or special fabric, gate is pre-placed and the grout is pumped under pres-
depending on the purpose and exposure. The jacket sure, segregation is not a problem and virtually all
form is placed around the section to be repaired, cre- substrate voids will be filled with mortar. These factors
ating an annular void between the jacket and the surface make TSC an ideal material for applications where con-
of the existing member. The form should be provided siderable congestion of reinforcement or other embed-
with spacers to assure equal clearance between it and ment, or difficult access exists. The ability of the grout
the existing member. to displace water from the voids between aggregate
A variety of materials including conventional con- particles during injection makes this material particu-
crete and mortar, epoxy mortar, grout, and latex- larly suitable for underwater repairs [2].
modified mortar and concrete have been used as Since most repairs are made on older Portland
encasement materials. Techniques for filling the jacket cement concrete that will not undergo further signifi-
include pumping, tremie, or two-stage concrete [3]. cant shrinkage, the repair material must also be
essentially shrinkage-free or be able to shrink without
1.1.2 Joint construction losing bond.
Cold joints – Cold joints are formed within the mass Shrinkage of cementitious repair materials can be
of TSC when pumping is stopped for longer than the reduced by using mixtures with very low water-cement
grout remains plastic. When this occurs, the insert ratios or by using construction procedures that mini-
pipes should be pulled to just above the grout surface mize the shrinkage potential.
before the grout stiffens, and rodded clear. To resume The drying shrinkage of normal concrete is caused
pumping, the pipes should be worked back to near by physical-chemical properties of the cement paste. In
contact with the hardened grout surface and pumping TSC the grout fills only the cavities, and the basic
resumed, slowly for a few minutes to create a mound mass of concrete is the stone skeleton only. The drying
870
Applied Load
Contact
Points
Grain Fracture
Stress
Concentration
points
Micromorements and
rotations of grains
871
Table 2. Split Tensile Strength of TSC at 28 Days. point-to-point contact of the stone aggregate par-
ticles.
Water to Cement to Ft (lab.) Ft (theo.) 4.3 The modulus of elasticity as a function of com-
cement ratio sand ratio (MPa) (MPa) pressive strength of the TSC is elaborated. The
modulus values for specific types of aggregate
0.40 3.35 3.37
0.45 3.14 3.16 can be described by the linear constant functions.
0.50 2:1 2.83 3.01 4.4 The relationship between tensile strength and
0.55 2.27 2.81 compressive strength, referred in this paper
0.45 3.34 3.13 shows that the tensile strength of TSC increases
0.50 3.02 2.90 with the increase in its compressive strength. This
0.55 1:1 2.86 2.70 relationship can also help the engineers in
0.60 2.53 2.60 designing the TSC structures.
REFERENCES
Table 3. Double-punch tensile strength results of TSC at
28 Days. ACI Committee 304. 1992, “Guide for the use of preplaced
aggregate concrete for structural and mass concrete
Water to Cement to Ft (lab.) Ft (theo.) applications”. American Concrete Institute 1992
cement ratio sand ratio (MPa) (MPa) (Reapproved 1997).
Abdelgader, H. S. 1998, “Applications of two-stage concret-
0.40 2.38 2.29 ing methods”. Scientific Papers of Technical University
0.45 1.81 2.11 of Gdansk, Poland, 1998, 55, No. 570, pp. 93–100.
0.50 2:1 1.78 2.00 Abdelgader, H. S., Ghabib, M. A. and Gorski, J., 2002,
0.55 1.73 1.83 “Concrete elements cast in fabric forms”. Betonwerkt
0.45 2.36 2.09 Fertigteil-Technik, (BFT), No. 8, 2002, pp. 24–32,
0.50 2.09 1.90 Germany.
0.55 1:1 2.05 1.74 Abdelgader, H. S., 1996, “Effect of quantity of sand on the
0.60 1.49 1.66 compressive strength of two-stage concrete”. Magazine
Concrete Research, 1996, 48, No. 177, pp. 353–360.
Abdelgader, H. S. and Górski, J., 2003, “Stress-strain rela-
tions and modulus of elasticity of two-stage concrete”.
a compressive load is applied to a concrete cylinder Journal of materials in civil engineering. ASCE. 2003.
along its axis through two steel punches placed on the 15, No. 4, pp. 329–334.
top and bottom surfaces of the cylinder [8]. The dou- Abdelgader, H. S. and Górski, J., 2002, “Influence of grout
ble-punch tensile strength test results obtained for TSC proportions on modulus of elasticity of two-stage con-
are presented in Table 3. crete”. Magazine Concrete Research 2002, 54 No. 4,
pp. 251–255.
Abdelgader, H. S., 1999, “How to design concrete produced
4 CONCLUSIONS by a two-stage concreting method”. Cement Concrete
Research, 1999, 29, No. 3, pp. 331–337.
Abdelgader, H. S. and Ben-Zeitun, A. E., 2004, “Effect of
From this study it can be concluded that: grout proportions on tensile strength of two-stage con-
4.1 TSC is very efficient material for repairs of dete- crete measured by split and double-punch tests”.
riorated concrete elements. Structural Concrete 2004, 5, No. 4, pp. 173–177.
4.2 The drying shrinkage of TSC is lower than that of
NC. Where the reduced shrinkage is due to the
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