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P. K u m a r M e h t a I a n d P i e r r e - C l a u d e C.

A i t c i n ~

Principles Underlying Production of High-Performance Concrete

REFERENCE: Mehta, P. K. and Aitcin, P. C., "Principles Under- What Is High Performance Concrete?
lying Production of Itigh-Performance Concrete," Cement, Concrete,
and Aggregates, CCAGDP, Vol. 12, No. 2, Winter 1990, pp. 70- Compressive strength, which is easily regulated by controlling
78. the water-cement ratio, has served well in the past as the principal
criterion for performance of ordinary concrete. Unacceptable
ABSTRACT: Durability rather than high strength appears to be the rates of deterioration in many recently built concrete structures
principal characteristic for high-performance concrete mixtures being
developed for use in hostile environments such as seafloor tunnels, exposed to aggressive environments show that this criterion is
offshore and coastal marine structures, and confinement for solid and no longer adequate for ensuring long-time durability, which
liquid wastes containing hazardous materials. Strength, dimensional should indeed be the primary requirement for high performance.
stability, impermeability, and high workability .are usually the prin- ACI Committee 201 defines the durability of concrete as its
cipal characteristics required of high-performance concrete.
ability to resist weathering action, chemical attack, abrasion, and
In this paper an overview of the composition of concrete and its
effect on the properties desired for high performance is given. This any other process of deterioration. Weathering includes envi-
overview can be used as a basis for selection of component materials ronmental effects, such as exposure to cycles of wetting and
and mix proportioning. A new step-by-step procedure for mix pro- drying, heating and cooling, and freezing and thawing. Chemical
portioning is described. The calculated mix proportions from this deterioration processes include acid attack and expansive chem-
procedure appear to be consistent with the state-of-the-art laboratory
and field practice. Also, a brief review is given of concrete production ical reactions such as sulfate attack, alkali-aggregate attack, and
and construction practices essential for making a high-performance corrosion of steel in concrete. Consequently, in order to be clas-
end product. sified as HPC, a concrete should meet the following specifica-
tions:
KEYWORDS: concrete strength, impermeability, durability, high
performance, dimensional stability, cement paste, aggregate, mineral
admixtures, superplasticizer, proportioning, strength grading 1. Impermeability: Since the penetration of moisture and
harmful ions is necessary for most chemical attacks, the imperme-
ability of concrete has to be the first line of defense. The tra-
In the coming decades, concrete will be increasingly called
ditional tests for measurement of water permeability are very
upon to serve as a construction material for hostile environments
cumbersome and often do not give reproducible data. For ap-
such as seafloor tunnels, offshore piers and platforms, sewage
plication to concrete with very low coefficient of permeability
pipes, and confinement structures for solid and liquid wastes
(e.g., 1 × 10- ~ m/s), a chloride-ion permeability test ( A A S H T O
containing toxic chemicals and radioactive elements. Also, due
277) appears to be more suitable. In this test, the rate of per-
to the heavy cost of repair or replacement, most of these struc-
meation of chloride ions is expressed in terms of coulombs. A
tures will be required to have a service life of hundreds of years,
concrete mixture showing 500 C or less current flow in a 6-h
instead of 40 to 50 years normally expected from ordinary con-
chloride permeability test is considered to be virtually imperme-
crete. High-performance concrete (HPC) mixtures are being de-
able.
veloped to meet this challenge.
2. Dimensional stability: A high elastic modulus, low drying
High performance is generally assumed to be synonymous with
shrinkage and creep, and low thermal strain are some of the key
high strength, although this is not true in every case. For instance,
factors contributing to high-dimensional stability of concrete,
Birchall and Kelly [1] were able to produce exceptionally high-
which is essential for counteracting any undesirable stress effects
strength cement-based products containing polyvinyl acetate.
produced as a result of volume changes under conditions of re-
However, the moisture resistance and long-term durability of the
straint. With naturally occurring materials, although it is not
material are not satisfactory. Similarly, by hot pressing, Roy and
difficult to produce concretes of 60 to 100-MPa compressive
Gouda [2] produced a 470-MPa cement paste in the laboratory,
strength, the increase in the elastic modulus is not proportional.
but the material is not suitable for application to most concrete
However, compared to 20 to 25 GPa (3 to 4 by 10" psi) elastic
elements, which are cast in place. Clearly, there is a need for
modulus for conventional concrete, it is possible to obtain 40 to
defining the essential characteristics of HPC and developing
45 GPa (6 to 7 by 106 psi) elastic modulus for HPC mixtures
guidelines for producing the material with conventional pro-
containing suitable materials and mix proportions.
cessing methods.
Creep and drying shrinkage strains in concrete, frequently as
tProfessor of civil engineering, University of California at Berkeley,
Berkeley, CA 94720. high as 0.08% each (as measured by the ASTM Test Method C
~Professor of civil engineering, University of Sherbrooke, Quebec, 157 [Test Method for Length Change of Hardened Hydraulic
Canada. Cement Mortar and Concrete] and C 512 [Test Method for Creep
0149-61 :'3/90/0012-007052.50 © 1990 by the American Society for Testing and Materials
70

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MEHTA AND A'iTCIN ON HIGH-PERFORMANCE CONCRETE 71

of Concrete in Compression], respectively), are highly dependent curing technology are other factors in concrete production which
on the aggregate type and content [3]. To achieve high-dimen- also have considerable effect on the microstructure and prop-
sional stability it is desirable to reduce the magnitude of these erties of the product. Before specific guidelines for the selection
strains by limiting the total volume of the cement paste in con- of materials, mix proportions, and concrete production methods
crete and by using a coarse aggregate which has high strength are discussed, it will be helpful to undertake an overview of the
and elastic modulus. With proper materials and mix proportions, composition of concrete and its effect on properties.
experience shows that it is possible to bring down the 90-day
drying shrinkage strain to less than 0.04%.
An Overview of the Composition of Concrete and its Effect
on Properties
What Are the Problems? According to a simple model, concrete is a composite material
Making a special product usually calls for some changes in con- consisting of two components, namely cement paste and aggre-
ventional processing technology. For a multicomponent material gate. The cement paste is the binder for the aggregate, which is
such as concrete, this not only will require a review of the criteria the discontinuous phase. As a first approximation, the perme-
used for the selection of concrete components and mix propor- ability, strength, dimensional stability, and other properties of
tions but also the production methods, i.e., mixing, handling, concrete depend both on the binder/aggregate ratio and the qual-
and curing. ity of each of the two components.
A major problem in producing high-performance concrete is A dry mixture of well-graded fine and coarse aggregates con-
the assumption by earlier researchers that high strength and high tains approximately 21 to 22% void space which must be filled
performance are synonymous. Whereas this is not strictly true, by the binder. However, in practice, at least 25% cement paste
as discussed above, in most cases, high durability to certain ag- by volume is needed to produce workable concrete mixtures.
gressive conditions, such as abrasion and erosion, has been Normal aggregates are generally strong and dense, hence con-
achieved by the use of high-strength concrete mixtures since they crete permeability and strength are determined by the porosity
possess high impermeability. Because the concept of HPC as and the type of hydration products in the cement paste. Cement
given here is relatively new and because no previous laboratory pastes hydrated with targe amounts of water are usually weak
data on HPC mix proportioning exists, the authors are compelled and permeable because they contain a high volume of big cap-
to use in this paper high-strength formulations as a first step for illary pores, large crystals of hydration products (especially cal-
developing HPC mixtures. cium hydroxide), and microstructural inhomogeneities. With
The selection of materials is a problem because cements and normal concrete (>0.4 water/cement ratio), the presence of
aggregates are available with widely varying compositions and coarse aggregate particles in the cement paste matrix gives rise
properties, and there are no clear guidelines as to the cement to nonhomogeneous distribution of water d~ring placement and
and aggregate types most suitable for use in HPC. The situation consolidation. This is because, due to the aggregate "wall effect,"
is complicated by the fact that a number of chemical and mineral local regions of high water/cement ratio adjacent to the aggregate
admixtures must be used simultaneously (also there is a prolif- surface are formed. The weak interfacial zone between cement
eration of these admixtures on the market), and there are no paste and aggregate explains why the strength and impermea-
simple rules by which one can easily make a judicious choice. bility of the cement pastes, with a given water/cement ratio, are
The selection of mix proportions is a serious problem because reduced by the presence of coarse aggregate in concrete.
the relationship between strength and water-cement ratio, which Naturally, for low permeability and high strength of concrete,
is the backbone of mix-proportioning methods for ordinary con- it will be desirable to reduce both the water and aggregate con-
crete mixtures, is not sufficient to meet all the requirements of tent. In fact, concrete mixtures of exceptionally high strength
HPC as discussed above. It seems that at very low water-cement and low permeability have been produced by researchers by using
ratios, the type and dosage of mineral admixtures have a strong very low water/cement ratios (0.08 to 0.2) and very high cement
influence on the strength and other characteristics of concrete. paste contents (40 to 50% by volume). These are of little or no
Also, the aggregate type and content, to which conventional mix- value for application to structural concrete practice because of
proportioning methods do not pay adequate attention, must be poor dimensional stability and high cost of fabrication. This is
given serious consideration due to their great influence on the because, due to their dry consistency, heat and pressure are
dimensional stability of concrete. The published literature does needed to consolidate them. In conclusion, with increasing ce-
not contain a simple set of rules or a step-by-step method by ment paste content in concrete, the strength and impermeability
which someone interested in making a HPC mixture with locally will be enhanced, but the dimensional stability will be impaired.
available materials is able to select the proper materials and mix For HPC, it seems that 35% cement paste by volume represents
proportions for the first trial batch. As a result, following an an optimum solution in balancing the conflicting requirements
empirical approach, a large number of laboratory trials are gen- of strength, workability, and dimensional stability.
erally needed before a mix design is arrived at, satisfying the
strength and workability requirements. Usually an extensive test-
Selection of Materials
ing program has to be undertaken in order to optimize the
concrete mixture with respect to other characteristics, such as In addition to the cement paste-aggregate ratio, aggregate type
dimensional stability and long-term durability to given en- has a great influence on concrete dimensional stability. For in-
vironmental conditions. stance, a mismatch in the elastic moduli or coefficient of thermal
Finally, the sequence in which the component materials are expansion between the cement paste and aggregate will cause
added during the mixing operation, the efficiency of the mixer, cracking when the structure is exposed to frequent cycles of
the method of transporting and placement of concrete, and the temperature changes. Also, at a given cement paste-aggregate

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72 CEMENT,CONCRETE,AND AGGREGATES

ratio, the use of an aggregate with a very low elastic modulus cement paste is a primary consideration in the selection of ma-
results in concrete which shows high creep and drying shrinkage. terials for making HPC. Commercial cements meeting the ASTM
From the standpoint of long-term dimensional stability, concrete Specification for Portland Cement (C 150) for Type I portland
mixtures containing coarse aggregates derived from limestone or cement vary considerably in chemical composition and fineness,
basalt are generally known to perform better than those con- both of which influence the water requirement for normal con-
taining quartzitic sandstones or fluviatile gravel. Having consid- sistency. Also, physicochemical interactions between some ce-
ered the dimensional stability aspects, we can now examine how ments and water-reducing admixtures are known to cause rapid
the choice of aggregate type and cement paste quality would stiffening or slump loss, which often requires retempering of a
influence other properties of HPC. The authors have discussed concrete mixture with additional water. For example, some su-
the microstructural dependence of high-strength concrete mix- perplasticizers contain significant amounts of free sulfate, which
tures in detail elsewhere [4], therefore only a summary will be may contribute to abnormal stiffening of a cement paste made
presented here. with a high-C3A portland cement. The loss of consistency is
associated with the formation of ettringite, a calcium sulfoalu-
minate hydrate, which is known to immobilize large amounts of
Aggregate
free water by surface adsorption.
At a given cement content, most properties of concrete are Hanna et al. [6] have described a simple test method for eval-
adversely affected by increasing the water content. This under- uating the rheology and slump loss tendency of cement-super-
scores the importance of using well-graded clean aggregates that plasticizer combinations. A specially designed mixer called
are free from silt, clay, and friable particles. As fine aggregate Rheopump is used for quick, homogeneous dispersion of cement
(<0.5 mm), natural sands with a medium-to-high fineness mod- in water containing the superplasticizer; paste fluidity is deter-
ulus (viz. 2.5 to 3) are generally adequate. For use as coarse mined by measuring the time taken to empty 1 L of cement paste
aggregate, equidimensional particles, obtained by crushing a through a conical container, which is a modified Marsh cone.
dense limestone rock or a plutonic-type igneous rock (such as The test results showed that some portland cements with higher
granite, syenite, diorite, and diabase), are usually satisfactory. 8% C3A were prone to the slump loss problem, which is aggra-
There is some controversy regarding the choice of maximum vated by high alkali and sulfate contents. Since low-C3A cements
size of aggregate (MSA). With high-strength concrete mixtures, tend to be slow in setting and hardening when compared to high-
there is a large amount of data showing that the use of larger C3A cements, ASTM Type II cements ground to a higher fineness
than 25-mm MSA generally impairs the strength and imperme- than normal are generally well suited for making HPC. Due to
ability of concrete. Since the aggregate-cement paste interracial their low heat of hydration and other desirable effects associated
zone is strong in HPC, the aggregate can indeed be strength with the presence of mineral admixtures, as will be discussed
limiting, which is seldom a matter for concern with conventional below, ASTM Type IP portland-pozzolan cement and ASTM
concretes. With most rocks, reducing the MSA to 10 to 15 mm Type IS portland-slag cement should be seriously considered.
often eliminates any internal defects present within the aggregate
particle (such as microcracks, large pores, and inclusions of soft
Chemical Admixtures
minerals). Hence, 10 to 15 mm MSA may be considered optimum
for HPC. Chemical admixtures are added to concrete to accomplish a
An experimental study by the authors [5] showed that similar number of objectives, such as improving consistency, controlling
concrete mixtures containing either a local granite or a gravel the time of set, and providing protection against deterioration
aggregate gave significantly lower strength than those containing by freezing and thawing cycles. With HPC, the reduction of water
either a diabase or a limestone aggregate. Loading and unloading content in a concrete mixture, while maintaining the desired
of specimens in the elastic range produced much wider hysteresis workability, is of foremost importance. At normal dosage, the
loops in the case of concretes containing the granite and gravel conventional water-reducing admixtures, such as derivatives
aggregates. Since a large residual strain on unloading is indicative from sulfonated lignin, are able to reduce the water content of
of either a weak interracial zone or sources of weakness present concrete mixtures by 5 to 10%. At high dosages, the conventional
within the aggregate particle, the authors concluded that studies water-reducing admixtures cause excessive retardation. In the
of this type are valuable in evaluating coarse aggregates for use seventies, the advent of high-range water-reducing chemicals,
in HPC mixtures. popularly known as superplasticizers, provided a method of ob-
It may be noted that all granite and gravel aggregates may not taining high-consistency concrete mixtures at very low water con-
be necessarily unsuitable for use in HPC mixtures. For instance, tents and without causing excessive retardation.
in the northwestern United States, a glacial gravel has been The superplasticizers are high molecular weight anionic sur-
successfully used to make 120-MPa concrete. factants derived from sulfonated formaldehyde of naphthalene
or melamine. When used in quantities ranging from 1 to 2%
solid by weight of cementitious materials, they produce a pow-
Cement
erful dispersing effect on the cement paste, which can be rela-
With a given high-quality aggregate, the strength and perme- tively short-lived. To get around this problem, a portion of the
ability of concrete mixtures are controlled by the quality of the superplasticizer dosage may be saved for later addition when the
cement paste, which, in turn, depends on the physical and chem- concrete mixture has arrived at the job site. The choice of the
ical characteristics of cement, the type and dosage of chemical superplasticizer type is generally determined by cost, dosage,
and mineral admixtures, the original water-cement ratio, and the and compatibility with other components of the cement paste.
degree of hydration. It is not uncommon to achieve the desired properties in concrete
Minimum water requirement for a given consistency of the by using a mixture of the two superplasticizer types, or by using

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MEHTA AND A'fTCIN ON HIGH-PERFORMANCECONCRETE 73

a mixture of a superplasticizer and a normal water-reducing with fly ash or slag may be advantageously used. This is because
chemical. The latter is a cost-effective approach when set retar- not only condensed silica fume (0.1-~m average particle size, 20-
dation is needed in addition to water reduction. m2/g surface area) is very expensive but also increasing dosages
of this admixture require correspondingly higher dosages of the
superplasticizer for proper dispersion. Note that superplasticizers
Mineral Admixtures
are also much more expensive than normal water-reducing chem-
Mineral admixtures are fine powders generally composed of icals. It should be noted that a substantial saving in the use of
silicate glasses or noncrystalline silica which, in the presence of superplasticizer usually occurs as a result of partial substitution
moisture, calcium ions, and hydroxyl ions, slowly hydrate to form of portland cement by a mineral admixture due to reduction in
cementing products. Volcanic glasses and tufts, calcined clays, the C3A content of the cementitious sygtem. Although 15 to 25%
and diatomaceous earth have long been in use as mineral ad- silica fume by weight or by volume of cementitious materials has
mixtures. However, increasingly in use are siliceous by-products, been used in laboratory mixtures, the authors do not recommend
such as granulated blast-furnace slag, fly ash, and condensed using more than 10%. For HPC, an optimum solution is to use
silica fume. A comprehensive classification of mineral admix- a combination of 10% silica fume with 15% fly ash or slag by
tures, with their physical and chemical characteristics, is given volume.
in earlier publications [3,4}.
The incorporation of mineral admixtures in concrete can lead Proportioning of High-Performance Concrete Mixtures
to so many technical advantages that no concrete mixtures should
be made without them unless there are special reasons. First, Mix proportioning is the process of determining the right com-
the presence of fine particles of a mineral admixture in fresh bination of component materials that will produce a concrete
concrete, especially pozzolanic admixtures, results in consider- mixture with the desired characteristics at the lowest possible
able improvement of rheological properties, such as cohesiveness cost. Even with ordinary concrete the process is not easy because
and stability. By segmenting the channels of flow of water in the it involves the art of balancing various conflicting requirements.
cement paste, the particles of mineral admixture are generally Extensive laboratory testing must often be carried out before a
able to reduce bleeding and segregation, which become the pri- satisfactory proportion of materials is arrived at.
mary causes of microstructural nonhomogeneity in concrete, es- The cost effectiveness of the mix-proportioning process de-
pecially in the cement paste-aggregate interracial zone. Second, pends very much on the availability of a computational method
by increasing the time of set and by reducing the rate of slump which would permit the determination of proportion of com-
loss in fresh concrete, the mineral admixture is able to provide ponent materials for the first trial batch as accurately as possible.
some degree of control over the slump loss problem, which can To be generally applicable to a wide variety of materials, the
be troublesome with superplasticized concrete mixtures. It computational method has to be more or less independent of the
should be noted that a concrete mixture that is hard to place and material characteristics. .For instance, the ACI Committee 211
consolidate will not result in a satisfactory end product. Third, procedure for proportioning concrete mixtures with up to 40-
fine particles of a less reactive solid (compared to portland ce- MPa compressive strength is applicable to aggregates with wide-
ment), when well dispersed in the cement paste, provide nu- ranging mineralogical and granulometric (grading) characteris-
merous nucleation sites for the precipitation of hydration prod- tics. The ACI procedure cannot be used for concrete mixtures
ucts. Scanning electron microscopic studies have confirmed that, with more than 40-MPa compressive strength, 200 to 250-mm
at a given water-cement ratio and degree of hydration, the hy- slump, especially when the properties of concrete are highly
drated cement pastes containing mineral admixtures are gener- sensitive to the aggregate characteristics and water content of
ally composed of nondescript (poorly crystalline) products with the concrete mixture. The authors have attempted to develop a
a homogeneous distribution of fine pores. Therefore, from the simple step-by-step procedure described here, which can be used
standpoint of strength and impermeability, the microstructure of to determine the proportion of materials for the first trial batch.
cement paste containing a mineral admixture will be superior to Before describing the procedure, it will be desirable to review
a similar cement paste without any mineral admixture. In the the general considerations underlying some of the assumptions
latter case, the microstructure is heterogeneous and character- necessary for development of the procedure.
ized by local areas of high concentration of large pores as well
as large crystals of calcium hydroxide from which microcracks General Considerations
usually originate [3].
From a clear understanding of the mechanisms by which min- Ratio between cement paste and aggregate: It is assumed that,
eral admixtures enhance the properties of concrete [7], it is ob- by using a suitable coarse aggregate, adequate dimensional sta-
vious that the performance of a mineral admixture would depend bility of HPC concrete (e.g., elastic behavior, drying shrinkage,
on particle size, pozzolanic and cementitious characteristics, de- and creep) can be obtained at a fixed cement paste/aggregate
gree of uniform dispersion, and curing conditions. High-quality ratio of 35 to 65% by volume.
fly ash and ground blast-furnace slag, which are usually less Strength grading: Although strength is not the sole criterion
expensive than portland cement, may be used in quantities rang- for high performance, concretes with more than 60-MPa com-
ing from 20 to 30% by mass of total cementitious material. Since pressive strength generally show very low permeability (i.e.,
they tend to reduce not only the heat of hydration but also the < 10- ~' m/s) and satisfactory weathering characteristics, such as
early (3 and 7-day) strength, larger dosages are usually avoided abrasion resistance. Therefore, compressive strength can be used
with HPC mixtures. When high early strength is a consideration, as a basis of mix proportioning and quality control. With most
for example, in cold weather concreting, condensed silica fume natural aggregates, it is possible to make concretes of up to 120-
(which is highly pozzolanic) or a mixture of condensed silica fume MPa compressive strength by improving the strength of the ce-

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74 CEMENT,CONCRETE, AND AGGREGATES

ment paste, which can be controlled through the choice of water choice is between sulfonated derivatives of naphthalene or me-
content and type and dosage of admixtures: For the purposes of lamine. The industrial products vary considerably in composition
mix proportioning, it may be convenient to divide the 60 to 120- and interaction with different portland cements and admixtures,
MPa strength range into several strength grades. therefore a clear preference does not exist in favor of either of
Water cement: With conventional concrete mixtures the mixing the two groups of superplasticizers. Some researchers have re-
water content depends on the aggregate MSA and the slump of ported that melamines produce a higher water reduction but tend
concrete. Since HPC will be made with a rather narrow range to cause a more rapid slump loss. Ronneberg and Sandvik [9]
of MSA (10 to 15 ram) as well as slump (200 to 250 ram), and have reported that melamines produce considerably less retar-
since slump can be controlled by the superplasticizer dosage, it dation than naphthalene and are more compatible with air-en-
is assumed that both MSA and slump need not be taken into training admixtures. Preliminary laboratory tests are, therefore,
consideration for determining the water requirement. A review essential for determining which type and brand of superplasti-
of high-strength concrete mixtures produced in different parts of eizer is more compatible with the given portland cement and
the world (with widely different materials) shows that a general other admixtures that will be used.
inverse relationship exists between water content and concrete Normal dosage of superplastieizer ranges from 0.8 to 2% solid
strength. It is assumed that this relationship can be exploited for by weight of cementitious materials. For the first trial batch, 1%
prediction and control of concrete compressive strength. superplasticizer is recommended. Since superplasticizers are ex-
Cement content: Fresh cement paste contains anhydrous ce- pensive, several trials may be necessary to determine the opti-
ment, water, and air. High-strength concrete mixtures require mum dosage needed to achieve a satisfactory rheotogy of the
thorough homogenization by vigorous mixing, therefore they given cement paste without causing undesirable retardation. It
tend to entrap approximately 2% air even when no air-entraining is not uncommon to use two thirds or three fourths of the total
chemicals have been added. With a fixed cement paste volume superplasticizer dosage during the mixing of concrete and the
(35%), if the volumes of water and air are known, the volume remainder at the job site. Also, since superplasticizers are gen-
of cement or cementitious materials can be calculated by differ- erally added in the form of solutions, the water present in the
ence. Of course, larger volumes of entrained air (viz., 5 to 6%) solution must be considered when computing the superplasticizer
may have to be assumed when air entrainment is needed for dosage and the mixing water requirement for concrete.
freezing and thawing durability. Ratio between fine aggregate and coarse aggregate: It was de-
Type and dosage of mineral admixtures: A simple approach is termined that the optimum proportion of aggregate in HPC mix-
to consider one of three options. According to the first option, tures is 65% by volume. The distribution between fine and coarse
portland cement alone may be used without any mineral admix- aggregates depends generally on the aggregate grading and
tures. In the strength range recommended for HPC (60 to 120 shape, the rheology of the cement paste, and the desired work-
MPa), this option should only be exercised when absolutely nec- ability of concrete. Due to the relatively high cement paste vol-
essary. This is because, without the incorporation of mineral ume in HPC mixtures, usually it is not necessary to use more
admixtures, many important technical benefits associated with than 40% fine aggregate by volume of the total aggregate. There-
their use will not be available (for instance, superior handling fore, for the first trial batch, a 2:3 ratio between the fine aggre-
characteristics of fresh concrete, improved resistance to thermal gate and the coarse aggregate may be assumed.
cracking, and better long-term durability to corrosive environ-
ments). According to the second option, a partial cement re-
Step-By-Step Procedure
placement is made with one or more mineral admixtures. From
the standpoint of reduction of heat of hydration, better worka- Based on the general considerations discussed above, the fol-
bility, and enhancement of the microstructural characteristics of lowing sequence of steps may be used to compute the weight of
well-hydrated cement pastes, experience shows that approxi- materials needed for the first trial of a 1 m 3 batch of nonair-
mately 25% cement should be substituted with a high-quality fly entrained concrete.
ash or slag. As a first approximation it is convenient to assume
a 75:25 volumetric proportion between portland cement and the
Step 1: Choice of Strength
selected mineral admixture.
It should be noted that the improvements in Strength and The 60 to 120 MPa strength range is arbitrarily divided into
impermeability characteristics resulting from the use of fly ash five strength grades, namely 65, 75, 90, 105, and 120 MPa, av-
or slag are usually not available until after at least 28 days moist erage strength of standard-cured concrete specimens at 28 days.
curing at normal temperatures. With some mineral admixtures, In general, the weather-resisting characteristics of concrete will
even longer curing periods are necessary to achieve the expected improve with increasing strength but so will the cost. Assuming
results. The effects associated with the use of mineral admixtures that the local aggregate is not strength limiting, the choice of
can be accelerated by a partial substitution of condensed silica strength should be made from a cost-benefit analysis.
fume for fly ash or slag, which is the third option. For instance,
instead of 25% fly ash, a mixture of 10% silica fume and 15%
Step 2: Estimation of Mixing Water
fly ash by volume may be used.
Type and dosage of water-reducing admixtures: The degree of From a given strength grade, Table 1 is used to estimate the
reduction in water content and increase in workability that is maximum content of mixing water. This estimate is based on
desired with HPC is not possible with normal water-reducing experience with high-slump superplasticized concrete mixtures
chemicals. Most suitable for this purpose are superplasticizers or containing 12 to 19 mm MSA. By correcting for the extra water
high-range water reducers (Class F) meeting ASTM Specification present in the superplasticizer (also in aggregates, if wet), the
for Chemical Admixtures for Concrete (C 494). Generally, the batch mixing water can be calculated (see Steps 6 and 7).

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MEHTA AND A'fTCIN ON HIGH-PERFORMANCECONCRETE 75

TABLE l--Relationship between average compressive strength and ences in the aggregate specific gravity compared to the assumed
maximum water content. values, appropriate correction should be made.
Strength Avg Strength, Maximum Water
Grade MPa Content, kg/m3 Step 6: Superptasticizer Dosage
A 65 160 If there is no prior experience with the superplasticizer, it is
B 75 150 suggested to start with 1.0% superplasticizer (on anhydrous solid
C 90 140 basis) by weight of cementitious materials. When the specific
D 105 130
E 120 120 gravity of the superplasticizer solution and the weight fraction
of solids in the solution are known, it is easy to estimate the
volume of the solution for a given batch. The following example
shows how the calculations are made.
Step 3: Volume Fraction of Cement Paste Components For Strength Grade A (65 MPa) with Option 3, the total weight
of cementitious materials will be 500 kg/m 3. For the trial batch,
Since the total volume of cement paste is 0.35 m 3, subtracting 1% superplasticizer solids, therefore, amounts to 5 kg/m 3. If the
the mixing water content (Step 2) and 0.02-m 3 entrapped air
weight fraction of solids in the solution is 40%, the weight of the
content, the calculated volumes of the total cementitious material solution is 5 divided by 0.4 = 12.5 kg/m 3. If the specific gravity
for each strength grade are shown in Table 2. Also shown in of the solution is 1.2, the volume of the solution is 12.5 divided
Table 2 are the volume fractions of portland cement and mineral by 1.2 = 10.4 L/m 3. This amount of water must be subtracted
admixtures, assuming one of the following three options: from the mixing water (Step 2), as discussed next.
Option 1: Portland cement (PC) alone. Note that the weight of water in 10.4 L/m 3 superplasticizer
Option 2: Portland cement plus either fly ash (FA) or blast- solution is equal to t0.4 × 1.2 × 0.6 = 7.5 kg/m 3.
furnace slag (BFS) in 75:25 ratio by volume.
Option 3: Portland cement + either FA + CSF (condensed
silica fume) in 75:15:10 ratio by volume, respec- Step 7: Moisture Correction
tively. Since the mix proportions in Table 3 are on SSD basis, de-
pending on the moisture condition of batch aggregates, the ap-
Step 4: Estimation of Aggregate Content: propriate moisture corrections in both fine and coarse aggregate
must be m~tde. A corresponding correction in the batch mixing
From the total aggregate volume (0.65 m3), assuming a 2:3 water in Table 3 is also made for the amount of water present
volumetric ratio between the fine and coarse aggregate for Grade in the superplasticizer solution (see Step 6).
A mixture, the individual volume fractions will be 0.26 and 0.39
m 3, respectively. For other grades (B to E), due to the decreasing
water content and increasing superplasticizer content, somewhat Step 8: Trial Batch Adjustment
lower fine/coarse aggregate volume ratios may be assumed with Due to many assumptions underlying the proposed method,
increasing strength; for instance, 1.95:3.05 for Grade B, the calculated mix proportions for the first trial batch serve only
1.90:3.10 for Grade C, 1.85:3,15 for Grade D, and 1.80:3.20 for as a guide. Several laboratory trials using the actual materials
Grade E. may be required before one arrives at the right combination of
materials and mix proportions which satisfy the given criteria of
workability and strength. The following suggestions are offered
Step 5: Calculation of Batch Weights
for the purpose of making the needed adjustments.
Typical specific gravity values for normal portland cement, fly If the concrete mixture is too stiff, the superplasticizer dosage
ash (Class C) or blast-furnace slag, and condensed silica fume should be gradually increased until the desired consistency is
are 3.14, 2.5, and 2.1. Typical specific gravity values for natural obtained. Increasing the superplasticizer dosage may be accom-
siliceous sand and most normal-weight gravels or crushed rocks panied by certain unwanted effects, such as a tendency for seg-
are assumed to be 2.65 and 2.70, respectively. Using the data regation and/or set retardation. The former may be corrected by
from Step 3 (Table 2) and Step 4, the calculated saturated surface increasing the ratio between the fine and coarse aggregate or by
dry (SSD) weights are shown in Table 3. For significant differ- using a fine aggregate with a lower fineness modulus. For mix-

TABLE 2--Volume fraction of components in 0.35-m3 cement paste, m3.

Total Opt/on 3
Strength Cementitious Option 1 Option 2 PC + (FA or BFS) +
Grade Water Air Materials PC only PC + (FA or BFS) CSF

A 0.16 0.02 0.17 0.17 0.1275 + 0.0425 0.1275 + 0.0255 + 0.0170


B 0.15 0.02 0.18 0.18 0.1350 + 0.0450 0.1350 + 0.0270 + 0.0180
C 0.14 0.02 0.19 0.19 0.1425 + 0.0475 0.1425 + 0.0285 + 0.0190
D 0.13 0.02 0.20 .. ." 0.1500 + 0.0500 0.1500 + 0.0300 + 0.0200
E 0.12 0.02 0.21 .. .° 0.1575 + 0.0525 0.1575 + 0.0315 + 0.0210

"Concrete Grades D and E are not made without mineral admixtures.

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76 CEMENT,CONCRETE, AND AGGREGATES

TABLE 3---Mix Proportions (SSD) for the first trial batch, kg/m 3.

Cementitious Materials
Avg
Strength Strength, FA or Total" Coarse Fine Total
Grade MPa Option PC BFS CSF Water Aggregate Aggregate Batch W/C

A 65 1 534 ... 160 1050 690 2434 1).30


2 400 )~ 160 1050 690 24(~ 0.32
3 400 64 "36" 160 1050 690 241~ 0.32
B 75 1 565 ... 150 1070 670 2455 0.27
2 423 ]i3 150 1070 670 2426 0.28
3 423 68 "38' 150 1070 670 2419 0.28
C 90 1 597 ... 140 1090 650 2477 0.23
2 447 li9 140 1090 650 2446 0.25
3 447 71 "40' 140 1090 650 2438 0.25
D 105 . . . .

3 471 75 "42' 130 1110 630 2458 0.22


E 120 . . . . . . .
2 il b 24s6 019
3 495 79 '44' 120 1120 620 2478 0.19

"Total water includes the water in the superplasticizing admixture, the dosage of which may range from 10 to 20 L/m3, depending on consistency
and strength requirements.

tures with no mineral admixtures, this problem may be resolved strength mixtures, the strength of concrete can be very sensitive
by incorporation of silica fume or fly ash or both. To solve the to even small changes in the water content.
set retardation problem, combinations of other types or brands From the data in Table 4, it is difficult to establish a direct
of locally available superplasticizers and cements should be relationship between the water/cementitious ratio and strength.
tested. Modified superplasticizers containing set accelerators, For example, Concrete Mixtures 7 and 11, which have the same
which claim not tO cause excessive set retardation, are also avail- water/cementitious ratio (0.28), showed considerably different
able commercially. It should be noted that when the cause of strengths, i.e., 72 and 93 MPa, respectively. Also, in this regard,
stiff consistency of a concrete mixture is high content of reactive it is interesting to compare Concrete Mixtures 6, 9, and 10 from
C3A in the cement, additional dosages of superplasticizers alone a recent study reported by Read et al. [15]. These three mixtures
may not work. In such cases, an increase in the water/cement have the same water/cementitious ratio (0.27) but significantly
ratio becomes unavoidable. different strengths. Keeping the cementitious content approxi-
If the 28-day compressive strength of the trial mix is lower mately the same (485 kg/m3), the values for the 28-day avg
than the specified average strength, an examination of the frac- strength were 70, 82, and 91 MPa, respectively, for the mixtures
ture surface of concrete specimens and strain-strain curves may containing 0, 8, and 12% silica fume, respectively. This confirms
provide a clue to the weakest component of the composite. In that rather than the water/cementitious ratio, it is the combi-
the case of frequent debonding between cement paste and coarse nation of water content and mineral admixture type and dosage
aggregate particles, either the cement paste in the transition zone which determines the concrete strength. It is important to note
needs strengthening or the aggregate is too smooth. In the former here that in spite of the increasing dosage of silica fume in Con-
case, control of bleeding by reduction in the water content and/ crete Mixtures 6, 9, and 10, the water content was held constant
or incorporation of fine particles of a suitable mineral admixture by the use of increasing dosage of the superplasticizer. Thus,
may solve the problem, In the latter case, the use of crushed concrete consistency need not depend on the water content, as
aggregate should be considered. is the case with conventional concrete mixtures. It may be
pointed out here that the typical reported values for slump and
air content of fresh concrete mixtures shown in Table 4 are 175
Field and Laboratory Experience with Mix Proportioning
to 250 mm and 1.5 to 2.5%, respectively.
To evaluate the above described procedure for proportioning In regard to mineral admixtures, Concrete Mixtures 2 and 3
high-performance concrete mixtures, the authors have reviewed contained 20 and 29% Class C fly ash, respectively, whereas
the published information on a variety of field and laboratory concrete mixture 7 contained 35% slag by weight of cementitious
mixtures. Selected data from this review is presented in Table 4 materials. Mixture 4 and 8 contained 7 to 8% silica fume in
and a discussion on the data follows. addition to 28 and 30% slag, respectively. It seems that concrete
It is noted that Concrete Mixtures 1 and 2, which were pro- mixtures of up to 70 or 80 MPa can be made by about 25%
duced during the seventies, contained normal water-reducing cement replacement with fly ash or slag alone. With higher 28-
admixtures. All other concrete mixtures in Table 4 were made day strength requirements, the simultaneous use of silica fume
during the eighties and contained superplasticizing admixtures. is helpful. For 90-MPa and higher strength levels, silica fume has
From the water requirement of superplasticized concrete mix- been invariably used in dosages varying from 7 to 12% (avg 10%)
tures (Nos. 3 to 15), it is clear that within a narrow range of of the total cementitious materials.
water contents, 124 to 148 t / m 3, the concrete strengths varied Finally, it is interesting to compare the actual mix proportions,
between 70 and 120 MPa. This confirms the view that, with high- using a wide variety of materials reported in Table 4, with the

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MEHTA AND A'iTCIN ON HIGH-PERFORMANCE CONCRETE 77

TABLE 4--Mix proportions for selected high-strength concrete mixtures.

Component Materials in 1-m3 concrete batch, kg/m3


Avg Water to
Compressive Cementitious Material Super- Cementitious
Description of Strength, Total Fine Coarse plasticizer, Ratio by Ref.
No. Concrete 28-day MPa PC FA BFS CSF Water Aggregate Aggregate L/m3 Weight No.

1 Water Tower Place, 65 500 60 ...... 178 608 1068 . . .a 0.32 10


Chicago
2 Commerce Tower, 65 390 100 ...... 161 575 1141 . . .a 0.33 11
Houston
3 International First 80 360 150 ...... 148 603 1157 3* 0.29 12
Plaza, Dallas
4 Nova Scotia Plaza, 82 315 ... 135 36 145 745 1130 6 0.30 13
Toronto
5 Experimental column, 90 500 ...... 30 135 700 1100 15 0.25 16
Montreal
6 Laboratory mixture 70 485 . . . . . . . . . 130 762 1143 3.4 0.27 15
7 Laboratory mixture 72 317 . . . 167 ... 133 749 1145 7.0 0.28 15
8 Laboratory mixture 80 315 . . . 155 35 143 744 1142 7.5 0.29 15
9 Laboratory mixture 82 449 . . . . . . 39 130 758 1149 11.0 0.27 15
I0 Laboratory mixture 91 427 . . . . . . 59 132 754 1139 14.9 0.27 15
11 Laboratory mixture 93 450 . . . . . . 50 140 687 1108 17 0.28 14
12 Laboratory mixture 97 500 . . . . . . 42 138 675 1130 10 .0.25 5
13 Laboratory mixture 100 486 . . . . . . 54 135 661 1112 20 0.25 14
14 Laboratory mixture 103 580 . . . . . . 70 140 620 1025 12 0.22 8
15 Laboratory mixture 107 517 . . . . . . 58 126 641 1126 25 0.22 14

°Concrete Nos. 1 and 2 contained only a normal water-reducing admixture; Concrete No. 3 also contained a normal water-reducing admixture in
addition to a superplasticizer.

recommended mix proportions for the first trial batch (Table 3), Although very high-strength (>80 MPa) concrete mixtures of
which are based on the mix-proportioning method proposed by Table 4 invariably contain silica fume, Option 2 of Table 3 sug-
the authors. For Grade A concrete (65 MPa), the recommended gests that this is not essential. If high quality fly ash or slag is
mix proportions according to Option 2 of Table 3 (400 kg/m 3 available and adequate curing is insured (which is especially the
portland cement, 106 kg/m 3 fly ash or slag, and 160 L/m 3 water) ease with massive structures due to moisture retention and adi-
compare well with the actual mix proportions for Concrete Mix- abatic temperature conditions), it is assumed that the ultimate
ture 2 of Table 4 (390 kg/m 3 portland cement, 100 kg/m3 fly ash, strength (e.g., 90-day) of concrete mixtures using Option 2 mix
and 16 L/m 3 water). For Grade B concrete (75 MPa), the rec- proportions would not be different from Option 3 mixtures.
ommended mix proportions according to Option 2 of Table 3 In regard to fine aggregate and coarse aggregate, the data in
(423 kg/m 3 cement, 113 kg/m 3 fly ash or slag with a total 536 kg/ Table 4 show that in the 65 to 120 MPa range the total aggregate
m 3cementitious material, and 150 L/m 3water) compare well with content and the fine/coarse aggregate proportions did not vary
the actual proportions for the two 80-MPa concrete mixtures significantly with concrete strength, as expected, in spite of dif-
(Nos. 3 and 4) of Table 4. Note that Concrete Mixtures 3 and 4 ferences in aggregates' physical characteristics. On average, ap-
contain 500 to 510 total cementitious material, including fly ash proximately 650 kg/m 3 fine aggregate and 1100 kg/m 3 coarse
or slag, and 145 to 148 L/m 3 water. For Grade C concrete (90 aggregate were used with concrete mixtures listed in Table 4,
MPa), the recommended mix proportions according to Option which compares well with the recommended mix proportions
3 of Table 3 are 471 kg/m 3 cement, 75 kg/m 3 fly ash or slag, 42 shown in Table 3.
kg/m 3 silica fume (558 kg/m 3 total cementitious material), and
140 L/m 3 water. Field Concrete 5 contained 530 kg/m 3 cemen-
Concrete Production and Construction Practice
titious material and 135 kg/m 3 water and compares well with the
recommended mix proportions. Laboratory Mixtures 10 and 11 The strength and durability of high-performance concrete de-
of Table 4 are similar in mix proportions, except that the total pend more on microstructural extremes than on the average
cementitious materials in the latter is approximately 500 kg/m 3 microstructure (for instance, the weakest link in the chain may
(because they do not contain any fly ash or slag). Similarly, for be a local concentration of voids or undispersed silica fume).
Grade D concrete (105 MPa), the recommended mix proportions This is why the sequence of batching, the efficiency of mixing,
according to Option 3 of Table 3 are 471 kg/m 3 cement, 75 kg/ the methods of transport and placement, and the degree of con-
m 3 fly ash or slag, 42 kg/m 3 silica fume (total 588 kg/m 3 cemen- solidation and curing play as much a part in determining the
titious material), and 130 L/m 3 water. This compares well with performance of the end product as the selection and propor-
Concrete Mixtures 13 and 15 of Table 4. Concrete Mixture 13 tioning of materials. In this regard, a detailed review of the
(100 MPa) contained 486 kg/m 3 cement, 54 kg/m 3 silica fume production and construction practice for durable concrete ele-
(total 540 kg/m 3 cementitious material), and 135 L/m 3 water. ments is given elsewhere [17], anti-only a summary is presented
Concrete Mixtures 15 (107 MPa) contained 517 kg/m 3 cement, below.
58 kg/m 3 silica fume (total 575 kg/m 3cementitious material), and The batching sequence and methods should be aimed at pro-
126 L/m 3 water. ducing a concrete mixture which is as homogeneous as possible.

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78 CEMENT,CONCRETE, AND AGGREGATES

For instance, an experimental study by the authors (unpublished) the selection of materials and mix proportions for high-perfor-
showed that coating of coarse aggregate particles with silica fume mance concrete. This approach is used to develop a step-by-step
before adding other component materials to the mixer produced procedure for determining the mix proportions. Using this pro-
lower strength concrete because the silica fume added in this cedure, the calculated mix proportions are given for the first trial
manner was not properly dispersed in the concrete mixture. The batch for high-performance concrete mixtures in the 60 to 120-
standard method is to obtain first a homogeneous mixture of the MPa compressive strength range. The calculated mix proportions
coarse and the fine aggregate in the mixer and then add the compare well with the accumulated field and laboratory expe-
cementitious materials followed by water and the superplasti- rience of many researchers. This procedure may not be perfect,
cizer. High-speed mixing of superplasticized cement paste alone, but it is simple and provides a rational approach by which mix
with equipment such as described by Mass [18], subsequently proportions for high-performance concrete can be determined
followed by aggregate addition, is an interesting idea worthy of without undertaking extensive laboratory trials.
exploration for HPC mixtures.
Similarly, to prevent segregation of the concrete mixture, the
References
equipment and methods for transporting and placing concrete
must be regularly checked. Following placement, consolidation [1] Birchalt, J. D., and Kelly, A., "New Inorganic Materials," Scientific
by vibration is necessary even with flowing concrete mixtures in American, Vol. 248, 1983, p. 104.
order to remove pockets of entrapped air and obtain a uniform [2] Roy, D. M. and Gouda, G. R., "Optimization of Strength in Ce-
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distribution of coarse aggregate and water. Concrete mixtures pp. 153-162.
with high-cement contents, especially those containing silica [3] Mehta, P. K., Concrete: Structure. Properties, and Materials, Pren-
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of Materials and Mix Proportions for High Strength Concrete,"
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Finally, proper curing or maintenance of adequate humidity 1990.
and temperature conditions for a certain time period is essential [5] Aitcin, P. C., and Mehta, P. K., "Effect of Coarse Aggregate Type
for the hydration reactions of cementitious materials without on Mechanical Properties of High-Strength Concrete," ACI Ma-
which the process of developments of strength and impermea- terials Journal, Vol. 87, No. 2, March-April 1990, pp. 103-107.
]6] Hanna, E., Luke, K., Perraton, D., and Aitcin, P. C., "Rheological
bility will be hindered. As long as the concrete temperature is Behavior of Portland Cement Pastes in the Presence of a Super-
sufficiently above freezing (viz. >5°C), external moist curing plasticizer," ACI SP-119, ACI, Detroit, 1989, pp. 171-188.
provides the best way to seal in the mixing water, which is suf- [7] Mehta, P. K., "Studies on Mechanisms by which Condensed Silica
ficient for hydration. Because HPC mixtures have a higher con- Fume Improves the Properties of Concrete," Proceedings, CAN-
MET workshop on condensed silica fume in concrete, Montreal,
tent of cementitious materials, there is a tendency to assume that Canada, 1987.
they require a longer moist-curing period than ordinary concrete. [8] Aitcin, P. C., Sarkar, S. L., and Diatta, Y., "Microstructural Study
Working with a high-strength concrete mixture, Asselanis et al. of Different Types of Very High Strength Concretes," Proceedings,
[19] found that a seven-day moist curing period was sufficient to Materials Research Society Symposium, Vot. 85, 1987, pp. 261-
make the concrete impervious enough; therefore, further moist 272.
[9] Ronneberg, H., and Sandvik, M., "High Strength Concrete for
curing is not necessary to enhance the compressive strength. North Sea Platforms," Concrete International, Vol. 12, No. 1, 1990,
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[10] High-Strength Concrete in Chicago High-Rise Buildings, Chicago
Concluding Remarks Committee on High-Rise Buildings, Report No. 5, 1977.
[11] Cook, J. E., "Research and Application of High-Strength Concrete
Unacceptable rates of deterioration in concrete structures, Using Class C Fly Ash," Concrete International, Vol. 4, No. 7, 1982,
such as highway pavements, bridge decks, piers, locks, and dams pp. 72-80.
are causing serious concern about long-term performance of con- [12] Cook, J. E., "10,000 psi Concrete," Concrete International, Vol.
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for Tall Buildings," Proceedings, Conference on Utilization of High
pollutants is making new demands on concrete for high perfor- Strength Concrete, Stavanger, Norway, 1987, pp. 641-654.
mance. [14] Kawai, T., Yamazaki, N., lmai, M., Tachibana, D., and Inada, Y.,
In developing high-performance concrete, one Of the problems "Study on Application of 100 MPa Strength Concrete," personal
is the lack of a clear definition as to what constitutes "high communication, Shimizu Corp., Tokyo, Japan, 1989.
[15] Read, P., Carette, G., and Malhotra, V. M., "Strength Develop-
performance." There is increasing awareness that high perfor- ment Characteristics of High-Strength Concrete Incorporating Sup-
mance should be synonymous with high durability and not with plementary Cementing Materials," Proceedings, Symposium on
high strength. Besides strength, the other important properties Utilization of High-Strength Concrete, Berkeley, CA, May 1990.
which contribute to high durability are high dimensional stability [•6] Aitcin, P. C., Laplante, P., and Bedard, C., "Development and
(i.e., low shrinkage and creep), impermeability, and high work- Experimental Use of a 90 MPa Concrete," ACI SP-87, ACI, De-
troit, 1985, pp. 51-70.
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portions for a concrete, these requirements can be in conflict ronment," ACI SP-109, ACt, Detroit, 1988, pp. 1-28.
with each other, and, therefore, an adequate understanding of [181 Mass, G. R., "Premixed Cement Paste." Concrete International,
the concrete microstructure and its influence on the properties Vol. i1. No. 11, 1989, pp. 82-85.
is essential before attempting to develop high-performance con- [19] Asselanis, J., Aitcin, P. C., and Mehta, P. K., "Effect of Curing
Conditions on the Compressive Strength and Elastic Modulus of
crete mixtures that may be suitable for industrial application. Very High Strength Concrete," Cement, Concrete, and Aggregates,
Based on fundamental microstructure-property relationships Vol. 10, No. 1, 1989, pp. 80-83.
in concrete, the authors have described a rational approach for

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