ASTM categories of admixtures

ASTM C494 specifies the requirements for seven chemical admixture types. They are: Type A: Water-reducing admixtures Type B: Retarding admixtures Type C: Accelerating admixtures Type D: Water-reducing and retarding admixtures Type E: Water-reducing and accelerating admixtures Type F: Water-reducing, high range admixtures Type G: Water-reducing, high range, and retarding admixtures

WHAT SPECIAL PERFORMANCE DO YOU NEED? High Strength Concrete Admixtures containing microsilica (condensed silica fume) are used to meet high strength and low permeability requirements. Benefits include reduced permeability, increased compressive and flexural strengths, and increased durability. Applications include high-strength structural columns, less permeable parking garage decks, and abrasion resistant hydraulic structures. Silica fume can be used in concrete to produce compressive strengths approaching 20,000 psi under jobsite conditions. This admixture can be added in a slurry or in a dry form, whichever meets the batching equipment needs. In either case, performance is the same. Strength Enhancement Concrete strength enhancement can be achieved through use of superplasticizer admixtures to produce a low water/cement ratio giving high performance concrete. These admixtures promote a high slump, extremely flowable concrete that achieves high strengths while providing superior workability and pumpability. High range water-reducing admixtures can also be used for precast/prestressed structures where it is desirable to keep the water/cement ratio to a minimum for low permeability and high early strengths without set retardation.They are also used for concrete requiring high-early stripping strengths. Set Retardation

Set retarders are used where delay in setting time is required to ensure sufficient placement, vibration or compaction time. Set retarders permit application of higher temperature curing of precast/prestressed concrete without negatively affecting the ultimate strength.

Applications: Long hauls Trucks waiting a long time even for a small pour Undermanned placement crew Slow pour rate

Things to consider: Project location long or short haul Size of pour Rate of pour Placement method Environment exterior, interior Thick sections (if dry windy conditions, early surface drying while the underlying concrete is still soft can make finishing difficult and result in a wavy or cracked surface When a set retarder may not be required Short hauls with quick placement Cool moist interior location Residential or commercial basement Fast pour rate Set Acceleration Set accelerators work by accelerating cement hydration, which results in shortened setting times and increased early age strengths, particularly in cooler temperatures. They increase the rate of early strength development and reduce time required for curing and protection At one time, calcium chloride was the predominant accelerating admixture. However, it is now considered by many to be a main contributor to long-term concrete problems. In Europe, use of calcium chloride is banned for some applications. Chloride is considered to contribute to corrosion of reinforcement or embedded metal in concrete. In turn this corrosion has been associated with spalling, cracking, loss of bond and if left uncorrected can cause eventual failure of the element involved.

Now, chloride-free set accelerators are available based upon other chemicals. Some of these newer admixtures also can act as ASTM C494 Type E water-reducers. Corrosion Protection Reinforced concrete that is exposed to deicing salts and marine environments is particularly susceptible to chloride-induced corrosion. A well-designed, durable, low permeability concrete mix will provide some protection against chloride-induced corrosion of reinforcement. Corrosion inhibitors can be effective in parking structures, bridges and marine environments. Other ways of reducing corrosion are to use penetrating surface sealers to help prevent chloride penetration, epoxy-coated rebar, or silica fume in the mix. Silica fume can increase durability and reduce permeability. Non-chloride containing set accelerator admixtures are available which conform to ASTM C 494 Type C. Calcium chloride has been used in the past because it is relatively inexpensive and provides set acceleration and early strength development. However, the corrosive effects of the chloride have been observed as much as 20 years after the concrete was poured. Thus, non-chloride containing admixtures have been developed for use where potential corrosion of embedded or stressed steel must be avoided. As with all other admixtures, manufacturers instructions for its use in conjunction with other admixtures and dosage must be followed to be effective. Water Reduction in the Mix Water reducers have become so important in concrete, that they could be considered the fifth ingredient. They can be used to: (1) increase slump, (2) lower the water-cement ratio, or (3) reduce cement content. Water reducers come as Low Range, Mid Range, and High Range Superplasticizers. There are enough different admixtures available that it is possible to select one that meets the need of a particular project whether it is tall columns that need a mix that pumps easily, or an easy-tofinish durable floor slab. In general, they provide the required slump with less water in the mix, and may provide higher strength concrete without increasing the amount of cement. Conventional water reducers

Are required to achieve a minimum 5% water reduction. A conventional water reducer can reduce slump by about 1 to 2 inches without the addition of water. Mid-Range water reducers Can reduce water content by at least 8% and as much as 15%. They tend to be stable over a wider range of temperatures and tend to give more consistent setting times. These reducers work most effectively in mixes designed to have a slump in the range of 4 to 5 inches. Particularly useful in hot weather concreting by counteracting the accelerating effect of high ambient and concrete temperatures Slow the setting rate of concrete Delay initial set of concrete Keep concrete workable during placement High-Range water reducers (superplasticizers) Can reduce water content from 12% to as much as 40% and are typically used in concretes designed to have slumps of 8 to 11 inches. They can be used to either increase slump (by 4 to 8 inches) or lower the water content of hot weather concrete mixes. Used to increase flowability. Flowability Superplasticizers (High-Range Water Reducers) can make a low-to-normal slump concrete into a high-slump flowing concrete which can be placed with little or no vibration. However, the change in slump usually lasts only about 30 to 60 minutes depending upon the brand and dosage rate. High-range water reducers fall into either ASTM C494 Type F or Type G classification. In either case, they can be used to produce very high slumps without segregation, an ideal situation where increased flowability is necessary due to congested reinforcement. Other applications and benefits of high-range water reducers include: difficult wall placements narrow forms sections with blockouts, penetrations, or embedded items pumping high vertical distances fast placement of concrete increased lift heights and free fall distances Note: The increased thinness of the concrete mix means that forms should be tight to prevent leakage even through small joints which can result in fins and discoloration.

Type F superplasticizers Added at the job site and keep concrete flowable for a short period of time. At some point, the concrete will lose slump quickly. Type G superplasticizers Can be added either during batching or at the job site. This admixture will delay setting, but cause the concrete to be flowable for a longer period of time which could delay finishing. If haul times are particularly long, Type G can be added at the plant. However, if delivery is delayed too long, the effects can be diminished. Redosing is possible to regain the plasticity of the mix and manufacturers recommendations should be followed closely. Concrete Admixtures that Control Cracking (Reducing Drying or Shrinkage Cracking) Hydrated cement paste shrinks as it loses moisture from its extremely small pores. As the moisture is lost in these small pores, the surface tension of the remaining water tends to pull the pores together which results in a loss of volume over time. Shrinkage reducing admixtures (SRAs) are designed to decrease the effects of drying shrinkage by reducing the surface tension in these pores. It should be noted that the type of aggregate and the cement properties themselves can influence the amount of cracking that can occur. Thus, it is important to test local project-specific materials if doing shrinkage testing. Curing also affects cracking. In slabs, the top tends to dry out first and shrinks while the lower sections still have a higher moisture content. This difference in moisture can be altered by use of Shrinkage Reducing Admixtures, which alter the way water migrates through the concrete and results in a more uniform moisture profile.

Related Posts:

High-Strength Concrete Benefits of Using Silica Fume in Concrete Measures to avoid cracking in fresh concrete Concrete vs. Shotcrete, Whats the Difference? What Should I Know About Concrete Testing?

High-Strength Concrete

In the early 1970s, experts predicted that the practical limit of ready-mixed concrete would be unlikely to exceed a compressive strength greater than 11,000 psi (76 MPa). Over the past two decades, the development of high-strength concrete has enabled builders to easily meet and surpass this estimate. Two buildings in Seattle, Washington, contain concrete with a compressive strength of 19,000 psi (131 MPa). The primary difference between high-strength concrete and normal-strength concrete relates to the compressive strength that refers to the maximum resistance of a concrete sample to applied pressure. Although there is no precise point of separation between high-strength concrete and normal-strength concrete, the American Concrete Institute defines highstrength concrete as concrete with a compressive strength greater than 6000 psi (41 MPa). Manufacture of high-strength concrete involves making optimal use of the basic ingredients that constitute normal-strength concrete. Producers of highstrength concrete know what factors affect compressive strength and know how to manipulate those factors to achieve the required strength. In addition to selecting a high-quality portland cement, producers optimize aggregates, then optimize the combination of materials by varying the proportions of cement, water, aggregates, and admixtures. When selecting aggregates for high-strength concrete, producers consider the strength of the aggregate, the

optimum size of the aggregate, the bond between the cement paste and the aggregate, and the surface characteristics of the aggregate. Any of these properties could limit the ultimate strength of highstrength concrete. Admixtures Pozzolans, such as fly ash and silica fume, are the most commonly used mineral admixtures in high-strength concrete. These materials impart additional strength to the concrete by reacting with portland cement hydration products to create additional C-S-H gel, the part of the paste responsible for concrete strength. It would be difficult to produce high-strength concrete mixtures without using chemical admixtures. A common practice is to use a superplasticizer in combination with a water-reducing retarder. The superplasticizer gives the concrete adequate workability at low water-cement ratios, leading to concrete with greater strength. The water-reducing retarder slows the hydration of the cement and allows workers more time to place the concrete. High-strength concrete is specified where reduced weight is important or where architectural considerations call for small support elements. By carrying loads more efficiently than normal-strength concrete, high-strength concrete also reduces the total amount of material placed and lowers the overall cost of the structure.

The most common use of high-strength concrete is for construction of high-rise buildings. At 969 ft (295 m), Chicagos 311 South Wacker Drive uses concrete with compressive strengths up to 12,000 psi (83 MPa) and is the tallest concrete building in the United States.

Benefits of Using Silica Fume in Concrete

Silica Fume has been used all over the world for many years in the area where high strength and durable concrete were required. Silica Fume improves the characteristics of both fresh and hard concrete. 1. Reduce of Concrete Permeability For provision of a concrete resistant to the most aggressive environment, the most important property is the permeability. Lower the ingress of movement of water or chemicals; lower the deterious reactions such as sulfate attack, reinforcement corrosion The reaction between Silica Fume and the calcium hydroxide, released as the cement hydrates, provides a dense impermeable pore structure. Although the total porosity of the Silica Fume concrete is similar to the OPC concrete the average pore size is much finer, conducting to a large reduction of permeability. 2. Improvement of concrete mechanical Performances The Silica Fume reacts with the cement paste to form additional strong Calcium Silicate Hydrate (CSH) providing higher strength. Silica Fume reduces bleeding and enhances the cement paste bond to the aggregates. Thanks to its pozzolanic effect (reaction with Ca(OH)2 ), and therefore to the strength improvement, Silica Fume can be used to reduce to the cement content of the mix. In addition of the cost saving benefit, this will reduce the total heat of hydration and can improve the performances of the concrete in terms of chemical resistance. 3. Improvement of Concrete Sulfate resistance Prior to develop the advantages of using Silica Fume to improve the concrete sulfate resistance, it may be interesting to highlight the basics form of sulfate attacks and the properties of sulfate resisting cement.

The use and deterioration of concrete in environments containing sulfates has led to the development of special sulfate resisting cements. It has also spawned significant research into the use of supplementary cementitious materials to improve sulfate resistance. The utility of Silica Fume for enhancing the resistance of concrete to sulfate attack has been widely studied. Sulfate resisting cements (type V) have a low C3A content to minimize the risk off sulfate attack. However, this does not necessarily provide immunity: - as certain sulfate react with hydrated lime and the calcium silicate hydrate the sulfate resisting cement provide less protection than expected. - Low C3A cements are more susceptible to reinforcement corrosion attack. The basic forms of sulfate attack are the following: The reactive aluminates in the cement will react with the gypsum in cement during hydration. This process is harmless as the ettringite does not produce expansive forces and is stable in sulfate solutions. If the quantity of reactive aluminates in the cement is too high, then their hydrate form will be available to react with sulfates after the cement has hardened. This will produce expansive ettringite and cracking of the concrete. Aluminate Hydrate + Calcium Hydroxide + sulfate + water => Ettringite. The second principle cause attack is the acid interaction of sulfates ions and calcium hydroxide, causing gypsum formation. Calcium Hydroxide + sulfate + water => Gypsum It has been shown that the cation (calcium, Magnesium, Aluminium, Ammonium) of the sulfate salt affects the type and the severity of the attack. 4. Improvement of Reinforcement Corrosion Protection In a marine structure, the performances of the concrete in terms of sulfate resistance must be taken into consideration for concrete design but the resistance to chlorides diffusion through the concrete is generally a main concern as well. Some studies conducted in several countries proved that Type 1 cements (with high C3A content) blended with Silica Fume used in combination with a high range water reducer provide

high durable performance against chloride-induced reinforcement corrosion and against sulfate attack. The main reasons of this result can be summarize as follows: - Silica Fume reduces the permeability of the concrete. Water and chemicals ingress are thus reduced. - The ability of high C3A cement to complex with chlorides results in the formation of insoluble compound, able to reduce the mobility of free chloride ion to the reinforcement-concrete surface.

Measures to avoid cracking in fresh concrete

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June 17, 2010Posted in: Articles, Concrete

Generally, the contractor shall allow for all necessary measures to monitor and avoid cracking in fresh hydrating concrete, regardless the size or volume of the pour. Such measures shall be to the satisfaction of the Engineer and shall be such that maximum surface crack width on hardened concrete measure immediately after the pour does not exceed 0.004 times the nominal cover of the main reinforcement.

The contractor shall allow for and provide approved instrumentation for the measurement of internal temperature changes in large pours. The maximum concrete temperature at the point of delivery shall not in general exceed the lower of either 37 degree C, or 6 degree C above the prevailing shade temperature in accordance with the recommendations of ACI. The limiting internal temperature differential measured across the extreme faces of concrete mass shall not exceed 25 degrees C at any time. Curing of hardened concrete shall be executed in accordance with the curing specification. Generally, the element surface shall not be cooled to dissipate heat from the concrete. Curing

methods, such as the wetting of heated concrete elements exposed to prolonged and direct radiation, which induce temperature gradients within the concrete mass are strictly prohibited. For large pours, the contractor shall allow for and take extra precautions to reduce concrete temperature gradient and to prevent the loss of surface moisture. Such measures include but are not limited to: Keeping all mix constituents shaded where possible to reduce their temperatures in the stockpile Cooling of mixing water and/or replacing part or whole of the added water with ice. Reducing the cement content by the use of admixtures (but not below that required for the durability) Using a cement with a lower heat of hydration Injecting liquid nitrogen after mixing of concrete Restring the time between mixing and placing of the concrete to not more than 2 hours Providing approved surface insulation continuously over all exposed surfaces to prevent draughts and to maintain uniform temperature through the concrete mass Initiating curing immediately after final tamping and continue until the approved surface insulation system is fully in place Providing shade to the concrete surface to prevent heat gain from direct radiation. If the surface exhibits crack after compaction, it shall be retamped to close the cracks while the concrete is still in plastic stage.

Concrete vs. Shotcrete, Whats the Difference?

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December 24, 2009Posted in: Articles, Concrete

Concrete vs. Shotcrete, Whats the Difference?

Concrete is truly a versatile building material. Concretes in use today are formulated with very specific performance characteristics in mind and include lightweight, heavyweight, porous, fiberreinforced, mass, high-performance and cellular concretes to name just a few. Each provides

specific characteristics or properties for their intended use. These properties are achieved by intentional formulation and control of such variables as cement content and type, pozzolan type and content, aggregate type, admixtures used, the addition time and rate of those admixtures, as well as other, often subtle, differences. One widely used specialty concrete is known as shotcrete. The major difference between shotcrete and its close cousin, concrete, is the placement method. Concrete is discharged from a ready-mix truck, placed on the ground or in forms and then must be vibrated for compaction. By contrast, the shotcrete process, whether using wet or dry material feed, does not require forming or compaction thereby enhancing design creativity and application flexibility, often resulting in a savings of time or money.

Shotcrete, was originally called Gunite when Carl Akeley designed a doubled chambered cement gun in 1910. His apparatus pneumatically applied a sand-cement mixture at a high velocity to the intended surface. Other trademarks were soon developed known as Guncrete, Pneucrete, Blastcrete, Blocrete, Jetcrete etc. all referring to pneumatically applied concrete. Today Gunite equates to dry-mix process shotcrete while the term shotcrete usually describes the wet-mix shotcrete process. At point of application, both are typically referred to as shotcrete. Dry-mix process shotcrete, introduces and mixes the required water at the application nozzle as the dry cementitious materials (fly ash, slag, silica fume etc.) and aggregates are delivered through the gun The nozzleman controls mix consistency, adjusting water addition to suit the changing conditions of the work area. The dry-mix process also is well suited for sporadic application operations since the majority of the water only comes into contact with the cementitious materials as it leaves the nozzle.The wet-mix process utilizes concrete delivered to the job that is thoroughly mixed excluding of any required accelerators. The ingredients are generally delivered in ready-mix trucks as with normal concrete. Accelerators or other admixtures may still be metered into the slurry at the nozzle along with air under pressure to increase the velocity of the material and improve control of the application or shooting process. The impact velocity of properly applied shotcrete instantly compacts the material, yielding an in-place mix that is richer in cement and higher in strength than the same mixture prior to

placement. Typically, a fine aggregate dry-mix shotcrete mix delivered in a 1:3 cement to aggregate proportion upon entering the application gun results in a 1:2 cement to aggregate ratio when in place. What appears to be a waste of materials and a dust nuisance known in the trade as rebound and overspray, actually results in dense, high-strength shotcrete as a portion of the aggregate ricochets off the receiving surface and away from the placement location. The loss through rebound will vary depending upon the dryness of the mix, the shooting distance from the surface, wind conditions, etc. The intended thickness is generally overshot, trimmed back to the design thickness and finished to the desired surface texture and appearance. While the dry mix process sounds quick and economical, it requires precautions to ensure application quality. The nozzlemans workmanship and experience are critical, since the nozzleman controls the critical water-to-mix ratio going into application equipment. With the wet-mix process, the nozzleman has no control over the consistency of the mix delivered to the job site, but can control the velocity of the materials and the addition of accelerators as the mix leaves the nozzle. Just as in concrete mix designs, the water-to-cementitious materials ratio remains the single most important parameter influencing the compressive strength, shrinkage and overall durability of the final product. Application technique is also crucial and less forgiving than ordinary ready-mix. Good shooting technique can mean the difference between a dense high-strength material or one that looks good on the finished surface but actually has underlying sand pockets, voids and poorly encased reinforcing steel. Poor application technique increases the probability of cracking and its negative ramifications.The shotcrete process is more versatile than conventional concrete placement. If the shooting surface is sound, clean and accessible, shotcrete can be applied in very difficult or complex shapes or sections where conventional concrete formwork would prove difficult or impossible as well as cost prohibitive. Shotcrete is especially applicable for unique shapes desired in complex shapes, swimming pools and other unique features of aquatic parks. It can also be an excellent overlay and repair material for existing structures because of its potential to achieve good bond strength and low permeability. The nuances and differences between concrete and shotcrete are too numerous to cover in a short article. Selecting a concrete placement method, whether it be conventional concrete, wet-mix or dry-mix process shotcrete, can be a challenging task, since there are positive aspects of each for almost every application. While it is true that one approach may be more applicable, adaptable or economical than another, the final concrete placement selection for the project should be based on project design, material performance criteria and overall budget.

What Should I Know About Concrete Testing?

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March 10, 2010Posted in: Articles, Concrete

What Should I Know About Concrete Testing?

The concrete Slump Test was created to help consistently measure the concrete workability. The workability of the concrete is an important factor for those placing the concrete. A workable concrete mix properly flows and fills the form properly, leaving minimal voids at the form face and completely surrounding any rebar to create a bond. The Slump Test should be familiar to most workers on a construction site. The wet concrete is placed in a steel cone form and placed on a non-absorbent surface, with the wider portion of the cone being down. The steel cone form is then lifted off, allowing the wet concrete to slump down a bit, depending on the mix design. A dry mix may only slump 1 to 2. Normally specified slump is around 4. Slumps of 6 to 7 can be achieved through the use of high range water reducing agents (super-plasticizers). Special mixes for pumping concrete tend to have high slumps.

Another important test for concrete is the cylinder compression test. Concrete strength is generally called its 28 day compressive strength. Why 28 days? What is magic about 28 days? Nothing. The 28 day period for testing the compressive strength of concrete is an arbitrary time selected to give consistency to the testing procedures. Thus, the 28 day compressive strength of concrete has become the standard in the industry. So when 4,000 psi concrete is specified for a concrete beam, this means that the actual placed concrete should have a compression strength above 4,000 psi after 28 days. Since the strength of concrete continues to increase over time, a standard time period for concrete strength measurement is necessary. The concrete cylinders that are made to determine the 28 day strength can also be broken earlier and provide useful information. Cylinders are commonly broken at 7 days, which normally have developed about 75% of the 28 day strength. Its nice to know 3 weeks earlier if there is a problem with a concrete batch. Breaking cylinders at 3 days can also yield useful data. If a supported slab has been placed, the 3 day concrete breaks can be used to determine if stripping or the forms and form supports will be safe. So concrete cylinder breaks provide a number of useful bits of information. The basics of making the cylinders should be understood by the Construction Supervisor. When the wet concrete is being placed, cylinders 6 in diameter and 12 high are filled with concrete and carefully consolidated, (see Making Concrete Cylinders for Testing). These cylinders then cure, hopefully in conditions similar to the curing conditions for the main concrete pour. The concrete cylinders harden in a few hours and are stored for future testing.

That testing consists of placing the cylinder in a machine that presses on the cylinder top and bottom, adding axial force until the cylinder crushes. The amount of force required to crush the cylinder becomes the compressive strength for that cylinder. For a concrete sample that is broken after 28 days The cylinder is 6 diameter, so it has an area of 3.14 x Diameter squared /4 A = 3.14 x 6 x 6/4 A = 28.26 square inches If the force required to break the cylinder was 97,500 pounds Then the compressive strength is 97,500 pounds / 28.26 square inches = 3,450 psi The Construction Supervisor also needs to pay attention to the care and storage of the concrete test cylinders between the time they are made and broken. A few years ago, during the construction of an addition to a sewage pumping station building, the Construction Supervisor stored the concrete test cylinders inside the pumping station for protection from harsh weather. When the cylinders were broken at 28 days, the supposedly 4,000 psi concrete was achieving only 2,500 psi of compressive strength. Talk immediately began about tearing out the new concrete walls and the finger pointing for responsibility started. A core boring was taken from the wall and the concrete tested well above the 4,000 psi requirement.

So what happened? It seems no one considered what a constantly vibrating pump room floor would do to the setting process of the concrete. The moral of the story is that concrete test cylinders cause enough problems on a project that the Construction Supervisor should have a clear, agreed upon plan for their making, storing, breaking and reporting. Construction Knowledge.net