Unique Concrete Technologies

By: Ron Vaughn, Northeast Solite Corporation

SOLITE®1

LEARNING OBJECTIVES

1 SCC (Self-Consolidating Concrete)

2 Flowable Fill (Controlled Low-Strength Material)

3 Cellular Concrete (Low Density Concrete)

4 Lightweight Concrete

5 Shotcrete

6 Pervious Concrete

7 ICF’s (Insulated Concrete Forms)

8 Tilt-up Concrete Structures

Attendees will learn about the eight (8)

unique concrete technologies that follow:

Topic Index:

1 SCC (Self-Consolidating Concrete)

2 Flowable Fill (Controlled Low-Strength Material)

3 Cellular Concrete (Low Density Concrete)

4 Lightweight Concrete

5 Shotcrete

6 Pervious Concrete

7 ICF’s (Insulated Concrete Forms)

8 Tilt-up Concrete Structures

1- SCC (Self-Consolidating Concrete)

• Highly flowable, yet stable concrete

• Fills formwork without the need for manual placement

• Consolidates around reinforcing without added vibration

RHEOLOGY:

The science of the deformation and flow

of materials.

SSelf-Consolidating Concrete T20

1. When the SCC flow reaches 20 inches

in diameter, indicated by a circle

marked on the slump flow board, the

stopwatch is stopped.

2. The time is reported to the nearest 0.1

seconds.

3. Typical values are 2-5 seconds with

higher values indicating greater

stability.

4. The T20 is determined during the

slump flow measurement. The

stopwatch is started when as the

Abram’s cone is first lifted.

20”

Slump Flow with T-20

SCC Test Methods – Slump Flow

1. A traditional Abram’s Cone (normal or inverted) is filled in one lift (no rodding or other

consolidation) with SCC, taking care to be sure the sample is well mixed and not

segregated in the sampling process.

2. The cone is then raised over 5 seconds to a height of 12 inches, allowing the fluid

concrete to flow onto the slump flow board.

3. The slump flow is the diameter of the resulting concrete “patty” obtained from the

average of measuring the greatest diameter and diameter perpendicular to this direction

4. The result is reported to the nearest half inch.

Guess

which

one was

made

using

SCC!

2- Flowable Fill

(Controlled Low Strength

Material)

Flowable fill may have strengths up to 1200 psi

Catagories:

Excavatable or Removable is up to 300 psi

Non-excavatable or non-removeabable is 300 psi to 1200 psi

Composition of Flowable FillFill

• Cementitious with: (Portland Cement, Fly

Ash and/or Slag)

• Sand

• Water

• Air (Usually 10 to 30%

Property Comparisons

Property CLSM Typical Concrete

Cast Density 75-115 pcf 150 pcf

28-day

compressive

strength

100 psi or less 3000 psi

Slump Flowable 3” - 5”

Voids Before Placement

Bulkheading required to contain flow

Placement Procedure

Placement Procedure

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3 - Cellular Concrete

(Low-Strength Fill)

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What is Cellular Concrete?

ACI Definition: Low-

Density Cellular

Concrete is a material

made with hydraulic

cement, water and

preformed-foam.

Recipes may include

fly ash, and admixture.

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Cellular Concrete

(Low-Strength Fill)

Benefits Benefits

A. Generally low in cost load reduction

B. Placed by Pump or Gravity

C. Lightweight

D. Durable and Noncorrosive

E. Permanent and Stable

F. High Slump (Self Leveling)

G. Provides100% Compaction in Fill Spaces

H. No Shrinkage

I. Range of Densities & Strengths

J. Freeze-Thaw Resistant

K. Insulating

L. Low Absorption & Permeability

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Cellular Concrete

Road Section

Structural Concrete Options

Classification and Density

• Normal Weight 150 PCF

• Normal Weight w/IC 144 PCF

• Modified Density 126 PCF

• Lightweight 113 PCF

• 100% Lightweight 90 PCF

4 - Lightweight Concrete

Rotary Kiln Making Lightweight

Aggregate

Lightweight Aggregate

Lightweight AggregateNormal Aggregates

Preconditioning of the

Lightweight Aggregate

• It is essential that the lightweight aggregate fines has sufficient absorbed moisture

• If it is not pre-wet, its beneficial results are reduced.

External CuringSprinkling, Wet Burlap, Ponding, Fogging

Curing 20mm

Penetration

Full SlabCuring

withLWAS

Internal CuringSaturated Lightweight Aggregate Sand

Lightweight Aggregate

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CURING

External CuringSprinkling, Wet Burlap, Ponding, Fogging

Curing 20mm

Penetration

Full Slab

Curing withLWAS

Internal CuringSaturated Lightweight Aggregate Sand

Lightweight Aggregate

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CURING

Seneca Indian Casino,

Niagara Falls, NY

Paul Brown Stadium

Cincinnati, OH

Projects with Lightweight

Concrete

Key Bridge

over Potomac

between VA

& DC

Brooklyn

Bridge

NYC

Governor Nice Bridge

Dahlgren, VA Rt. 301 across

the Potomac

Point of Rocks Bridge Maryland Rt. 15 across the Potomac

Additional Lightweight Projects

5 - Shotcrete

• The ACI definition of shotcrete follows: mortar or concrete pneumatically projected at high velocity onto a surface; also known as air-blown mortar, and gunned concrete.

• Shotcrete, dry-mix: shotcrete in which most of the mixing water is added at the nozzle.

• Shotcrete, wet-mix: shotcrete in which the ingredients, including water, are mixed before introduction into the delivery hose; accelator, if used, is normally added at the nozzle.

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Shotcrete Process

Materials used in the shotcrete process are generally the same as

those for conventional concrete. Shotcrete projects also call for the

same types of reinforcing as specified for conventional concrete.

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Some Applications:

Retaining Walls

Slope Protection

Bridge Retrofits

Unreinforced

Masonry

Structural Repairs

Overhead Repairs

Swimming Pools

Ponds

Water Features

Artificial Rocks

Shotcrete

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Shotcrete

ARTIFICAL ROCK – It is sculpted, colored, and stained

shotcrete that is made to simulate the appearance of real

rock. It is also called ”Faux Rock” and it can be used in many

applications.

Pervious concrete is a special type of concrete with high

porosity used for concrete flatwork applications that allows

water from precipitation and other sources to pass directly

through, thereby reducing the runoff from a site and allowing

groundwater recharge. This is also called porous concrete,

permeable concrete, no fines concrete, and porous pavement.

It is used in parking areas, residential streets, pedestrian

walkways, and greenhouses.

6-PERVIOUS PAVEMENT

Cross Section

The proper utilization of pervious concrete is a recognized Best

Management Practice by the US Environmental Protection

Agency(EPA) for providing first flush pollution control and storm

water management. It contributes to Storm Water Control and

Purification through the Use of Higher Strength Pervious Concrete

and Bio-remediation when using Absorbent Lightweight Aggregate

as the base layer. It also reduces the need for separate storm

water retention ponds and allows the use of smaller capacity

storm sewers.

Pervious Concrete

Pervious & Infiltration Systems

View Stormwater as a Resource

•Slow down the flow, allow to

infiltrate

•Manage stormwater on-site

•Reduces pollutant loads to

waterbodies

The Edison Environmental Center

in NJ and the Science Museum

(National Fish & Wildlife) in VA

projects show that infiltration and

pervious are a good combination to

better handle and purify storm

water. Science Museum, VA

Establishment of Infiltration and

Pervious Concrete System

Using Expanded Shale Lightweight

Aggregate Sand (LWAS) to Provide

Higher Flexural and Compressive

Strength to Pervious Concrete

Highway Shoulders and Parking

Areas Through the Improved

Hydration of the Cementitious

Material, and Through the Improved

Bio-remediation of the Porous

Aggregate

Pervious Pavement

w/ESA Base

Infiltration

The use of LWA as the stone

reservoir below the pervious

pavement increases the void

content and water handling

capacities for the storm water in

the system. It provides superior

filtering, reservoir capacity,

nitrogen removal and p-sorption.

Using LWA® decreases the depth

of the layer that is required with

normal weight aggregates. Bio

agents are harbored in the LWA

pores and do not wash out

completely in rain events.

Trench along pavement edge

V-Trench

Stone filled trench

Pervious Concrete with Infiltration

Pervious

Concrete

Placement

6”

Pervious

Slab

Pervious Concrete with Internal Curing

Internal Curing Can Replace 6 mil Poly for Curing

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7-ICF’s (Insulated Concrete Forms)

Insulating concrete forms are hollow blocks or panels made of

expanded polystyrene insulation (EPS) or other insulating foam that

construction crews stack to form the shape of the walls of a building.

The workers then fill the center with reinforced concrete to create the

structure.

ICF construction sandwiches a heavy, high strength concrete between

two layers of a light and highly insulated form. This combination

creates a wall with many desirable properties: air tightness, strength,

sound attenuation, insulation, and mass.

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ICF’s

Insulated Concrete Forms are

revolutionizing modern construction and

rapidly changing the way we build

structures. Cost effective, sustainable

and environmentally friendly, ICF

construction is a superior way to build.

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ICF’s

ICF’s make stronger, quieter,

healthier, and more efficient

buildings. They reduce

construction time and labor

costs., offer cost savings, provide

superior comfort, protect the

environment, and ensures

maximum safety. About 1/6 of the

sound gets through an ICF wall

compared to an ordinary framed

wall. Their superior insulation, air

tightness, and mass can reduce

the operating cost of HVAC by up

to 40%.

8-Tilt-up Concrete Structures

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Tilt-up construction is ready-mixed concrete placed in

horizontal forms at the construction site and then tilted up to

form walls. Panels are cast as near to the final position as

possible. The most convenient casting base is most often the

concrete floor slab of the building. The wall panels are cast on

the base concrete , cured, and then tilted into a vertical

position and moved into place with a crane.

MGM Disney World

Orlando, FL

Tilt-up Warehouse

York, PA

Tilt-up

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Tilt-up construction is most frequently used for one story

commercial buildings such as warehouses, office buildings,

or big box stores. However two, three, or four story are

becoming more common place.

Tilt-up can also be colored, textured, and shaped to meet

almost any architectural demand using techniques such as

form liners, pigments, brick facing, curved surfaces, and

exposed aggregate

Questions

• Expanded Shale Aggregate is manufactured in a _______ _______ .

• Answer:___________

• Structural Concrete make with expanded shale lightweight coarse aggregate and natural sand will have an approximate air dry density of:_____PCF

Answers

• Expanded Shale Aggregate is manufactured in a Rotary Kiln .

• Answer: Rotary Kiln

• Structural Concrete make with expanded shale lightweight coarse aggregate & natural sand will have an approximate air dry density of: 113 PCF

• Answer: 113

Questions

• Tests used with Self-Consolidating Concrete include which of the following:

• A) Slump Flow B) T-20 C) Both

• Answer: ___________

• Preconditioning of the lightweight aggregate with sufficient absorbed moisture is essential?

True______False______

Questions

• Tests used with Self-Consolidating Concrete include which of the following:

• A) Slump Flow B) T-20 C) Both

• Answer: C) Both

• Preconditioning of the lightweight aggregate with sufficient absorbed moisture is essential for Internal Curing?

True___X___False______

Questions