CONCRETE OF YESTERDAY,
TODAY AND TOMORROW
By Dr. A K Chatterjee,Whole-time
Director,ACC Limited
INTRODUCTION
From the ancient relicts
it appears that lime mortars and pozzolanic concretes have been in the
service of mankind for at least a few thousand years. However, after the
invention of Portland cement in 1824, there was the appearance of modern
concrete that extended the range of technically achievable goals. For most
of the second half of the 19th century, the use of concrete was by and
large governed by the individual skill, experience and innovativeness of
the architects and builders. The lack of any effort to organise the knowledge
gained through experience and research resulted in the concetration of
the know-how in a few hands, widespread failures, inefficient and uneconomical
use of the materials. However, at the beginning of this century, in the
aftermath of industrial revolution, there was a boom in construction activities
which led to an increased attention to concrete technology and improved
application practices. This was a direct outcome of the public perception
of high risk to the life and property involved in the large-scale construction
projects using this material and technology. Consequently, at the beginning
of this century, both in Europe as well as in the United States, considerable
efforts were made to organise the available knowledge on structural engineering
and concrete technology so as to regulate the growth of construction activities
towards human safety and durability.
As a result of these
efforts concrete turned out to be the most widely used man-made product.
It is second only to water as the world's most heavily consumed substance.
During the 20th century there has been phenomenal growth of the Portland
Cement Concrete Industry. The world wide annual consumption of concrete
today is approximately eight billion tonnes and due to increasing urbanisation,
it is expected to grow steadily during the coming century. However, a general
concern for lack of durability is perceived as the prime threat to the
future of concrete. The visible deterioration of concrete structures and
the need of repair and rehabilitation are progressively compelling us to
take the durability of concrete more seriously now than ever before. There
is a growing interest in building more durable structure with extended
service life because of rising costs of repair and rehabilitation.
The present article
is aimed at culling out a comparative scenario of concrete that was made
in the past, what is made now and what would be made in near future.
CONCRETE OF THE PAST
The archeological remnants
indicate that the use of building materials from a clay-based mixture was
established in the bronze age (about 3000 BC). The same age is also taken
as the period when the use of air-hardening lime started. This obviously
was linked with the discovery of fire and chanced calcination of limestone
in fire rooms. It appears from the excavations of Mohenjo-daro and Harappa
in the Indian subcontinent that the art of brickmaking and properties of
lime mortars were also known to the Indians at that era. More or else around
the same time (2500 BC), as the researches on the Pyramid of Cheops revealed,
the Egyptians discovered gypsum as a binder. It is believed that the Phoenicians
systematised the practice of mortar preparation with burnt lime and volcanic
ash. From the Phoenicians the use of lime was transmitted to the Greeks,
Romans and other civilisations down to modern times. A sample of concrete
(based on calcined limestone, volcanic ash etc. of Greek and Roman invention),
which had been underwater in the harbour of Puzzuoli (Italy) over 2000
years, had been physically retrieved and studied. The concrete walls of
the cistern at Kameiros on the Greek Island of Rhodes, built about 500
BC show that this type of material can last at least 2500 years.
There is a controversial
theory that the Pyramid rocks were then cast in wooden moulds in their
final location. Using a variation of what we call match casting, one or
more sides of the blocks were cast directly, against neighbouring blocks
producing the perfect fit as close as 1/500th of an inch. How else could
massive blocks weighing as much as 30 tonnes be built at thirty stories
height, involving placement of two and half million blocks in a span of
20 years reign of the Pharaoh Cheops ? To-day, even the head of the Sphinx
is suspected to be made of ancient concrete.
It is interesting to
note that "concrete" or "opus caementium" had been elaborately documented
by Vitruvius, a first century BC Roman architect and engineer. Classification
of volcanic ashes suitable for the preparation of lime mortars, mix ratios
required for walls, plasters and other applications, procedures for making
mortars and concrete, etc. had been reportedly covered in those documents.
From those records and from the relicts of Roman aqueducts, it is evident
that the lime-pozzolana concrete making in the period from the 19th to
2nd centuries BC had reached a high level of perfection.
Many observers of ancient
architecture are struck by the vast difference in quality between original
structures and more recent repairs. Modern restoration of the sphinx done
between the last ten and fifty years is already damaged, while repairs
made a few centuries ago with gypsum mortar prevented damage by causing
a protective crust on the surface. Similarly within the last half a century
the concrete blocks used for the restorations on the Step Pyramid at Saqqara
have already cracked. All these observations raise a basic question was
the ancient concrete more durable ? If so, why ?
CONCRETE IN TRANSITION
With the fall of the
Western Roman empire, the building materials technology suffered a setback
with decadence of constructions. While lime and lime pozzolana binders
continued to retain their practical importance, at the end of the 18th
century there was much activity in Europe to discover an inorganic binder
of improved properties. All these activities culminated in Joseph Aspdin
inventing Portland cement in 1824 and I C Johnson on perfecting the production
technology and hardware for Portland cement in 1847.
The rebirth of to-day's
concrete dates back to these inventions and innovations. Subsequently in
1880 Hennebique introduced the concept of reinforced concrete building.
Since then structural portland cement concrete has been routinely produced.
Its use gained momentum at the turn of the last century and increased sharply
after the World War.
CONCRETE MAKING
AS SEEN TODAY
Typical Portland cement
concretes have volume fractions of aggregate that range approximately from
0.7 to 0.8. The remaining volume is occupied initially by a matrix of fresh
cement paste consisting of water, cement air voids and often admixtures.
While the aggregates occupy most of the volume, they are relatively inert
and intended to be stable. It is the cement paste matrix that undergoes
the remarkable transformation from nearly fluid paste to rock-hard solid,
transforms plastic concrete into an apparent monolith, and controls many
important engineering properties of hardened concretes Successful use,
therefore depends on understanding the nature of concrete. The steps to
obtain concrete performance are conceptually illustrated in Fig 1. The
process starts with a mix design and specification developed for a particular
application. It is followed by selection and acquisition of constituent
materials and processing of these materials in accordance with the specifications.
Presumably if the design, selection and implementation steps are properly
conducted, the concrete properties and performance will meet job requirements.
However, it is nalve to assume that the steps to obtaining properties and
performance can be achieved without accommodating variations. But the question
remains as to what level of variations can be accepted without any detrimental
impact on programme.
Mix Designs
and --> Specification
|
Constituent
Materials (Cement,-->
Min, AdmixAgg:
Chem Admix Water)
|
|
V
|
Processing
(Batching,
Mixing,-->
Transporting,
Placing,
Finishing,Curing)
|
Concrete properties-->
(Rheological,
Mechanical,
chemical)
|
|
|
|
V |
Concrete
to
Performance
(Construct-
ibility,
Strength Durability)
|
|
Evalution
(Sampling,
Testing,Reporting) |
|
Evalution Sampling,
Testing,
Reporting) |
|
Fig.
1. Consistency of concrete properties as related to its production process
Further, with improvements
in concrete technology, concrete has become more versatile, but also more
complex in that the number of mix constituents has increased. It is rare
to encounter concrete that consists only of cement, fine aggregates, coarse
aggregates and water. Today most mixes also contain chemical or mineral
admixtures or both. To minimise the variability of concrete, it is necessary
to maintain the uniformity of constituent materials.
Present Status of
Concrete Quality
It is a common knowledge
that the normal concrete with compressive strength ranging from 20 to 40
MPa is adequate for most structural applications. The tensile and flexural
strengths of such concrete are relatively low and, therefore, the material
tends to crack easily under tensile stress. A concrete with a few visible
cracks shall continue to perform satisfactorily under compressive loading,
however; if the cracks are interlinked with the micro cracks, the susceptibility
of concrete to water penetration and deterioration is greatly increased.
The use of high strength
concrete (HSC) (more than, say 60 MPa) during the recent past has proved
to be advantageous. It has enabled the construction industry to design
taller, longer, slimmer and lighter structures. One major disadvantage
of HSC is that the material is more brittle than normal concrete and there
is no load-carrying capacity beyond ultimate stress. Therefore, while using
HSC in structural members, it is essential to provide ductility in the
members by some means. Thus, the use of HSC, per se, did not offer any
significant relief to the issue of non-durability of concrete.
Notwithstanding this
shortcoming of HSC, the strength property of concrete has been continuously
improved. In reality the concrete strength has increased almost four times
in the last two decades from about 30-40 MPa to 130-140 MPa. In fact, ultrahigh
strengths exceeding 300 MPa have been achieved in the laboratory. However
from the point of view of long-term durability of structures, what is more
important is the impermeability of concrete and not strength alone. This
consideration has led to the development of High Performance Concrete (HPC),-
the concrete of tomorrow.
REQUIREMENTS AND PROPERTIES
OF HPC-THE FUTURISTIC MATERIAL
HPC has been defined
as concrete with improved constructability, improved durability and improved
mechanical properties. Compared with conventional concrete, HPC meets one
or more of these requirements :
-
Places and compacts easier
-
Achieves high strengths
at early ages
-
Exhibits superior long term
mechanical properties such as strength, resistance to abrasion or impact
loading, and lowpermeability.
-
Exhibits volume stability
and thus deforms less or cracks less
-
Lasts longer when subjected
to chemical attack, freezing and thawing, at higher temperatures.
-
¨Demonstrates enhanced
durability
These properties cannot
be achieved routinely with traditional constituent materials and normal
mixing, placing and curing methods. Thus new materials, new equipment and
new construction methods are often needed, along with training programmes
to help ensure desired results.
By and large the following
table shows the difference in properties between normal and high performance
concretes :
Properties |
Normal Concrete |
HPC |
Compressive strength,
MPa |
30-45 |
100-300 |
Modulus of Elasticity,
GPa |
25-30 |
50-85 |
Fracture Energy J/m2 |
80-120 |
1000-3000 |
Diffusivity,m2/s |
5*10-11
-1*10-11 |
5*10-13
-1*10-13 |
| Period of strength Development(Days) |
7-10 |
2-4 |
Barrier to Proliferation
of High Performance Concrete
The most critical barrier
preventing the rapid introduction of high-performance concrete to the market
is the lack of enabling technologies to support cost-effective commercial-scale
production. It is felt that the enabling technologies should directly support
the following classes of potential commercial applications :
-
Construction with low maintenance
needs
-
Construction enabling rapid
progress to completion
-
Earthquake resistant construction
-
Infrastructure repair, retrofit
and renovation
In addition to technical
barriers, the construction industry presents unique institutional barrier
to the introduction of new technology.
Fragmentation of the
industry and a conservative user community have made liability issues a
barrier. High technical risks further add to the rise of liability in construction
projects. The accelerated development of building codes is essential since
there are limitations with the use of existing design methods for high
performance concrete construction. Incidentally, some beginning has been
made in our country with the introduction of the revised code IS 456-2000,
which has now quite a few provisions that would go a long way in producing
HPC.
Driving Forces for
High-Performance Concrete
Advances in the Materials
Science and processing of cement-based materials in the past two decades
have set the stage for production of a new generation of HPC. These developments
are centered around micro structural engineering, composition modification,
controlled or reduced porosity and transport, control of rheology, fibre
reinforcement for energy absorption, control of setting and strength development,
and heat release. Some examples are provided below:
* Innovative Materials
Systems and Processing Technologies
-
Chemical and mineral
admixtures
-
Corrosion-resistant
steel reinforcement systems
-
Fibre reinforcement
including carbon fibres
-
DSP, MDF and Reactive
Power Concrete
-
Recycling of concrete
materials
* Innovative Structural
Design Concepts and Methodologies
-
Integrated design
methodologies (to establish limit states of design)
-
HPC structural elements
and systems
-
Strengthening and
retrofitting of structures
-
Fire resistance
* Commercially
upscalable Cost-Effective Construction Systems
-
Extrusion technology
for fibre reinforced cement-matrix composites
-
Microwave curing technology
-
Rapid forming technology
-
Rapid mixing, placing
and curing facilities
-
Autoclaved and aerated
products
-
Rapid repair and renovation
of underground pipes
* Performance
Prediction and Monitoring Technologies
-
Measurement, recording
and analysis of fracture and fracture growth in the submicron
range(interferometers)
-
Embedded network of
fibre optic sensor
-
Computational models
for microstructural engineering and service life prediction
The challenge for
high-performance construction materials and systems is translating this
knowledge to our infrastructure that will be characterised by :
-
Superior strength, toughness
and ductility
-
Enhanced durability/service
life
-
Increased resistance to
abrasion, corrosion, chemicals and fatigue
-
Initial and life-cycle cost
efficiencies
-
Improved response to natural
disasters and fire
-
Aesthetics and environmental
compatibility
NEW TRENDS IN MATERIALS
AND PROCESSES
The significant improvements
in concrete construction and its performance in recent times would not
have been possible without the use of mineral and chemical admixtures in
concrete. While the use of mineral admixtures such as fly ash, blast furnace
slag, silica fume, etc. has proved to be eco-friendly and cost-effective
and has led to the improved durability performance of concrete, the use
of chemical admixtures has also been beneficial, in that it enabled concrete
to be produced and placed in applications which would have been extremely
difficult otherwise.
There has been a rapid
rise in the consumption of chemical admixtures throughout the world during
the past two to three decades. In the UK, the proportion of concrete containing
chemical admixtures has increased from 10 percent to over 50 percent during
the past two decades and the trend in other developed countries would be
more or less on the similar lines.
Interesting developments
are occurring in the field of super-plasticisers, air-entraining agents,
anti wash-out admixtures and waterproofing materials. Some promising new
superplasticisers which can be independent of the addition procedure and
are able to maintain slump levels for at least 1-2 hours have been investigated
to replace the traditional products. Similarly, preformed bubble reservoirs
in the form of porous particles or hollow plastic microspheres of size
10 to 50 micron - have found to possess a potential to replace air entrainment
method to produce frost-resistant concrete. In Japan, anti wash-out admixtures,
water-soluble cellulose-type or polyacrylamide-type polymers have been
used for effective underwater placement of concrete, the need for which
is incidentally bound to grow in the future. Also in Japan, polymer-modified
paste or slurry with a very high polymer-cement ratio of 50 percent or
more is applied over million m2 of reinforced concrete substrate each year
as a liquid applied waterproofing membrane with thickness ranging between
2 to 4 mm. Recently, an interesting waterproofing material which solidifies
in water has been developed in Japan and it has a potential as a shock-absorbing,
waterproof, backfill material for tunnels and drains.
The performance of concrete
can be improved with the addition of fibres and polymers and a great deal
of work has already been done with some promising results in both these
areas. Fibre-reinforced concrete (FRC) is generally produced by adding
steel, polymer, glass and carbon fibres and such addition leads to improvements
in flexural strength, toughness and impact resistance. Recently, a strong
interest is evinced in carbon fibres. In addition a new generation of micro-fibres,
which can be used at higher addition rates to bring about major improvements
in the mechanical properties of FRC, is being developed. Slurry-infiltrated
fibre concrete (SIFCON) with micro-fibre contents upto 20 percent and compact
reinforced composites (CRC) having very high compressive and flexural strengths
are the promising developments in this area.
Polymers have already
made a considerable headway in the field of concrete and their use enhances
certain properties of concrete, mainly the tensile and flexural strengths,
chemical resistance, toughness, bond, impermeability, etc.
They are used in concrete
for varied purposes such as improved bonding, pore-sealing, reducing permeability
to water and aggressive chemicals, self-levelling, dust proofing and a
host of other functions. Currently, considerable interest is oriented towards
the use of polymer-modified mortar and concrete for repair and rehabilitation
of deteriorated concrete structures.
While the above-mentioned
advances in the sphere of cencrete technology have indeed been impressive
and immensely beneficial, an almost entirely new set of exotic materials
is now emerging. These new advances have occurred as a result of "manipulating
of microstructure and controlling the chemistry, or both, of cements" and
have led to the development of more advanced cement matrix composites,
with some materials crossing even the boundaries of the traditional cementitious
materials. These include, the materials formed by densification through
pressure and heat with properties approximating those of fired ceramics,
strong macrodefect-free (MDF) cements produced by special processing; materials
termed as DSP (densified systems containing homogeneously arranged, ultra
fine particles) which are ceramic-like materials formed as a result of
chemical reactions occurring at or near ambient temperatures and are known
as chemically bonded ceramics (CBC).
GOAL SETTING FOR HIGH
PERFORMANCE CONCRETE
Many natural disasters
including earthquakes have focussed attention on the fragility of any country's
built environment. Looking from another perspective, it has been realised
that the costs of an inadequate infrastructure are enormous. It is therefore,
felt that the HPC-related technologies are needed to achieve the following
technical goals for large-scale concrete constructed facilities :
-
100% increase in durability
(service life) with a commensurate reduction in maintenance costs.
-
50% reduction in time required
for construction
-
100 to 1000-fold increase
in energy-absorbing capacity without a compromise in strength or stability
for earthquake resistant structures.
-
50% increase in service
life of infrastructure after repair,retrofit and renovation
It is obvious that the actual
benefit from these goals will contribute substantially to the nation's
economy and to the quality of life of our people.
It is generally projected
that India would ultimately turn out to be the most populous country of
the world. It is also expected that a country like India would require
a strong infrastructural base, consisting of extensive roadways, railways,
ports, water sypply systems, power plants, sanitation facilities and drainage
network. It is often projected that an investment of the order of Rs. 80,000
crores may be necessary.
Further there is gross
shortage of over 20 million dwelling units and the existing infrastructure
is in a stage of disrepair.
With this kind of an
outlook for the potential of the construction industry, it is high time
that we look at upgrading the technological plane of this construction
industry. In this context the emerging world of high performance materials
and systems becomes relevant. The need to implement a research, development
and deployment programme to exploit the potential of high performance materials
and systems is evident and timely.
CONCLUSION
In the evolutionary
history of mankind, it is now believed that construction as a human activity
would have started almost ten thousand years ago but apparently the first
five thousand years saw only construction through juxtaposition of stoneblocks
without any binders. The history of cement relates to the subsequent five
thousand years, when clay, lime, gypsum and natural polymers were used
as binders. In this long history of cements, the story of Portland cement
and modern concrete does not span even two hundred years.
It is generally surprising
that the structures built 2500 years ago are still surviving but it is
not so surprising when seen scientifically to explain "why". It seems that
extensive use of pozzolanic materials, non-use of steel in the structures,
placement of thick structural members and adoption of very rigid QC measures
were the major factors contributing to the durability of ancient buildings.
With the advent of Portland cement and RCC, there has been a significant
shift in the mode and techniques of construction, leading to faster onset
of structural distress in a very extensive manner. Search for solutions
to these problems has now led us to realise that the design and placement
of concrete cannot rely on "strength'alone, instead the concept of "durability"
needs to be emphasized by producing more impermeable and easily constructable
concrete. Thus lately, high performance concrete has made its appearance
in the field of construction with promise of durability and service ability
of structures. Interestingly, the use of mineral and chemical admixtures
in HPC resembles similar approaches adopted in ancient concretes. Does
"science", like history, also repeat itself? |