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PERFORMANCE CONCRETE
KALMATRON CORPORATION
276 Michelle Court,
South San Francisco, CA 94080 USA
Phone: +1 (415) 385-3290
website: www.kalmatron.com
e-mail: KalmatronWorld@aol.com
Fax: (650_872-2555
Alexander V. Rusinoff Kalmatron for High Performance Concrete Page 1 2004
This concrete is applicable with RHEOLOGICAL ADVANTAGES OF CONCRETE WITH KALMATRON KF-A
shotcrete providing high adhesion and Reduces shrinkage, 200300 micro-strains is a typical result. Just no cracks
waterproofing advantages. Increases compressive strength by 20 to 35%
Exothermic heat is lower 30% to 50%
No flakes, efflorescence, dusty spots, or slid areas
Water impermeability is 100% starting at 50 mm or 2 concrete thickness
Highest resistance to chemical and climate corrosions
Increases frost-resistance up to 35%
Tensile Resistance is higher up to 40%
Contains approximately 3% macro and 97% micro pores
A concrete mix contains a lot of structurally useful minerals, which are not used at all since the active agent is water
only. Water is not active enough to involve them in hydration and hardening processes. KALMATRON
KF-A admixture provides agitation of cementitious mixes in chain reactions. The gradated solubility of
KALMATRON KF-A components sets up a sequence from first reaction to fourth, if the initial dosage of water is
reduced enough and mixing done completely. Otherwise, as practice shows, the whole chain of reactions will be
delayed by 30 days. But the final performance of this product will be the same as described below.
1. Dissolution of cement grain by speeded hydration. The stage when standard hydration speed increases due to
weakening of molecular tensions of water with electrolytes formed by KF-A. The standard reactive bawl of a
concrete batch has some potential energy which should be spent on hydration and structure formation. With KF-A
part of this energy goes to the electrochemical decay of cement grains and after that on to hydration itself. The
results of this reaction are:
The chemical heat of hydration is lower. The tensional heat of water absorption subsides proportionally as the
area of the cement gel surface increases. That means much lower exothermic reaction heat.
Prolonged equalization of solution concentrations during the mixing and transportation of the concrete mix give
the best compaction, which results in low slump with high workability.
Also, this retards the shrinkage dynamic in the first 60 days.
Provides natural increase in structural strength by enhanced compaction.
Similarity to known: This type of reaction may be recognizable in the application of salts with some plasticizer.
On the first 28 days it gives a huge increase in strength. But the consequences of such an application after 45 days
are recognizable also since concrete gets dusty, cracked, and fragile because the ion-kation exchange is out of
control. It means that concentrations of inter porous solutions are really high with immediate ability for self-
crystallization before the concrete hardening process begins. That creates opposing tensions in the concrete body.
Early crystallization means aging of concrete before maturing.
2. Oxidation of metal containing elements. Involvement of negatively charged artificial minerals provides magnetic
reorientation of water dipole molecules and particles of cement grain. Weakening of their relations by reorientation
causes ordered rotation with considerable freedom to be involved in the hydration reaction with a greater amount of
cement particles. Thats why KF-A has higher effectiveness with lower quality cements. This reaction results in:
Similarity to known: Actually, this reaction is similar to the function of magnetized water. The distinguishing part is
that the KALMATRON KF-A admixture provides a more stable residual polarizing effect. The followers of
KALMATRON KF-A created an admixture which only functions like this with well-ground magnetic materials. Test
results are not stable and have never been applied in the field because natural concrete magnetic conductivity is
random enough.
3. Colloidation of free molecules of water the thickening of water by solutions with high concentrations. Since
most cement grains are hydrated and the inter porous liquid-vapor part is represented by natural mineralogical
cementitious solutions, then:
Numerous mineralogical sediments become natural centers of cementitious solutions and densify until
crystallization. Solutions with lower concentrations stay diffuse to the close of the colloid phase in accordance with
gradated concentrations. The speed of colloidation is slow and the whole process may take decades.
Alexander V. Rusinoff Kalmatron for High Performance Concrete Page 3 2004
Similarity to known: This reaction is recognizable in natural hardening. The difference is that the KF-A admixture
provides structural formation by hardening much faster and relatively more simultaneously from surface to depth.
4. Stabilization of the gel of the cement paste. Obviously, this is a result of naturally growing viscosity of
solutions in cement paste. The approximate time of this process is from 7 hours to fourteen months, which is much
longer than for conventional cement paste. The longer term of the gel phases presence in the concrete body
results in:
Growth of micro-structural density;
Dynamic growth of liquid impermeability;
Increase of crystalline containing part by natural drying of cement gel;
Stable and predictable growth dynamic of compressive strength;
Dominant type of continuous porous system up to 97%;
Lower pore suction ability, below 5%, with reduced superficial tensions of saturation;
Creep of concrete is stable and indicative after 91 days.
Modern admixtures and supplementary materials for the concrete mix are dedicated to improving applicability and
concrete rheology. Hydration of cement relies on the amount of water and mixing time only. Relative to cement
hydration, all this amount of water and admixtures work as thickeners or thinners of the water-cement solution,
which creates concrete structure independently from compaction of aggregates within the cement dough.
No enhancing chemical reactions occur with the hydration of cement grains in this case.
It is known that unhydrated cement grains present a major problem in new concrete structures (Fig. 2). Even the
final product of the cement clinker has a lot of foreign inclusions in the frame of the cement structure. During
hydration of Portland cement, approximately 25% to 30% of the hydration products form calcium hydroxide, which
is also known as free lime. This has no cementitious value by itself. It is soluble in water and is the cause of the
powerful conduction of liquids through the concrete body. However, 30% of cement in a concrete mix becomes not
only useless, but also harmful for the durability of the concrete structure.
Concrete mix with KF-A needs 10% to 30% less water than the
standard concrete mix design. Nevertheless, workability is even
better with lower slump. KALMATRON KF-A hydrates almost all of
Figure 4. Shotcrete Technologies Inc. did an
the cement grains, which effectively produces good workability at a
emergency repair project for the CO D.O.T. on
I-70 with KALMATRON KF-A. The shotcrete lower slump of only 2 3 (65mm90mm). The entire reduced
was applied with slump 2 or 64 mm, the amount of water is used to hydrate all of the cement grains, leading to
temperature of concrete mix in the hopper was complete compaction of concrete structure. There is no extra water
lower than outside temperature by 8 F or added to provide workability and there is no bleed water because all
4.5C. of the water is effectively utilized.
Alexander V. Rusinoff Kalmatron for High Performance Concrete Page 5 2004
Workability can be defined as the amount of useful internal work necessary to produce
full compaction (of concrete mix) [1]. The test, known as the compacting factor test, was
developed at the Road Research Laboratory and is described in BS 1881: Part 2: 1970
and ACI Standard 211.3-75. Therefore, the Workability Test lets us recognize the
Slump 2
suitability of the present concrete mix for a particular job, but the Slump Test can only
show the complete list of ingredients for the targeted concrete mix design. There are two
main distinctive groups for slump recognition
MEDIUM SLUMP The application of the same standard concrete mix with medium slump
2 to 4 (50-100 mm) needs less labor time for vibration and flattening because the Slump 3
workability is really good. But it needs more cement and fine aggregates and takes time to
get full slump, which causes insufficient volumes for casting, additional concrete batches,
and another extension of labor time for targeted filling of mold and curing to avoid heating,
shrinkage, bubbling, cracking, etc. as prescribed for the standard concrete mix.
Field of application: roads vibrated by hand-operated machines; mass concrete
foundations; vibrated reinforced concrete slabs, beams etc.
1. Low slump for one step technology of application (precast, stucco, etc.)
2. Workability with stable viscosity of concrete mix until hardening will begin.
th th
3. Early strength that matches targeted compressive strength appears on 7 to 10 day.
4. Liquid impermeability in 24 hours and growth during another 90 days.
5. Slowly growing flexibility during the first 45 days.
Concrete specimens with The most widely known way to improve concrete quality is
Silica Fume increasing the cement content or applying fine-grained
cement in an attempt to achieve a higher volume of cement
gel. Increasing the cementitious volume of cement paste
with KALMATRON KF-A results in some specific
performances of the concrete mix.
It can also be regarded as a measure of a materials homogeneity [1]. Obviously, the bigger the volume of the
cementitious paste, the higher the homogeneity of the concrete batch. Cementitious paste has the highest electric
conductivity and contains moisture longer than other concrete ingredients. In a post maturing concrete age, the gel
and liquid phases are responsible for concrete resistance to industrial and climate corrosions.
The present test demonstrates that KALMATRON KF-A is a concrete class-upgrading admixture for conventional
and High Performance Concrete that was proven in numerous practical applications.
Alexander V. Rusinoff Kalmatron for High Performance Concrete Page 7 2004
Pore blockers are very popular and people use this term for concrete impermeability. But the problem with concrete
is that it is not a homogeneous material and to add something else into its body means to multiply those problems.
Some product applied on or mixed with concrete has the ability to clog pores by growing into them like foreign
crystals. Nobody knows about the speed and volume of crystallization of those crystals and what the rheology of
these crystals is and how it will work for linear extension under cycling hydro-thermal conditions. The thickness and
mass of the concrete structure are crucial factors for a foreign pore blocker.
ri 2U Cos 2UCos rI
h = d r = Ln 0;
(2)
ro r g g ro
which simply and encouragingly shows that minimizing the difference between the radii of capillaries in the center
and at the surface of the concrete structure (dominantly continuous porosity) increases water impermeability.
The maturing concrete mix develops a capillary-porous system during cement hydration and gel hardening.
Actually, these voids are trace-ways of gas-bubbles from the exothermic reaction of cement hydration. The longer
the time of hardening, the longer it takes a bubble to escape from inside the cement dough up to the surface. That
is why slump and shrinkage are so high there. Of course the diameter of capillary-porous voids will be bigger when
the exothermic reaction is longer. This is one of the reasons why retardation of concrete hardening causes
structures to crumble and have low resistance to liquid permeability.
The same results occur with fast hardening and high speed
strengthening concretes, where bubbles are captured in the
cement paste and create inter structural tensions that are generally
directed from inside to outside of the concrete body. Further
development of tensions causes an increase of micro cracks, with
consequent reduction of compressive strength. Resistance to liquid
permeability is unstable, resulting in unpredictable and abrupt
leakage.
The pressure of inter porous gases might be as low as possible, as described by equation (3), which is integrated
by three independent functions n, V, and t.
Rtn ni VI tI
2 2 2 2
P = = - R ndn dV/V tdt = 0.5R (n o - n i ) (t i - t i ) Ln [VI / Vo ], (3)
V no Vo to
Wherein:
no; nI number of cement grains at the beginning and after hydration, respectively; since nI <<no the integral will
get a negative sign and finally no 0;
Vo; VI volume of cement gel produced from cement grains at the beginning and after hydration;
tI; to - final and initial temperatures of exothermic reaction, respectively;
R Gas Constant;
______
2 2
= t i - t I entropy of cement hardening, where the volume of cement gel has been represented by equation (4):
R
2
R 0.5 n o
2 P
Ln VI = 0.5 n o ; or : VI = e ; (4)
P
i.e., the volume of cement gel has an exponential relationship with the complex of straightly and inversely related
parameters. This is the answer to how to increase the volume of cementitious paste. Since the number of cement
grains no and the entropy of cement hardening are constants in equation (4), we have to reduce the inter
porous pressure of exothermic gases P. KALMATRON KF-A was developed for this.
Further integration of equation (4) will show a factorial growth of no! which in thermodynamic terms means that
active surfaces increase during the decay-hydration process. But it will not affect previously accomplished
processes.
Hydrothermical and barometrical balance between outside humidity and moisture in the concrete subsurface is the
best hydroseal, as it works in natural rock. In regular concrete, the free molecules of water are involved in
hydrothermical and barometrical migrations in the capillary-porous system of concrete and passively depend on
outside changes. Because of this, even the sorption ability has a slowly growing dynamic through time.
During the hydration of cement gases are produced, and as the gases are released they create pores that mark
their passage through the still plastic concrete. In normal Portland cement the gas produced is carbon dioxide; this
gas must build up a bubble of a certain critical mass before it is able to rise to the surface. As a result, the pores
formed are large and are known as macro pores. The exothermic reaction provides enough heat for macro pores to
be produced and may even be dominant in the porosity forming process.
In concrete containing KF-A and the same cement the gas produced is
Acetylene (15) and it is released as soon as it is formed. The result is that the
gas bubble is very much smaller and so is the resulting pore diameter, hence
the pores are known as micro pores. Due to lower exothermic heat, the
process of pore formation goes much slower. The smaller pore diameter
means higher gas/vapor inter porous pressure, which prevents water from
penetrating the concrete.
According to research [2] of core temperatures for a hardening concrete mix, KALMATRON KF-A provides a
noticeably lower concrete core temperature of cement hydration in concrete mix. The conclusion is based on a
reduction of exothermic temperature in the concrete mix with KF-A shown in Fig. 9.
th
At 1000 minute we can see the drop of tempe-
rature to 5.25C (41.9F) relative to the control
specimen. This is about 25% from the highest
exothermic peak. For the trial specimen itself the
readings range from 31.5C (88.7 F) to 27.75C
(81.95 F). For the control specimens these figu-
res range from 33C (92F) to 30.5C (86.9 F).
This is significant entropy for such a process as
the hydration of cement in a sampling volume.
The heat of hydration consists of the chemical heat of reactions and the heat of water absorption on the surface of the
cement gel formed during the hydration process. These processes are consequent. In the first hours of hydration
regular cements give high heat indication, up to 500 joules per gram (120 cal/g). The heat of absorption is
approximately 25% of the summary heat indication, which is relevant to the current measurements mentioned above.
With some delay, the heat of absorption will dominate until the final setting time. The delay is explained by the
difference between hydration and absorption speeds. The faster the speed of hydration the sooner the absorption
process starts. The bigger the volume of gel forming, the less free water is left for other processes and that is why the
heat of absorption is lower. The difference between the high heat energy of cement hydration and the low heat energy
of absorption is the entropy of concrete structure formation. Obviously, KALMATRON KF-A reduces entropy by
reducing hydration heat emission that equalizes both reactions speeds.
Free calcium oxide in cement forms calcium hydroxide when mixed with water (7). Calcium hydroxide then
takes part in exchange reactions with sodium nitrate and calcium carbonate and sulfate and with calcium
chloride to form low-soluble and hardly-soluble acicular crystals of hydroxonitrates Ca(OH)NO3 (9) that will
continue to grow well after the complete formation of the cement stone structure by using free pore water
and Ca ions released from the cement stone gel.
Alexander V. Rusinoff Kalmatron for High Performance Concrete Page 10 2004
These crystals have a micro-reinforcing effect on segregation within voids under the effects of temperature, shrinkage
and corrosion. Therefore, a primary structure reinforcement framework is formed within the concrete mix as early as
the setting stage. This framework is built up in the direction of mass transfer of a diffusion flow.
Adding metal oxide ions to compounds dissolved in water has a polarizing effect on dipolar water molecules to lower
the number of molecular bonds of water. Owing to weak bonds in the presence of calcium hydroxide, an alkali group is
released into the water to protect calcium against dissolution at the maturing stage:
Tricalciumalumochloride formed as a result of reaction (13) forms hardly soluble solid phases when water is released
for simultaneous hydration reactions. The alkali and the internal pore moisture form solutions inhibiting metal corrosion
that also have a low eutectic temperature of -126 F (-70 C) when the cement stone is in a stable phase stage.
At a stage when phases are unstable, owing to the weak bonds of water molecules that are depolarized with chlorine
ions and weak bonds of the reaction products (8), nitrate ions react, and the sequence of these reactions is determined
by their inherent chemical activity, the alkali levels of the solution, and the intermediate reaction product - calcium
aluminate - with which the following dissociation reaction is most likely:
This reaction yields a low-soluble double salt of calcium hydro-nitro-aluminate with an increase in pore fluid pH. The
stability of the reaction (16) is insured by an almost simultaneous reaction of sodium sulfate. The consumption of
starting components for another reaction (10) results in their shortage and in a one-way character of dissociation:
3Ca(OH)2 + 3Na2SO4 + 31H20 + Ca3(AlO3)2 3Ca0 Al2O3 CaSO431H2O + 6NaOH , yielding calcium hydrosulfoaluminate. (20)
Therefore, if such an electrolyte is added at a concentration that insures a change in solubility of mineral binders
without reacting with them, with a subsequent formation of hardly soluble complex compounds - calcium
hydrosulfoaluminate, calcium chloroaluminate and tricalcium chloroaluminate from the resulting solution, the overall
volume of the crystalline component of the structure increases all at once parallel with normal concrete cure.
The advantage of complex additives is explained by the fact that although the rate of formation of double salts is lower
than in the case of a single additive (which is due to the consumption of calcium aluminate of the liquid phase for
hydration), cement components can react at a lower reaction constant. Moreover, a protracted reaction allows the ion
force of free water (which later becomes the pore fluid) to become stronger so as to form saturated solutions from
additional double hydrate salts.
Calcium electrolytes containing calcium accelerate hydration and hardening of silicate phases of cement owing to a
higher probability of formation of three-dimensional germs of a new phase. These electrolytes also disperse the
products of hydration through dissociation with anion-kation groups:
+ -
Ca(OH)2 + Na2CO3 CaCO3 + 2Na + 2OH (21)
The above-described processes insure a high hardening rate and a fast rise of concrete strength. The use of KF-A
additive insures a better use of the potential of alite 3CaOSiO2C3S. Ions of electrolyte that are still in the liquid phase
are products of displacement. They form salvation shells at the boundaries of kation fields, thereby preventing free
calcium from leaving the structure-forming reactions. At the same time, nitrate ions accumulate in the free water
polarized with chlorine ions to form solutions of increasing ion strength. These solutions will, in turn, accelerate the
hydration of alite. The manifest relay-like character of these processes allows alite to develop to a greater extent into a
symmetrical three-dimensional conglomeration with isotropic properties.
+ -
Involved Na and SO also participate in exchange reactions
similar to (13). However, it should be noted that these
components used as herein disclosed decelerate dissociation
of ions because of accumulation of alkali in the aqueous
solution in the presence of calcium hydroxide. Silica Fume
This allows the group of belites 2CaOSiO2 (-C2S) that are
lagging in their development in comparison with alite to cause
an exponential increase in the group of calcites and silicates
that failed to be attached in previous hydration reactions.
Adding electrolytes results in the intensification of chemical reactions and a better solubility of cement clinker minerals
with water. They also accelerate the exchange reactions. The resulting products of hydrolysis and hydration, which are
Alexander V. Rusinoff Kalmatron for High Performance Concrete Page 12 2004
in the form of crystals and gel, actively coagulate. It should be noted that gel expands due to the absorption of a large
amount of water. This enhances adhesion of the aggregate of the mix and results in the clogging of pores and
compaction of the concrete stone.
It should be noted that the presence of lime-based elements in cement improves the isotropy of a concrete structure. It
is known that a scatter of test results is mainly associated with, and depends on, ambient temperature and mixing
water temperature. These temperatures affect the rate and completeness of the above-described reactions. Also, it
stabilizes the local temperature field of the mix during the lime based elements quenching. A stable quenching reaction
is insured by making a specific choice of particle size and moisture content of those elements and also of the
water/cement ratio. Therefore, the relay-like character of the reactions results in the rapid formation of a primary
framework of acicular crystals of calcium hydroxo-salts at the stage of concrete setting. This framework is overgrown
with lamellar crystals of calcium sulfoaluminate, calcium nitrochloroaluminate and calcium hydrosilicate. The formation
of hardly-soluble crystalline structures raises the density of the cement stone and acts like a micro-reinforcement.
These structures reduce the permeability of concrete and preserve its plastic properties.
Resistance of concrete to chemical corrosion depends on its liquid and gas conductivity and dynamic wetting ability.
Liquid-gas conductivity can be determined by evaluation of macro and micro pores, where a domination of micro pores
is preferable. The dominance of micro pores in the cement stone gel with diameters of 15 provides absolute liquid-
gas impermeability by high inter porous pressures of gases and vapors as the products of concrete batch hydrothermic
reactions.
HP CONCRETE AS IT IS
What happens if we pour some oil into the concrete batch? Obviously, slump
and workability will be great, and even the initial properties of concrete will
exceed expectations, but retardation of hydration will occur and the final
concrete structure will be fragile, or became fragile under cycling temperature/
moisture or chemical corrosion.
We can observe the same effect with other hydration retarders such as:
Super fine fillers (fly ash, sandy dust, volcanic dust, etc.). a). Trial and control (from left to right)
Soluble organic fillers (kaolin, lignite, etc.). specimens are after 90 days into 25%
Plasticizers based on organic soluble minerals. of sulfuric acid solution.
Premixed accelerators for hardening, which need much less time than
required for hydration.
Organic retarders of hardening which prevent hydration itself.
Any crystal growers based on fast blowing minerals.
On the pictures shown at right are the comparative tests results of traditionally
enhanced concrete mix designs with regular concrete mixes transformed to
High Performance Concrete by KALMATRON KF-A. Twice bigger looses of
aggregates are obvious with control specimens.
b).Control Quartzite concrete specimen
Most concrete features depend on the volume and speed of hydration of the
had weight loss of 2.5% after 90 days in
cement grain. High Performance Concrete must be designed with a maximum sewage tank.
of rheologically uniformed ingredients to allow the performance of natural
materials properties. The cementitious part should act like glue among natural
aggregates. KALMATRON KF-A is designed to enhance the natural
performance of cementitious paste, its volume and original properties.
KALMATRON KF-A was tested, specified, and applied for structures that
come in contact with aggressive media, such as ammonia, alkalis, sugar,
sulfates, chlorides, sea-water, and distillate petroleum products. Other fields of
successful application are sewage systems, zinc plants, uranium mines, food
processing plants, wineries, sea structures, airports, roads, etc.
c).Trial Quartzite concrete specimen
3
with premixed 7.5 Kg/m KF-A had
Controlled setting time, high compressive strength, absence of cracks, high
weight loss of 1.4% after 90 days in
tensile and flexural strength, impermeability, sulfate and alkali resistance, frost sewage tank.
resistance and low labor efforts for preparation and use --- those are the main
characteristics of the concrete mix with KALMATRONKF-A. Figure 14. a, b, c.
It is proven that KALMATRON KF-A as an admixture to concrete mix provides stable high-cementitious effects on
different stages of the forming concrete structure; it cant be identified otherwise than the performance of cured High
Performance Concrete.
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