SPECIAL

CONCRETES
LIGHT WEIGHT
CONCRETE
WHY LIGHT WEIGHT CONCRETE?

High self weight is one of the

disadvantages of conventional concrete.
Density of normal concrete is 2200 to
2600 kg/m3.
 ADVANTAGES
Density of concrete varies from 300 - 1850
kg/m3
Reduction of dead load
Important particularly in case of weak soil and tall
structures floors and walls can be made with light
weight concrete
Faster rate of construction
Lower haulage and handling cost
Lower thermal conductivity than conventional
concrete can be used in extreme climatic
conditions
 HOW TO MAKE?
By replacing normal aggregate by
cellular porous or light weight
aggregates- Light weight aggregate
concrete
By introducing gas or air bubbles in
mortar- Aerated concrete
By omitting sand fraction from
aggregate- No fines concrete
 CLASSIFICATION
Based on manufacture:
Light weight aggregate concrete.
Aerated concrete.
No fines concrete.
Based on purpose:
Structural light weight concrete.
Lighter than normal concrete
Strong enough to be used for structural purposes
(min strength 17 MPa)
Non load bearing light weight concrete.
Insulating concrete.
 Light Weight Aggregate Concrete

Light weight aggregates:

Natural aggregates:
Pumice
Diatomite
Volcaniccinders
Saw dust
Rice husk

Artificial aggregates:
Artificial
cinders
Foamed slag
Expanded shales and slates
Sintered fly ash
Thermocole beads
Light Weight Aggregate Concrete -
Properties

Density varies from 300 to 1900 kg/m3.

Strength varies from 0.3 to 40 N/mm2.
Cement content varies from 200 to 500
kg/m3.
Comparatively lesser workability.
Strength of LWC depends on:
Density of concrete.
Grading of aggregate.
w/c ratio.
Degree of compaction.
 Precautions
Light weight aggregates have high and
rapid water absorption quality.
Waterproofing of aggregate is done by
coating with bitumen or silicon
compounds.
Reinforcement used in light weight
aggregate concrete is prone to corrosion.
Reinforcement should be coated with
anti corrosive compound.
 AERATED CONCRETE
Also referred to as gas concrete/ foam
concrete/ cellular concrete.
Method: introducing air or gas into a
slurry of Portland cement and finely
crushed siliceous filler.
When mix sets and hardens uniform
cellular structure is formed.
Manufacture can be done in 3 ways.
Manufacture of Aerated Concrete

By formation of gas by chemical reaction

within the mass during liquid or plastic state.
By mixing preformed stable foam with the
slurry.
Using finely powdered metal (eg. Al powder)
with slurry - known as Gasification
Metal reacts with Calcium Hydroxide liberated
during hydration process to generate hydrogen
gas giving cellular structure
Used in large scale manufacture- curing done by
autoclaving.
Properties of Aerated
Concrete
Density varies from 300 to 800 kg/m3.
Thermal insulation.
Low density grades- for insulation
purposes.
Medium density grades for building
blocks, load bearing walls.
Higher density grades prefabricated
structural members with steel
reinforcement.
No Fines Concrete
Concrete consists of cement, coarse aggregate
(usually single sized) and water.
Fine aggregate fraction is omitted.
Density varies from 1600 to 1900 kg/m3 (with
normal aggr.); 360 kg/m3 (with light weight aggr.);
Strength depends on w/c ratio, agg/cement ratio
and unit wt. of concrete.
Made with aggregate-cement ratio from 6:1 to 10:1.
Coarse aggregate size: passing 20 mm and retained
on 10 mm.
Formwork can be removed faster
Workability by experienced visual examination
Advantages of No Fines Concrete

Architecturally attractive.
Mechanical compaction is not needed.
Less stripping time.
Lesser drying shrinkage than conventional
concrete.
Less paste content.
Point to point contact between aggregates.
Disadvantages:
Bond strength is very low- cannot be used
directly for reinforced concrete.
 HIGH DENSITY CONCRETE
Density varies from 3360 to 3840 kg/m3.
50% higher than unit wt. of conventional
concrete (2400 kg/m3 ).
Density of 5280 kg/m3 can be attained with
iron as FA and CA
Excellent shielding material- Used in nuclear
energy industry - construction of radiation
shields.
Aggregates with specific gravity greater than
3.5 is used- Magnetite, ilmenite, limonite,
hematite
 Heavy weight aggregate
Unit weight > 2100 kg/m3.
Bulk density of corresponding concrete > 3200
kg/m3
Examples : magnetite, limonite, hematite,
ilmenite
Steel shots and punch scraps are also available
Aggregates are chosen depending on its local
availability and their properties
Heavy weight concrete is used in special
structures such as radiation shields
VACCUM CONCRETE
This method helps a high workable
concrete to attain higher strength.
Excess water added for higher workability
( which is not used for hydration) is
withdrawn by means of vacuum pump,
after placing of concrete.
Rate of extraction of water depends on:
Workability
Max size of aggregate
Proportion of fines
Agg/cement ratio
 Equipment:
Consists vacuum pump, water separator and filtering
mat.
Filtering mat - rubber seal all round the periphery,
expanded metal sheet, a sheet of wire gauge.
By using vacuum pump, excess water is sucked from
concrete through fine wire gauge
At least one face of concrete must be open to
atmosphere- to create pressure difference.
 SHOTCRETE
Guniting- pneumatically applying mortar of less
thickness
Gunite is a mixture of Portland cement, sand and

water, shot into the place by compressed air.

The force of jet impacting on the surface compacts

the material.
Shotcreting- pneumatically applying mortar of
larger thickness, with small CA
Can be used on vertical and overhead, as well as

on horizontal surfaces and is particularly useful for

restoring surfaces spalled due to corrosion of
reinforcement
SHOTCRETE
A cement-sand mix, in the ratio 1:2 or 1:3
depending upon the requirement, is applied
at high pressure over the surface with the
help of specialized equipment.
Guniting is extensively used to rehabilitate

concrete bridges, dams, spillways, buildings,

marine structures, etc.
There are two different methods of spraying:

Dry mix process

Wet mix process
 Dry mix process
Cement and sand are mixed and fed into special air
pressurised mechanical feeder (Gun).
Mix is metered into delivery hose by a feed wheel
within gun
Material is carried through delivery hose to a special
nozzle by means of compressed air
A pressure water tank is attached and connected with
nozzle for water supply
Mortar with mixture and water at high pressure is
jetted from nozzle at high velocity to the surface.
This process is often used for repair work.
It is because of its fast application process and
restoration of structural strength at an early stage.
Dry mix process
Wet mix process
Concrete is mixed with water before
conveying through delivery pipe to the
nozzle.
This method is discarded.
Guniting