5th Concrete Research in India (CRI)

Symposium
Saturday, September 14, 2019 | IC&SR Building | IIT Madras, Chennai,
India

DEVELOPMENT OF RESEARCH METHODOLOGY

OBJECTIVES

• To understand potential research problems

• To propose possible solutions

PROCEDURE

 Understanding the problem statements

 Brainstorming

 Proposal of solutions
PROCEDURE

 Understanding the problem statements

5 THEMES 10 PROBLEMS
 Special Cements and Supplementary Cementitious Materials
PROBLEM 1 PROBLEM 2
 Durability – Transport Mechanism PROBLEM 1

PROBLEM 3 PROBLEM 4 TEAM 1A TEAM 1B

 Durability – Corrosion Mechanism
PROBLEM 5 PROBLEM 6
 Special Concrete – Mechanical Performance
PROBLEM 7 PROBLEM 8
 Recycled Materials and Sustainability
PROBLEM 9 PROBLEM 10
PROCEDURE

 Brainstorming

TEAM 1A TEAM 1B
TEAM 2A TEAM 2B
TEAM 3A TEAM 3B
TEAM 4A TEAM 4B
TEAM 5A TEAM 5B
TEAM 6A TEAM 6B
TEAM 7A TEAM 7B
TEAM 8A TEAM 8B
TEAM 9A TEAM 9B
TEAM 10A TEAM 10B
PROCEDURE

 Proposal of solutions

• Material selection

• Mechanical characterization

• Design methodology

• Practical implications
LET'S THINK, DISCUSS AND
MEET WITH SOLUTIONS!!!!
 Special Cements and
Supplementary Cementitious Materials
BACKGROUND AND MOTIVATION

TERI Report 2017; Barcelo et al. 2014, Hanein et al. 2018

BACKGROUND AND MOTIVATION
• Efficient production • Calcium sulfoaluminate cement
• Alternative fuels • Reactive belite cement
• Clinker reduction • Geopolymer cement
• Alternative binders • Magnesia based cement
• Solidia cement
PROBLEM STATEMENT 1
Special cements for hazardous waste containment

Specific concerns for design of

barriers:
No or significantly less
migration of contaminants
Resistant to chemical attack
High density and strength
Current solutions:
Can
Red mud liners
CONCRETE
Polymer gel barrier be a viable
solution?
Sodium bentonite
Polymeric flexible membrane liners
PROBLEM STATEMENT 1
Objective

To identify an economical and ecological binder system to

produce concrete for hazardous waste containment.

• To study the mechanical properties of special cement.

• Microstructural characterization to understand the pore

characteristics and phase development.

• To assess the binder for durability properties.

SOLUTION 1A
Methodology
1. Characterization of raw materials

2. Strength characterization (Compressive strength, hoop

strength, flexural strength)

3. Durability studies (Chemical resistance, permeability)

4. Thermal resistance

5. Biological deterioration

6. Compatibility of cement with reinforcement

SOLUTION 1A
Possible Solutions
1. Geopolymer Cement 2. Limestone Calcined Clay

• High strength Cement (50% clinker + 30%

calcined clay + 15% limestone +

• Acid resistance
5% gypsum)
• Long term durability
• Ecological
• Geological analogues
• Chemical resistant
• Archeological analogues • Dense microstructure

3. Polymer coating on OPC based concrete

SOLUTION 1B
Solution and methodology
Scope Properties to study Testing Program
 Focus on nuclear waste  Improve pore  Material
 Special case and not for refinement characterization
mass application  Containment of  Hydration progress
radiation
 High temperature
Identify a binder  Effect of calorimetry
• Selection of Materials temperature
 XRD and TGA
• CSA or blends of  Chemical effects
cement or  Microstructure
• SCMs along with  Identify cracks development using
radiation absorption  Microstructure SCM
materials development  Porosity and Pore
• Mix design connectivity using MIP
• Low w/b ratios and UPV
• Life cycle and Economy  Strength and durability
PROBLEM STATEMENT 2
Supplementary cementitious materials

• To develop a concrete using SCMs to achieve early

compressive strength to transfer the prestress after 48 hrs
of casting
• Fresh properties
• Early age strength evolution of concrete
 SOLUTION 2A
• Selecting a suitable SCM • Evaluating the fresh
Fineness properties of the material
 Density Setting and hardening
Reactivity test Workability – (admixture)
XRD test Calorimetric test

• Identifying suitable admixture • Determining the strength of

Workability the concrete mix
Early strength gain Compression test
Tension
• Optimization of the materials Flexural
Particle packing density Bond
% Replacement Creep
Shrinkage
 SOLUTION 2B
• Areas to address • Selection of material:
 Workability and early setting • Reactivity
 Early strength • Physical and chemical aspects
 Effect of SCM on the concrete system

• Tests on the system level to be addressed

• Workability • Permeability (Pore structure)

• Strength evolution (compressive strength) • Packing density

• Bond strength • pH

• Creep and shrinkage

Durability – Transport Mechanisms
 BACKGROUND AND MOTIVATION
1010 CE Big temple, Damages in modern structures
Thanjavur

Still sturdy Durability – a concern

Difference? - The role of porosity and permeability

Root cause of durability problems varies with exposure conditions

How to ensure durability of concrete in RC structures ?

How to scientifically design building materials for longevity?
PROBLEM STATEMENT 3
Performance based design and control of concrete durability

Terminal infrastructure - Ennore port, Elevated corridor of Delhi metro,

Chennai, Tamil Nadu New Delhi

• Examine (hypothetically!) the possible concrete durability

problem that could occur in superstructure and substructure of these
RC structures
• Chart out theories related of transport phenomena and role of
cement chemistry to investigate the concrete durability in such
conditions
SOLUTION 3A
List Chennai- Port Delhi- Elevated Corridor

Problem Statement Superstructure: Superstructure:

Carbonation Carbonation
Substructure: Substructure:
Water Absorption Sulphate attack
Sulphate attack
Chloride attack

Theories Diffusion(Fick’s law; Henry’s Diffusion

law) Darcy’s law
Darcy’s law
Capillary forces
Material Selection Optimization of mix Using Optimization – hydroxyl
Different materials (SCM’s), ions, and permeability
Reactivity, Surface Area,
Chemical Composition
Solution Lower rates for target service life and lower chemical
SOLUTION 3B
• Ternary blended system – Clinker (60%) + Alcofine slag + Class F Fly ash
• Characterization
• Micro-analytical
• MIP - Pore structure refinement
• XRD – Phase composition
• Durability
• Bulk diffusion
• Accelerated Chloride Migration test
• Oxygen permeability
• Accelerated Carbonation test
• Wenner 4 probe resistivity
• Electrochemical tests – LPR
• Parameters to be assessed
• Chloride diffusion coefficient
• Chloride threshold
• Resistivity
• Carbonation coefficient
PROBLEM STATEMENT 4
Crystallization damages in building materials
Damage in masonry units Damage of rocks and
concretes in cold weather

Damages in masonry structure on the Concrete pavement in Leh – Khardungla

sea front, Fort Danesberg -Tranqbar, TN Pass – Highest motorable road in the world
PROBLEM STATEMENT 4
Crystallization damages in building materials
Damage in masonry units

• Identify the damage mechanisms and the theory behind them

• How can we prevent them in existing structures and new constructions?

Hint: Pores/Voids are sometimes beneficial in building materials

 SOLUTION 4A : 1. Salt crystallization

Salt + Water = Solution  Pores

On evaporation/precipitation, Solution = Vapor

+ Crystallization  Crystallization pressure

Causes:
Small sized pores
Percolation of salt and moisture
Frequent wetting and drying
Efflorescence and subflorescence
Solutions:
1. Restrict entry of salt/water- using
water repellent coatings
2. Replacement with compatible material
(where necessary)
3. Choice/proper maintenance of binder
4. Choose bricks with large pores
5. Addition of compressible gels in the
production of bricks
 SOLUTION 4A : 2. Free-thaw damage

Solutions:
Causes:
Air-entraining admixtures
When temperature goes to zero
Porous aggregates
Differential pressure
Super absorbent polymers
 SOLUTION 4B
• We have identified the problem as salt crystallization, freeze &thaw
cycle
Solution to curb Salt crystallization effect:
• In salt crystallization, the increase in the size of a crystal increases the
pressure on the small pores of a wall thus causing failure.
Salt + Water = Solution  Pores

On evaporation/precipitation, Solution = Vapor +

Crystallization  Crystallization pressure

• With respect to the existing structures, If we restrict the growth of the

crystal by cleaning the surface and replace with the compatible
material, obviously we can restrict this attack.

• Using polymer coatings, surfactants in upcoming construction modules

will detain the rate of salt crystallization effect.
 SOLUTION 4B
Solution to curb Freeze & Thaw effect:
• This effect occurs when the water molecules in concrete tend to
freeze and expand beyond the volume constraints of the concrete.
• Concrete is saturated when the pores are filled with water and
when the water molecules freeze, it expands leading to increase in
volume thus getting distressed. Also it causes the bond in cement
around the aggregate to break & the concrete can crack at those
phase.
• With respect to the existing structures, we can restrict the growth
of the crystal by incorporating biopolymers in the form of
coating.
• Using air entrainment at the time of concreting will provide
equally distributed pores for water accumulation and reducing the
pressure.
Durability – Corrosion Mechanism
BACKGROUND AND MOTIVATION

• Reinforced concrete structures

are designed for a service life
of 100+ years.
• Corrosion of reinforcement
causes premature deterioration
and reduces the service life.
• In 2014, the direct cost of corrosion
in India was Rs. 4 lakhs crores/year
 3 to 4% of GDP
PROBLEM STATEMENT 5
Corrosion performance of steel
• India has long coastal line
• Many mega projects are being
constructed
 Highways
 Seaports
 Airports
• Choice of materials are plenty.
How to choose?

https://www.researchgate.net/publication/333790027_A_systematic_data_collection_on_chloride-
induced_steel_corrosion_in_concrete_to_improve_service_life_modelling_and_towards_understanding
_corrosion_initiation
PROBLEM STATEMENT 5
Corrosion performance of steel
OBJECTIVE
• To assess the corrosion performance of various types
of steel used in the construction field.

TMT rebars Fusion Bonded Stainless steel

Epoxy coating
(FBEC) rebars

Prestressing strands Galvanized steel bars

Cement Polymer
Composite (CPC) coated
rebars
SOLUTION 5A

1) Cast the concrete cylindrical specimen with rebar embedded at the centre
2) Cure it for 28 days
3) Exposure conditions
a) Expose it to wet-dry. Immersion in salt water and expose it to sunlight.
b) Accelerating chloride ion penetration

4) Different ways of testing the corrosion activity are listed below

i. Measure Half-cell potential with respect to standard reference electrodes
and compare it ASTM C876 standards. Based on the comparison of
different rebars with respect to half-cell potential, we can choose the best
method
ii. Assume all the specimens are corroding. Extract steel rebars after
exposure condition and measure tensile strength in all the steel specimens
and come up with the best rebar
iii. Electrochemical impedance spectroscopy – To detect the changes in the
resistance of steel
SOLUTION 5B

Test Methods

1) Based on ASTM C 876 (Half cell Potential)

2) Strain gauge at steel interface– resistivity

measurement

3) Quantifying amount of oxygen, moisture

required to initiate corrosion - sensors
PROBLEM STATEMENT 6
Assessment of bond strength
Imperfection – Damage

After chloride arrival Epoxy coating

Corrosion product

• Damages on epoxy coating

– Accelerates corrosion
– Bond loss

To study the reduction in bond between the steel and

concrete due to corroded epoxy coated reinforcing steel
https://adsproshield.com/wp-content/uploads/2017/12/Epoxy-bar.jpg
SOLUTION 6A
Materials
 Uncoated rebar
 Coated rebar (uniform coating thickness)
Exposure of coated rebars in marine environment(1,3 & 6 months)
(i) visual observation of rebars
(ii) loss of weight in rebar
M30 concrete
Methodology
 Preparation of specimen with coated and uncoated rebar
 Controlling specimen with lab and marine environment
 Testing of specimens at 2,3 & 6 months
 Comparing bond strength and observation of corrosion levels at different ages.
SOLUTION 6A
Test methods

Conclusion
The bond strength and the corrosion levels of the specimens
are compared.
The suggestion is given for the epoxy coated steel used under
different exposure condition.
SOLUTION 6 B
• Test conducted: Pull-out test
• Specimen of 150 mm x 150 mm x 150 mm size
• Dia of Rebar 12 mm
Rebar Damage Concrete type Corrosion Corrosion Rate
Rate
0% Chloride free 1 µA / cm2 2 µA / cm2

1% Premixed 1 µA / cm2 2 µA / cm2

2% Premixed 1 µA / cm2 2 µA / cm2

• Exposure to chlorides – by pre-mixing 3% NaCl in concrete

• To measure the bond strength at varying degrees of corrosion
using Gecor equipment (measuring corrosion rate)
 Special Concrete –
Mechanical Performance
BACKGROUND AND MOTIVATION
Conventional Special
concrete concrete

High rise building Long span bridge Repair and retrofit

Tunnel lining Pervious pavement

 BACKGROUND AND MOTIVATION

High performance Self-compacting

High strength Pervious

Special
concrete

Textile reinforced

Polymer

Fibre reinforced Light-weight

PROBLEM STATEMENT 7
Special Concrete

Roofing system Facade Curved member

Condition 1
Thin member

Bridge
PROBLEM STATEMENT 7
Special Concrete

Concrete bench near sea shore Corrosion!!

Condition 2
Exposure to aggressive environment
PROBLEM STATEMENT 7
Special Concrete

OBJECTIVES

 Select a suitable material!!

 Propose the design methodology!!

Justify!!!
SOLUTION 7A

• Material selection
Textile reinforced concrete
• Mechanical characterization
Axial tension; Flexure; Durability
Textile reinforced
• Design methodology concrete
Parametric study based on properties from test
• Practical implications
Availability and site practice
SOLUTION 7B
Material Selection for corrosion resistant
• PSC
• Ferrocement
• FRP-Bars: GFRP, CARBON,Aramid
• Textile Reinforced Concrete

Material Parameters:
Concrete Reinforcement composite
Compressive test Tensile Test Flexure Test
Split Tensile Pull Out Test
Direct Tensile Test
SOLUTION 7B

Design
• Capacity: Flexure from 4 point load test
• Development length: Pull out Test
• F.O.S: Brittle, more F.O.S
Socio-Economical Aspect:
• Difficult to accept, since no code provisions
• Brittle material
• Economic for GFRP, Costly for carbon fibers
PROBLEM STATEMENT 8
Cracks in concrete pavement due to heavy loads
Ancient roads Recent urban roads

Magnitude of load ↑

Traffic volume ↑

Solution: Concrete
pavement!!
PROBLEM STATEMENT 8
Cracks in concrete pavement due to heavy loads

Cracks in concrete pavement How to achieve this??

PROBLEM STATEMENT 8
Cracks in concrete pavement due to heavy loads

• What material will you choose?

• What type of material characterization has to be

performed?
??
• How will you use it in the design?
SOLUTION 8A
Material Selection

• Fibre reinforced concrete – resist the crack

Steel fibre– better ductility – macro-crack
Synthetic fibre– microcrack
Carbon fibre– costly
Synergistic combination
• High strength self compacting concrete
Flowability
To reduce workability issues – better workmanship
Better surface finish
To resist high magnitude of loads
SOLUTION 8A
Type of test to be conducted
• Material test
 Los Angeles abrasion test
 Material properties of cement, flyash, aggregates, fibres
• Fresh properties
 Self compacting concrete - optimum viscosity modifiers and admixtures
• L-box
• V-funnel
• J-ring
• Marsh cone test
• Hardened properties (Material performance)
 Compression – stress-strain curve
 Flexural (4-point) – post-peak (fracture test – 3point) – optimum dosage and
l/d ratio
 Cyclic loading test
 DIC – Crack patte
SOLUTION 8A
Design methodology

• Self-compacting concrete
EFNARC – mix design

• Fibre reinforced concrete

Japanese/Euro code - characterisation
Fib code – criteria based on usage
SOLUTION 8B

• Two solutions
Self-Healing Concrete
Changing pavement design using Hybrid fibers
Micro and Macro fibers

Material Characterization – To account for flexural strength and ductility

Design Method – Considering Strength and Ductility as design

parameters.

Practical Implication – To increase service life and performance of

pavement.
Recycled Materials and Sustainability
BACKGROUND AND MOTIVATION

Why?
• Magnitude of wastes produced is
about 700MT/year (GIZ, 2016) in
India
• Huge social costs involved in waste
handling
• Environmental issues (Landfilling,
leaching, air pollution)
• Illegal dumping

Composition of C&D waste

PROBLEM STATEMENT 9 :
Utilization of C&D Waste
How to utilize all the fractions of C&D waste in concrete
pavement?

Subgrade
Subbase
Base course
Concrete pavement

4.75 mm 10 mm 20 mm
SOLUTION 9
Residential and road waste Identify the source
Segregation
Concrete Masonary Mixed

Size reduction
< 4.75 mm
Fines
< 10/20 mm

Impact
Water absorption
Material testing Abrasion
Etc.

Desired Compressive strength

properties Flexural strengthv Gradation

Concrete pavement Base course Sub-Base course Subgrade

PROBLEM STATEMENT 10
Eco - efficiency of Recycling
• Methods to prove eco-efficiency
 Social benefits
 Environmental benefits
 Economic benefits
• Which is more eco-efficient
i) Recycled materials
ii) virgin materials
To measure the sustainable potential of recycled aggregates
compared to virgin aggregates
SOLUTION 10
Life Cycle Assessment – Calculating the Environmental Impacts

Data Collection – Quarry

- Crushing units (Natural aggregates and Recycled aggregates)

Processing of Data – Input materials for the process for unit quantity

Impact calculations :
• Energy consumption,
• GHGs
• Raw material depletion
• Land occupation
• Dust and noise
• Carcinogens

Interpretation and Decision making

THANK YOU!!!!