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A case study on modifying the fire resistance of self-compacting concrete

with expanded perlite aggregate and zeolite powder additives

Article  in  Asian Journal of Civil Engineering · June 2014

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 ASIAN JOURNAL OF CIVIL ENGINEERING (BHRC) VOL. 15, NO. 3 (2014)
PAGES 339-349

A CASE STUDY ON MODIFYING THE FIRE RESISTANCE OF

SELF-COMPACTING CONCRETE WITH EXPANDED PERLITE
AGGREGATE AND ZEOLITE POWDER ADDITIVES

S. Bakhtiyari∗a, A. Allahverdib and M. Rais-Ghasemic

a
Fire Research department, Building & Housing Research Center, Tehran, Iran.
b
Cement Research Center, School of Chemical Engineering, Iran University of Science and
Technology, Tehran, Iran.
c
Department of Concrete Technology, Building & Housing Research Center, Tehran, Iran

Received: 10 August 2013; Accepted: 20 October 2013

ABSTRACT

Self compacting concretes (SCC) containing quartz powder are sensitive to spalling, when
exposed to fire. It was attempted to modify the fire resistance of this kind of SCC with use
of additives. As a case study, expanded perlite aggregate, zeolite powder and a mix of them
was added to the SCC recipes and their fire behaviors were evaluated. The specimens were
exposed to high temperatures, up to 1000˚C and their residual compressive strengths were
measured. The SCC specimen containing zeolite powder additive suffered from explosive
spalling. But, the addition of expanded perlite and mix of perlite/zeolite resulted in
considerable improvement of fire resistance of samples.

Keywords: Self compacting concrete; fire resistance; spalling; quartz; expanded perlite;
zeolite.

1. INTRODUCTION

Fire resistance is a property of materials that prevents or retards the passage of excessive
heat or flames under conditions of use. For building elements, it is defined as the ability of
the element to confine a fire or to continue its structural function, or both, for a stated period
of time [1]. Two important parameters for evaluating fire resistance of a construction
element are load-bearing capacity and integrity. The later means that no large crack is
produced in the separating element so that the fire and large heat can pass through it.
Therefore, the loss of strength and cracking of the specimens are the important factors which
are to be considered for evaluating the fire behavior of the test specimens. The fire test

∗
E-mail address of the corresponding author: bakhtiyari@bhrc.ac.ir (S. Bakhtiyari)
340 S. Bakhtiyari, A. Allahverdi and M. Rais-Ghasemi

methods and philosophies are discussed in [Error! Reference source not found.2].
Concrete is the most important construction material in the world [3], therefore a lot of
experiments have been carried out on fire resistance of traditional concretes. However; the
fire behavior of new concretes, like SCC and high performance concrete (HPC) can be very
different compared to traditional concretes [4-6].
The main reasons for failure of a concrete element at high temperatures are spalling and
loss of strength. Spalling is the most dangerous threat for concrete elements at high
temperatures. It may occur at medium-high temperatures (mostly around 400-700°C fire
temperature) and may result in failure of the concrete element. Internal pore pressure of
water vapor is the main reason of spalling of concrete [4-8]. Hertz [Error! Reference
source not found.7] discussed the different reasons of spalling of concretes.
Self-compacting concrete (SCC) is a type of concrete that fills all sections of forms
without need to mechanical vibration. It has reasonable flow-ability, homogeneity,
resistance against segregation and mechanical strengths [9-16]. As a high volume of fine
powders are used in SCC along with chemical super-plasticizers, it has a higher packing
density relative to traditional concretes. Therefore the internal pore pressure due to
vaporization of water at elevated temperatures would be increased and this can increase the
risk of spalling of concrete if exposed to fire. Hence; SCC has generally lower fire resistance
relative to traditional concretes. As SCC is a new material, only a few investigations have
been carried out on its fire resistance. Ye [17 and 18] studied the phase distribution and
micro-structural changes of SCC, normal concrete (NC) and high-performance concrete
(HPC) cement pastes at high temperature. He showed that the SCC pastes had different
behavior and microstructure at high temperatures relative to the NC and the HPC pastes.
Boström [Error! Reference source not found.19] investigated the fire resistance of a
number of SCC and NC specimens in a full scale furnace. All specimens spalled in the first
minutes of the tests, but the SCC specimens spalled more severe than the NC ones. Persson
[Error! Reference source not found.20] investigated the fire behavior of some SCC mixes
containing limestone filler. Spalling was widely observed in all the SCC samples. Normal
samples showed a better fire resistance.
Bakhtiyari and colleagues [Error! Reference source not found.21] investigated the
effects of quartz and limestone powders on fire behavior of SCC in small scale. Their
investigation showed that the kind of powder in a SCC may significantly affect the fire
behavior and risk of spalling. The SCC containing quartz powder showed 18-36% increase
in residual compressive strength at 500°C. For a 70 MPa quartz-contained SCC; highly
explosive spalling was seen even at a furnace temperature of 350°C [Error! Reference
source not found.21]. The reason, confirmed by mechanical, XRD, thermal and
porosimetry analyses [Error! Reference source not found.21], was that the partial
pozzolanic activity of the quartz powder was enhanced at high temperatures (about 500°C)
and hence accelerated the strength development of the concrete. Such an effect, however;
could result in increased internal pore pressure and therefore a higher risk of spalling of the
concrete. The SCC containing limestone powder showed lower tendency to spalling, but its
compressive strength was continuously reduced by increase of temperature [Error!
 A CASE STUDY ON MODIFYING THE FIRE RESISTANCE OF SELF-COMPA... 341

Reference source not found.21].

The results showed that SCC, depending on the used filler, could be more susceptible to
spalling in fire compared to normal concrete. Quartz powder showed positive effects on
residual mechanical strength of SCC at high temperatures, but the mix was very sensitive to
spalling. Therefore; it is worthwhile studying and modifying the fire resistance of SCC
concretes containing quartz powders, to achieve an SCC with modified fire resistance and
with less loss of residual compressive strength at high temperatures, which is worth for
continuing the stability and integrity of the construction element exposed to fire.
Addition of light-weight aggregates is a usual way for improving the fire resistance of
concrete. Expanded perlite aggregate has been widely used in fire-resistant concretes and
fire-proofing materials. It is produced at temperatures higher than 900°C, hence it has
inherently a good resistance against high temperatures. Its porous structure can help
reducing internal pore pressure of the concrete and hence reduces the risk of spalling. It
reduces the thermal conductivity of the product and therefore lowering the heat transfer to
internal layers of the concrete. Zeolites are another natural hydrated alumino-silicate
mineral, which has been used in concretes as a very active pozzolanic material [Error!
Reference source not found.22]. It has open structure and can accommodate different ions
and molecules in its pores. Zeolites have micro-porous structure. Therefore it can be
speculated that zeolite might accommodate water vapor molecules in its micro pores and
decrease the internal vapor pore pressure at high temperature. Although in other side,
because of pozzolanic effect, it can increase the packing density of the concrete, which has a
counter effect.
In this case study, we investigated the effects of fine expanded perlite aggregate (EPA)
and zeolite powder on fire behavior of SCC. For this purpose; the specimens were exposed
to high temperatures in a furnace. The spalling behavior of specimens and change of residual
strengths were evaluated. The results were compared with reference specimens.

2. EXPERIMENTAL

2.1 Materials
The powders consisted of ASTM-C150 standard type 2 Portland cement (PC), and very fine
quartz and zeoloite powders. The chemical analysis of the used PC was as following, in
percent: CaO = 61.72, SiO2= 21.18, Al2O3 = 4.10, Fe2O3 = 4.05, MgO = 1.20, Na2O +
0.658 K2O =0.6. Using these values in the Bogue's equation, the cement phases are achieved
as following, in percent: C3S = 48.43, C2S = 24.19, C3A = 4.01, C4AF = 12.32. The quartz
powder with high purity was used as filler. The chemical analysis showed a purity of more
than 97% for the quartz powder. The chemical analysis of the used zeolite showed that it
was mainly consisting of SiO2 and Al2O3 of 67.79% and 13.66%; respectively. The particle
size distribution (PSD) of the powders was determined using the laser scattering
technique, by an apparatus made by Sympatec, Germany. The related curves for the PC
and the used powders are shown in Figure 1.
342 S. Bakhtiyari, A. Allahverdi and M. Rais-Ghasemi

Figure 1. Cumulative PSD-curves of PC and filling powders

A commercial ether-carboxylic based product was used as super-plasticizer.

Standard aggregates, complied with ASTM C33 were used. The aggregates were of three
size fractions, consisting natural sand (0-4.75 mm), crushed coarse aggregate (4.75-12.5
mm) (gravel 1) and partial-crushed coarse aggregate (9.5-19 mm) (gravel 2). The
characteristics of the aggregates are presented in Table 1.

Table 1: Characteristics of the used aggregates

SSD density Dry density Water abs. in Particles < 75
(g/cm3) (g/cm3) SSD (%) µm (%)
Sand 2.56 2.49 3.22 1.86
Gravel 1 2.58 2.53 1.99 0.3
Gravel 2 2.57 2.54 1.98 0.25
SSD = Surface Saturated Dry

The perlite chemical analysis results were as follows: SiO2 = 73.52, Al2O3 = 16.15, Fe2O3 =
2.60, CaO = 4.76, MgO = 0.60, SO3 = 0.00, Cl- = 0.02, Na2O = 2.04, K2O = 1.42, LOI = 10.23.
Pozzolanic activity of the used powders (quartz and zeolite) and EPA was assessed with
thermal analysis method. This data was needed for discussions on fire resistance results,
which is presented in the following section. A paste of powder/hydrated lime of equal
proportions was prepared and cured for 9 days in a sealed cylinder at 50°C. DSC/TG
analysis tests were then carried out on the specimens and their pozzolanic activity was
computed based on the remaining mass of the free lime. The following pozzolanic activities
were acquired, according to thermogravimetry method: quartz powder = 26%, zeolite
powder = 85% and perlite = 42.73%.

2.2 Test methods

2.2.1 SCC flow properties
The flow properties of the fresh SCC (slump flow, V funnel and L box tests) were tested
according to the European guidelines [23]. The description of the test methods are described
in the relevant references [23-25].
 A CASE STUDY ON MODIFYING THE FIRE RESISTANCE OF SELF-COMPA... 343

2.2.2 Mechanical properties of the hardened concrete

The compressive and the tensile strengths were measured according to EN 12390-3:2000
and ASTM C496 (Brazilian splitting method), respectively. The cubic specimens with
150 mm sides and the cylindrical specimens with diameter of 150 mm × 300 mm height
were cast for mechanical tests.

2.2.3 Fire resistance

The specimens were placed in a laboratory furnace in unloaded condition at four different
temperatures, i.e. 150, 500, 750 and 1000°C. The used time-temperature curves for heating
the specimens and the ISO 834 standard fire time-temperature curve are shown in
Figure 2. The specimens were kept in the furnace for two hours after reaching to the target
temperature. Then the furnace was turned off and the specimens were left in the furnace for
about 24 hours in order to reach equilibrium with the ambient temperature. The appearances
of the specimens were visually assessed, photographed and then their residual masses and
compressive strengths were measured. The spalling behavior of the specimens was also
assessed. Two specimens were tested for each mix.

Figure 2. The used time-temperature programs

2.3 Specimens casting and curing

Castings of the specimens were carried out according to EN 12390-2:2000. After keeping
the specimens at moist condition for about 24 hours, they were de-molded and maintained
under water at 23°C to reach the age of 7 days. Thereafter, they were kept in controlled
laboratory condition (25± 5°C and 42± 3% humidity) until the tests were performed. This
curing regime is nearly close to the actual conditions of the casting of the concrete in many
countries, especially for the regular building uses (like residential). If the specimens were
kept under water for the entire curing time, the tendency to explosive spalling had been very
high. This viewpoint has also been taken into account by other researchers [20, 26-28] for
the same reasons.

2.4 Mixtures proportions and the characteristics of samples

The mixtures proportions are given in Table 2. The S4 was the reference SCC recipe [29].
The S4-P35, S4-Z10 and S4-P35-Z10 codes are used in the table for the quartz-
contained SCC containing 35% EPA (on volume basis) as substitution of sand, 10%
344 S. Bakhtiyari, A. Allahverdi and M. Rais-Ghasemi

zeolite as substitution of cement, and compound of 35% EPA-10% zeolite; respectively.

The characteristics of the fresh mixes and the mechanical strengths of the hardened
concrete specimens (cured 28 days under water) are presented in Table 3. The presented
mechanical strengths are average of 3 results, tested on cube specimens.

Table 2: Proportions of mixes∗

CA (kg/m3) FA (kg/m3) SP
PC EPA Z W
Code 4.75-12.5 12.5-19 0-2 0-5 (% of
(kg/m )3
(kg/m3) (kg/m3) (kg/m ) 3
PC)
(mm) (mm) (mm) (mm)
S4 320 313 313 306 715 - - 175 1.35
S4-P35 320 313 313 196 458 62 - 175 0.65
S4-Z10 288 313 313 306 715 - 32 175 1.3
S4-P35-Z10 288 313 313 196 458 62 32 175 0.95
∗) All the mixes had also 185 kg/m3 quartz powder content in their formulations.
PC = Portland cement, CA = Coarse aggregate, FA = Fine aggregate, EPA = expanded perlite
aggregate, W = Water content, SP = super-plasticizer.

Table 3: Test results on fresh and hardened SCC mixes

h2/h1 in V fl. V 28-day
SLF T500 FD 28-day comp.
Code box time funnel tensile st.
(mm) (s) (kg/m3) st. (MPa)
test (s) T5 (s) (MPa)
S4 640 2.0 0.84 4.0 4.0 2265 43.2 3.5
S4-P35 830 1.5 1 4.0 4.2 2285 38.7 2.8
S4-Z10 615 1.8 0.82 5 5 2255 42.0 4.6
S4-P35-
Z10 825 1.8 0.95 7 18 2278 42.9 3.9

SLF = slump flow, V fl. = V funnel flowing time, FD = fresh density, cyl. = cylindrical.

3. RESULTS AND DISCUSSION

Preliminary, the S4-Z10 specimen was tested at first at 400°C and a very explosive spalling
was observed. The reason should be the high packing density of the zeolite-contained
concrete because of high pozzolanic activity of zeolite and partial activity of quartz powder.
These together could result in high internal pore pressure of the concrete exposed to high
temperature and consequently in an explosive spalling. Therefore; the Z10 specimens were
removed from the investigation.
The measured residual compressive strengths of the modified specimens are depicted in
Table 4. The relative residual compressive strength results are shown in Figure 3. The
residual strengths at 1000°C are not shown, because the specimens were completely
destructed at this temperature.
 A CASE STUDY ON MODIFYING THE FIRE RESISTANCE OF SELF-COMPA... 345

Table 4: Residual compressive strength of specimens

Change of Mass loss, No. of
f c, 25 , av. f c ,res , av.
Code comp. sSt., av. spalled
(MPa) (MPa) av., (%) (%) specimens
S4-150 44.3 ± 0.1 2.5 1.8 -
S4-500 43.2 ± 1.1 51.3 18.8 6.4 1 of 2
S4-750 - - - 2 of 2
S4-P35-150 41.2 ± 1.4 0.98 2.4 -
S4-P35-500 40.8 ± 1.4 53.8 ± 1.2 31.9 6.6 -
S4-P35-750 21.1 ± 4.4 - 48.3 7.3 -
S4-P35-Z10-
40.7 ± 1.0 1.41 1.4 -
150
S4-P35-Z10-
42.9 ± 1.4 65.6 ± 1.5 6.12 6.1 -
500
S4-P35-Z10-
(24.2) (- 43) - 2 of 3
750
fc , 25 = compressive strength of control specimens at 25 °C; f c, res = residual compressive
strength; comp. st. = compressive strength.

Figure 3: Relative residual compressive strength of specimens at different temperatures

The compressive strength of EPA-contained SCC was very close to the control specimen,
S4. This is in agreement with other researches [30]. No spalling was occurred for EPA-
contained specimens, while explosive spalling was observed for S4 specimens at 500°C and
750°C. In other words, the addition of EPA to the recipe resulted in improvement of fire
behavior of SCC and elimination of spalling risk, while no reduction in compressive
strength occurred at normal temperatures. This is potentially a very value result for
application purposes. The main reason should be the high porosity of EPA, which could
reduce the internal pore pressure of concrete at high temperatures. This is in agreement with
Turkmen’s results [30] which reported the increase of apparent porosity of concrete with
addition of EPA.
Whilst one of S4 specimens spalled at 500°C and the second one, which didn’t spall,
showed about 18% increase of residual compressive strength, the residual compressive
strength of the EPA-contained specimen showed about 32% increase at this temperature.
The partial pozzolanic activities of the powder and EPA, enhanced at high temperatures
346 S. Bakhtiyari, A. Allahverdi and M. Rais-Ghasemi

and in presence of water vapor which together produces an internal autoclave condition,
should be responsible for increase of residual compressive strength. This phenomenon was
shown before with use of XRD, thermal analysis and porosimetery tests for fine quartz
powder [21].
Comparison of partial pozzolanic effects of quartz powder and EPA showed that the used
fine EPA had even more pozzolanic effect than quartz powder. Hence; the pozzolanic
activity brought by simultaneous existence of quartz powder and EPA was much more
effective than quartz powder alone and a higher residual strength was achieved at 500°C.
The partial pozzolanic activity of EPA has been also shown by other researchers [30, 34].
The accelerated hydration of the cement phases at high temperatures has been also shown
by Peng [31] with XRD studies on hardened cement pastes. According to his studies, the
contents of C2S and C3S phases were reduced at about 400-500°C and the content of CSH
was conversely increased, which was considerable at 500°C. It is rare to see large strength
gains at 500°C [5, 28, 32]. Hertz [Error! Reference source not found.32] reported the
increase of residual compressive strengths of silica fume concretes with temperature up to
350°C and then a decrease. Poon [Error! Reference source not found.28] tested different
pozzolanic concretes at high temperatures. He reported about 13-20% strength gains up to
200°C for concretes containing fly ash, silica fume and blast furnace slag, but after that
about 3-7% decrease was observed at 400°C.
The results of zeolite-contained SCC were interesting. The S4-Z10 specimen had been
explosively spalled at 400°C in a severe manner, not seen before by the authors. But; none
of S4-P35-Z10 specimens spalled at 500°C. Two of three specimens were spalled at 750°C,
but with a very lower severity relative to Z10 specimens. The severities of spallings were
low for P35-Z10 specimens and only a corner type spalling was observed after opening the
furnace door. One of specimen didn’t spall at this temperature. A very interesting result was
that the residual compressive strength of P35-Z-10 specimen at 500°C was 66.0 MPa, i.e.
about 53% increase relative to the control specimen, which was very notable and not seen
before for other pozzolanic concretes in literature. The reason should be a considerable
acceleration of the strength development of hydration reactions at high temperatures due to
internal autoclaved condition and simultaneous existence of three pozzolanic materials, i.e.
EPA and zeolite and quartz powders. One of S4-P35-Z10 specimens, which didn’t spall at
750°C, suffered from about 43% reduction in residual compressive strength, nevertheless
was still better than the other mixes at the same temperature.
The results showed that not only the spalling of the SCC can be controlled with addition
of mixture of fine EPA and zeolite powder, but also a high strength SCC with improved fire
resistance rating can be achieved. The optimization of the formulation is a matter of
research. The rational mixing ratios, physical and properties, durability in different
conditions are needed to be investigated. Standard fire resistance tests on medium or large
scale specimens are other fields of studies. Micro-structural studies and variation of phases
at incremental temperatures would be helpful for understanding the real phenomena
responsible for physical and mechanical properties of the compound.
 A CASE STUDY ON MODIFYING THE FIRE RESISTANCE OF SELF-COMPA... 347

4. CONCLUSIONS

In this case study, the fire resistance of SCC concretes containing quartz filler was improved
with addition of EPA and mix of zeolite powder/expanded perlite aggregates. EPA was used
as replacement of sand and zeolite powder was used as substitution of the cement. Both the
residual compressive strengths of mixes and their spalling behaviors were considerably
improved. High porous nature of EPA should result in lower internal pore pressure of the
concrete and hence; reduce the spalling risk in case of fire. On the other hand, the enhanced
pozzolanic effects of both zeolite powder and fine EPA at high temperatures and in presence
of internal water vapor, resulted in accelerated hydration of the cement paste around 500°C.
Therefore; a higher residual compressive strength was attained close to this temperature that
should be considered as useful for higher resistance of the construction element against fire
exposure and imposed loads.

Acknowledgments: Building and Housing Research Center provided financial and

laboratory supports for this research.

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