6 SPECIAL MATERIALS USED IN

CONCRETE CONSTRUCTION

SPECIAL MATERIALS IN CONCRETE

INDUSTRY
1. FERROCEMENT
Ferrocement is a type of reinforced concrete composed of concrete with small aggregate (or coarse cement
mortar), 12 to 30 mm thick, reinforced with a minimum of two layers of small diameter, orthogonally
woven wire mesh separated by 3 to 6 mm diameter galvanized spacer wires or weld mesh. The cement
mortar is made with plasticizers and polymers to make it dense without pores. Due to the closely spaced
wire mesh, shrinkage cracks are absent in this work.

This method can be used to provide protective reinforced membrane for rehabilitation of distress RCC
members. A number of constructions like making a small non-load bearing partitions or even a small water
tank can also be made with cement mortar laid on a layer of weld mesh and chicken mesh by an
experienced worker without solid formwork.

2. FIBRE REINFORCED CONCRETE (FRC)

Different forms of fibres

Fiber reinforced concrete is the Portland cement concrete mixed with uniformly dispersed short length
fibres. These fibres can be natural fibres like coir or man-made fibres like steel, carbon, polymer etc. we
generally use the second type of fibres, the most common type being steel fibres. They are available in
different forms.

They are commonly used for the construction of industrial floors and road pavements. Today, many types
of fibres have been developed to be used with concrete for many purposes. Both steel and polypropylene
fibres are used for placing of concrete by shotcreting (or guniting). Fibres reinforced concrete not only
prevents early shrinkage cracks but also improves strength and ductility of the reinforced sections.

3. FIBRE REINFORCED POLYMER (FRP)

This is one important modern development in the repair of RC members. We have polymers as one of the
concrete chemicals. We have also different types of strong fibres like carbon, glass or aramid (a synthetic
or organic fibre). These two are joined together for the manufacture of modern FRP product. Many such
products are available. Some are strong only in one direction – along the length. Others are strong in both
directions – along the length and the breadth.

The FRP is very strong and hence, it can be used as reinforcement. It can be bonded to the concrete by
using a high strength epoxy resin as an adhesive. We can also stretch the fibre along its length and then
bond it to the concrete member so that it acts as a prestressing device. The RC member is ten under
prestress. Thus, it can be used both as reinforcement and a prestressing device.
4. CEMENTCRETE (MICROCONCRETE)
In most of the repair works, we use concrete with the coarse aggregate of size 6 mm to 8 mm (mostly
below 10 mm). This concrete with small-sized coarse aggregate is called cementcrete or microconcrete.
Microconcrete with chicken mesh can be used in places in repair works.

5. GEOPOLYMER CONCRETE (CONCRETE

WITHOUT PORTLAND CEMENT)
An alkaline liquid is made to react with silicon and of geologic origin or produced as an industrial
byproduct. This produces concrete without Portland cement. As the chemical reaction that occurs to
produce binders is a polymerization process, such concrete is termed as polymer concrete. Our
conventional concrete is Portland cement concrete or simply cement concrete. Geopolymer concrete can be
produced from ground granulated blast furnace slag (GGBS) and alkaline liquids. Water is added to this
concrete only for workability and easiness in placing the concrete. On the other hand, in Portland cement,
concrete water is necessary for the hydration of cement.

6. SILICA FUME CONCRETE

Silica fume concrete is the concrete wherein silica fume (very finely divided pozzolanic material) is used
to produce high strength Portland cement concrete. The addition of silica fume is to be not more than 10%
by weight of cement. Superplasticisers are also needed to produce the necessary workability. If the depth
of repair is less than 150 mm, then an epoxy bonding agent should be used to bond fresh silica fumes
concrete to the old concrete.

10 RULES TO FOLLOW WHILE

PLACING CONCRETE IN HOT
WEATHER
PLACING OF CONCRETE IN HOT WEATHER
HOT WEATHER CONCRETING
For normal concreting operations the temperature of concrete should vary between 150C to 250C to enable
it to attain its full ultimate strength within 28 days. In case concreting is carried out in extreme hot weather
conditions, the rate of hydration of cement gets accelerated and the water in the concrete mix dries out
rapidly. This in turn results in formation of stresses which cause shrinkage cracks and damage to the
concrete.

The adverse effects of hot weather can be minimized by taking following precautions while concreting in
extreme hot weather conditions.

1. USE RETARDING ADMIXTURE

Add retarding agents in concrete to lower the rate of hydration of cement.
2. LOWER THE TEMPERATURE OF AGGREGATE
Keep the temperature of concrete ingredient as low as possible. Temperature of aggregate may be lowered
by stockpiling the aggregate in shaded areas and also by sprinkling cold water on the stock piles.

3. LOWER THE TEMPERATURE OF WATER

Use cold water for making concrete. In certain cases, crushed ice may be used to bring down the
temperature of water and to obtain concrete mix having temperature within desirable limits.

4. FAST TRANSPORTING OF CONCRETE

The mixed concrete should be transported and placed in position within the shortest possible time, so as to
minimize the losses due to evaporation and rise of temperature.

5. SPRINKLING OVER FORMWORK AND

REINFORCEMENT
Sprinkle cold water over the formwork and reinforcement just before the placement of concrete. This
prevents the loss of water from concrete due to absorption by these materials.

In case of construction of roads, sprinkle water over the prepared sub-grade before placing concrete.

6. PLACING OF CONCRETE AT NIGHT

Schedule the time of placing of concrete in night when the ambient temperature is very low as compared to
day time.

7. SPEED UP THE WORK

The work should be executed with utmost speed, since delays will affect the concrete adversely due to hot
weather conditions.

8. PROTECTION FROM DIRECT SUN RAYS

After placing in positions, the concrete surface should be adequately protected from exposure to direct sun
rays by erecting sunshades.

9. PROTECTION FROM WIND

Erect wind breaks over the finished concrete surface so as to protect the concrete surface from wind.

10. CURE CONTINUOUSLY

The concrete should be continuously cured with sufficient water during the first few hours and thereafter
the surface should be kept moist for the full duration of curing.