I CALCESTRUZZI AD ALTE PRESTAZIONI

S. Cangiano

Cremona, 21.04.2009
Contents
INTRODUCTION

NATIONAL REGULATIONS AND EXAMPLES OF

UTILISATION OF HPC
HPC MIX DESIGN: THE CURRENT APPROACH

PHYSICAL AND MECHANICAL PROPERTIES

HPC VALIDATION BY A COOPERATIVE TESTING

PROGRAM

CTG - Italcementi Group

What is a High Performance Concrete?
According to ACI Committee 316

HIGH PERFORMANCE CONCRETE

Concrete meeting special combinations of
performance and uniformity requirements that cannot
always be achieved routinely using conventional
constituents and normal curing, mixing, placing and
curing practices.

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 Performances usually requested to
concrete
FRESH STATE :
RHEOLOGY (Ease of placement, Absence of segregation)
HARDENED STATE
MECHANICAL PROPERTIES
Mechanical strength
Young Modulus
Toughness
Fatigue behaviour
Time dependent strain (Shrinkage, Creep)
DURABILITY :
Chemical (sulphate attack, leaching, etc)
Physical (Freeze/thaw Cycles, Fire Resistance, Abrasion, etc)

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 ENHANCED PERFORMANCES AND THEIR
CONSEQUENCES

RHEOLOGY (SSC)
Reduction of Savings in
construction time construction
HARDENING RATE
costs

FINAL STRENGTH Increase of available

space
ELASTIC PROPERTIES Structural section
reduction Savings:
(Young mod., Poisson Forms,
ratio) Self weight,
Transport costs,….

Savings in
DURABILITY Increase of service
maintenance
(Permeability, freeze life
costs
attack, fire,…)

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Contents
INTRODUCTION

NATIONAL REGULATIONS AND EXAMPLES OF

UTILISATION OF HPC

HPC MIX DESIGN: THE CURRENT APPROACH

PHYSICAL AND MECHANICAL PROPERTIES

HPC VALIDATION BY A COOPERATIVE TESTING

PROGRAM

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 CONCRETE CLASSES ACCORDING TO UNI EN 206 -1
Compr.
C8 C12 C16 C20 C25 C30 C35 C40 C45 C50 C55 C60 C70 C80 C90/ C100/
Str. /10 /15 /20 /25 /30 /37 /45 /50 /55 /60 /67 /75 /85 /95 105 115
Class
Min.
Char.
Cylinder
8 12 16 20 25 30 35 40 45 50 55 60 70 80 90 100
Strength
fck,cyl
[N/mm2]
Min.
Char.
Cube
10 15 20 25 30 37 45 50 55 60 67 75 85 95 105 115
Strength
fck,cube
[N/mm2]

A B
D. M. 14.01.08

A: per classi superiori a C45/55 la res. caratt. e tutte le altre grandezze che hanno influenza sulla resistenza e
la durabilità del conglomerato devono essere accertate prima dell’inizio dei lavori tramite una apposita
sperimentazione preventiva e la produzione deve seguire specifiche procedure per il controllo di qualità.

B: per classi superiori a C70/C85 occorre la autorizzazione del Servizio Tecnico Centrale su parere del
Consiglio Superiore dei Lavori Pubblici.

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 HPC in European Building Codes

• Eurocode 2 fck,cube≤ 105 N/mm2

• The Netherlands (CUR) fck,cube≤ 105 N/mm2

• Spain (EHE) fck,cube≤ 115 N/mm2

• Germany (DIN) fck,cube≤ 115 N/mm2

C50/60 C70/C85 C90/C105

A B
D. M. 14.01.08

A: per classi superiori a C45/55 la res. caratt. e tutte le altre grandezze che hanno influenza sulla resistenza e
la durabilità del conglomerato devono essere accertate prima dell’inizio dei lavori tramite una apposita
sperimentazione preventiva e la produzione deve seguire specifiche procedure per il controllo di qualità.

B: per classi superiori a C70/C85 occorre la autorizzazione del Servizio Tecnico Centrale su parere del
Consiglio Superiore dei Lavori Pubblici.

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 EXAMPLES OF HPC UTILISATION
Viaducts and bridges

Pertuiset Bridge – France

Rck 80 MPa

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EXAMPLES OF UTILISATION OF HPC

Viaducts and bridges

Storebelt Bridge – Denmark

Rck 65 MPa

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EXAMPLES OF UTILISATION OF HPC

Viaducts and bridges

Pont du Millau – France (2004) Rck 75 MPa

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 Examples of HPC utilisation
Thermal Power Plant – Niederaussem (Germany - 2002)
Mechanical Properties
Main Goal : High Resistance
Rck (28d) 75 MPa
to acid attacks due to SOx and
Elastic Modulus 43 GPa NOx

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 Examples of HPC utilisation

Two Union Square – Seattle (USA)

Mechanical Properties

Rcm (28d) 70 MPa

Elastic Modulus 50 GPa

Mix Design
Cement 513 Kg/m3
Silica Fume 43 Kg/m3
Superplasticizer 18.8 Kg/m3
Aggregates 1765 Kg/m3
Water 130 Kg/m3
w/c ratio 0.25

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 Examples of HPC utilisation

World Trade Center (Rep. San Marino)

Designer: N. Foster

Rcm,28= 100 Mpa

Design strength
Rck = 80 MPa

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 Examples of HPC utilisation
Church “Dives in Misericordia” - Roma
Designer: R. Mayer

Rcm, 28 = 75 MPa Design strength

Es,28 = 40,000 MPa Rck = 55 MPa

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Contents
INTRODUCTION

EXAMPLES OF UTILISATION OF HPC AND NATIONAL

REGULATIONS

HPC MIX DESIGN: THE CURRENT APPROACH

PHYSICAL AND MECHANICAL PROPERTIES

HPC VALIDATION BY A COOPERATIVE TESTING

PROGRAM

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 BASICS OF HPC MIX DESIGN

HPC’s must be obtained by:

9 Increasing the strength of the cement matrix (reduction

of its porosity);

9 Strengthening of interfacial bond between cement

matrix and aggregate;

9 Suitable choice of aggregates

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 MAIN REQUIREMENTS FOR HPC CONSTITUENTS

CEMENT AND SUPPLEMENTARY CEMENTITIOUS MATERIALS:

¾ PORTLAND CEMENT CLASS 52.5 R TYPE I (EN 197-1)MUST BE
GENERALLY USED (Cement content 400 – 700 kg/m3);
¾ Portland cements class 42.5R may be also used for HPCs with
compressive strength up to 55-65 MPa (the i. e. the lower range of the
HPCs)

AS SUPPLEMENTARY MATERIALS MAY BE USED

(in conformity to EN 206 and related standards)

9 Industrial by-products (fly ash, slag and silica fume)

9 Natural products (natural pozzolans and calcined clay)

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 MAIN REQUIREMENTS FOR HPC CONSTITUENTS
According to ACI Committee 363
AGGREGATES:
SAND:
¾THE GRADING OF SAND MUST BE MAINLY RELATED TO
WATER DEMAND (WORKABILITY) OF THE MIX
¾CLEAN AND HARD PARTICLES ARE GENERALLY
PREFERABLE.
COARSE AGGREGATE :
¾CLEAN AND SUFFICIENTLY HARD PARTICLES
¾REGULAR SHAPE IS GENERALLY PREFERABLE;
¾MAXIMUM DIMENSIONS:
THE HIGHER THE TARGETED COMPRESSIVE STRENGTH THE
SMALLER THE MAXIMUM SIZE OF THE COARSE AGGREGATE
SHOULD BE. Compr. Max Size (Φ
Strength maxmm)

75 [MPa] 20 – 28

100 [MPa] 10 – 20

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 MAIN REQUIREMENTS FOR HPC CONSTITUENTS

SUPERPLASTICISERS:
THESE ADMIXTURES ALLOW A STRONG REDUCTION OF W/C RATIO AND
PROVIDE EXCELLENT RHEOLOGICAL PROPERTIES.
In particular the use of new generation of these admixtures, based on acrylic
polymers, combined with a suitable aggregate grading permit to obtain concretes
having Self Compacting behaviour (SCC) and Very High Strengths.

More useful and detailed information can be found also in: “Linee Guida su: Calcestruzzi
Strutturali Alta Resistenza” – Consiglio Superiore dei Lavori Pubblici – Servizio Tecnico Centrale”

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 PRODUCTION, TRANSPORTING,PLACING AND CURING HPC
(ACI Committee 363R)
PRODUCTION:
HPC ARE PRODUCED IN THE SAME WAY AS USUAL CONCRETES, USING THE SAME
PRODUCTION EQUIPMENTS:
EVEN IF TRUCK MIXERS MAY BE USED, IT IS STRONGLY RECOMANDABLE TO
PRODUCE HPC/HSC IN READY MIX PLANT WITH A CENTRAL MIXER

CRITICAL POINT:
WEIGHTING DEVICES MUST BE CALIBRATED REGULARLY (ESSENTIAL
REQUIREMENT) (SENSITIVITY TO WATER CONTENT: AN INCREASE OF 3-5 l/m3
CORRESPOND TO A DECREASE OF 10 TO 20 MPa
TRANSPORTING AND PLACING
HPC CAN BE TRANSPORTED BY A VARIETY OF METHODS AND EQUIPMNTS:
TRUCK-MIXERS, CONVEYOR BELTS, PUMPING (IN MANIY CASES HPC ARE VERY
SUITABLES FOR PUMPING (OWING TO HIGH CEMENT CONTENT AND SMALL SIZE
AGGREGATE)

CRITICAL POINT: HPC/HSC FRESH MIXES ARE VERY SENSITIVE TO TEMPERATURE

Problems Acceptable Ideal Acceptable Problems

5 10 15 20 25 30 °C

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 PRODUCTION, TRANSPORTING,PLACING AND CURING HPC
(ACI Committee 363R)
CURING:
AT WATER-CEMENT RATIO BELOW 0.4 THE ULTIMATE DEGREE OF HYDRATION IS
SIGNIFICANTLY REDUCED IF FREE WATER IS NOT PROVIDED
WATER CURING, OR A SUITABLE FOG CURING, IS STRONGLY RECOMMENDED
ALSO TO AVOID SHRINKAGE INDUCED CTACKING OF CONCRETE.

Good fogging Applying curing compound

while concrete is still fresh

Good fogging

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 MICOSTRUCTURAL PROPERTIES
TOTAL POROSITY
THE TOTAL POROSITYOF NORMAL STRENGTH (NS), HIGH STRENGTH (HS) AND VERY HIGH
STRENGTH (HHS) WAS DETERMINED BY Hg INTRUSION AT INCREASING PRESSURE UP TO
1000 Mpa ON CORED SPECIMENS (f 21 x h 70mm)
Fc,28 PHg
CODE
[Mpa] [%]
NS 35.6 11.4
HHS 130 6.70

15 15
NS-Plain HHS - Plain
Cumulative Distribution [%]

Cumulative Distribution [%]

NS - 30 HHS-80
NS - 60 HHS-270
12 12

9
NS-Plain 9

6 6
HHS-Plain
3 3

0 0
101 102 103 104 105 101 102 103 104 105
Pore Radius [nm] Pore Radius [nm]

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 STRESS- STRAIN RELATIONSHIPS
STRESS-STRAIN RELATIONSHIPS

THE ULTIMATE STRAIN AT

MAXIMUM STRESS εc0 FALL
IN THE RANGE OF -0.003<
εc0 <0.002 And INCREASES
WITH INCREASING
COMPRESSIVE STRENGTH.

From Nilson, A. in “Utilisation of high strength concrete, Proc., Stavanger 1987

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 ELASTIC PROPERTIES OF HSC

MODULUS OF ELASTICITY:
It may be estimated from the moduli of its components on the basis of theory of
composite materials. According to D. W. Hobbs (Tech. Rep. C.C.A. Dec. 1969):

[(Ea − Em )Da + (Em + Ea )]Em 50000

E=

Modulus of elasticity [MPa]

(Em + Ea ) + (Ea − Em )Da 40000
0 00 0 MPa
E m=3
Where: 30000

Em=El. Mod. Cem. P.(15÷30 MPa)

20000
Ea= El. Mod. Agg. (40 ÷60 MPa)
Em=15 000MPa
Da=Vol. frac. Agg. 10000
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

Aggregate Fraction (Da)

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 TIME DEPENDENT DEFORMATIONS (SHRINKAGE)

Hydraulic shrinkage measurements are

carried out in a conditioned room (20±2°C; 50
±5% R.H.) after 24 h from the specimen
casting

According to ACI 363 the shrinkage is unaffected by

changes in w/c ratio, but is approximately proportional to
the water content per m3 in concrete.
Hydraulic shrinkage of HPC/HSC is generally not greater
than that of lower strength concrete.

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 TIME DEPENDENT DEFORMATIONS (CREEP)

According to Eurocode 2:
40
σ
εcc (∞, t 0 ) = ϕ(∞, t 0 ) ⋅ ( c ) NS C
HS C
Ec 0 σc=0.3 σmax

Specific strain [με/MPa] (εcc/σc)

30 σmax= 40 MPa
In order to evaluate the
creep coefficient ϕ(∞, t 0 )
the experimental data were
20
fitted by L’Hermite formula:
⎡ ⎛ 1 ⎞k1 ⎤
ε(t ) − ε0 = ε∞ ⎢1 − ⎜⎜ −k 2 t
⎟⎟ e ⎥
⎢⎣ ⎝ 1 + t t 0 ⎠ ⎥⎦
10
σmax= 85 MPa σc=0.3 σmax

NS C HS C 0
0 1 2 3 4
ϕ(28,50) 2.37 1.33 Time [weeks]
ϕ(∞,50) 2.51 1.34

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 DURABILITY PROPERTIES OF HPC
HPC/HSC ARE GENERALLY DURABLE CONCRETES

TEST METHOD Typical values

Water
EN 12390 - 8 < 5 mm
penetration
Oxygen
UNI 11164 < 10-18 m2
permeability
< 10 mm after 5 years of
Carbonation UNI 9944
exposure
Chloride < 5 mm after 28 d of
UNI 9944
penetration exposure

Scaling Mass loss < 0.1 kg/m2

EN 1338
resistance after 56 cycles

Freeze thaw F.D. >0.95 after 300

UNI 8087
resistance cycles

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Contents
INTRODUCTION

EXAMPLES OF UTILISATION OF HPC AND NATIONAL

REGULATIONS

HPC MIX DESIGN: THE CURRENT APPROACH

PHYSICAL AND MECHANICAL PROPERTIES

HPC VALIDATION BY A COOPERATIVE TESTING

PROGRAM

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 CIS - E* – CTG JOINT RESEARCH ON HPCs
Coordination of the project:
CISE: A.Migliacci, A.Franchi, P.Ronca CTG:L. Cassar
• The research activity was shared by different units:

Polytechnic of Milan
¾ Research Group - Rheological & Mechanical Properties (Biolzi, Cattaneo, Rosati,Muciaccia)
¾ Research Group - Time dependent deformations and modelling (Cedolin, Di Luzio, Cusatis)
¾ Research Group - Thermal properties (Gambarova, Bamonte, Felicetti)
University of Brescia
¾ Research Group - Mechanical Properties (Plizzari)
University of Bergamo
¾ Research Group - Mechanical Properties (Riva, Meda)

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¾ Research Group – Mix Proportioning & Physical Properties (Cangiano, Morbi, Carminati)

*) Costruzioni dell’Ingegneria Strutturale in Europa

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CIS - E* – CTG JOINT RESEARCH ON HPCs

•Two different mix design has been developed (Rck75 and Rck90) by
CTGT.

•Main goals

9 Workability maintenance for a long period of time;

9 High compressive strength at early age;
9 High final compressive strength
9 High durability
9 Easy availability of raw materials

*) Costruzioni dell’Ingegneria Strutturale in Europa

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STARTING MATERIALS

¾ Cement Type I 52,5R

¾ Limestone Filler

¾ Natural rounded aggregates (3-4 Fractions ; φmax 16 mm)

¾ Acrylic based super plasticizers (AXIM)

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 Rheological properties
BOTH THE CONCRETE CLASSES SATISFIED ALL THE REQUIREMENTS
POSED BY OF EUROPEAN GUIDELINES (EFNARC) ON SCC.
prEN 206-9 Classes

Rck>75 ¾ Workability: 9 Flow > 780 mm after 2 hours SF3

9 Time Flow < 6 sec after 2 hours VS2

9 Funnel Time < 20 sec after 2 hours VF2

Rck>90 ¾ Workability: 9 Flow > 800 mm after 1 hour SF3

1° solution 9 Time Flow < 4.5 sec after 1 hour VS2
up to 60’
9 Funnel Time < 20 sec after 1 hour VF2

Rck>90 ¾ Workability: 9 Flow > 800 mm after 2 hours SF3

2° solution 9 Time Flow < 6 sec after 2 hours VS2
by 60’ to 120’
9 Funnel Time < 20 sec after 1 hour VF2

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 COMPRESSIVE STRENGTH (CUBIC – UNI EN 12390-3)
120 R cm ( t ) = β cc ( t ) ⋅ R cm 28
⎡ ⎡ 1
⎤⎤
⎢ ⎛ ⎞
⎟ ⎥⎥
28
( t ) = exp s ⎢1 − ⎜
2
β cc s = 0,2 for rapid hardening cements
⎢ ⎢ ⎝ t ⎠ ⎥⎥
⎣⎢ ⎣ ⎦ ⎦⎥
100
Compressive Strength [MPa]

80

60
+ 40%

40

Rck 75

20 Rck 90

Eurocode Rck75

1 3 7 28 Eurocode Rck90 60
0

Age [d]

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 ELASTIC MODULUS (DYNAMIC – UNI 9771)
55

50

Elastic Modulus [GPa]

45

40

35

30

MED Rck45
25

MED Rck 75
20

MED Rck 90
15
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30

Age [d]

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HPC: HYDRAULIC SHRINKAGE (FROM 24 H UP TO 60 DAYS)
According to UNI 7086 on beam specimens 10x10x40 cm
1 7 28 60
0

Age [d]
-50

-100
Hydraulic Shrinkage [με]

-150

-200

-250

-300

-350

-400 Rck45
Rck 75
-450
Rck90
Eurocode Rck90
-500

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 DURABILITY PERFORMANCES
OXYGEN PERMEABILITY (UNI 11164)
Flow
Test cells meter

20
Permeability Specific Factor [10 m ]

Pressure
2

regulator
18 Rck45
-19

O2
16 15E-19
14
Pressure
gauge
12 Test specimen
Rck75
10
8,25E-19
8
Rck90
6
4,25E-19
4

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 DURABILITY PERFORMANCES
Freeze – thaw cycles (without deicing salts) UNI 7087
5 DEGRADATION FACTOR Fd,n
Test Chamber
Specimen
Temperature [°C]

0 ⎛ DEMspec ⎞ ~
Fd ,n = ⎜ ⎟ Fd ,0 DEM: Dynamic
⎜ DEM ⎟
-5
⎝ ref ⎠nthcycle
Elastic Modulus

-10
~ ⎛ DEMspec ⎞
Fd ,0 = ⎜ ⎟
-15 WATER AIR WATER ⎜ DEM ⎟
⎝ ref ⎠before test

-20
Time [h]
-25
0 4 8 12

NOTE:
According to UNI 7087 the concrete is acceptable
If the Degradation Factor after 300 cycles is > 0.7

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 DURABILITY PERFORMANCES
RESISTANCE TO FREEZE/THAW (UNI 7087)
1

0.9
Degradation Factor

0.8

0.7
Limit of acceptability according to UNI 7087

0.6
Rck 90
0.5 Rck 75
Rck 45

0.4
0 50 100 150 200 250 300 350
N° Cycles

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 DURABILITY PERFORMANCES
Freeze – thaw cycles (in presence of deicing salts)
3% NaCl
Rubber EN 1328 30

⎡ Scaled mass⎤
25
Specimen
water solution 20
Limits for the cycle
m56 = ⎢ ⎥
⎣Testing area⎦56 cyclces
15

Temperature [°C]
Polythene 10
film 5

-5

Polystyrene Test -10

box specimen -15

-20

-25
0 4 8 12 16 20 24

Time [h]

Mass-loss after 85 freeze-thaw 0.03

cycles [kg/m2]
NOTE:
According to EN 1328 the concrete is acceptable
If the mass loss after 56 cycles < 1kg/m2

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 DURABILITY PERFORMANCES
WATER ABSORPTION (UNI 9526)
0,60

0,50
Water Absorption %

0,40 Rck45
Rck75
Rck90
0,30

0,20

0,10

0,00
0 10 20 30 40 50 60

Time [d]

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 DURABILITY PERFORMANCES
Carbonation (UNI 9944)

MIX Cast 28d +30d +90d +180d +360d

Reference 07/02/06 07/03/06 06/04/06 05/06/06 03/09/06 02/02/07

INT 0,0 0,0 1,0 2,5

EXT 0,0 2,0 3,0 5,0

Rck75 02/05/06 30/05/06 29/06/06 28/08/06 26/11/06 25/05/07

INT 0,0 0,0 0,0 0,0

EXT 0,0 0,0 0,0 0,0

Rck90 I 04/07/06 01/08/06 31/08/06 30/10/06 28/01/07 27/07/07

INT 0,0 0,0 0,0 0,0

EXT 0,0 0,0 0,0 0,0

Rck90 II 10/10/06 07/11/06 07/12/06 07/02/07 07/05/07 07/12/07

INT 0,0 0,0 0,0 0,0
EXT 0,0 0,0 0,0 0,0

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 DURABILITY PERFORMANCES
CHLORIDE ION DIFFUSION
The chloride ion diffusion was measured according to NT Build 492
(accelerated test)

30
Reference
25
DAverage *10-12 [m2/g]

20

15

10

5
Rck90
0

Reference Concrete

Rck90

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 HIGH TEMPERATURE RESISTANCE

Tmax [°C]: 150, 300, 450, 600, 750

Tmax 2 hours
Temperature [°C]

The mixes were reinforced with:

Polymer fibres % (*)
Macrofibres (L= 20 mm; Φ= 200 – 250 μm) 0.24
Microfibres (L= 6 mm ; Φ= 40 – 50 μm)
Co
0.05
(15

oli
(30 ting

*) On dry mix
/h)

ng
°C
a
°C
He

/h)

Room Temperature

0 10 20 30 40 50
Test carried out at Politecnico di Milano by dr. P.
Time [h] Bamonte, prof. R. Felicetti and prof. P. Gambarova

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 RESIDUAL PROPERTIES
SLOW THERMAL CYCLES
140 THERMAL SHOCK
Compressive strength [MPa]
120

100

80
The specimens have
been introduced and
60
maintained into the
40 oven at 600°C for 30’
20

0
20 150 300 450 600 750
Temperature (Tmax) [°C]
THERMAL SHOCK (Tmax 600 °C)

NO
WITH EXPLOSIVE WITHOUT
POLYMER EXPLOSIVE
SPALLING POLYMER
FIBRES SPALLING
Residual Comp. Strength: 47.5 [MPa] FIBRES

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HPC As Architectural Concrete
FAIR FACED SURFACES

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 CONCLUSIVE REMARKS

9At present time with available technology and equipments it is

possible to ease produce, transport and cast HPC;

9HSC are durable concretes, even if specific performances must be

verified by testing (e.g. durability);

9Some critical points (e.g. high plastic shrinkage, need of extended

suitable water or fog curing) may be overcome.

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 THANK YOU FOR
YOUR KIND ATTENTION

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