Bergamo ACI Italy Chapter

3rd Workshop of Italy ACI Chapter on
The New Boundaries of Structural Concrete

Bergamo (Italy) October 3-4, 2013
HEAVY AND LIGHT-WEIGHT CONCRETES AT HIGH

TEMPERATURE: DO THEY BEHAVE SIMILARLY TO
ORDINARY CONCRETE?
Pietro G. Gambarova
In collaboration with Patrick Bamonte, Francesco Lo Monte and
Chiara Rossino
Department of Civil and Environmental Engineering - DICA
Politecnico di Milano Milan (Italy)
Topics
Heavy and light-weight concretes: definitions

Heavy concrete: barite as a heavy aggregate
Light-weight concrete: EPS beads as micro void-formers
ACI and fib code provisions for ordinary concrete at high
temperature (residual conditions)
Mix designs considered in this research project
Thermal cycles and test set-up
Thermal diffusivity
Stress-strain curves in uniaxial compression
Mechanical decay and deformability
Porosity
Concluding remarks
(Damage indexes, mass loss, pore size)
ACI Italy Chapter Bergamo October 2013
Heavy and light-weight concretes:

definitions
ACI 318M 11
Light-weight concrete : c = 1440-1840 kg/m3 (fc 17.2 MPa)
EN 206 1
Light-weight concrete : c = 800-2000 kg/m3 (fc 17 MPa)
Italian Design Code for Buildings (2008)
Light-weight concrete : c = 1400-2000 kg/m3
Ordinary concrete : c = 2400 kg/m3
Heavy concrete : c = 2800-5000 kg/m3
Commonly-used values for structural purposes

Light-weight concrete : c = 1600-1900 kg/m3
Ordinary concrete : c = 2300-2400 kg/m3
Heavy concrete : c = 2800-5000 kg/m3 (natural aggregates)
Heavy concrete (1)
1.
Heavy concretes are used whenever good attenuation properties are

requested against X and rays, as in the structures of the reactor
building in nuclear power plants, in the radioactive-waste
repositories and in the X-ray chambers of medical facilities
high mass per unit volume
heavy aggregates (hematite, magnetite, ilmenite, corindon, barite:

= 3600-5300 kg/mc, or steel scraps and shots, = 7800 kg/mc)
soluble organic superplasticizers (to increase compactness)
2.
Ordinary-to-heavy concretes are also used to stop fast neutrons in

the core of the reactor in nuclear power plants high content of
bound water in the aggregates:
colemanite, limonite, borocalcite, serpentine, = 2500-4300 kg/mc
Heavy concrete (2)
Heavy/self-consolidating concrete
High-/ultra high-performance/
fiber-reinforced concrete
Heavy/self-consolidating concrete
High-performance/
self-consolidating/
polymer/heavy
concrete
Shotcrete
Ordinary concrete
Heavy concrete (3)
Typical values of the mass per unit volume

Cement content = 350-400 kg/m3
Cement type Portland, blended, aluminous
6000-6500 kg/m3 steel scrap, fc = 75 MPa
5000-5500
colemanite + steel scrap, fc = 115 MPa
4500-5000
barite + steel scrap, or
hematite + steel shot, fc = 60 MPa
4000
hematite, fc = 75-80 MPa
3500
ilmenite or magnetite, fc = 75-85 MPa
3500
limonite + steel shot, fc = 60 MPa
3000-3500
limonite, barite or magnetite, fc = 35-45 MPa
2800-3000
copper-slag aggregate, fc = 70-95 MPa
Heavy concrete (4): barite
Barium Sulphate BaSO4 with = 3600-4500 kg/m3

rather soft material (hardness - Mohs scale = 3.0-3.5) with a
finely microfractured structure
microfractures partly filled with heat-sensitive clay containing
small amounts of chalcedony, quartz and zeolites
very stable material up to 1580C
subjected to higher creep at high temperature than ordinary
aggregates
thermal dilatancy of baritic mortar very close to that of coarse
baritic aggregates at any temperature reduced thermal
incompatibility between the mortar and the coarse aggregates
Coefficients of thermal expansion and creep coefficients

(from Crispino, 1972)
20
1.2
1.0
cr/el
th [10-6/C]
15
10
LA - limestone
5
0.8
0.6
0.4
LM - lim. mortar
BA - barite
(a)
BM - bar. mortar
0
0
100
200
300
400
500
T [C]
Coefficients of thermal expansion:

baritic mortar and aggregate (top)
versus limestone mortar
and aggregate (bottom)
limestone concrete (T = 300C)
0.2
(b)
barite concrete (T = 450C)
0.0
0
20
40
60
80
100
120
140
days
Creep coefficients:
baritic concrete (top)
versus limestone
concrete (bottom)
160
180
Barite Crystalline Rhomboidal System

Colorless / white / yellow / pale blue crystals
Light-weight concrete with EPS beads

(1)
1.
10
A two-way approach to the reduction of concrete mass per unit

volume:
reduction of the mass per unit volume of the aggregate (by using
for instance expanded-clay particles)
creation of voids inside the concrete mass (by using for instance
polymeric particles Expanded-Polystyrene Syntherized particles)
2.
sustainable constructions: materials recycling EPS from ground

polystyrene waste
3.
high-temperature behavior and fire resistance:
plenty of information on expanded-clay concrete;

no information at all on EPS concrete.
EPS concrete (2)
11
very good insulation properties

rather low mechanical properties because of the notch effect
and the zero strength of EPS particles (da 8 mm), contrary to
expanded-clay aggregate
mixing problems because of the buoyancy of EPS particles
as an aggregate, EPS is very cheap;
EPS content by volume: from 15
to 20% in structural concrete.
Typical block of EPS concrete

The white dots are EPS beads: melting at
100C, decomposition at 230-270C and
ignition at 450-500C
ACI and fib provisions for the mechanical

decay of vibrated concrete:
12
Test conditions: HOT at high temperature / RESIDUAL past cooling

Aggregates: calcareous-siliceous
Specimens state during heating: stressed-unstressed
Mix designs considered in this research

project (1)
13
1. Heavy concretes - One baritic concrete cured in

different conditions (T = 20 750C):
Mix MM cured for 3 years in moist conditions,
fc = 27 MPa, w/c = 0.50
Mix MD cured for 3 years in ordinary environmental
conditions, fc = 35 MPa, w/c = 0.50
2. Light-weight concretes - Two EPS concretes with

different cement contents (T = 20-700C):
Mix M1 with c = 643 kg/m3, fc = 25 MPa, w/c = 0.34
Mix M2 with c = 815 kg/m3, fc = 26 MPa, w/c = 0.27
3. Reference concrete Mix M0 with c = 286 kg/m3,
mixed aggregates, fc = 24 MPa, w/c = 0.70
Mix designs (2): baritic and reference

concretes
CE
SE
M0
14
MM
MD
Concrete Mix
CE (1963)
SE (2005)
M0-Ref.
MM-Moist
MD-Dry
Cement Type [c (kg/m3)]
C-I
[406]
C-I
[400]
C-II-A 42.5N
[286]
C-II-B 42.5N
[340]
C-II-B 42.5N
[340]
Baritic aggregate [Size] (mm)

Mass per unit volume (kg/m3)
Content (kg/m3)
[0-37.5]
4500
3022
[0-20]
4000
2746
[0-20]
4000
2500
[0-20]
4000
2500
Sand - siliceous + gravel

mixed 0-20 mm (kg/m3)
796 + 989
Fine/medium aggr. - mixed, 0-8 mm

(kg/m3)
129
174
Water added to saturate the aggr. (kg/m3)
30
30
30
Effective water (kg/m3) [w/c]
198 [0.49]
160 [0.40]
200 [0.70]
187 [0.55]
170 [0.50]
Plasticizer/Superplasticizer p/sp
(kg/m3) p/c[sp/c]
4.1 1%
adipic acid
2.5 [0.6%]
Sikament 163
3.9 [1.4%]
acrylic
1.7 [0.5%]
polycarboxylate
1.7 [0.5%]
polycarboxylate
Viscosity modifier vm
(kg/m3) [vm/c]
3.9 [1.4%]
Nominal mass/actual mass per unit volume

(kg/m3)
3630/-
3308/3250
2309/2239
3188/3104
3216/3059
Entrapped air by vol./ moist. content by

mass (%)
-/3.1
1.0/3.4
2.0/1.4
Cylinder strength fc (MPa)

Secant modulus Ec (GPa) - c fc/2
25
-
47
29.0
25.8
23.3
27.4
24.6
34.6
26.3
Mix designs (3): EPS and reference

concretes
15
3 Mix Designs (lean/rich/very rich mixes)

Concrete Mix
M0 Ref. Mix
M1 LWC1
M2 LWC2
Cement CEM II A-LL R 42.5 - c (kg/m3)
286
643
815
Mixed aggregates = Sand + gravel (kg/m3)*
809 + 1006
475 + 591
620 + 310
Water (kg/m3) [w/c]
200 [0.70]
220 [0.34]
220 [0.27]
Expanded-Polystyrene-Syn. Beads EPS

(kg/m3)**
5.09
5.32
Super Plasticizer sp (kg/m3) [sp/c]
3.90 [1.4%]
7.05 [1.1%]
9.11 [1.1%]
Air-Entraining Agent ae (kg/m3) [ae/c]
2.12 [0.33%]
2.73 [0.33%]
Viscosity Modifier vm (kg/m3) [vm/c]
3.90 [1.4%]
7.05 [1.1%]
9.11 [1.1%]
Nominal mass/Actual mass (kg/m3)
2309/2239
1951/1899
1991/1951
Compressive strength at 90 days (MPa)
25.8
26.9
28.4
(*) water-saturated surface-dry conditions (da = 12 mm)

(**) 3-mm beads; EPS = 38 kg/m3; vEPS (EPS vol. fraction) = 13-14%
16
Thermal cycles and test set-up (1):

residual tests
6 reference temperatures : 20, 105/150, 250/300, 400/500, 550/600

and 750/700 C in baritic/EPS concrete
heating/cooling rates: T/t = +1/-0.25C/min
rest at the reference temperature: t = 2 hours
2 - 3 specimens tested for each mix and temperature
800
750C
(a)
700
cooling in furnace
(-15C/h)
MD: fc20 = 34.6 MPa
105C
30
550C
heating in
furnace
(60C/h)
500
400
300
[MPa]
T [C]
600
(b)
35
400C
250C
limit of controlled cooling
200
105C
100
20
15
10
750C
0
4
400C
drying in oven (105C)
room temperature
25
12
16
20
24
28
32
t [h]
Thermal cycles
(baritic concretes)
36
0
0
[]
Test repeatability
(baritic concretes)
10
Thermal cycles and test set-up (2)
17
strain-controlled and displacementcontrolled tests

electro-mechanical INSTRON press
(Pmax = 100 kN)
3 resistive gauges at 120, baselength 50* or 100** mm, astride
the mid-height section
(pre peak; peak)
3 LVDTs at 120 placed between
the press platens (post peak)
(*) Baritic concretes
(**) EPS and reference concretes
Diameter = 100 mm; length = 200 mm
Thermal diffusivity (1): baritic concrete

vs. ordinary concrete
18
D = /( c) = vh R2/ 4 T = [L2 / t] = [m2 / s]

= thermal conductivity
c = specific heat
vh = heating rate
T = surface-to-axis thermal
differential
= mass per unit volume (density)

R = radius of the cylinder
0.8
Thermal Diffusivity, D [mm2/s]
EC2 ( = 2350 kg/m3)

EC2 ( = 3100 kg/m3)
0.6
MD
MM
M0
0.4
0.2
(b)
0.0
0
Cylinder instrumented with two

thermocouples inside the furnace
D=
100
200
300
400
500
600
vh R2
4 T
700
T [C]
Mixes M0, MM and MD versus

EC2 provisions
Thermal diffusivity (2): EPS and LWA

concretes vs. ordinary concrete
19
Expanded-clay
concrete and EC2
EPS concrete
and EC2
fc20 = 26, 27 and 28 MPa

(Milan, 2012)
fc20 = 39 and 56 MPa
Residual stress-strain curves in

compression (1): baritic concretes
35
(a)
20
M0: fc20 = 25.8 MPa
M0
30
20C
[MPa]
25
150C
20
300C
15
500C
10
5
700C
0
0
(b)
35
[]
10
20C
25
MM
105C
250C
20
400C
15
550C
10
0
4
[]
14
16
20C
105C
MD: fc20 = 34.6 MPa
250C
25
400C
550C
20
15
750C
10
5
2
(c)
30
750C
12
35
MM: fc20 = 27.4 MPa
[MPa]
[MPa]
30
10
MD
5
0
0
[]
Mixes M0 and MM are slightly more ductile than Mix MD

10
Residual stress-strain curves in

compression (2): EPS concretes
M0
M1
21
M2
EPS Mixes M1 and M2 are more brittle than ordinary Mix M0

EPS Mix M1 is the most heat-sensitive
In EPS Mix M2 the very high cement content reduces heat sensitivity
Mechanical decay and deformability (1):

baritic concretes in compression
22
Normalized compressive strength and elastic modulus

(a)
1.0
0.8
fcT/fc20
0.8
0.6
MD: fc20 = 34.6 MPa
0.4
Siliceous
MM: fc20 = 27.4 MPa

0.2
20
c
M0: f
0.6
Carbonate
MD: fc20 = 34.6 MPa
0.4
MM: fc20 = 27.4 MPa
= 25.8 MPa
Carbonate
0.2
100
Siliceous
M0: fc20 = 25.8 MPa
ACI
EC4
0.0
200
300
400
500
600
0.0
700
T [C]
100
200
300
400
500
600
700
T [C]
ACI
MD: Ec20 = 26.3 GPa
1.0
fib
MM: Ec20 = 24.6 GPa

M0: EC20 = 23.3 GPa
0.8
EcT/Ec20
fcT/fc20
(b)
1.0
Phan and Carino (1998)

0.6
Phan and Carino

(1998)
0.4
Ec secant modulus
c 0.5 fc
0.2
(b)
0.0
0
100
200
300
400
T [C]
500
600
700

baritic concretes in tension/compression
MD: fct,sp20 = 2.97 MPa
1.0
M0: fct,sp20 = 3.46 MPa
EC2 (direct tension

hot conditions)
0.6
C1T []
fct,spT/fct,sp20
0.8
0.4
MD: c120 = 1.5
MM: fct,sp20 = 2.31 MPa
23
MM: c120 = 1.8

M0: c120 = 2.5
2 [1+5.57.10-3(T-175)]
4
3
2 [1+4.70.10-3(T-250)]
2
0.2
1
0.0
(a)
0
0
100
200
300
400
500
600
700
T [C]
Normalized tensile strength
100
200
300
400
500
600
700
T [C]
Peak strain in compression

EPS concretes in compression/tension
fcT / fc20
24
fctT / fct20
EcT / Ec20
c1(T)
25
Porosity (1): baritic concretes
28
28
24
24
20
20
Porosity [%]
Porosity [%]
Capillary porosity measured via Mercury Intrusion MIP and

via Water Absorption - WAP
Values indicated in the literature : 9-11% for w/c = 0.55-0.75 at
20C (Neville and Brooks, 1999)
Mix M0 Ref. Mix : 14.5% and 16.5% at 20C
Mix MM (moist) : 16.6% and 17.8% at 20C
Mix MD (dry)
: 14.5% and 16.5% at 20C
16
12
8
MIP at 20C
MD: %
MM: 16.6 %
MIP
(a)
M0: 14.5%
0
16
12
WAP
Water absorption at 20C

MD: %
MM: 17.8 %
(b)
M0: 16.5%
0
100
200
300
400
500
600
700
T [C]
100
200
300
400
T [C]
500
600
700
Porosity (2): EPS concretes
26
Mix M0 Reference Mix (lean mix) : 14.5% -16.5% at 20C

Mix M1 LWC1 (rich mix) : 26.1% and 14.8% at 20C
Mix M2 LWC2 (very rich mix) : 21.2% and 11.2% at 20C
At 20C : Porosity MIP - Porosity WAP EPS volume fraction
Porosity (3): EPS concretes
27
Mixes M1 and M2:

white dots at 20C = EPS beads ( 3 mm)
black dots at 300,600C = voids left by EPS melting and gassification
Concluding remarks (1)
28
Stress-strain curves in compression: both baritic and EPS

concretes behaves like ordinary concrete with the strain at the
peak stress from 0.2% to 0.7% (T = 20-700/750C), which
increases linearly with the temperature above 200-250C
(150C for ordinary concrete)
Toughness: at low/medium temperatures baritic concrete is
slightly more brittle in compression than ordinary concrete,
while EPS concrete is definitely more brittle, as shown by the
slope of the softening branches
Normalized compressive strength: baritic concrete tends to be
slightly less heat-sensitive than ordinary concrete above 400C,
while EPS concrete is more heat-sensitive at any temperature,
unless disproportionate amounts of cement are used; however,
on the whole there is a satisfactory agreement with the curves
provided by ACI
29
Normalized elastic (secant) modulus: baritic concrete tends to

be a bit softer than ordinary concrete most probably because of
the microfractured nature of barite, while EPS concrete is
definitely weaker most probably because of the voids and their
notch effect
Normalized tensile strength by splitting: no significant
differences between baritic and EPS concretes, and ordinary
concrete, and rather good agreement with EC2
Thermal diffusivity: compared to ordinary concrete, baritic
concrete exhibits a lower thermal diffusivity at any temperature,
mostly because of the larger mass per unit volume, while EPS
concrete has a much lower thermal diffusivity at any
temperature, similarly to expanded-clay concrete
30
Porosity: aligned with ordinary concrete in baritic concrete;

much larger in EPS concrete, where MIP and WAP yield very
different values at room temperature, because of the
hydrophobic nature of EPS beads
Sustainability:
- in baritic concrete, no questions, as its use has no
alternatives in certain cases
- in EPS concrete, recycled polystyrene, greater insulation
properties and lower mass are a plus,
but more cement and lower mechanical properties are a
minus!
Difficult to make ends meet!
31
Thanks for your attention!
Damage indexes (1): baritic concretes
Ultrasonic-wave velocity
(longitudinal waves)
MD: vus20 = 3420 m/s
1.0
MM: vus20 = 3470 m/s

M0: vus20 = 4125 m/s
0.8
vusT/vus20
32
Ultrasonic-wave velocity index

0.6
0.4
Elastic-modulus index
0.2
0.0
0
100
200
300
400
500
600
Correlation between the indexes
700
T [C]
1.0
1.0
(a)
(b)
MD
MM
0.8
0.8
0.6
550C
400C
M0
0.6
DE T
fcT/fc20
750C
(c)
0.4
250C
0.4
T
D = 1 -
20
T
v
0.2
0.0
0.0
0.2
vusT
vus20
0.4
0.6
105C
ET
D = 1 - 020
E0
0.2
T
E
0.8
0.0
0.2
DvT
0.4
DET
0.6
0.8
1.0
0.0
0.0
0.2
0.4
DvT
0.6
0.8
1.0
Damage indexes (2): EPS concretes
33
Ultrasonic-wave velocity
(longitudinal waves)
Ultrasonic-wave velocity index
Elastic-modulus index
Correlation between the indexes
34
Heat-induced mechanical damage: the two indexes related to the

ultrasonic velocity and to the elastic modulus show that baritic
concrete keeps an initial well defined linear behavior at any
temperature, while EPS concrete exhibits an increasingly nonlinear
behavior with the temperature
Baritic concrete: moisture content and

mass per unit volume
35
1.05
(b)
1.00
T = 105C
T/20
Mass Loss [%]
After two weeks:

MD: 1.4 %
0.95
MD: c20 = 3059 kg/m3
MM: c20 = 3104 kg/m3
0.90
M0: c20 = 2239 kg/m3
MM: 3.4 %
(a)
M0: 3.1%
0
0
10
12
t [day]
EC2
0.85
14
100
200
300
400
500
600
T [C]
(a) Mass decrease due to free-water expulsion at 105C

(b) Mass loss at high temperature: free- and bound-water expulsion
700
36
Log Differential Intrusion [mL/g]
Baritic concrete: porosity

0.06
M0
20C
300C
0.05
600C
0.04
0.03
0.02
(a)
0.01
0.00
0.01
0.1
10
100
0.06
MM
20C
250C
0.05
550C
750C
0.04
0.03
0.02
(c)
0.01
0.00
0.01
0.1
10
100
Pore Size Radius [m]

0.06
MD
20C
250C
0.05
550C
750C
0.04
0.03
0.02
(b)
0.01
0.00
0.01
0.1
10
100
EPS concrete: moisture content and

mass per unit volume
37
(a) Mass decrease due to free-water expulsion at 105C.

(b) Mass loss at high temperature: free- and bound-water expulsion +
EPS melting (100C), decomposition (230-270C) and ignition (450500C).
EPS concrete: porosity
38
Differential intrusion (in log scale) as a function of pore radius
Test modalities (1)
39
Abrams M.S., 1971. Compressive Strength of

Concrete at Temperatures to 1600 F (870C).
Temperature and Concrete, ACI SP 25.
Test modalities (2)
stressed specimens
40
unstressed specimens
Thermal diffusivity
41
D = /( c) = [L2 / t] = [m2 / s]
where:
= thermal conductivity = [Q / (L T t)] = [cal / (m C s)]
= mass per unit volume (density) = [M / L3] = [kg / m3]
c = specific heat = [Q / (M T)] = [cal / (kg C]
According to Khoury et al. (1984):
D = vh R2/(4 T)
where:
vh = average heating rate of the specimen
R = spacing of the thermocouples TC1 and TC2
T = thermal differential between the thermocouples
Typical set-up

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3rd Workshop of Italy ACI Chapter on

The New Boundaries of Structural Concrete

HEAVY AND LIGHT-WEIGHT CONCRETES AT HIGH

Heavy and light-weight concretes: definitions

ACI Italy Chapter Bergamo October 2013

Heavy and light-weight concretes:

Commonly-used values for structural purposes

ACI Italy Chapter Bergamo October 2013

Heavy concrete (1)

Heavy concretes are used whenever good attenuation properties are

heavy aggregates (hematite, magnetite, ilmenite, corindon, barite:

Ordinary-to-heavy concretes are also used to stop fast neutrons in

ACI Italy Chapter Bergamo October 2013

Heavy concrete (2)

ACI Italy Chapter Bergamo October 2013

Heavy concrete (3)

Typical values of the mass per unit volume

ACI Italy Chapter Bergamo October 2013

Heavy concrete (4): barite

Barium Sulphate BaSO4 with = 3600-4500 kg/m3

ACI Italy Chapter Bergamo October 2013

Heavy concrete (5): barite

Coefficients of thermal expansion and creep coefficients

Coefficients of thermal expansion:

limestone concrete (T = 300C)

barite concrete (T = 450C)

Heavy concrete (6): barite

Barite Crystalline Rhomboidal System

ACI Italy Chapter Bergamo October 2013

Light-weight concrete with EPS beads

A two-way approach to the reduction of concrete mass per unit

sustainable constructions: materials recycling EPS from ground

high-temperature behavior and fire resistance:

plenty of information on expanded-clay concrete;

ACI Italy Chapter Bergamo October 2013

EPS concrete (2)

very good insulation properties

Typical block of EPS concrete

ACI Italy Chapter Bergamo October 2013

ACI and fib provisions for the mechanical

Test conditions: HOT at high temperature / RESIDUAL past cooling

ACI Italy Chapter Bergamo October 2013

Mix designs considered in this research

1. Heavy concretes - One baritic concrete cured in

2. Light-weight concretes - Two EPS concretes with

Mix designs (2): baritic and reference

Cement Type [c (kg/m3)]

Baritic aggregate [Size] (mm)

Sand - siliceous + gravel

Fine/medium aggr. - mixed, 0-8 mm

Water added to saturate the aggr. (kg/m3)

Effective water (kg/m3) [w/c]

Nominal mass/actual mass per unit volume

Entrapped air by vol./ moist. content by

Cylinder strength fc (MPa)

ACI Italy Chapter Bergamo October 2013

Mix designs (3): EPS and reference

3 Mix Designs (lean/rich/very rich mixes)

Cement CEM II A-LL R 42.5 - c (kg/m3)

Mixed aggregates = Sand + gravel (kg/m3)*

Water (kg/m3) [w/c]

Expanded-Polystyrene-Syn. Beads EPS

Super Plasticizer sp (kg/m3) [sp/c]

Air-Entraining Agent ae (kg/m3) [ae/c]