13 Special Applications in Concrete Construction
13.1 Ferrocement
Ferrocement is not a kind of cement, but is a type of thin wall reinforced concrete, commonly
constructed of hydraulic cement mortar reinforced with closely spaced layers of continuous and
relatively small size wire mesh, generally supported by a small diameter steel bars. The small
diameter bar reinforcement, in addition to giving strength, contributes to form a skeleton of the
desired profile on to which the fine wire mesh can be securely attached. The mesh may be made of
metallic or other suitable material.
Originally the steel was used for the mesh. The term ferrocement implies the combination of a
ferrous reinforcement embedded in a cementitious matrix.
Unlike conventional concrete, the assemblage of mesh in its final desired shape, which may be
complex, can be plastered with mortar directly in place without the need for a formwork. This
feature makes the material suitable for making shell structures. Ferrocement has a high tensile
strength – to – weight ratio, toughness, and superior behaviour in cracking in comparison to
conventional reinforced concrete. Hence, it can be used as a relatively light, watertight material.
The special properties make ferrocement an attractive material for such construction applications
like, silos, water tanks, roofs, boats, barges, prefabricated housing units, permanent forms for
conventional concrete.
13.2 Polymer Concrete (PC)
Polymer concrete is a class of composite material in which the binder is an organic polymer. The
polymer families most commonly used are: epoxies, polyesters, methacrylates, and polyurethanes.
Polymer concrete is used for structural applications where strength, stiffness, durability, and ease in
moulding provide an advantage over cementitious materials.
Some of the structural applications are: wall fascia panels, equipment vaults, machine bases,
drainage systems, and hazardous waste containers.
13.3 Polymer-Modified Concrete (PMC)
Polymer-modified concrete is defined as hydraulic cement and aggregate combined at the time of
mixing with organic polymers that are dispersed or redispersed in water. This dispersion is called a
latex.
Polymer-modified concrete is also called, polymer-Portland-cement-concrete (PPCC), and latex-
modified concrete (LMC).
Some of the polymer latexes are: styrene-butadiene, polychloroprene, polyacrylic ester, styrene-
acrylic, vinyl acetate copolymer, polyvinyl acetate, rubberized asphalt, and epoxies.
Polymer dispersions are added to the concrete to improve the properties of the final product. These
properties include: improved bond strength to concrete substrates; increased flexibility and impact
resistance; improved resistance to penetration of water and aqueous solutions; and improved
resistance to frost action.
13.4 Cellular Concrete and Aerated Concrete
Cellular concrete is a light-weight material. The material contains stable, small air or gas cells
uniformly distributed in the mix. The gas cells or air bubbles can be formed by incorporating gas
forming materials like aluminium powder into the mix, or by entraining considerable amount of air
mechanically by high-speed mixing, or by adding stable preformed foam made in a foam making unit
137 CE 592 – Concrete Technology
with the aid of compressed air, [Link] using foam concentrates such like modified proteins
Coarse aggregate is not normally used in the mixes, but fine aggregates of different types are
included. Some types of light-weight aggregates used are: expanded clay, sintered fly ash, perlite,
vermiculite, and pumice. In fact, this type of concrete contains up to 80 percent air. The material is
so light that it floats on water.
After its initial set, the resulting “cake” is wire cut into precisely-sized blocks or panels, and then
heated with high pressure steam (autoclaved). The heat helps the material to cure faster so that
blocks and panels maintain their dimensions. Reinforcement is placed within panels prior to curing.
The product is called autoclaved aerated concrete (AAC).
This material is used where enhanced thermal and sound insulation is required.
13.5 Controlled Low-Strength Material (CLSM)
Controlled low-strength material, sometimes called controlled low strength cementitious material is
a self-compacted, cementitious material used primarily for projects such as structural fill, foundation
support, pavement base, and conduit bedding in place of compacted soil. Setting, hardening, and
the lack of further compaction and densification are advantages of this material over soil,
particularly for accelerated construction. CLSM is defined as a material that results in a compressive
strength of 8 MPa or less. Most current applications require unconfined compressive strengths
around 2 MPa. This lower strength requirement is necessary to allow for future excavation of CLSM.
13.6 No-fines or Pervious Concrete
This is a type of light-weight concrete made by mixing cement paste and normal weight coarse
aggregate. The resulting material is porous. Hence, now it is used for pervious roads, and parking
areas. Pervious pavements are environmentally friendly.
Water-cement ratio is to be controlled to form a stable cement slurry coating on aggregate particles.
13.7 Reactive Powder Concrete (RPC)
Reactive powder concrete is an extremely high-strength concrete. The compressive strength is in the
range 200 MPa to 800 MPa. The ingredients are: cement, silica fume, fine sand, quartz powder,
water, high-range water-reducing admixtures, steel fibres, and polypropylene fibres. Aggregates
have to be proportioned for minimum voids. Steel fibres are to give the toughness, and
polypropylene fibres are for forming water vapour vents when the concrete is exposed to fire,
minimising the risk of shattering and exploding.
Fresh concrete has to be applied with pressure, and cured by subjecting to elevated temperature.
13.8 Geopolymer or Inorganic Polymer Concrete
Binder of the material is an inorganic polymer. Alumino-silicates such as fly ash, ground granulated
blastfurnace slag, combined with alkali solutions such as sodium hydroxide makes the geopolymer
binder, and to which aggregates are mixed to form geopolymer mortar or concrete. Unlike in
hydraulic cement, setting and hardening of the binder is not by hydration but by polymerisation, and
the reactions release water, instead of fixing. Depending on the ingredients, the compounds set and
harden at room temperature, or at a curing temperature raised around 60 -80 °C.
Geopolymers can be proportioned to have high strength. Though comparatively expensive, the
material has high fire and chemical resistance.
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13.9 Fibre-Reinforced Polymer (FRP) Reinforcement
Common material used as reinforcement in concrete is steel. Steel is susceptible to corrosion. In
order to have long working life by minimise the risk, galvanised steel, stainless steel, and epoxy-
coated steel are used. Fibre-reinforced polymer, in the form of rods and strips, is an expensive
alternative. The fibres are glass or carbon. One special application of this material is when it is
required to bore tunnels across reinforced concrete walls in future development projects.