CONCRETING METHODS THAT PRODUCE LOW

CARBON
Prof. Hakim Abdelgader,
Civil Engineering Department, Tripoli University
Email: [email protected]
Dr. Ali El-Baden,
Civil Engineering Department, Tripoli University
Email:[email protected]
Dr. Ahmed Segayer,
Civil Engineering Department, Tripoli University
Email:[email protected]
Dr. Abdulmunaem Fahema,
Civil Engineering Department, Tripoli University
Email:[email protected]

Abstract
A new types of concretes have been produced recently which is completely dissimilar from the
conventional concrete in the method of mixing, handling, pouring, consolidation, behaviours,
cost .etc., Such as two-stage concrete (TSC) and Rock-Filled Concrete (RFC). Two-stage
(Pre-placed Aggregate) concrete (TSC) unlike normal concrete (NC), it is made by first placing
the coarse aggregate in the formwork and then injecting a grout consisted of sand, cement and
water to fill the voids between the aggregate particles. The main benefits of the method are
widely appreciated as Low heats of hydration, high compressive strengths and density,
economic savings, practically no mass shrinkage, low coefficient of thermal expansion,
excellent bond to existing structures. A new type of concrete named rock-filled-concrete
(RFC), which was based on the technology of self-compacting concrete (SCC), has already
been employed in hydraulic engineering structures. The construction technology of RFC
mainly consists of two processes: filling the working space with large scale rock mass and
pouring the SCC into the pre-packed rock body. Less cement in the composite, which results in
less heat of hydration, makes the temperature control of RFC much easier, and this new
construction method leads to fast construction speed, high concrete quality and low cost.
This paper presents two special types of concrete; two-stage concrete and rock filled concrete
and presents the advantages and special requirements for each of the two special types of
concrete and their uses.
Keywords: Two-Stage Concrete, Rock Filled Concrete, Self Compacting Concrete, Mass
Concrete Construction

1. Introduction
The concrete industry has been widely developing in many ways such as the methods of pouring
concrete in order to achieve high quality concrete and low cost. Some of these new concretes
have been produced which is completely different from conventional concrete in the method of
mixing, pouring with no need for the normal compaction methods which require more labour,
tools and higher costs. This paper presents two special types of concrete: Two-Stage Concrete
and Rock Filled Concrete. Two-stage (Preplaced aggregate) Concrete is a simple concept; it is
made using the same basic constituents as traditional concrete: cement, coarse aggregate, sand
and water as well as mineral and chemical admixtures. As the name implies, the coarse
aggregate is laid first then the cement grout is poured by pumping tubes which are directed to
the bottom of the formwork. The grout fills the voids between the aggregate particles. The
Two-Stage Concrete differs from conventionally placed concrete in that it contains a higher
percentage of coarse aggregate; consequently, the properties of the coarse aggregate appear to
have a greater effect on the properties of the concrete, Abdelgader and Najjar. (2009). The
second type is special concrete known as Rock Filled Concrete, RFC, which is a combination of
consolidation Self Compacting Concrete (SCC) and large block or rock with the minimum size
of 300mm. In general, RFC is produced by filling the working space with large-scale blocks of
rock to form a rock-block mass first, and then, by either pumping SCC into the working space
or pour it directly on to the surface of rock-block mass. The environmental impact of RFC
should be assessed in addition to the engineering and economic advantages mentioned above.
More than a half of RFC volume is composed by rock mass with a grain-size larger than 30cm,
which could be used in the job site without any other treatment. And it only needs to mix SCC
to fill the space between rock blocks, which is the rest minor part of RFC, Warner (2005). The
employment of RFC not only reduces the quantity of cement in concrete, but also reduces the
scale of aggregate processing plant and the concrete mixing plant, which results in the reduction
in environmental load and energy consumption. The advantage and special requirements for
each of the two special types of concrete and their uses are presented in this paper.

2. Two-stage concrete
Two-Stage concrete (TSC) is considered to be one of the modern techniques in the concreting
industry. Two-stage (Pre-placed Aggregate) concrete (TSC) unlike normal concrete

(NC), it is made by first placing the coarse aggregate in the formwork and then injecting
a grout consisted of sand, cement and water to fill the voids between the aggregate
particles as shown in Figure 1. The technology of concrete made in this two-stage method is
quite different from the normal traditional concrete, not only in the method of placement but
also in that it contains a higher proportion of stone aggregate; consequently, the properties of the
coarse aggregate appear to have a greater effect on the properties of the concrete than on the
cement mortar.

2.1 Properties of coarse aggregate

The choice of stone aggregate is of great importance in respect to the two-stage concrete
method; the aggregate that is used in (TSC) should be washed, free of surface dust and other
impurities. The void content of the aggregate should be as low as possible and is usually
achieved when the coarse aggregate is graded uniformly from the smallest allowable particle
size to the largest size, ACI 304R (2005). It is typically 40 mm or larger; if aggregates smaller
than 20 mm are used then the injected grout tends to bridge the interstices, thereby impeding
grout flow. The mechanics of the two-stage concrete is depended on the mechanical properties
of the coarse aggregate, because of the point-to-point contact of the coarse aggregate.

Figure 1: Philosophy of TSC concreting

2.2 Properties of grout

The grout that is used in (TSC) normally consists of ordinary Portland cement and well graded
sand. The flow of the grout around the aggregate is essential, therefore some admixtures are
normally recommended to improve the flow of the grout, improve penetrability, and control the
potential for both shrinkage and bleeding.

2.3 Propagation of mixture in coarse aggregate

The problem of flow and curve of mixture propagation in coarse aggregate is an important
economic question. Mathematically the description of propagation is very difficult. General
empirical equation of propagation curve has been derived, Abdelgader (1999), and described in
Equation1 as follows:
y
( x 1)
2

(1)

Where:
= thickness of stone layer (m); = (abf) ; a = parameter dependent of mixture
fluidity.; b = parameter dependent of stone : shape, size, kind of grain, surface , number and
relation of fraction; f = Environment of construction; = (cde); c=parameter dependent of

efficiency of flushing pipe(m3/min.); d=parameter dependent of perforation; e= parameter

dependent on the kind of excavation bottom; t = time (min.); x = distance from flushing pipe
(m); y = level of mixture mirror in stone (m).

2.4 Grouting systems

The injection is achieved by pumping the grout through vertically mounted pipes which almost
reach the bottom of the section to be cast. These pipes are rigid, normally 20 mm in diameter
and placed at 1.5 m centres, ACI 304R (2005). As the grout is pumped into the form the
injection pipes are slowly raised. Injection of grout into small units can be achieved by pumping
into the bottom of the form.

2.5 Advantages of using TSC

The two-stage concrete completely differs from the normal concrete in the placement and
implementation method. Some of the advantages of two-stage concrete are given as following:
2.5.1 Economics
The cost of two stage concrete is nearly 40% less than the cost of normal concrete. This is
related to the reduction of cement content by some 30% with no need for compaction or
vibrating, Abdelgader (1995). In the case of using (TSC) method for underwater concreting, the
cost of water-tight forms and dewatering may be eliminated and preparatory work can be done
under water.
2.5.2 Compressive strength of TSC
The compressive strength (fc`) of two-stage concrete was tested with and without admixture at
28 days. Based on the results, a relation for fc' has been assumed, according to the design
algorithm presented Abdelgader (1999). For the compressive strength of two-stage concrete
(fc`), an empirical equation was calculated using the following formulae:
fc` =A + (B) *w/c + (C) * (w/c)D + (E) * c/s (MPa)

(2)

Where: fc` stands for the estimated compressive strength of two-stage concrete, w/c is the
water-to-cement ratio and c/s is the cement-to-sand ratio. Table 1 presents the values of the
regression coefficients.
The experimental results from Equation 2 shows that the effects of different types of admixtures
on the compressive strength of two-stage concrete. Compressive strength without admixture was
found lower than compressive strength with admixture (super plasticizer). The possible reason
for this decrease in strength was due to the low fluidity of the grout. Same behaviour noticed
when super plasticizer was used to achieve a grout with high fluidity. The possible reason for

the low strength in the series (super plasticizer) might be associated with the bleeding of water
in grout as observed through a transparent cylinder tube.
Table 1 Regression coefficients of equation (2)
E

R2

3.70

0.883

-1.68

2.42

0.944

68.45

0.47

2.63

0.891

126.75

0.52

1.88

0.660

Type of grout

Without admixture*

-3.67

11.20

3.96

-1.79

43.90

-32.55

-3.27

-14.31

-39.83

-25.70

-87.70

Superplasticizer
Expanding admixture
Combination of superplasticizer and
expanding admixture

*Does not include water/cement ratio = 0.38 at all cement sand ratios
2.5.3 Tensile strength of TSC
The tensile strength of TSC was investigated at 28 days. The tensile strength is calculated using
equation 3 as specified by ASTM C 496 (1990), as follows:
Ft=2P/ HD

(3)

Where: ft =tensile strength; P = maximum applied load; and H and D = length and diameter of
the specimen, respectively.
The values of tensile strength for grout proportions are estimated by equation 4. No cause was
apparent for the relatively high tensile strength. However, it is believed that the amount of
coarse aggregate content, method of placement and the greater mechanical interlocking among
the particles could be responsible for the high tensile strength. Failure in tensile strength was
restricted principally due to the line of split and occurs through the mortar and coarse aggregate.
ft =A + (B) * w/c + (C) * (w/c)D + (E) * c/s (MP)

(4)

Where: ft stands for the estimated tensile strength of two-stage concrete, w/c is the water-tocement ratio and c/s is the cement-to-sand ratio. Table 2 demonstrates the values of the
regression coefficients.
2.5.4 Compressive and tensile strength of TSC
There is a good correlation between the compressive strength and tensile strength of (TSC).
The compressive strength and the tensile strengths of (TSC) were investigated at 28 days for all
grout proportions. On the basis of these results a relationship between tensile and compressive
strength of TSC has been statistically derived. See Equation 5.

ft = (A) + (B) +fc`+ (C) (fc`)D (MPa)

(5)

Where: ft is tensile strength and fc` is compressive strength, A,B,C and D are regression
coefficients given in Table 3, Abdelgader and Elgalhud (2008). The measured tensile strength
of TSC is in fact higher than that predicted by the ACI equation for conventional concrete. The
greater mechanical interlocking among the particles could be responsible for this high tensile
strength.
Table 2 Regression coefficients of equation (4)
Type of grout
Without admixture*
Superplasticizer
Expanding admixture
Combination of superplasticizer and
expanding admixture

R2

-0.25

1.26

0.67

-1.29

0.51

0.833

-12.75

-25.27

39.03

0.50

0.39

0.860

-11.54

-23.20

36.12

0.52

0.48

0. 960

9.82

-7.41

-1.37

-1.39

0.42

0. 855

*Does not include water/cement ratio = 0.38 at all cement sand ratios
Table 3 Regression coefficients of equation (5)
Type of grout

R2

Without admixture*

-49.67

-0.44

38.63

0.150

0.724

Superplasticizer

39.97

0.36

-32.28

0.100

0.800

Expanding admixture

-4.30

-0.30

1.82

0.658

0.721

Combination of superplasticizer and

162.65

1.15

132.28

0.108

0.680

expanding admixture

2.5.5 The modulus of elasticity

The modulus of elasticity of two stage concrete is slightly higher than that of conventional
concrete because of point-to-point contact of the coarse aggregate and is mainly affected by the
mechanical properties of stone aggregate. Extensive laboratory tests on the two-stage concrete
using three different types of coarse aggregate (rounded, crushed, and mixed) and three different
grout proportions (w/c = 0.45, 0.50, and 0.55; c/s = 1/1.5, 1/1, and 1/0.8) were performed to
describe the concrete mechanical properties, Abdelgader and Grski (2003). The results
obtained and their statistical analysis enables formulation of the following comments. The
linear part of the stress-strain curve may reach as much as 4060% of the compressive strength
of the specimens as shown in Figure 2.

Figure 2: Graphical presentation of estimating two stage concrete modulus of elasticity

The static modulus of elasticity (ETSC) as a function of the compressive strength of the twostage concrete (fc`) is derived. See Equations 6a, 6b and 6c.
For rounded aggregate:
ETSC=28.7+0.080 fc`

(GPa)

(6a)

For crushed aggregate:

ETSC=33.9-0.049 fc`

(GPa)

(6b)

(GPa)

(6c)

For mixed aggregate:

ETSC=34.9-0.090 fc`

The strength limit values in Eq. (6) are: 22 MPa fc` 32 MPa
The two-stage concrete static modulus of elasticity, for the examined types of aggregates and
grout proportions, is mainly influenced by the mechanical characteristics of the aggregates
i.e., the compressive cylindrical strength, surface texture, and grading. The type of grout has a
significant effect. The characteristic mechanical properties of the two-stage concrete can be
explained by the specific stress distributions, which occur mainly through the particles of coarse
aggregate (skeleton of the aggregate). Relationships between modulus of elasticity and its
compressive cube strength are shown in Figure 3.

Figure 4: Relationships between modulus of elasticity and its compressive cube strength

2.5.6 Shrinkage
TSC differs from conventional concrete in that it contains a higher percentage of coarse
aggregate, Abdelgader(1996). Because of the point-to-point contact of the coarse aggregate as
shown in Figure 1, drying shrinkage of TSC is about one-half that of conventional concrete.
This property in TSC needs more research work to be clarified.
2.5.7 Segregation of the aggregate
The risk of having aggregate segregation is completely avoided in TSC since the coarse
aggregate is placed before adding the other remaining concrete constitutes. In the case of using
the two-stage concrete method for underwater concreting, the dense grout displaces upwards the
water available between aggregate particles, producing a high aggregate/cement ratio concrete
with point-to-point aggregate contact.
2.5.8 The cold joints
In the case of normal concrete, the cold joints should be executed in specific locations, but in
the case of two-stage concrete these can be executed in any location, because the coarse
aggregate pieces cross the joint, bond and shear , which in the majority of cases, will be
adequate.

3. The uses of two-stage concrete

TSC can be used for many applications just as:

TSC is suitable for use in effecting repairs and making additions to concrete structures.

Where placement by conventional methods is difficult (e.g., massive reinforcing steel).

When low-volume change of the repair concrete is required to avoid cracking caused by
excessive tensile stresses in the overlay concrete because of dry shrinkage and restraint
provided by existing concrete.

Where underwater placement is necessary because dewatering is difficult, expensive, or

impractical and water conditions permit. In the case of using two-stage concrete
method for underwater concreting, the water and air being displaced upward by the
rising grout front. Injection is continued until a free washout of grout is emitted from
the top of the pour and the voids between the aggregate is completely filed by the
cement grout.

4. Rock-filled concrete
Rock-filled concrete (RFC) is a new type of concrete for massive concrete construction works
based on the technology of Self Compacting Concrete (SCC). It is produced by pouring ready
mixed SCC into the voids of large blocks of rock with the minimum size 300 mm in the
formwork. The SCC fills the void space between the blocks due to its good fluidity and
segregation resistance, and thereafter the mix sets to form the RFC mass. Figure 4 shows, RFC
as a combination of consolidated SCC and large blocks, Xuehui, Mmiansong, Hu zhou and
Feng (2009).

Figure 4: Rock-filled concrete

4.1 Advantages of using rock-filled concrete

There are many advantages for the employment of RFC in practical structures

Low heat of hydration because the use of low cement content which makes it more
easier to ensure temperature control

Allowing continuous pouring of SCC to reduce the construction time, Concrete Society
Technical Report (2008).

No need for compaction by using SCC results in compaction being ensured independent
of the quality of construction work, Newman and Seng (2003).

Simplifying the aggregate production and concrete mixing machinery contributing to

cost reduction

Using the rock-block mass as skeleton of concrete results relatively little drying and
shrinkage

Reducing noise as well as energy consumption contributes to lower emissions of the

greenhouse gas (GHG) carbon dioxides and also sulphur dioxide.

4.2 Applications of rock-filled concrete

RFC has been put practical use in the following hydraulic projects:
4.2.1 Experimental dam construction
RFC was first used in a gravity dam in a reservoir project in Beijing. The 13.5 m high, 2,000 m3
gravity dam was finished in 2005.
4.2.2 Auxiliary dam in Baoquan pumped storage project
After successfully employed in experimental gravity dam RFC was applied in part of the
auxiliary dam of the upper reservoir in Henan Baoquan pumped storage project.The dam was
designed as a 50000 m3 , masonary construction , such as low construction with RFC to solve
the problems in the practical masonary construction, such as low efficiency and low
construction quality . It was finished in 2006 and the picture of the site during RFC construction
is shown in Figure 5.
4.2.3 Gully backfill in Baoquan pumped-storage project
After finishing the RFC construction on part of the auxiliary dam at Baoquan, most of the
engineers involved, including those with the owners, designer and construction, understood
more about the benefits of RFC and came to an agreement on using RFC instead of
conventional vibro-compacted in the gully backfill project. The total volume of the backfill
project was 130,000 m3 ,and approximately 50,000 m3 of them was constructed with RFC.
4.2.4 Caisson backfill in Xiangjiaba hydropower project
RFC was also employed in the Caisson backfill in Xiangjiaba hydropower project, which would
be the third largest hydropower station in China. Approximately 70,000 m3 of RFC had been
constructed in the Caisson backfill project and it was finished in the end of 2007. See Figure 5.

(a)- Auxiliary dam

(b)- Cassion

Figure 5 : Caisson backfill and Auxiliary dam examples

5. Conclusions

The cost of two stage concrete is almost 40% less than the cost of normal concrete.
This is related to the reduction of cement content by 30% and there is no need for
compaction or vibrating of concrete.

The risk of having aggregate segregation is completely avoided since the coarse
aggregate is placed before adding the other remaining concrete constitutes.

Bond of two-stage concrete is excellent because the grout used to consolidate the preplaced aggregate penetrates surface irregularities and pores to establish initial bond.

In the case of normal concrete, the cold joints should be executed in specific locations,
but in the case of two-stage concrete can be executed in any location, this is because
the strength of two-stage concrete depends specifically on the coarse aggregates itself.

The use of Rock Filled Concrete gives many advantages related to quality, cost and
environment considerations.

The RFC gives low heat of hydration because the use of low cement content which
makes it easier to ensure temperature control.

RFC Allows continuous pouring of SCC and reduce the construction time

In RFC method there is no need for compaction as using SCC results in compaction
being ensured independent of the quality of construction work

Simplifying the aggregate production and concrete mixing machinery contributes to

cost reduction

Using the rock-block mass as skeleton of concrete results relatively little drying and
shrinkage

6. References
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International Conference on Sustainable Built Environment Infrastructures in Developing
Countries, pp. 315-324 , ENSET Oran (Algeria).
Warner J ( 2005) PreplacedAggregate Concrete , Concrete International , -27 : 34-38.
American Concrete Institute (2005) Guide for Measuring, Mixing, Transporting, and Placing
Concrete , ACI 304R, 1-15, USA, 2005.
Abdelgader H S (1999) How to Design Concrete Produced by A Two-Stage Concreting
Method , Cement and Concrete Research 29-3 : 331-337.
Abdelgader H S (1995) Polcrete Economical Method For Dams , Proceeding of the MWA.
International conference on dam engineering 1: 1-4, August(1995), Kuala Lumpur, Malaysia.
ASTM C696 (1990) Test For Splitting Tensile Strength of Cylindrical Concrete Specimens,
American Society for Testing and Materials, Philadelphia, Pennsylvania, USA.
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Concrete , Journal of Materials in Civil Engineering ASCE 15- 4 : 329-334.
Abdelgader S and Elgalhud A (2008) Effect of Grout Proportions on Strength of Two-Stage
Concrete , Structural Concrete 9-3 : 163-170.

Abdelgader H. S. (1998) Applications of Two-Stage Concreting Methods , Scientific

Papers , 55-570: 93100, Technical University of Gdansk, Poland.
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Xuehui A, Miansong H, Hu Z and Feng (2009) Rock Filled Concrete in China , Special
report.
American Concrete Institute (1998) ACI 546.2R-98 Guide to Underwater Repair of Concrete
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