CONCRETE IN THE MIDDLE EAST

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1 CONCRETE IN THE MIDDLE EAST ALKALI REACTIVITY IN CONCRETE STRUCTURES Presented by : Eng. ELIE J. SFEIR

2 INTRODUCTION What is the Alkali-Reactivity? The alkali reaction is a chemical reaction between some particles or fragments of the Silicate or Carbonate existing in the Aggregates, and the Cement Alkalis. This reaction refers to the attack of aggregates in presence of the alkali ambiance of the cement, creating the silicate or carbonate reactions, which will create the Expansion, under certain conditions and the Swelling of the Concrete.

3 What is the Alkali-Reactivity? These materials or aggregates such as silicates, microcrystalline, crypto-crystalline or quartz are the main factors of these reactions. They are simply detected by the testing procedures indicated here after according to ASTM Standards.

4 What is the Alkali-Reactivity? The identification of the reactive aggregates by Petrographic Examination is not enough, and the preliminary tests should be completed by additional one, existing years ago especially in North America. These tests criticized, because they are so Slow, but they are always Reliable.

5 PATHOLOGY AND EXTERNAL MANIFESTATIONS: The disorders appears generally at different variable intervals of times, generally between Two and Ten years of the age of the concrete structure. The pathology and external manifestations are observed threw several symptoms: Internal Micro-cracks. Visible Cracks appears on the concrete surfaces.

6 Formation of Cracks in different sizes and shapes (as honey combs) in large and small ones, oriented in the same direction of the steel bars reinforcement distribution. Formation of Calcite and white Efflorescence and almost transparent frost and jelly.

7 Presence of Pimples and Craters with exploded concrete fragments, localized in the form or aspect of small cones due to the reaction of superficial coarse aggregates visible in deep concrete and detached from the concrete surfaces finishes. Movements and deformations. Presence of colorations and or discoloration of the concrete surfaces.

8 Therefore, the development of the Alkali Reactivity phenomenon in concrete is due to three consecutives factors: a) Presence of Alkalis materials in the Cement. b) Presence of Deleterious Reactive Raw materials known to be potentially deleteriously alkali-silicate reactive, and or alkali carbonate reactive. c) Presence of Water and or, humid environment.

9 IDENTIFICATION AND TESTING PROCEDURES: The first factor need an investigation of the reactions developed between the Cement and the Aggregates, which develop the Alkali Silicate Reactivity (ASR), or the Alkali Carbonate Reactivity (ACR). The second factor, is related to the preventive procedure to be taken by the designer during the assessment and interpretation of the concrete raw materials, and to investigate their sources (Quarries, crushing plants ).

10 Crushing Plants Quarries

11 The third factor is related to the Type of the Project and the corresponding environment. This includes the classification of the materials potentially deleteriously alkalis and silicate reactive, by conducting the appropriate Tests according to ASTM Standards.

12 These tests are, but not limited to the following: a) ASTM C295 Standard Guide for Pectrographic Examination of Aggregates for Concrete. The Petrographic Examination outlines procedures of determination of the physical and chemical characteristics of materials proposed for use as aggregates and their performance in their final intended use. This method should establish whether the aggregates contain chemically instable minerals or not.

13 b) ASTM C227 Standard Test Method for Potential Alkali Reactivity of Cement-Aggregate Combinations (Mortar bar Method). This test method covers the determination of the difference (increase or decrease) between the initial and the final length of the mortar specimen due to the presence of alkalis in cement.

14 c) ASTM C289 Standard Test Method for Potential Alkali Silica Reactivity of Aggregates (Chemical Method). This test method covers chemical determination of the potential reactivity of an aggregate with alkalis in Portland Cement Concrete as indicated by the amount of reaction during 24 hours at 80 0 C, between 1N Sodium hydroxide solution, and aggregate that has been crushed and sieved to pass 300 μm and be retained on a 150 μm sieve.

15 d) ASTM C586 Potential Alkali Reactivity of Carbonates Rocks for Concrete Aggregates (Rock Cylinder Method). The purpose of this test method is to classify the characteristics of carbonate rocks while immersed in a solution of sodium hydroxide (Na OH) at room temperature. The expansion changes due to the reaction between cement alkalis and carbonate rocks or aggregates should be interpreted carefully with full recognition of aggregates sources. Appreciable Expansion should indicate the need for further tests according to the test method ASTM C1105.

16 e) ASTM C1105 Standard Test Method for Length Change of Concrete due to Alkali-Carbonate Rock Reaction. The objective of this test is to determine the length change of hardened concrete due to expansive alkali-carbonate reaction involving hydroxide ions associated with alkalis (sodium and potassium), and certain calcite dolomites and dolomite limestone: Alkali silica reaction containing siliceous rocks. Alkali-carbonate reaction containing dolomite in some calcite dolomites and dolomite limestone.

17 RECOMMENDATIONS FOR THE DISORDERS DUE TO ALKALI- REACTIVITY 1.Classification of different types of projects according to French Standards NF:

18 Category 1 a. Concrete Class maximum B20 MPa. b. Non-load bearing elements of the structure. c. Structural elements can be demolished or substituted. d. Temporary structural elements. e. Cyclopean concrete. f. Asphalt bituminous concrete. Category 2 a. Buildings or structures exposed to water table and Water Tanks. Category 3 a. Dams and all projects requiring maximum security and stability. The formation of alkalireactivity in this type of structure is Totally Not Allowed. b. Reactors of nuclear centers, tunnels, bridges, monuments, and all other prestigious projects requiring High Level of Security.

19 Structure exposed to water Concrete well Tunnels

20 Dams: Mass Concrete exposed to water continuously

21 Therefore, the following Levels of Prevention, are as listed here below: a) Level A: No special recommendations are required. b) Level B: The following steps shall be taken: Alkali reactivity tests shall be performed at specialized laboratories. Reporting all required values and interpretation of the results including recommendations regarding any additional investigations that may be required to evaluate adverse properties by the petrographic examination that has been performed.

22 c) Level C: No exceptions The aggregates shall not be alkali silicate or carbonate reactive.

23 Environment Project Category Dry/Few Humidity Humidity /Water Presence Humidity/ Thawing and Freezing Marine Ambiance Acceptable risks A A A A Tolerable risks A B B B Unacceptable risks C C C C

24 Superstructure exposed to Humidity Structure below Water table

25 2. Conclusion: The Structural Designer of the project, shall specify the level of the required prevention as follows: Level A: No recommendations. Level B: Required all necessary tests on aggregates (Chemical and physical tests). Level C: Aggregates classified reactive requiring the utilization of Cement with Slag and Additional Additives.

26 METHODOLOGY: 1. The procedure of qualification and identification of aggregates requires a deep research about reactive particles in aggregates. This research can be realized by Petrographic Examination of the aggregates and verification of the potentiality of aggregates with instant and long term tests.

27 2. The complete Petrographic Examination of aggregates will require the use of optical microscopy. A complete investigation of a particular problem may require examination of aggregates, or of the selected constitutions by means of additional procedures such as: X-ray diffraction analysis. Differential thermal analysis. Infrared Spectroscopy. Microscopical methods.

28 After these identifications, the aggregates are classified: No presence of reactive particles (Non Harmful) Non reactive (NR). Containing reactive particles Harmful in critical situations to the aggregates and to the Concrete; and are classified Potentially Reactive (PR).

29 If the Expansion of the aggregates is below a certain determined level, the aggregates are classified Non- Reactive (NR); if not they are classified Potentially Reactive (PR). Also, a chemical test based on the evolution of the ratio of SiO2/Na2O versus time, can be Indicative to classify the aggregates correctly.

30 PREVENTIONS: To prevent this type of Pathology, it will be required to recuperate, or identify the potential reactive aggregates and to establish a procedure of the selection of the aggregates contributing in the concrete mix. To choose the appropriate type of cement with alkalis non-reactive and non-harmful to the concrete mix and his constitutions in order to avoid any later risk of formation of Alkali-Reactivity.

31 It is an essential matter to adopt Preventive guidelines in order to avoid defects in the concrete due to the alkali reactivity, especially in Dams, Water Tanks and other structures exposed to Water permanently. The risk of reactivity due to the presence of alkalis and to the process of formation of alkalis in concrete and in contradictory to the cement with high percentage of Slag or Blended Cement with Slag, which is very Offensive and create an Obstacle against formation of alkali-reactivity.

32 So, the choice of the type of cement based on tests of concrete is essential for final interpretation and judgment. Otherwise, the Blended Cement with Slag can be considered as an Offensive and Obstacle to the problems in concrete, and resistance to aggressive water. The Low Heat Cement was very used in large scale in so many projects.

33 The Micro - Silicate and the Fly Ash are excellent additives for usage in cement to avoid these obstacles and these problems that may occur in the concrete. Therefore, to prevent all risks of Alkali Reactivity, we should go for a better choice in the Selection of Aggregates from the appropriate quarries and in the selection of the corresponding Cement type in the concrete mixtures:

34 Use of Ground Granulated Blast-Furnace Slag (GGBS). Fly Ash type F (FA). Silica Fume (SF). Low Alkali cement. Low Heat Cement (Type CS). Additional precautions may be useful, such as: Use of Washed Coarse and Medium Aggregates. Use of crushed sand produced only from Limestone with percentage of fines passing Sieve # 200 less than 5%, and a continuous grading between 2 and 6mm.

35 Finally, The usage of Supplementary Cementations Materials (SCM) will lead to a better: Durability and Sustainability of the Concrete Structures

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