Development of Polystyrene Foam Plates and Sprayed Concrete for Three-Layer Products and Structures

Energy saving is one of today’s biggest challenges. Since the construction industry is very energy intensive, there is a question of drastic reduction of energy consumption in all types of buildings. There are different approaches to this issue, but ultimately there is a need to create materials that have high thermal resistance.

Durability of clinker reduced shotcrete: Ca2+ leaching, sintering, carbonation and chloride penetration

The reduction of clinker use is mandatory to lower the negative environmental impact of concrete. In shotcrete mixes, similarly to the case of conventional concrete, the use of supplementary cementitious materials (SCMs) and proper mix design allow for the substitution of clinker without compromising the mechanical properties. However, the impact of the substitution on the durability of shotcrete needs to be further assessed and understood. The results from the present study, obtained from real-scale sprayed concrete applications, show a reduction of the Ca2+ leaching and sintering potential of clinker-reduced shotcrete mixes due to the presence of SCMs. This positive effect, crucial for low maintenance costs of tunnels, is mainly related to a reduced portlandite content, which on the other hand negatively affects the carbonation resistance of shotcrete. Additionally, the hydration of SCMs positively influences the chloride penetration resistance presumably due to a combination of microstructural changes and changes in the chloride binding capacity. Differences found in the pore size distribution of the various mixes have low impact on the determined durability parameters, in particular compared to the effect of inhomogeneities produced during shotcrete application.

Review of Sprayability of Wet Sprayed Concrete

Wet sprayed concrete quality is affected by more production factors than cast concrete, particularly due to the propulsion through the nozzle and the flash set caused by the set accelerator. Practitioners often use the term “sprayability” to describe these factors. We propose a definition of “sprayability” that relates the application to the final properties of the hardened sprayed concrete and review factors affecting it: concrete constituents, proportioning, and application mechanics. These factors affect the hardening and the structure of the hardened sprayed concrete – the porosity, permeability and durability. We consider improving sustainability through proportioning with increased share of supplementary cementitious materials, calculate the placed composition and focus on factors that affect water transport, and hence durability. Due to the spray application and flash-set, irregular compaction voids dominate the macro pore structure of sprayed concrete. Studies of permeability of sprayed concrete have shown that it is possible to obtain low permeabilities given adequate composition and curing. Presumably these samples have been well-cured, uncracked and with non-percolating macro voids. Given observations of cracks in sprayed concrete linings and the macro voids, important further studies will be on the effect of accelerator, compaction porosity and cracking on permeability.