Basic Terminology
Aggregates: Volume Fillers in Concrete Mixes
Aggregates are granular mineral components primarily used to increase the volume of construction materials. The greater the proportion of aggregates in a concrete mix, the more cost-effective the product becomes, as it requires less cement. Several types of aggregates are used in concrete mixtures, including "Apulia" (25 mm), "Lentil" (19 mm), "Pea/Sesame" (9.5 mm), and natural sand (1.18 mm). Aggregates also influence the concrete’s weight, strength, durability, and lifespan.
Hydration & Curing
Hydration is the chemical process that occurs as concrete hardens, during which the cement bonds with water and releases significant heat. Keeping the concrete wet is crucial to complete this process, as water promotes proper bonding and hardening, while preventing overheating that could cause fissures and compromise the concrete's integrity. Curing is the process of keeping concrete wet for seven days to complete hydration, achieve maximum strength, and prevent fissures during the initial drying phase caused by moisture differences between the inner and outer layers.
Betkal: Lightweight and Workable Concrete
Betkal is a type of standard concrete modified with a foaming agent, resulting in a more flexible and workable material. The mix typically includes sand, cement, and a special hardening inhibitor. Often referred to as “lightweight” or “foamed concrete,” Betkal features a structure composed of approximately 60% air bubbles, which significantly reduces its weight. It is commonly poured beneath the waterproofing layer on flat roofs to create slopes and prevent rainwater accumulation. The air-filled structure also enhances its thermal insulation properties.
Concrete Strength: The Water-to-Cement Ratio
Concrete mixes are classified by strength levels, ranging from B-10—the lowest grade, containing lightweight aggregates and less cement—to B-70, the highest grade, which uses iron spheres and a higher cement content. The primary factor influencing concrete strength is the water-to-cement ratio. To measure strength, a fresh concrete sample is poured into a cube mold. After consolidation and 28 days of curing, its compressive strength is tested in a laboratory using a hydraulic press.
Cement Powder abd Binding Process
Cement is a powder made from limestone and clay-rich soil, used to bond and bind the components of concrete. The fineness of the cement grinding directly influences concrete strength—the finer the cement, the stronger the concrete. Concrete typically weighs between 2,200 and 2,500 kg per cubic meter, depending on the type of aggregates and the amount of cement in the mix. Binding is the process in which the cement pulp loses its flexibility and solidifies. The continued strengthening of the solid material over time is known as hardening or stiffening.
Additives for Concrete Mixes
Additives are ingredients incorporated into concrete mixes to impart specialized properties—such as accelerating strength development or enhancing resistance to extreme temperatures. One notable example is a crystalline additive that enables the concrete to self-heal by sealing cracks up to 0.4 mm wide. This additive creates a long-term protection mechanism within the concrete, even under high hydrostatic pressure.
Concrete Lifetime: Wear Resistance
Concrete is designed to withstand various types of wear over several decades. Dense concrete helps prevent the penetration of harmful substances. In cases where the concrete must endure particularly aggressive materials, it should be further densified using specialized additives or cements tailored to the specific exposure conditions.
Maximum Granule (Stone) Size
Determining the maximum stone size in concrete is essential to match the material to the construction element and transportation method. For standard concrete, the largest aggregate used is "Apulia" (25 mm), followed by "Lentil" (19 mm), and "Pea/Sesame" (9.5 mm).
Different Types of Concrete
Imported concrete is produced at dedicated batching plants and delivered to the construction site in concrete mixer trucks. Throughout the journey, the concrete is continuously mixed to ensure consistency and uniform quality. Concrete for smoothing is designed for casting horizontal elements that require a higher-quality finish than standard concrete. It contains a higher proportion of fine particles to facilitate easier finishing. Reinforced Concrete is a construction method that combines concrete with an elastic material, typically steel, to create a particularly strong building material. Steel meshes or bars are embedded in the concrete during casting, resulting in a composite material capable of withstanding various types of stresses. Prestressed or post-tensioned concrete is strengthened through compression to create a stable structure capable of bearing heavy loads and withstanding earthquakes. Pumpable concrete is designed to flow through rigid or flexible duct systems, with a maximum granule size of 25 mm to ensure smooth pumping.
Exposure Level: The Ability to Withstand Different Environmental Conditions
According to the Standard, there are 11 exposure levels, each representing the specific environmental conditions the concrete must withstand. Levels range from Exposure Level 1 for desert areas or interior walls to Exposure Level 11 for elements exposed to highly aggressive environments, such as coastal areas or chemical exposure.
Concrete Slump Test
The concrete slump test measures the workability and flowability of fresh concrete at the site. Using an Abrams Cone (SII 26 2.1), the test assesses consistency based on the degree of subsidence, typically ranging from 4 to 8 inches. Greater subsidence indicates easier handling (pushing, compacting, leveling), while lower subsidence ("drier" concrete) reduces the risk of fissuring during drying and hardening.
Concrete Spread Test
The concrete spread test measures the diameter to which concrete spreads, indicating its flowability, self-levelling ability, and sensitivity to segregation. During the test, the concrete spreads over a metal surface, and the average of the puddle’s length and width is calculated.
Bentonite: The Additive that Enhances Concrete Waterproofing
Bentonite is a naturally occurring material formed from the decomposition of volcanic ash, known for its high water absorption and expansion capabilities. In concrete, bentonite enhances sealing properties and improves water resistance, making it especially suitable for subterranean structures, water reservoirs, and any application requiring a high level of waterproofing.