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Repair is an indispensable part of the maintenance of structures over their lifetimes. Structural grouting is a widely used remediation technique for concrete components, trenches, mine subsidence, dam joints, restoration of masonry structures, and geological stabilizations. A structural grout system should be injectable in narrow spaces and hence include ingredients with finer particles. Ultrafine cements are ideal for these type of demanding grouts due to their superior properties compared to that of the less expensive, but coarser ordinary Portland cement (OPC). Supplementary cementitious materials (SCMs) are often used to replace OPC clinker based binder in order to modify certain properties and to reduce costs. The most commonly used SCMs are fly ash (FA), and ground granulated blast furnace slag (GGBS). For various special applications microsilica (MS), and metakaolin (MK) are also used. Identifying the optimum replacement contents of OPC by SCMs are a challenge during the design of such grouts. The aim of this experimental study is to investigate the effect of the selected SCMs (FA, MS and MK) on the slump flow, time of efflux, viscosity, shrinkage, and compressive and flexural strength of ultrafine cement based grouts with constant water-binder ratio and superplasticizer content. The test program was formulated using Box-Behnken design principles. Maximum percentages of replacement with ultrafine cement was 6% by volume of cement for MS and 16% for FA, and MK. The results suggest that most investigated grouts have the potential to be used for structural applications. The appropriate quadratic models are then formulated through statistical tools and presented as response surfaces. The trends indicate that fly ash improves the rheological properties, whereas microsilica and metakaolin positively affect shrinkage and mechanical properties to some extent. Based on the influence of SCMs and priorities among the properties, Decision Matrix Analysis (DMA) is carried out to select the most suitable ones among the SCMs. The analysis suggests that microsilica and fly ash are more suitable as SCMs than metakaolin without affecting the properties.
Most factors acting on concrete rheology work at an extremely small-scale level. Influencing factors in the millimetre or centimetre area are essentially restricted to sand and aggregates. The latter, however, make up 50 to 70% of the total volume of most concretes – a fact often ignored in research on controlling concrete processing properties.
Whereas suitably chosen concrete admixtures and additives can influence rheology in a very targeted manner, sand and aggregates are less suitable for controlling rheology but nonetheless contribute to the rheology of the Overall system. The actions of sand and aggregate can impose themselves upon the actions of admixtures and additives
and, in unfavourable circumstances, even render them redundant. For this reason, any results concerning the processability of binding agent systems can only be transferred to concrete with great care. It is important to better understand the action of sand and aggregates in order to be able to harmonise them in such a way that they complement the action of superplasticisers positively, instead of
working against them. Savings on costs can also be made by this targeted fine-tuning.