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THE USE OF CONCRETE SET RETARDERS

S TO P P I N G C O N C R E T E ’ S C L O C K
Karl Millard is a gold and silver smith artist represented in the collections of several of Australia’s state
galleries. Whether working with metals or concrete, Karl’s interest is in making art by intervening in the
period when a material changes from a liquid to a solid state, from the plastic to the hard.

Last year, Karl worked for some time with the developer the Vitalis Group. His brief was to develop
design-cum-sculptural proposals for several elements of a proposed high-rise apartment tower in the
Melbourne suburb of St Kilda. For Karl, it is the plasticity of concrete that is intrinsic to its potential in
art...and architecture.

Enter the Cement and Concrete Association. Following discussions with us, Karl became interested in
the possibilities of concrete set retarders.
Cement & Concrete Association of Australia Set retarders are chemical agents that are applied to the surface of the formwork to retard the setting

EDITOR GRANT ROBERTS

E-mail: grant@ccaa.com.au

C&CAA ADDRESSES: CENTRAL DIVISION

NSW & ACT
Cement & Concrete Association of Australia
Locked Bag 2010
ST LEONARDS NSW 1590

NORTHERN DIVISION
QUEENSLAND
Cement & Concrete Association of Australia
348 Edward Street
BRISBANE QLD 4000

SOUTHERN DIVISION
VIC, SA, WA, NT, & TAS.
Cement & Concrete Association of Australia
No1 Hobson Street
SOUTH YARRA VIC 3141

TECHNICAL INFORMATION: TECHNICAL INFORMATION SERVICE

Fax 1300 360 298
E-mail NSW, QLD, ACT: inquiry_n@ccaa.com.au
E-mail VIC,SA,WA,NT,TAS: inquiry_s@ccaa.com.au
LIBRARY:
CEMENT & CONCRETE ASSOCIATION LIBRARY
The Librarian
Cement & Concrete Association of Australia
Locked Bag 2010
ST LEONARDS NSW 1590
Telephone: 02 9903 7721
Facsimilie: 02 9437 9473
E-mail: sheena@ccaa.com.au
DISCLAIMER:
The Association is a non-profit organisation sponsored by the
cement industry in Australia to provide information on the many
uses of cement and concrete. This Guide is distributed by the
Association for that purpose. Since the information provided is
intended for general guidance only and in no way replaces the
services of professional consultants on particular projects, no
legal liability can be accepted by the Association for its use.

All images by C&CAA except:

PHOTOGRAPHY Stopping concrete’s clock, images by Karl Millard;
CREDITS: Exposed Aggregate for Concrete, images courtesy of Portland
Cement Association.

Levenspiel [lev@netspace.net.au]
DESIGN/LAYOUT: Boothroyd Levenspiel
PRODUCTION: Vaughan Printing
PRINTING: HiTech Graphics
SCANNING:
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stop

time of the surface of the concrete as it cures.
Various strengths affect the surface of the
concrete to different depths. Depths of up to ten
millimetres are normal. Under the surface, the
unaffected concrete hardens in the normal way
to its specified strength. The concrete panel is
lifted from the mould, usually within 24 hours.
The cement paste under the influence of the
set retarder is removed by water spraying and
brushing, usually to reveal underlying
aggregates.
Set retarders are manufactured with water or
solvent bases, and are of different viscosities to
suit different applications.
Karl applied the retarder to paper and plastic
form liners by brushing in some cases, and at
other times, by screen printing.
aggregates and cement colours. The colours were not applied later as a coating, but were an integral
part of the casting process.
For face down casting, they were placed in the mould, over the retarder, as a thin layer, followed by the
backing layer of concrete (or cement only) to make a monolithic bond. The colour is where the retarder
was not.
You could be forgiven for thinking some of the examples in relief are moulded, such is the definition that
results from the controlled application of the retarder and the fineness of the cement powder.
Suppliers of set retarders can be found in the Yellow Pages under ‘Concrete Additives’. Refer to MIX
Volume 1 for detailed information about colouring with mineral oxides.
These pages feature Karl’s 300 x 300 concrete samples and demonstrate the possibilities for colour and
pattern with the use of concrete set retarders.

The examples here, show various combinations

of mineral oxide colour toppings (not paint),

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STEPPING OUTSIDE THE SQUARE

J O H N WA R D L E A P P L I E S T H E C O O K I E C U T T E R T O P

This project demonstrates the versatility of precast concrete panels which is made possible
by their ability to cantilever and bridge openings. It is also a good example of the precision
achieved with the controlled conditions of a precaster’s yard.

This single-storey building (about 980m2) for the CSIRO Division of Wool Technology in
Geelong contains laboratories, offices and staff amenities. It received a commendation from
the Victorian Chapter of the Royal Australian Institute of Architects, at the 1997 awards.

The concept for the building rose from the rubble of a demolished warehouse that previously
occupied the site. A series of mannered lantern lights rise from the roof plane recalling the
humble precedent of the saw-tooth roof. The precast concrete panels, which today comprise
the shell of many warehouses, also undergo transfiguration in the hands of architects John
Wardle Pty Ltd.

With the budget spread thinly, sandblasted concrete panels offered economy for the capital
costs and long-term maintenance. Economical they they may be, but ordinary they’re not.
Usually you see precast panels with the window openings punched out of the centre. In this
project the window openings are made only when the panels are joined together. The joints
thus become intrinsic to the composition of the facade, and not an unhappy consequence of
the construction technique.

On the northwest corner of the building, an irregular shaped panel is bolted piggy-back
fashion onto the one behind. Apparently released from its functional duties, it is the surplus
panel—the precaster’s found object— raised in status. It is the architect’s clue to reading the
building’s shell.

PROJECT: CSIRO Division of Wool Technology

LOCATION: Henry Street, Belmont, Victoria [near Geelong]
ARCHITECT: John Wardle Pty Ltd
CONTRACTOR: Kane Constructions (Vic) Pty Ltd
PRECAST CONTRACTOR: Cambar Precast
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P R E C A S T C O N C R E T E PA N E L S

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SPECIFICATION GUIDE

E X P O S E D A G G R E G AT E S F O R C O N C R E T E
INTRODUCTION There are few limits to the combinations of aggregates, colours and textures in concrete. Each mix is as unique as a
finger print. Producing exposed aggregate concrete is not difficult, but it does demand some considered decisions.
Designers are concerned with the appearance of finished work. However the size, shape, and proportions of the
aggregates in the mix will also affect its workability, placement, cohesiveness, strength and durability.
Here we give some guidance for the selection of aggregates, where they can be found and an insight into the effects of
their size and shape. We also give an overview of ways to incorporate the aggregates. Limited space doesn’t allow us to
give any more than a snapshot of the techniques for exposing them. We will, however, look at these techniques in future
issues of MIX .

SELECTING AGGREGATES
Aggregates—the stones and sands of the mix—occur naturally. Numerous types, shapes and colours are mined or raked
from river beds for commercial use.
Where can you see them? If your project is comprised of precast panels you can draw on the knowledge of precast
manufacturers with experience in the production of reconstructed stone panels. If you make a trip to their casting yard,
you will probably find trial samples of past projects and a collection of jars containing various types of stones and sands
suitable for a concrete mix. If you find a precaster with a sample you like, a reliable memory, and a good filing system,
you may be able to specify exactly what you want, there and then. Nevertheless, it is a good start to the worthwhile
process of developing samples for your project.
If you’re considering concrete paving or a polished concrete floor, you could start by collecting some samples from local
terrazzo suppliers as reference material for your selections and the subsequent development of test samples. Remember
that traditional terrazzo has no sand in the matrix.
Alternatively you can find commercial suppliers of aggregates in the Yellow Pages under ‘Quarries, Stone Supplies’, or
‘Sand, Soil & Gravel’. Again, there is no substitute for your own leg work to find something special. Look under
‘Landscape Supplies’ for unusual aggregates and pebbles.

The following is an overview of the effects of the physical properties of the aggregates on the concrete in its plastic (wet)
and hardened states.

As defined by the Australian Standard AS 2758.1 Aggregates and Rock for Engineering Purposes-Concrete Aggregates,
a coarse aggregate has a nominal size not less than 5 mm, and a fine aggregate less than 5 mm. Grading is the
AGGREGATE GRADING, SHAPE AND DURABILITY distribution of particle sizes in a batch of aggregates. In a normal mix, an even distribution of sizes ranging from fine
through to coarse is usually sought to balance the demands for workability, cohesiveness, strength and durability.
In concrete’s plastic state, the cement and water in a mix lubricate the aggregates, allowing the concrete to be placed
Grading and worked. A mix with coarse grading—that is having a lower proportion of sand—will need less cement for workability.
However the absence of sand will produce a mix that is likely to segregate (the stones settle to the bottom) during
transport and placement, and bleed excessively (too much water rises to the top). On the other hand, a mix with a
greater proportion of fine sand results in a sticky mix needing more cement to make it workable and achieve the
specified strength.
Continuously graded aggregates in the usual proportions will however, result in a non-uniform distribution of the coarse
aggregates in exposed work. To achieve uniformity the intermediate aggregate sizes are often omitted in what is called a
‘gap-graded mix’. In gap-grading, a larger percentage of coarse aggregate and a small percentage of fine aggregate
sufficient for workability, are combined.

The shape of the aggregates will affect the workability of a mix in its wet state and its strength when hardened. Smooth,
rounded aggregates maximise the workability, however rough cube shaped stones will produce optimum strength.
Flat and elongated aggregates—referred to as ‘misshapen particles’—reduce workability and may also have an adverse
affect on strength because of their tendency to selective orientation and bridging resulting in air pockets. A good mix
design will limit the percentage of these particles in accordance with the Australian Standard AS 2758.1. If you have
selected a flaky, elongated aggregate to feature, it would be wise to consider the bonded topping method described
below.

Shape Two issues are particularly important in relation to the durability of exposed aggregate concrete. These are the
resistance to external abrasion and the resistance to attack by alkalies in the cement. External abrasion can result during
the handling and mixing of aggregates, from harsh weather conditions, or in the case of a floor, path or road, from the
movement of feet and cars. Consider these issues when specifying.
Some aggregates contain silica that reacts with the alkalies in cement. An alkali-silica gel results, which takes up
moisture, swells, and causes cracking. The common ones to note are chert, chalcedony, common opal, acid-glassy-
volcanic rocks, and mica. The glass often seen in terrazzo is used sparingly and in comparatively thin topping layers.

A broad range of colour mineral oxides can be blended and added to the mix in different proportions to colour the
Durability cement paste. MIX Volume 1 outlined the use of oxides. The suppliers will make samples of their pigments available for
inspection. At the development stage they can help determine the correct proportion of oxide powder to achieve the
colour you want. Small trial samples will help find the right proportions to be specified. They may also provide a
specification for their product and the method of dispersion through the concrete mix.
If the mix isn’t tinted with mineral oxides, you will find that the fine aggregates—that is the sand—will largely determine
the overall impression of colour. On the other hand, the more the coarse aggregates are proud of the surface, the more
their colour will dominate. So ensure the contractor stockpiles the sand from a single source to avoid colour variation.

COLOURING THE MATRIX
The colour of the cement will also affect the appearance. Cement falls broadly into three colour groups: white, off-white
and grey. Believe it or not, there is also beige produced in Western Australia. There are however, variations within a
given colour group.
The manufacturing of cement begins with the mining of limestone. Limestone has natural variations from quarry to
quarry. Manufacturing processes also vary. Consequently, one manufacturer’s grey cement could differ from another’s.
Consistency of colour is usually crucial in exposed concrete. To this end, specify the source of the cement supply, that is
the cement type and the supplier.The colour of the cement is particularly important if you plan to use a coloured oxide to
tint the cement paste. Off-white will tint differently to grey for example. Again a single source of cement supply is
important.

In the introduction we raised the matters of workability, placement, cohesiveness, strength and durability of concrete. All
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AS 2758.1
of these are important issues that are considered when designing a concrete mix. Australia is lucky to have
manufacturers of architectural precast concrete that are helpful and among the best in the world. Their cooperation offers
SELECTING A CEMENT COLOUR the specifier a shortcut.
Here’s how. First, convene a series of meetings with your consulting engineer and precaster. After a little argy-bargy and
probably some trial samples you will compromise on a sample that you like the look of, that the engineer is satisfied is a
sound mix design, and that the precaster can produce and finish for the price. This sample can then be identified by
name or number and is the basis for your specification and tendering. The precaster will have recorded the details of the
mix design, obviating the need to detail aggregate sizes and proportions.

In the case of floor slabs and paving there are three ways to incorporate aggregate.

SPECIFIYING AGGREGATES IN PRECAST CONCRETE
A concrete mix of 25 Mpa with a slump between 80-100mm is placed in the conventional way. This is a higher strength
grade than a common house slab mix, although it is the usual grade for commercial and industrial floors. The higher
strength will give the exposed concrete surface greater resistance to abrasion and minimise the probability of the
aggregates dislodging. The mix can also be coloured with mineral oxides as outlined above.
The concrete is placed and struck in the usual manner. Before it is floated however, the surface is ‘seeded’ with the
select aggregates by sprinkling them by hand or shovel. The aggregates are embedded into the surface by tamping, bull-
floating, and finally hand-floating. At this stage, the aggregates remain hidden by a thin layer of cement paste. One or a
number of techniques can be used to expose the aggregates to view. These are summarised below.
You will have to specify the types of aggregates and the distribution. Rather than specify a rate of distribution, it can be
effectively done by the development of samples to determine the appearance of the finished work. Allow for this in the
tender documents.

SPECIFYING AGGREGATES IN FLOORS AND EXTERNAL PAVING
Seeded surface
This method combines a conventional structural slab with an economical decorative veneer. A thin topping layer of
concrete containing the select aggregates is placed over a base slab of conventional concrete while it is in a pre-
hardened state. Generally this will be 25-50mm thick for coarse aggregates between 10-20mm. If you are thinking about
larger aggregates, the seeded technique outlined above may be more suitable. The base slab must be workable, but firm
enough to carry the weight of the concretor. The topping is placed, struck and floated. The base and topping harden
simultaneously, resulting in a monolithic bond. Again the topping can contain special cements and coloured oxides.

The aggregates can be mixed through the concrete at the batching plant in much the same way as a normal grey mix.
They are uniformly distributed through the concrete and have a direct influence on the workability, cohesiveness,
strength and durability of concrete. Consult your structural engineer for their opinion on the mix design. If your
aggregates differ significantly from those of a normal concrete mix, a specification can be developed in consultation with
the technical manager of the pre-mix supplier after a number of trial samples and strength tests.

Several different methods of exposing the aggregates are summarised below. Different techniques and combinations of
them, produce different appearances.

Grinding and polishing pads have carborundum particles or diamonds to cut the surface. When selecting aggregates
Aggregate topping consider their hardness which will affect the rate of wear and tear on the grinding pads, which in turn will have a bearing
on the cost.

After the initial setting stage the thin covering layer of cement paste is gently washed from the aggregates with a fine
water spray and soft broom. Timing is important. Surface set retarders can be used to buy time on larger jobs or during
hot weather.

Sandblasting (or grit blasting) is high pressure blasting of the hardened surface of concrete with waterborne or airborne
sand, or other abrasive medium.
Monolithic construction
The controlled conditions of a casting yard lend themselves to the use and management of acids. Dilute acids are
applied to hardened concrete for short periods, scrubbed and flushed with water.

A few weeks after the concrete has hardened, pneumatic tools with chisels or multiple points remove the cement paste
and fracture aggregates at the surface.

EXPOSING THE AGGREGATES MIX Volume 1 January 1999, C&CAA.

Guide to Concrete Construction 1994’, Joint publication of C&CAA and Standards Australia.
Australian Standard AS 2758.1 Part 1: Aggregates and Rock for Engineering Purposes-
Grinding Concrete Aggregates, Standards Association of Australia.

Water washing

Sandblasting

Acid etching

Bush hammering

FURTHER READING

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TIPS A SPECIFIER’S CHECKLIST

CONCRETE CURING METHODS

GENERAL CONSIDERATIONS
Type of element
Is the element vertical or horizontal? Some methods are affected by, or precluded, because of their
orientation. Curing by water ponding for example, is unsuited to vertical elements.
Is the member thin or thick? Thick sections such as large columns or mass concrete are mostly ‘self-
curing’ but require temperature gradient at outer layers to be limited.
Is the member insitu or precast? Precast members are suited to low-pressure steam curing whereas
precast products may benefit from autoclaving.

Does the location affect the availability or cost of some curing materials? For example, the scarcity of
Environment water in an arid region.
Is the weather likely to be hot or cold? If the temperature is higher than about 30o C or less than 10o C,
special precautions need to be taken.
Is the site exposed to winds? Special precautions may be required to prevent plastic shrinkage or
cracking and extra care may be required when using plastic sheeting.

IMPERMEABLE MEMBRANE CURING Is uniform concrete colour specified? If so, a constant stripping time will need to be maintained to avoid
Retaining the formwork hydration colour change.
Is there likely to be cold weather? This method allows easy addition of insulation.
What is the effect on site operations and construction cycle schedule?

Are there safety considerations? Plastic sheeting may be slippery, and hazardous in horizontal
Plastic sheeting applications.
Is there likely to be hot or cold weather? Sheeting colour should be selected to suit.
Is uniform concrete colour specified? If so, the sheeting must be kept clear of the surface to avoid
hydration staining.
Can seals be maintained with minimum risk of holes?
What is the effect on access and site operations?

What are the manufacturer’s recommendations? Both the application rate and the timing are critical for
Curing compounds effectiveness.
What is the concrete surface texture? Coarse textures require higher application rates.
Can a uniform application be achieved in the particular situation? Sites exposed to wind create
problems.
Is there likely to be hot or cold weather? A suitably pigmented compound can help.
Are there to be applied finishes (render, tiles, etc)? Compounds can affect the ‘bond’ of applied finishes.
Is there a health consideration? Compounds may be toxic and their use in enclosed situations therefore
hazardous.

Is suitable ‘dam’ material available? A clay soil is the most suitable.

Is there likely to be hot weather? Ponding is an effective way to maintain even temperature on slabs.
WATER CURING Is concrete colour or appearance a consideration? ‘Dam’ materials, particularly clay, tend to stain.
Ponding What is the effect on access and site operations?

What is the effect of run-off? Usually some form of drainage is required.

Can application be maintained continuously? Intermittent wetting and drying can be deleterious.
Is site exposed to winds? This makes continuous application very difficult.
Is the water supply adequate?
Will the required volume/timing damage the concrete surface?
Sprinkling What is the effect on site operations?

Is the site exposed to wind? Wet coverings are easier to keep in place than plastic sheeting.
Can coverings be kept continuously moist? Intermittent wetting and drying can be deleterious.
Is concrete colour or appearance a consideration? If so, sand should have low clay content; fabrics and
water should contain no impurities.
In the case of sand, is supply or removal a problem?
Can coverings effectively cover all surfaces?
Wet Coverings What is the effect on site operations?

Will there be a cost benefit through greater productivity? This usually results from quicker turnaround of
formwork.
Is high early strength required? Steam curing can help in achieving this.
What is the effect on the production cycle?

Will the process increase productivity?

Will the process increase quality?
ACCELARATED CURING Does the product require the process?
Low pressure steam

Autoclaving

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