Construction Materials

Cement & Concrete Porosimetry

Predict durability, optimize mix designs, and ensure long-term performance through comprehensive pore structure analysis and permeability characterization.

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$625B
Global Concrete Market
100yr
Design Service Life
10⁻¹²
m² Permeability Target
50nm
Critical Pore Threshold

Durability & Permeability Assessment

Pore structure governs transport properties and long-term concrete performance

Pore Structure Classification

Pore Size Categories (Powers Model)

  • Gel pores: <10 nm (non-harmful)
  • Capillary pores: 10-10,000 nm (critical)
  • Air voids: >10 μm (entrapped/entrained)
  • Critical threshold: 50 nm diameter
2026 Insight: AI-powered MIP analysis predicts 50-year chloride penetration with 95% accuracy.

Key Measurements

  • Mercury intrusion porosimetry (MIP) for full PSD
  • Total porosity and pore volume
  • Critical pore diameter and threshold
  • Permeability correlation from PSD

Transport Properties

Performance Criteria

  • Porosity: 8-15% typical
  • Permeability: 10⁻¹³-10⁻¹¹ m²
  • Chloride diffusion: <10⁻¹² m²/s
  • Water absorption: <5% by mass
Durability Link: Porosity <10% with threshold <30 nm ensures 100-year service life.

Critical Parameters

  • Pore connectivity and tortuosity
  • Katz-Thompson permeability model
  • Carbonation depth prediction
  • Freeze-thaw durability factor

Hydration & Microstructure Development

Early Age (1-7 days)

Porosity change 35% → 18%
CSH formation Rapid
Threshold shift 200 → 80 nm
Strength gain 70% of 28-day
Testing Daily MIP tracking

Critical period for pore structure refinement

Mature (28-90 days)

Final porosity 8-15%
Threshold 20-50 nm
Gel/cap ratio 0.2-0.6
Permeability Stabilized
QC testing 28-day standard

Design strength and durability achieved

Long-term (1+ years)

Porosity change ±2% variation
Carbonation Pore coarsening
ASR effects Microcracking
Sulfate attack Expansion damage
Monitoring Service life studies

Degradation mechanisms tracking

Mix Design Optimization

Water-Cement Ratio Effects

Lower w/c ratios produce refined pore structures with enhanced durability properties.

  • w/c = 0.65: Porosity 18%, threshold 80 nm
  • w/c = 0.45: Porosity 12%, threshold 40 nm
  • w/c = 0.30: Porosity 8%, threshold 20 nm
  • Each 0.1 reduction: 50% permeability decrease
Optimal: w/c = 0.35-0.45 for durability

Supplementary Cementitious Materials

SCMs refine pore structure through pozzolanic reactions and filler effects.

  • Silica fume: 50% threshold reduction
  • Fly ash: Enhanced long-term refinement
  • Slag: Improved chloride resistance
  • 30-50% replacement: Optimal porosity
Result: 70% permeability reduction at 90 days

Air Entrainment

Controlled air void system provides freeze-thaw durability without compromising strength.

  • Air content: 4-8% for freeze-thaw resistance
  • Spacing factor: <200 μm required
  • Void size: 50-300 μm optimal
  • MIP distinguishes capillary vs air voids
Target: Durability factor >80%

Self-Healing Concrete

Porosity evolution during autogenous healing of cracks monitored via MIP.

  • Crack width: <300 μm healable
  • Healing time: 28-90 days
  • Permeability recovery: 60-90%
  • Bacterial/crystalline additives tracking
Innovation: Extended service life by 50 years

Testing Standards & Protocols

Property Test Method Standard Typical Values
Pore size distribution Mercury intrusion ASTM D4404 10 nm - 100 μm range
Total porosity MIP or water saturation ASTM C642 8-15% for normal concrete
Permeability Rapid chloride test ASTM C1202 <2000 Coulombs
Air void analysis Microscopy + MIP ASTM C457 Spacing <200 μm
Freeze-thaw Rapid cycling ASTM C666 DF >80% after 300 cycles
Carbonation Phenolphthalein + MIP EN 14630 <5 mm/year penetration

Industry Case Studies

Marine Structure Durability

Challenge: Design 100-year service life concrete for offshore platform

Solution: Ultra-high performance concrete with optimized pore structure

  • Porosity: 6% (vs 12% conventional)
  • Threshold diameter: 15 nm
  • Chloride diffusion: 2×10⁻¹³ m²/s
Achievement: 150-year design life validated

Bridge Deck Rehabilitation

Challenge: Prevent premature deterioration from freeze-thaw and deicing salts

Solution: Air-entrained HPC with silica fume and optimized air void system

  • Air content: 6.5%, spacing: 180 μm
  • Durability factor: 95% after 300 cycles
  • 20-year field performance confirmed
Impact: $8M maintenance cost savings

Nuclear Containment Structure

Challenge: Ultra-low permeability for radiation shielding over 60+ years

Solution: High-density concrete with nano-silica pore refinement

  • Permeability: 5×10⁻¹⁴ m² achieved
  • Porosity: 4.2% (extremely low)
  • No measurable degradation after 10 years
Result: Exceeded regulatory requirements

Ensure Long-Term Concrete Performance

Expert porosimetry testing for mix design optimization and durability assessment

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