Method of forming a self-consolidating concrete construction with self-roughening properties

1. A method of forming a concrete structure comprising:

forming a first concrete from a mixture of components;

pouring a first amount of the first concrete with self-roughening properties derived only from the mixture of components used when forming the first concrete, wherein a first joint surface is formed by the first concrete; and

pouring a second amount of a second concrete on at least a portion of the first joint surface;

wherein the first joint surface provides a rough surface derived only from the mixture of components used when forming the first concrete so there is no post pouring modification to the first concrete to derive the self-roughening properties; and

wherein the first joint surface provides a rough surface so the bond and shear resistance of the interface between the first joint surface of the first concrete and the second concrete are sufficient to form the concrete structure therefrom.

2. The method of claim 1 , wherein the first concrete comprises a mixture and lightweight coarse aggregate (LWA);

wherein the mixture comprises cementitious material, coarse aggregate (CA), fine aggregate (FA), and water;

wherein the LWA has a specific gravity lower than that of the mixture; and

wherein the mass of the LWA is not less than approximately 5% of the mass of the CA in the first concrete.

3. The method of claim 2 , wherein the first joint surface has a concrete surface profile of 7 or greater; and

wherein the concrete surface profile is defined by the International Concrete Repair Institute's standard concrete surface profile (CSP).

4. The method of claim 2 , wherein the first joint surface has a CSP of 9.

5. The method of claim 2 , wherein the first concrete and the second concrete comprises substantially the same mixture of components.

6. The method of claim 2 , wherein the first concrete and the second concrete comprises different mixtures of components.

7. The method of claim 2 , wherein the first amount and the second amount are substantially the same.

8. The method of claim 2 , wherein the first joint surface is formed without manual interference.

9. The method of claim 2 , wherein the first joint surface is formed without manual interference via at least a portion of the LWA migrating through an amount of the first concrete.

10. A method of forming a concrete structure comprising:

forming a first concrete from a mixture of components;

pouring a first amount of the first concrete with self-roughening properties derived only from the mixture of components used when forming the first concrete, wherein a first horizontal joint surface is formed by the first concrete, the first horizontal joint surface formed free of manual interference; and

pouring a second amount of a second concrete on at least a portion of the first horizontal joint surface;

wherein the first horizontal joint surface provides surface roughness derived only from the mixture of components used when forming the first concrete sufficient so the bond and shear resistance of the interface between the first horizontal joint surface of the first concrete and the second concrete poured on top of the first horizontal joint surface are sufficient to form the concrete structure therefrom.

11. The method of claim 10 , wherein the first concrete comprises:

a mixture of:

a cementitious material;

coarse aggregate (CA);

fine aggregate (FA); and

water; and

lightweight coarse aggregate (LWA) having a specific gravity lower than that of the mixture;

wherein the mass of the LWA is not less than approximately 5% of the mass of the CA in the first concrete.

12. The method of claim 11 , wherein the first concrete further comprises very fine aggregate (VFA).

13. The method of claim 11 , wherein the cementitious material comprises approximately 16%-27% by weight of the first concrete.

14. The method of claim 11 , wherein the cementitious material comprises approximately 22%-27% by weight of the first concrete.

15. The method of claim 11 , wherein the CA comprises between approximately 31%-36% by weight of the first concrete.

16. The method of claim 11 , wherein the FA comprises between approximately 30%-35% by weight of the first concrete.

17. The method of claim 11 , wherein at least a portion of the LWA provides self-roughening properties without vibration to the first concrete.

18. The method of claim 10 , wherein the first concrete comprises:

Cementitious

lb/yd 3

Cement Type I/II

617

Fly Ash, Class F

459

Water

343

w/cm

0.318

Coarse Aggregates

# 67

1286

# 89

—

LWA

15%

Fine Aggregates

Natural sand

678.5

Manufactuted sand

678.5.

19. The method of claim 10 , wherein forming the first concrete comprises a self-consolidating concrete mixture comprising a sufficient amount of lightweight coarse aggregate (LWA) such that upon subsequent pouring of the first amount of the self-consolidating concrete mixture into steel plate composite modular structures, there is no post pouring modification to the self-consolidating concrete mixture to derive the self-roughening properties, and the pouring can comprises discontinuous concrete pourings.

20. The method of claim 19 , wherein the self-consolidating concrete mixture comprises coarse aggregate (CA), and the mass of the LWA is not less than approximately 5% of the mass of the CA in the mixture.

21. The method of claim 10 , wherein the first concrete comprises a self-consolidating concrete mixture comprising a sufficient amount of lightweight coarse aggregate (LWA) such that in use it forms the first joint surface comprising a self-roughening cold-joint having a concrete surface profile of 7 or greater, wherein the concrete surface profile is defined by the International Concrete Repair Institute's standard concrete surface profile (CSP).

22. The method of claim 10 , wherein the first concrete comprises:

Cementitious

lb/yd 3

lb/yd 3

Cement Type I/II

808

808

Fly Ash, Class F

161

161

Water

315

315

w/cm

0.326

0.326

Coarse Aggregates

# 67

1510

1510

# 89

—

—

LWA

—

10%

Fine Aggregates

Natural sand

712

712

Manufactured sand

712

712.