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1-Con Tech

This document discusses concrete technology and hydraulic cements. It provides information on: - The manufacturing process of Portland cement, which involves mixing calcium and silica sources like limestone and clays at high temperatures. - The components and reactions of concrete, including cement, water, sand, coarse aggregates, and the hydration reaction that causes concrete to harden. - The types and properties of hydraulic cements, specifically focusing on Portland cement, which is capable of setting and hardening underwater due to its calcium silicate composition. - The chemical analysis and composition of cements based on ASTM C114 standards. Major compounds include tricalcium silicate, dicalcium silicate, trical

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158 views37 pages

1-Con Tech

This document discusses concrete technology and hydraulic cements. It provides information on: - The manufacturing process of Portland cement, which involves mixing calcium and silica sources like limestone and clays at high temperatures. - The components and reactions of concrete, including cement, water, sand, coarse aggregates, and the hydration reaction that causes concrete to harden. - The types and properties of hydraulic cements, specifically focusing on Portland cement, which is capable of setting and hardening underwater due to its calcium silicate composition. - The chemical analysis and composition of cements based on ASTM C114 standards. Major compounds include tricalcium silicate, dicalcium silicate, trical

Uploaded by

ZELALEM
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPT, PDF, TXT or read online on Scribd
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Concrete technology

Balqa Applied University


Dep. of Civil Engineering

Dr. Nafeth A. Abdel Hadi


HYDRAULIC
CEMENTS
AND THEIR
PROPERTIES
Manufacturing Process

 Calcium silicates are the primary constituents of


Portland cement.
 Raw material for P.C. →Calcium & Silica
 Calcium: Limestone, chalk, etc (CaO+CO2)
 Silica: Clays and shales (SiO2+Al2O3+Fe2O3+H2O)

1/3 Clay ⌠ Raw mix should be well be homogenized


2/3 Calcium ⌠ before the heat treatment
Manufacturing Process

 Raw Mill Feed


Concrete Basics

 Portland cement, water, sand, and coarse are


proportioned and mixed to produce concrete
suited to the particular job for which it is
intended.
Definitions

 Cement → Powder
 Cement + Water → Cement Paste
 Cement Paste + Fine Aggregate (FA) → Mortar
 Mortar + Coarse Aggregate (CA) → Concrete
 Concrete is initially plastic, allows one to mold
into desired shape.
 Chemical reaction (hydration) and paste set of
concrete – producing strength and stiffness.
Hydraulic Cements

 Cements that harden by reaction with water


and form a water-resistant product.

 Portland Cement (P.C.)


 Portland cement is a hydraulic cement capable
of setting, hardening and remains stable under
water. It is composed of calcium silicates and
some amount of gypsum.
Cement

 Cement is a pulverized material that develops


binding forces due to a reaction with water

 Hydraulic Cement : Stable under water

 Nonhydraulic Cement : Products of hydration


are not resistant to water (i.e. limestone)
Cement Composition
CaCO3 (limestone)
2SiO2•Al2O3 (clay, shale)
Fe2O3 (iron oxide)
SiO2 (silica sand)

~ 1450oC

Kiln

3CaO•SiO2
CaO•SO3•2H2O
Gypsum + Clinker
2CaO•SiO2
3CaO•Al2O3
Finished interground
4CaO•Al2O3•Fe2O3
cement
Cement Chemistry
In cement chemistry, the individual oxides and clincker compounds are expressed by their
abbreviations

Short Hand Notation Reactive Compounds

 C (CaO, calcium oxide) C3S (Tricalcium silicate )

 A (Al2O3, alumina) C2S (dicalcium silicate)

 S (SiO2, silica) C3A (Tricalcium aluminate)

 S (SO3, sulfate) CSH2 (gypsum)

 H (H20, water) C4AF (tetra-calcium alumino ferrite)


Compounds of Portland Cement

 C3S 3CaO . SiO2


 C2S 2CaO . SiO2
 C3A 3CaO . Al2O3
 C4AF 4CaO.Al2O3.Fe2O3
 C4A3S 4CaO.3Al2O3.SO3

 C3S = Tricalcium Silicate

 C2S = Dicalcium Silicate

 C3A = Tricalcium aluminate

 C4AF = Tetracalcium aluminate ferrite


Cement Chemistry

 Hydration Reactions
 2C3S + 6H → C-S-H + 3CH (120 cal/g)
 2C2S + 4H → C-S-H + CH (62 cal/g)
 C3A + 3CSH2 +26H → C6AS3H32 (300 cal/g)
 2C3A + C6AS3H32 + 4H → 3C4ASH12
 C4AF + 10H + 2CH → C6AFH12

 C3S2H3 (C-S-H gel)


 CH (calcium hydroxide)
 C6AS3H32 (ettringite)
 C4ASH12 (monosulfate)
Chemical Analysis by ASTM C 114
ASTM C 114 Standard Test
SiO2 Silicon dioxide
Methods for Chemical
Al2O3 Aluminum oxide
Analysis of Hydraulic
Fe2O3 Ferric oxide
Cement
CaO Calcium oxide Major components
MgO Magnesium oxide
SO3 Sulfur trioxide
LOI Loss on ignition
Na2O Sodium oxide
K2O Potassium oxide
TiO2 Titanium dioxide
P2O5 Phosphorus pentoxide Minor components
ZnO Zinc oxide
Mn2O3 Manganic oxide
Sulfide sulfur
Chemical Analysis by ASTM C 114

Oxide Analysis Oxide Shorthand Common Name


Oxide %
CaO lime

SiO2 silica
SiO2 20.6
Al2O3 5.07 Al2O3 alumina
90 – 95%
Fe2O3 2.90 Fe2O3 ferric oxide
CaO 63.9
MgO M magnesia
MgO 1.53
K 2O K
K2O 0.73 alkalis
Na2O 0.15 Na2O N
SO3 2.53 SO3 sulfate
LOI 1.58 CO2 C carbonate
+ other trace elements H 2O water
Chemical Analysis by ASTM C 114:
Alkali Content
Oxide Analysis
Oxide %

Equivalent Alkali Content, Na2Oe


SiO2 20.6
Al2O3 5.07
Na2Oe = Na2O + (0.658 x K2O)
Fe2O3 2.90
CaO 63.9
MgO 1.53

K2O 0.73
Na2O 0.15
SO3 2.53
LOI 1.58
+ other trace elements
Bogue Potential Composition
Bogue Equations

C3S = 4.07C – 7.60S – 6.72A – 1.43F – 2.85S

C2S = 2.87S – 0.75C3S

C3A = 2.65A – 1.69F

C4AF = 3.04F

(Only valid when A/F  0.64)


Bogue Potential Composition: Example
Oxide Analysis Calculated Phase Composition
Oxide %
C3S = 4.07(63.9) – 7.60(20.6) – 6.72(5.07)
– 1.43(2.90) - 2.85(2.53) = 58.1
SiO2 20.6
Al2O3 5.07 C2S = 2.87(20.6) – 0.754(58.1) = 15.6
Fe2O3 2.90
CaO 63.9 C3A = 2.65(5.07) – 1.69(2.90) = 8.5 C3S 58.1%
MgO 1.53
C4AF = 3.04(2.90) = 8.8 C2S 15.6%
K2O 0.73
Na2O 0.15 Bogue Potential Composition: C3A 8.5%
SO3 2.53
LOI 1.58 C4AF 8.8%
Cement components
 Function of Cement Ingredients:
     Ingredients of ordinary cement, as mentioned
above , performs the following functions.
 Lime (CaO):It imparts strength  to cement It's
deficiency  causes cement to set quickly . Lime in
excess make the cement unsound .Hence it's
proportion in the cement is carefully maintained.
 Silica (SiO2): It imparts strength to cement.
 Alumina(Al2O3):This ingredient imparts quick
setting property to cement. Alumina in excess
weakens the cement.
Cement components
 Calcium Sulphate(CaSo4):This ingredient
increase the initial setting time of cement.
 Iron Oxide(Fe2O3): This ingredients imparts
color ,Hardness and strength to cement.
 Magnesia (MgO): This ingredient imparts
hardness and colour to cement. If it's
percentage exceed more than 5 then it causes
crack after mortar or concrete hardens.
Cement components
 (Sulphur): A small amount of Sulphur is useful
in making sound cement. The excess amount
make the cement unsound.
 Alkalies: The presence of this adversely
affects the quality of cement. and causes
efflorescence. If it exceed 1% in cement , it
leads to the failure of the concrete made out of
that cement
Effects of Chemical Composition of Portland
Cements on Strength
 In classic research from over seventy years ago
Bouge and Lerch* found that of the four
portland cement phases only C3S and C2S
developed appreciable compressive strength
when pure samples of each were hydrated.
Hydration of Portland Cement

 Hydration: Reaction with water


ASTM C 150 Standard Specification for
Portland Cement
ASTM C 150 Type:

I Normal

II Moderate sulfate resistance or heat

III High early strength

IV Low heat of hydration


V High sulfate resistance
Types of Portland Cement

 ASTM C 150, Standard Specifications for Portland Cement


 Type I: General purpose. For use when the special properties
specified for any other types are not required.
 Type II: For general use, more specially when moderate
sulfate resistance or moderate heat of hydration is desired.
 Type III: For use when high early strength is desired.
(limit the C3A content of the cement to maximum 15%)
 Type IV: For use when low heat of hydration is desired.
 Type V: For use when high sulfate resistance is desired.
(Maximum limit of 5% on C3A)
ASTM C 150 Standard Specification for
Portland Cement
ASTM C 150 Type:

I Normal
IA Normal, air-entraining
II Moderate sulfate resistance or heat
IIA Moderate sulfate or heat, air-entraining
III High early strength
IIIA High early strength, air-entraining
IV Low heat of hydration
V High sulfate resistance
ASTM C 150 Low-Alkali Portland
Cements
• Low-alkali cement  0.60% Na2Oe

• Optional requirement

• Only when potentially reactive aggregates are used


and no other measure is taken to control expansion
due to alkali-silica reactivity (ASR)

Note: The use of low-alkali


cement alone may not be
sufficient to eliminate the risk of
damage due to ASR
We can make cement
The Structure of Concrete
 The type, amount, size, shape & distribution of phases
present in a solid material constitute its structure.
Concrete Consists of aggregates, paste and voids. The
macrostructure of concrete is shown below:

A polished section
of concrete
The Microstructure of Portland Cement
Concrete

 The structure of the aggregates in concrete is


important but it can be characterized as a
microstructure which is visible to the human
eye.
 The limit of resolution of the unaided human
eye is approximately 1/5 millimeter which is
200 microns.
The Microstructure of Portland Cement Concrete

 The use of both light and electron microscopes


allows the study of the microstructure of
concrete at the submicron level.
 The microstructure of concrete can be divided
into regions:
 Cement Paste
 Transition Zone between Aggregate and
Cement paste
Structure of “un-damaged”
Concrete
 Macrostructure
 Aggregates (CA, FA)
 Hydrated cement paste (hcp)
 Entrapped air voids
 Microstructure
 Hydrated cement paste
 (Hydration products: C-S-H, ettriginite;
 mono sulfate; porosity: gel, capillary pores
 entrained/ entrapped air voids)
 Transition zone (TZ)
Microstructure of Concrete
(Hydration products)

CH C-S-H
Microstructure of Concrete
(Hydration products)

Ettringite
Capillary Porosity

 The originally-water-filled space within the cement


paste becomes the capillary pores which act as stress
concentrations and reduce the strength significantly.
 The strength of most engineering materials is
increased with a decrease in porosity, and by
controlling the water/ cement ratio
 The engineer is assured that the basic porosity of

the paste is also controlled. That is not to say the other


sources of porosity will not occur, but at least the
cement paste will have a given porosity.
Capillary Porosity

 Figure below shows a graphical representation of the


relative volumes of hydration products during
hydration.
Capillary Porosity Over a Range of W/C
Ratios

 If cement paste specimens are prepared with a


range of w/c ratios it is apparent that the
density of high w/c samples is much lower
than low w/c samples.

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