Concrete Technology

Hydr aul i c Cement s

Professor Kamran M. Nemati
Spring Quarter 2012
1
Concrete Technology
HYDRAULI C CEMENTS
AND THEI R PROPERTI ES
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Concr et e Basi cs
Port land cement , wat er, sand, and coarse
aggregat e are proport ioned and mixed t o
produce concret e suit ed t o t he part icular
j ob for which it is int ended.
Concrete Technology
Hydr aul i c Cement s
Professor Kamran M. Nemati
Spring Quarter 2012
2
Concrete Technology
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Def i ni t i ons
Cement Powder
Cement + Wat er Cement Past e
Cement Past e + Fine Aggregat e (FA) Mort ar
Mort ar + Coarse Aggregat e (CA) Concret e
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Concret e is init ially plast ic, allows
one t o mold int o desired shape.
Chemical react ion (hydrat ion) and
past e set of concret e - producing
st rengt h and st iffness.
Def i ni t i ons
Concrete Technology
Hydr aul i c Cement s
Professor Kamran M. Nemati
Spring Quarter 2012
3
Concrete Technology
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Cement is a pulverized mat erial t hat
develops binding forces due t o a react ion
wit h wat er
Hydraulic Cement St able under wat er
Nonhydraulic Cement Product s of
hydrat ion are not resist ant t o wat er (i.e.
limest one)
Cement
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Cement s t hat harden by react ion wit h
wat er and form a wat er-resist ant
product .
Por t l and Cement ( P.C.)
Port land cement is a hydraulic cement
capable of set t ing, hardening and
remains st able under wat er. I t is
composed of calcium silicat es and some
amount of gypsum.
Hydr aul i c Cement s
Concrete Technology
Hydr aul i c Cement s
Professor Kamran M. Nemati
Spring Quarter 2012
4
Concrete Technology
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Cement Chemi st r y
Short Hand Not at ion
C (CaO, calcium oxide)
A (Al
2
O
3
, alumina)
S (SiO
2
, silica)
S (SO
3
, sulfat e)
H (H
2
0, wat er)
React ive Compounds
C
3
S (t ricalcium silicat e)
C
2
S (dicalcium silicat e)
C
3
A (t ricalcium aluminat e)
CSH
2
(gypsm)
C
4
AF (t et ra-calcium
alumino ferrit e)
I n cement chemist ry, t he individual oxides and clincker
compounds are expressed by t heir abbreviat ions
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C
3
S 3CaO . SiO
2
C
2
S 2CaO . SiO
2
C
3
A 3CaO . Al
2
O
3
C
4
AF 4CaO.Al
2
O
3
.Fe
2
O
3
C
4
A
3
S 4CaO.3Al
2
O
3
.SO
3

=
=
=
=
ferrite aluminate m Tetracaciu AF C
aluminate Tricalcium A C
Silicate Dicalcium S C
Silicate Tricalcium S C
4
3
2
3
Compounds of Por t l and Cement
Concrete Technology
Hydr aul i c Cement s
Professor Kamran M. Nemati
Spring Quarter 2012
5
Concrete Technology
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Hydr at i on React i ons
2C
3
S + 6H C-S-H + 3CH (120 cal/ g)
2C
2
S + 4H C-S-H + CH (62 cal/ g)
C
3
A + 3CSH
2
+ 26H C
6
AS
3
H
32
(300 cal/ g)
2C
3
A + C
6
AS
3
H
32
+ 4H 3C
4
ASH
12
C
4
AF + 10H + 2CH C
6
AFH
12
C
3
S
2
H
3
(C-S-H gel)
CH (calcium hydroxide)
C
6
AS
3
H
32
(et t ringit e)
C
4
ASH
12
(monosulfat e)
Cement Chemi st r y
Concrete Technology
Hydr at i on of Por t l and Cement
Cal/g 120 3CH H S C 6H S 2C
3
+ + +
Cal/g 2 6 CH H S C 4H S 2C
2
+ + +
e) (Ettringit H S A C H S C AF, C A, C
4 3

Compound Composition Morphology Amount (% Vol.)
C-S-H
Variable
C/S ~ 1.5 to 2
Poorly crystalline
High surface area: higher
bonding energy
50 60%
CH
Ca(OH)
2
Large hexagonal crystals,
low surface area, and poor
bonding energy
20 25%
C-A-S-H
C
6
AS
3
H
32
Ettringite
C
4
ASH
12-18
Monosulfate
Long, well crystallized
needles
Hexagonal small
crystals
15 20%
Hydrat ion: React i on wi t h wat er
Concrete Technology
Hydr aul i c Cement s
Professor Kamran M. Nemati
Spring Quarter 2012
6
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Calcium silicat es are t he primary const it uent s
of port land cement .
Raw mat erial for P.C. Calcium & Silica
Calcium: Limest one, chalk, et c (CaO+ CO
2
)
Silica: Clays and shales (SiO
2
+ Al
2
O
3
+ Fe
2
O
3
+ H
2
O)

Clay 1/3
Calcium 2/3

ment heat treat

the before d homogenize
well be should mix Raw
Manuf act ur i ng Pr ocess
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Manuf act ur i ng Pr ocess
Aer i al Phot o of a Cement Manuf act ur i ng Pl ant
(Colorado)
Concrete Technology
Hydr aul i c Cement s
Professor Kamran M. Nemati
Spring Quarter 2012
7
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Manuf act ur i ng Pr ocess
Raw Mi l l Feed
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Manuf act ur i ng Pr ocess
Ki l n Li ne Over vi ew
This image cannot cur r ently be display ed.
Concrete Technology
Hydr aul i c Cement s
Professor Kamran M. Nemati
Spring Quarter 2012
8
Concrete Technology
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T = 1400C
Raw
(Limestone
+Clay)
Clinker+Gypsum
Grind
Portland Cement
Grind Mill
( )
( )
( )
( ) AF C
A C
S C
S C
O .Fe O 4CaO.Al
O 3CaO.Al
2CaO.SiO
3CaO.SiO
O H O Fe O Al SiO Clay
CO CaO Limestone
4
3
2
3
3 2 3 2
3 2
2
2
2 3 2 3 2 2
2

)
`

+ + +
+
Manuf act ur i ng Pr ocess
Rotary Kiln
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React ivit y of cement wit h wat er is
a funct ion of it s fineness.
Generally, t he finer a cement , t he
more rapidly it will react , and t he
st rengt h development will be
enhanced (expensive).
Fi neness
Concrete Technology
Hydr aul i c Cement s
Professor Kamran M. Nemati
Spring Quarter 2012
9
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Types of Por t l and Cement
ASTM C 150, St andard Specificat ions for
Port land Cement
Type I : General purpose. For use when t he special
propert ies specified for any ot her t ypes are not required.
Type I I : For general use, more specially when moderat e
sulfat e resist ance or moderat e heat of hydrat ion is desired.
Type I I I : For use when high early st rengt h is desired.
(limit t he C
3
A cont ent of t he cement t o maximum 15%)
Type I V: For use when low heat of hydrat ion is desired.
Type V: For use when high sulfat e resist ance is desired.
(Maximum limit of 5% on C
3
A)
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I n classic research from over sevent y years
ago Bouge and Lerch* found t hat of t he four
port land cement phases only C
3
S and C
2
S
developed appreciable compressive st rengt h
when pure samples of each were hydrat ed.
The compressive st rengt h found by Bogue and
Lerch* * are plot t ed in t he next Fig. as a
funct ion of age. Compressive st rengt hs of C
3
A
and C
4
AF, hydrat ed alone A and have not
been plot t ed explicit ly.
Ef f ect s of Chemi cal Composi t i on of Por t l and
Cement s on St r engt h
* T.C. Powers, The Non-Evaporable Wat er Cont ent of Port land Cement Past e: I t s Significance for
Concret e Research and I t s Met hod of Det erminat ion, ASTM Bullet in, No. 158, (May 1949) pp. 68-76.
* * R H Bouge and W Lerch I ndust rial Engineering, Chem. 26 873 (1934)
Concrete Technology
Hydr aul i c Cement s
Professor Kamran M. Nemati
Spring Quarter 2012
10
Concrete Technology
The compressive st rengt h found by Bouge and Lerch* * for hydrat ed samples of t he
pure cement phases C
3
S and C
2
S are plot t ed as a funct ion of age. The compressive
st rengt hs of C
3
A and C
4
AF, hydrat ed along and wit h gypsum, fall wit hin t he cross-
hat ched region labeled A and have not been plot t ed explicit ly. The t ime scale is
linear. The t ime scale is logarit hmic, which has t he effect of expanding t he early
ages, and t his shows t he differences bet ween st rengt h gain of C
3
S and C
2
S past es.
Ef f ect s of Chemi cal Composi t i on of Por t l and
Cement s on St r engt h
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The St r uct ur e of Concr et e
The t ype, amount , size, shape & dist ribut ion of
phases present in a solid mat erial const it ut e it s
st ruct ure.
Concret e Consist s of aggregat es, past e and voids.
The macrost ruct ure of concret e is shown below:
A polished sect ion
of concret e
Concrete Technology
Hydr aul i c Cement s
Professor Kamran M. Nemati
Spring Quarter 2012
11
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The st ruct ure of t he aggregat es in
concret e is import ant but it can be
charact erized as a macrost ruct ure
which is visible t o t he human eye.
The limit of resolut ion of t he unaided
human eye is approximat ely 1/ 5
millimet er which is 200 microns.
The Mi cr ost r uct ur e of Por t l and Cement Concr et e
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The use of bot h light and elect ron
microscopes allows t he st udy of t he
microst ruct ure of concret e at t he
submicron level.
The microst ruct ure of concret e can
be divided int o regions:
Cement Past e
Transit ion Zone bet ween Aggregat e
and Cement past e
The Mi cr ost r uct ur e of Por t l and Cement Concr et e
Concrete Technology
Hydr aul i c Cement s
Professor Kamran M. Nemati
Spring Quarter 2012
12
Concrete Technology
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St r uct ur e of un-damaged Concr et e
Macr ost r uct ur e
Aggregat es (CA, FA)
Hydrat ed cement past e (hcp)
Ent rapped air voids
Mi cr ost r uct ur e
Hydrat ed cement past e
(Hydrat ion product s: C-S-H, et t riginit e;
monosulfat e; porosit y: gel, capillary pores
ent rained/ ent rapped air voids)
Transit ion zone ( TZ)
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Mi cr ost r uct ur e of Concr et e
( Hydr at i on pr oduct s)
CH
C-S-H
Concrete Technology
Hydr aul i c Cement s
Professor Kamran M. Nemati
Spring Quarter 2012
13
Concrete Technology
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Et t r i ngi t e
Mi cr ost r uct ur e of Concr et e
( Hydr at i on pr oduct s)
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Charact erist ics of t he TZ
Large cryst als of Ett ringit e and
CH wit h preferred orient at ion
Porous St ruct ure
Mi cr ost r uct ur e of Concr et e
( Tr ansi t i on Zone)
Concrete Technology
Hydr aul i c Cement s
Professor Kamran M. Nemati
Spring Quarter 2012
14
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One way t o view cement past e is t o
consider t he hydrat ion of one grain of
cement .
The part ial hydrat ion of one grain of
cement is schemat ically represent ed in t he
next slide.
There are many det ails in t his process t hat
are not yet underst ood, but t here is
sufficient informat ion available t o allow a
consist ent ment al pict ure t o be considered.
The Mi cr ost r uct ur e of Por t l and Cement Concr et e
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The Mi cr ost r uct ur e of Por t l and Cement Concr et e
The hydrat ion product s
formed inside and out side
t he cement grain are
schemat ically represent ed.
The mult iple nat ure of t he
cement grain is neglect ed
and assumed t o be a
single phase t hat shows
t wo t ypes of product s.
P1 refers t o t he primary
port landit e which appears
early in t he originally
wat er-filled space.
Concrete Technology
Hydr aul i c Cement s
Professor Kamran M. Nemati
Spring Quarter 2012
15
Concrete Technology
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The hydrat ion of a number of cement grains
is schemat ically represent ed in t he next slide
at different degrees of hydrat ion.
The fresh past e (i.e., t he init ial combinat ion
of wat er and cement grains) is drawn t o
approximat ely represent t he 0.4
wat er/ cement rat io, and t hus t here are not
enough hydrat ion product s t o fill t he
originally-wat er-filled space and a capillary
porosit y remains in t he final microst ruct ure.
The Mi cr ost r uct ur e of Por t l and
Cement Past e
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A schemat ic represent at ion of t he hydrat ion of a number of cement grains. The mult iphase
nat ure t he cement grains has been neglect ed as t his is like t he hydrat ion of t ricalcium silicat e
alone. ( a) Fresh past e of wat er-t o cement rat ion of 0.4 is shown cement grains in t he
originally wat er-filled space. ( b) Aft er 33% hydrat ion, t he cement grains now have inner
hydrat ion regions and out er product s which form a columnar zone around each grain. ( c)
Aft er 67% hydrat ion, t he un-hydrat ed cores are clearly surrounded by t hick rims of inner
hydrat ion product s and t he columnar zone of out er product s is growing on t he surface of
each grain. The primary port landit e, P1, is shown wit h t he dendrit e morphology. ( d) At
100% hydrat ion, t he un-hydrat ed cement has been consumed but t he shape of t he original
cement grains can be dist inguished if t he inner product differs from t he columnar zone of
out er product s. The int ergrowt h of t he columnar zones from t wo different grains is shown
at several point s, but t his would be larger at low wat er/ cement rat ions.
Originally water-filled space = clear, unhydrated cement = , inner hydration products = ,
outer hydration products = , & primary portlandite = P1.
///
The Mi cr ost r uct ur e of Por t l and Cement Past e
Concrete Technology
Hydr aul i c Cement s
Professor Kamran M. Nemati
Spring Quarter 2012
16
Concrete Technology
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The originally-wat er-filled space wit hin t he
cement past e becomes t he capillary pores
which act as st ress concent rat ions and
reduce t he st rengt h significant ly.
The st rengt h of most engineering mat erials is
increased wit h a decrease in porosit y, and by
cont rolling t he wat er/ cement rat io t he
engineer is assured t hat t he basic porosit y of
t he past e is also cont rolled. That is not t o
say t he ot her sources of porosit y will not
occur, but at least t he cement past e will
have a given porosit y.
Capi l l ar y Por osi t y
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Figure below shows a graphical represent at ion of t he
relat ive volumes of hydrat ion product s during hydrat ion.
Graphical represent at ion of t he relat ive volumes of hydrat ion product s
during hydrat ion. The init ial w/ c is 0.5, and one unit of cement is shown t o
produce t wo volumes of hydrat ion product s.
Capi l l ar y Por osi t y
Concrete Technology
Hydr aul i c Cement s
Professor Kamran M. Nemati
Spring Quarter 2012
17
Concrete Technology
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I f cement past e specimens are prepared
wit h a range of w/ c rat ios it is apparent
t hat t he densit y of high w/ c samples is
much lower t han low w/ c samples.
This is illust rat ed in t he next slide in a
present at ion originally given by T.C.
Powers* .
* T.C. Powers, The Non-Evaporable Wat er Cont ent of Port land Cement Past e: I t s Significance for
Concret e Research and I t s Met hod of Det erminat ion, ASTM Bul., No. 158, (May 1949) pp. 68-76.
Capi l l ar y Por osi t y Over a Range of W/ C Rat i os
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Composit ion of Cement Past e at different st ages of hydrat ion. The
percent age indicat ed applied only t o past e wit h enough wat er-filled space
t o accommodat e t he product s at t he degree of hydrat ion indicat ed.
Capi l l ar y Por osi t y Over a Range of W/ C Rat i os