Concrete Flashcards
Manufacture process of cement
- begins w/ decomp of CaCO₃ @ ~900°C
- leaves calcium oxide CaO + libreates gaseous carbon dioxide (calcination)
- clincering process, CaO reacts @ high temp (1400-1500°C) w/ silica, alumina, ferrous oxide to form silicates, aluminates, ferrites of calcium which comprise the clincer
- clincer ground/milled together w/ gypsum + other additives to produce cement
decomp of CaCO3
CaCo₃–> CaO + CO₂
concrete
construction material composed of crushed rock/gravel + sand bound together w/ a hardened paste of cement and water
basic materials of concrete
- cement
- aggregates
- water
- admixtures
- voids
portland cements
- Ordinary Portland Cement (OPC)
- Rapid Hardening Portland Cement (RHPC)
- Sulphate Resistant Portland Cement (SRPC)
- White Portland Cement (WPC)
Portland cement - raw materials in clinker
- limestone
- iron stone
- sand
- shale
- clay
- other
unsustainability of cement manufacturing
- manif results in high levels of CO₂ output, third ranking producer of anthropogenic CO₂ in world
- 1 tonne of cement prod 780kg of CO₂
- 4-5% of total CO₂ emissions worldwide caused by cement prod
- extraction + processing: landscape degradation
- dust + noise pollution
- energy consumption + vehicle pollution of transportation
anthropogenic
man-made
cement manufacture
- limestone, shale, silica, iron oxides quarried from ground
- rock materials run thru crusher that turns rock into smaller pieces
- crushed limestone + Si + shale + iron oxides mixed together and run thru rotary kiln
- rotary kiln continuously mixes ingredients + “calcines” limestone so that CO₂ is driven off, forming clinker
- clinker ground to fine powder + mixed w/ gypsum (helps moderate how fast cement sets)
- bagged for sale
alternative cementitious (cement-like) materials
- blastfurnace slag cement (GGBS)
- pulverised-fuel ash cement (PFA)
- metakaolin
- rice husk ash
- silica fume
GGBS
- by-prod of iron smelting, quenched slag forms granules
- generally blended with OPC up to 70%
- reduced early age strength + early heat of hydration
- lower carbon footprint
how cements in Europe are classed
-based on perc of portland cement that has ben replaced/substituted
classes of cements in Europe
CEM I - OPC/RHPC (100% cement)
CEM II (65% cement)
CEM III (45% cement)
CEM IV (<45%)
CEM II-IV: OPC with limestone, PFA, or GGBS
when water is added to cement
- each compound undergoes hydration + contributes to final concrete product
- only calcium silicate contributes to strength
- tricalcium silicate: early strength, reacts more rapidly
- dicalcium silicate: late strenth
equation of hydration
Cement + H₂O -> Calcium Silicate Hydrate (C-S-H) + Ca(OH₂) + H₂O
cement compounds
Tricalcium Silicate C₃S
Dicalcium Silicate C₂S
Tricalcium aluminate C₃A
Tetracalcium aluminoferrite C₄AF
Gypsum
setting of cement and hardening of concrete
- a process of crystallization
- crystals form after certain length of time (initial set time), + interlock w/ each other
- cement + water that has crystallized in this way encloses aggregate particles + produces dense material
heat effect on setting and hardening
- speeds up setting + hardening of cement
- cold slows down + can even completely stop process
cement hydration
- setting + hardening results from chem reaction between cement + water, not drying process
- reaction exothermic + irreversible
- heat produced: “Heat of Hydration”
- usually workable up to 2 hours before it begins to set, then harden
- strength gain initially rapid, becoming progressively less
- strength gain continues indefinitely, provided moisture present (CURING)
cement at start of hydration vs at end
- hydration not yet occured, pores filled with water
2. hardening cement paste, majority of space filled with C-S-H
heat of hydration evolution stages
stage 1 stage 2 stage 3 stage 4 stage 5
stage 1
- initial dissolution
- hydrolysis of cement compounds occur rapidly w/ significant temp increase
stage 2
- dormant period
- evolution of heat slows down
- conc in a plastic state which allows problem free transportation + placing
stage 3 + 4
- concrete starts to harden
- heat evol increases due to hydration of tricalcium silicate
stage 5
-slow formation of hydrate products continues as long as water + unhydrated silicates present
cement hydration notes
- when you add water to cement, solid content of mixture increasing due to hydration
- cement particles suspended in water
- hydration continues as long as water is present + there are still unhydrated compounds in cement paste
concrete strength gain with time graph
check slides 1 pg 25
aggregates
- Gravels, crushed rock + sands that are mixed w/ cement + water to produce concrete.
- generally make 50%-80% of concrete mix
coarse aggregates
(stone)
do not pass through a 5mm sieve
fine aggregates
(sand)
pass through 5mm sieve
use of aggregates
- pack efficiently
- reduce spaces
- reduces cost
- modify + improve properties (strength + drying shrinkage)
quality requirements of aggregates
- durability: hard, adequate strength
- cleanliness: free from chem impurities, organic material + dust
aggregate types
- normal density (most gravels + crushed rock)
- lightweight (weak porous solids, good thermal properties)
- high density (radioactive screening)
use of normal density aggregates
used for normal concrete projects
use of lightweight aggregates
insulation
lightweight concrete structures
use of high density aggregates
shielding against nuclear radiation
water - required qualities
- free from impurities. cannot contain sugars, sulphates, chlorides
- sea water must not be used for reinforced concrete
admixtures
- small quantities of additives to conc mix to improve certain properties
- excessive amounts can have adverse effects on concrete
types of admixtures
- accelerators
- retarding agents
- water-repelling admixtures
- water reducing admixtures (plasticisers)
- air entraining admixtures
- superplasticiser
- self-compacting admixture
- foamed concrete
accelerators
- inc rate of strength gain at early stage
- Calcium Chloride CaCl, but may corrode steel
- does not inc final strength
retarding agents
-reduce rate of evol of heat
water-repelling admixtures
- improve impermeability of concrete (basements, water retaining structures)
- no substitute for sound concrete
water reducing admixtures (plasticisers)
- reduces amount of water req for given workability
- calcium ligno-sulphate
air entraining admixtures
- generate evenly dispersed air bubbles in mix
- improves durability against frost + marine environments
superplasticiser
- high flowing concrete
- allows some water removal + thus higher strength
self-compacting admixture
- high flowing concrete
- does not req compacting to get rid of trapped air
foamed concrete
high flowing conc w/ bubbles + without stone
voids (in order of largest to smallest)
- entrapped air
- entrained air
- capillary pores
- gel pores
why are retarding agents necessary
- necessary for large concrete pours
- transport for long distances
- provide time for grooves, curves, other architectural features
- avoid cold joints
cold joints
-plane of weakness in concrete caused by interruption/delay in concreting process
when cold joints occur
when first batch of conc has begun to set before next batch added, so two batches do not intermix
workability
ability of concrete to flow in a mold or formwork
perhaps through congested reinforcement, ability to be compacted to minimum volume
perhaps ability to perform satisfactorily in some transporting operation/forming process
fresh concrete, first 48 hours
- important for performance of concrete structure
- controls long-term behaviour, strength, Young’s Modulus, creep, durability
factors affecting workability
- water content: higher content higher workability (wb)
- fineness of cement: finer cement, faster loss of wb
- aggregate shape: more angular (crushed) more water demand
- grading: uniform grading - better wb
- admixtures
- time: timing of hydration
- temperature: higher temps lead to loss of wb
fresh concrete properties
- workability
- voids
- segregation
- bleeding
- shrinkage
- compaction + honeycombing
- grout loss
- curing
- surface finishes
air voids
air voids when using air-entraining admixture
-should be sufficient air voids within mix to ensure sufficient freeze thaw resistance
removal of air from concrete
agitating
segregation
-Separation of constituents of conc mix caused by excessive handling/vibration/improper gradation of aggregates.
laitance
Coarse aggregates separate towards bottom + cement paste forms a scum on the top
reduce segregation
- inc water content
- reduce water-cement ratio
- inc rate of hydration