Concrete Technology

18CV44
Sem:IV
By
Mrs Snehalata Hiremath
Assistant professor
Civil Engineering
Department
Tontadarya College of
Engineering
Contents
 Concrete Ingredients-Cement
 Manufacturing process, Chemical

composition and their importance

 Types of cement
 Testing on cement
 Fine Aggregate-
 GEOLOGY (RAW MATERIALS)

 The fundamental chemical compounds to produce cement clinker are:

 Lime (CaO)
 Silica (SiO2)
 Alumina (Al2O3)
 Iron Oxide (Fe2O3)

3
 Lime- excess will decrease the strength.
Deficiency will make it set quickly.
 Silica- higher silica increases the

strength but setting time is prolonged.

 Alumina- results in quick setting. Excess

alumina weakens cement.

 Iron oxide- for hardness and strength.
 Magnesia- hardness and colour
 SOURCES OF CaCO3
 Sedimentary deposits of marine origin (limestone)
◦ Marble (metamorphosed limestone)
◦ Chalk
◦ Marl
◦ Coral
◦ Aragonite
◦ Oyster and clam shells
◦ Travertine
◦ Tuff

6
 LIMESTONES
◦ Originate from the biological deposition of shells and
skeletons of plants and animals.
◦ Massive beds accumulated over millions of years.
◦ In the cement industry limestone includes calcium
carbonate and magnesium carbonate.
◦ Most industrial quality limestones is of biological
origin.
◦ The ideal cement rock 77 to 78% CaCO3, 14% SiO2,
2.5% Al2O3, and 1.75% FeO3.
◦ Limestone with lower content of CaCO3 and higher
content of alkalis and magnesia requires blending
with high grade limestone

7
SOURCES OF ARGILLACEOUS MINERALS
 Argillaceous mineral resources:
◦ Clay and shale for alumina and silica Iron ore for iron
◦ Other natural sources of silica and alumina are:
Loess, silt, sandstone, volcanic ash, diaspore,
diatomite, bauxite
◦ Shales, mudstones, and sandstones are typically inter
bedded with the limestone and were deposited as the
inland waters and oceans covered the land masses.
◦ Clays are typically younger surface deposits

8
Manufacture of Portland cement

 Manufacturing Process ( Stages)

◦ Raw materials selection
◦ Preparation of materials
◦ Burning
◦ Final processing
◦ Quality control

9
Raw materials

 Limestone (calcium carbonate) is a common

source of calciumoxide.
 Iron-bearing alumino -silicates are the most

common source of silica.

 Aluminum and iron oxides act as fluxing agents

i.e. lower fusion temperature of part of the raw

mix to a practical firing temperature

10
 Preparation of Materials
 Crush the materials and store them
 Blend the materials and grind them
 Store them and do final blending
 Blending – assure constant composition and

predictable properties.
 Wet, dry, and semi-dry processes
 Burn the materials
 Grind, blend, and store the materials

11
Cement Manufacturing Process
 WET PROCESS
Raw materials are homogenized by crushing, grinding
and blending so that approximately 80%of the raw
material pass a No.9 sieve.
The mix will be turned into form of slurry by adding
30 - 50%of water.
 It is then heated to about 2750ºF (1510ºC) in
horizontal revolving kilns (76-153m length and 3.6-
4.8min diameter.
Natural gas, petroleum or coal are used for burning.
High fuel requirement may make it uneconomical
compared to dry process.
Wet process is obsolete

12
 DRY PROCESS
◦ Raw materials are homogenized by crushing, grinding
and blending so that approximately 80%of the raw
material pass a No.200 sieve.
◦ Mixture is fed into kiln & burned in a dry state
◦ This process provides considerable savings in fuel
consumption and water usage but the process is
dustier compared to wet process that is more efficient
than grinding.

13
DRY PROCES & WET PROCESS
 In the kiln, water from the raw material is driven
off and limestone is decomposed into lime and
Carbon Dioxide.
 limestone = lime + Carbon Dioxide
 In the burning zone, portion of the kiln, silica

and alumina from the clay undergo a solid state

chemical reaction with lime to produce calcium
aluminate.
 silica & alumina + lime = calcium aluminate

14
 Burning process

 Sintering (become a coherent mass with no melting)

 Fusion (complete melting)
 Clinkering – only about¼ of the charge is in the liquid
state
 Kiln
 Long steel pipe
 Lined with refractory brick
 Inclined a few degrees
 Rotated at 60 to 200 rev/h
 Typically 6m (20 ft) in diameter and 180m (600 ft) long
◦ Time in the kiln from2 h (wet process) to 1 h (dry process)
or even (20 min)
◦ modern heat exchangers

15
 Four processes take place in the kiln: Evaporation 240 to 450°C
 Calcination 600 to 1100°C
 Clay decomposes (600°C)
 Limestone decomposes (700°C) – CO2 driven off
Formation of initial compounds (1000°C)
 Initial formation ofC2S (1200°C), formation of calcium
aluminates and Ferrites
Formation of melt (flux compoundsmelt) (1350°C)
 Clinkering – charge temperature is 1400 to 1600°C
Formation of C3S
 Cooling
Rate of cooling significantly affects the reactivity of the final
cement
 Klinker

16
 The rotation and shape of kiln allow the blend
to flow down the kiln, submitting it to gradually
increasing temperature.
 As the material moves through hotter regions

in the kiln, calcium silicates are formed

 These products, that are black or greenish

black in color are in the form of small pellets,

called cement clinkers
 Cement clinkers are hard, irregular and ball

shaped particles about 18mm in diameter.

17
Cement Clinkers

18
 The cement clinkers are cooled to about
150ºF (51ºC) and stored in clinker silos.
 When needed, clinker are mixed with 2-5%

gypsum to retard the setting time of cement

when it is mixed with water.
 Then, it is grounded to a fine powder and

then the cement is stored in storage bins or

cement silos or bagged.
 Cement bags should be stored on pallets in a

dry place

19
Cement Manufacturing

20
21
22
KILN

24
Cement Silos

25
Ordinary Portland Cement (OPC)
 Chemical composition of Portland Cement:
Tri-calcium Silicate (50%)
 Di-calcium Silicate (25%)
Tri-calcium Aluminate (10%)
Tetra Calcium Aluminoferrite (10%)
Gypsum (5%)

26
 Role of various ingredients of Cement
 FUNCTION :TRICALCIUM SILICATE
◦ Hardens rapidly and largely responsible for initial set &
early strength
◦ The increase in percentage of this compound will cause
the early strength of Portland Cement to be higher.
◦ A bigger percentage of this compound will produces
higher heat of hydration and accounts for faster gain in
strength.
 FUNCTION :DICALCIUM SILICATE
◦ Hardens slowly
◦ It effects on strength increases occurs at ages beyond
one week
◦ Responsible for long term strength

27
 FUNCTION :TRICALCIUM ALUMINATE
◦ Contributes to strength development in the first few days
because it is the first compound to hydrate .
◦ It turns out higher heat of hydration and contributes to
faster gain in strength.
◦ But it results in poor sulfate resistance and increases the
volumetric shrinkage upon drying.
 FUNCTION :TRICALCIUM ALUMINATE
◦ Contributes to strength development in the first few days
because it is the first compound to hydrate .
◦ It turns out higher heat of hydration and contributes to faster
gain in strength.
◦ But it results in poor sulfate resistance andincreases the
volumetric shrinkage upon drying.

28
Cements with low Tricalcium Aluminate
contents usually generate less heat, develop
higher strengths and show greater resistance
to sulfate attacks.
 It has high heat generation and reactive with

soils and water containing moderate to high

sulfate concentrations so it’s least desirable.

29
 FUNCTION : TETRACALCIUMALUMINOFERRITE
◦ Assist in the manufacture of Portland Cement by
allowing lower clinkering temperature.
◦ Also act as a filler
◦ Contributes very little strength of concrete even though
it hydrates very rapidly.
◦ Also responsible for grey color of Ordinary Portland
Cement

30
 Cement Properties and Tests
1. Fineness
 95% of cement particles are smaller than 45 micrometer

with the average particle around 15 micrometer.

 Fineness of cement affects heat released and the rate of

hydration.
 More is the fineness of cement more will be the rate of

hydration.
 Thus the fineness accelerates strength development

principally during the first seven days.

 Fineness tests indirectly measures the surface area of

the cement particles per unit mass :

Blaine air-permeability test (ASTM C 204)

31
32
2. Soundness
 Soundness is the ability of a hardened paste to retain

its volume after setting.

 A cement is said to be unsound (i.e. having lack of

soundness) if it is subjected to delayed destructive

expansion.
 Unsoundness of cement is due to presence of

excessive amount of hard-burned free lime or

magnesia
 Unsoundness of a cement is determined by the

following tests:
 Le-Chatelier accelerated test (BS 4550: Part 3)
 Autoclave-expansion test (ASTM C 151)

33
34
3. Consistency- IS:4031-1988(part 4)methods of physical
tests for hydraulic cement
 Consistency refers to the relative mobility of a freshly

mixed cement paste or mortar or its ability to flow.

 Normal or Standard consistency of cement is determined

using the Vicat’s Apparatus.

 The standard consistency of a cement paste is defined as

that consistency which will permit the vicat plunger to

penetrate to a point 5 to 7 mm from the bottom of the
vicat mould.
 For finding out initial setting time, final setting time,

soundness of cement and compressive strength of cement,

it is necessary to fix the quantity of water to be mixed in
cement in each case.
 This experiment is intended to find out the quantity of

water to be mixed for a given cement to give a cement

paste of normal consistency and can be done with the help
of vicat apparatus.
4. Setting Time IS 4031-1968 part V
 This is the term used to describe the stiffening of the

cement paste.
 Setting time is to determine if a cement sets according

to the time limits specified.

 Setting time is determined using either the Vicat

apparatus.
 In actual construction dealing with cement, mortar or

concrete, certain time is required for mixing,

transporting and placing. During this time cement
paste, mortar, or concrete should be in plastic
condition. The time interval for which the cement
products remain in plastic condition is known as the
setting time.

38
Setting Time
 Initial setting Time:Initial setting time is
regarded as the time elapsed between the
moment that the water is added to the cement
and the time at which the needle penetrates to a
depth of 33 to 35 mm from top is taken as
initial setting time.
 Final setting time: It is the period elapsed

between the time when water is added to the

cement and the time when needle makes an
impression but circular attachement fails to do
its impression on the test block.
 6. Compressive Strength

 Compressive strength of cement is the most important

property.

 The compressive strength of cement mortars is

determined in order to verify whether the cement
conforms to IS specifications and whether it will be able
to develop the required compressive strength of
concrete. The average compressive strength of at least
three mortar cubes (area of the face 50 cm2 )
composed of one part of cement and three parts of
standard stand should satisfy IS code specifications.

40
 The standard sand(Ennore sand) to be used in the test shall
conform to IS: 650-1991 or sand passing 100 percent through
2 mm sieve and retained 100 percent on 90 micron IS sieve.
2mm to 1mm -33.33 percent
1mm to 500 microns -33.33 percent
500mm to 90 microns-33.33 percent
 The material for each cube shall be mixed separately and the

quantity of cement standard sand and water shall be as follows:

 Cement 200 gms
 Standard sand 600 grms

 Water (P/4 + 3.0) percent of combined weight of

cement and sand, where p is the percentage of water
required to produce a paste of standard consistency.
 Hydration of cement
• When Portland cement is mixed with water its
chemical compound constituents undergo a series
of chemical reactions that cause it to harden. This
chemical reaction with water is called "hydration".
Each one of these reactions occurs at adifferent
time and rate. Together, the results of these
reactions determine how Portland cement hardens
and gains strength.
 OPC hydration

• Hydration starts as soon as the cement and water

are mixed.
• The rate of hydration and the heat liberated by the
reaction of each compound is different.
• Each compound produces different products when
it hydrates.
Tricalcium silicate (C3S). Hydrates and hardens rapidly
and is largely responsible for initial set and early
strength. Portland cements with higher percentages of
C3S will exhibit higher early strength.
• Tricalcium aluminate (C3A). Hydrates and hardens the
quickest. Liberates a large amount of heat almost
immediately and contributes somewhat to early strength.
Gypsum is added to Portland cement to retard C3A
hydration. Without gypsum, C3A hydration would cause
Portland cement to set almost immediately after adding
water.
• Dicalcium silicate (C2S). Hydrates and hardens slowly
and is largely responsible for strength increases beyond
one week.
• Tetracalcium aluminoferrite (C4AF). Hydrates rapidly but
contributes very little to strength. Its use allows lower
kiln temperatures in Portland cement manufacturing.
Most Portland cement color effects are due to C4AF.
Reactions of Hydration

 2C3S + 6H = C3S2H3 + 3Ca(OH)2

(100 + 24 = 75 + 49 )
 2 C2S + 4H = C3S2H3 + Ca(OH)2

(100 + 21 = 99 + 22 )
 C3A + 6H = C3AH6

[C3A + CaSO4 . 2H2O = 3Cao. Al2O3. 3CaSO4.

31H2O] Calcium Sulfo aluminate
7. Heat of Hydration
 It is the quantity of heat (in joules) per gram of un
hydrated cement evolved upon complete hydration at
a given temperature.
 The heat of hydration can be determined by a
conduction calorimeter.
 The temperature at which hydration occurs greatly
affects the rate of heat development.
 Fineness of cement also affects the rate of heat
development but not the total amount of heat
liberated.

49
Heat of Hydration
 The heat of hydration is the heat generated
when water and Portland cement react. Heat of
hydration is most influenced by the proportion
of C3S and C3A in the cement, but is also
influenced by water-cement ratio, fineness and
curing temperature. As each one of these
factors is increased, heat of hydration increases.
 For usual range of Portland cements, about

one-half of the total heat is liberated between 1

and 3 days, about three-quarters in 7 days, and
nearly 90 percent in 6 months.
 The heat of hydration depends on the chemical

composition of cement.
Fine aggregate
 Functions
1. It fills the voids existing in the coarse aggregate.
2. It reduces shrinkage and cracking of concrete.
3. By varying the proportion of sand concrete can be
prepared economically for any required strength
4. It helps in hardening of cement by allowing the
water through its voids.
5. To form hard mass of silicates as it is believed that
some chemical reaction takes place between silica
of sand and constituents of cement
Requirements
1. Fine aggregate should consist of coarse angular
sharp and hard grains.
2. It must be free from coatings of clay and silt.
3. It should not contain any organic matter.
4. It should be free from hygroscopic salt.
5. It should be strong and durable and chemical inert.
6. The size of sand grains should pass through
4.75mm IS sieve and should be entirely retained on
75 micron IS sieve
7. Fineness modulus limits-
fine sand-2.2-2.6
Medium sand-2.6-2.9
Coarse sand-2.9-3.2
Grading limits
 Very coarse sand (Zone I) and very fine sand
(Zone IV) is unsatisfactory for concrete
making.
 Coarse sand results in harshness, bleeding

and seggregation
 Fine sand results in more demand of water to

produce fluidity.
 Most suitable grading required to produce

good workable concrete is zone II.

Alternative to River sand(FA)
 M sand