Concrete Technology, 11563

Lecture 1: Introduction and Repetition 2012

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Bjrn Johannesson, BYG

Concrete technology REPETITION basic course

Casting Airport

Mold resund Bridge

Casting

Guggenheim Museum (NY)

Concrete bridge in southern France (The Millau Viaduct)

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Bjrn Johannesson, DTU

Concrete construction

Course 11563 Concrete Technology 2012

Introduction
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BJRN JOHANNESSON, DTU

Staff: Construction Materials, DTU

Ole Mejlhede Jensen Mette Geiker Bjrn Johannesson Staffan Svensson Kurt Kielsgaard Hansen

Concrete

Wood

Transport and sorption

Lisbeth Ottosen
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Judith Selk Albertsen

Assistant teachers Jens Hamann Bundesen

s092844@student.dtu.dk

Mia Schou Mller Lund

s071963@student.dtu.dk

Frederik Marthedal Christiansen

s071960@student.dtu.dk
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Teachers Juan Manuel Paz Garca, Ph.D. student

Lectures 4, 5 and 10 (Concrete chemistry) jugra@byg.dtu.dk

Wu Min, Ph.D. student

Lecture 8 (Moisture fixation) miwu@byg.dtu.dk

Mads Mnster Jensen, Ph.D

Lectures 7, 9 and 12 (Porosity development, moisture transport and durability) mmoj@byg.dtu.dk

My background Concrete research

Master of Science: Lund 1993 Ph.D.: Lund 2000

2003

2005

1988

2006

Bjrn Johannesson, BYG

Outline
Basic properties of concrete Composition of concrete mixes Workability of fresh concrete Hydration mechanisms (hardening) Treatment after casting Concrete durability

Description of the layout of the course

Bjrn Johannesson, BYG

Learning objectives
Knowing about the main components of concrete (and their properties)

Knowing the approximate mass concentrations of different components of concrete

Knowing the main chemical components of cement (and some of their properties)

Knowing the basics of hydration of different cement clinker minerals

Knowing about the importance of workability of fresh concrete

Knowing about the importance of treatment of concrete after casting

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Bjrn Johannesson, BYG

Outline
Basic properties of concrete Composition of concrete mixes Workability of fresh concrete Hydration mechanisms (hardening) Treatment after casting Concrete durability

Description of the layout of the course

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Bjrn Johannesson, BYG

Bjrn Johannesson, BYG

Concrete

Ca. 10 mm

The cement paste, i.e., cement mixed with water, forms a solid product. The hardened cement paste can be regarded as the glue joining the sand and gravel (stones) together in the concrete. The higher concentration of the paste, i.e., the lower water content in mix, the greater the strength.

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Concrete as a Material
Oil platform Three Gorges Dam

Three Gorges Dam

Hydro-electric power dam that spans the Yangtze in Sandouping, China. It is the largest hydro-electric power station in the world.

Ship locks for river traffic to bypass the Three Gorges Dam, May 2004

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Advantages disadvantages with concrete as a material

Advantages Ability to be cast (any shape) Economic Durable Sound-insulating Fire-resistant Energy-efficient Aesthetic properties Disadvantages Low tensile strength Low ductility Volume instability Low strength-to-weight ratio

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Bjrn Johannesson, BYG

Basic failure criterions of normal hardened concrete

Tension Compression

Compressive strength Flexural strength Tensile strength

35 MPa 6 MPa 3 MPa

Compressive strength 10 times higher than tensile strength

10 10 10 cm concrete cube
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Bjrn Johannesson, BYG

Example: Production quantities of concrete in the US

The annual consumption of concrete in the US corresponds to covering central Copenhagen with an 80 m thick layer.

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Typical engineering properties of concrete Property Elastic modulus Tensile strain at failure Coefficient of thermal expansion Density Value 28 GPa 0.001 10 106 /C 2300 kg/m3

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Bjrn Johannesson, BYG

Comparison of properties of different building materials

Material Density (kg/m3) Steel Wood Plastic Rock Concrete 7800 510 1000 2600 2300 Tensile strength (MPa) 500 75 50 20 3 Elastic modulus (GPa) 210 5 3 50 25 Thermal conductivity (W/(mK)) 50 0.5 0.1 3 3

Concrete: man-made rock

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Limitations
Concrete is brittle with low tensile strength

Volume stability can be a problem (caused by moisture changes and temperature changes) Creep can be a problem (deformation changes at constant mechanical loads)

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Concrete properties shapeable, high strength and durable

One of the tallest concrete buildings

Taipei 101 106 stories Taiwan, 2002 508 m

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Bjrn Johannesson, BYG

Concrete properties shapeable, high strength and durable

Burj Khalifa (2010) 828 m high 164 stories (156 in concrete) Vertically pumped concrete, 700 m Elevator 10 m/s

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Concrete properties shapeable, strength and durability

rsta Bridge, Stockholm

Complementing building to Ordrupgrd museum, Copenhagen

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Bjrn Johannesson, BYG

Concrete properties shapeable, strength and durability

CN Tower i Toronto, 1975 The worlds highest slip mold construction Height = 553.34 m ! Mechanical test of reinforced concrete column
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Bjrn Johannesson, BYG

Concrete properties shapeable, strength and durability

Concrete road produced around 1930 located outside Lund, Sweden

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Bjrn Johannesson, BYG

Outline
Basic properties of concrete Composition of concrete mixes Workability of fresh concrete Hydration mechanisms (hardening) Treatment after casting Concrete durability

Description of the layout of the course

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Bjrn Johannesson, BYG

Concrete composition
cement + water + sand + stone + (admixtures) cement paste cement mortar aggregates

concrete
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Cement + water + sand + stone + (admixtures)

Portland cement and its chemical composition
1.0 0 0.10

SiO 2
0.5
Sand rich in SiO2

0.5

Al 2O3

Clay rich in Al2O3

0.22

Portland cement 1.0

0 1.0 0.68 0.5 0

CaO
PC most common cement in use

Limestone rich in CaO

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Cement + water + sand + stone + (admixtures)

Drinkable water can be used as water in concrete

Seawater

land Bridge

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Cement + water + sand + stone + (admixtures)

The aggregates may not contain humus. (especially the small fractions, i.e., the sand). There should not be clay particles on the surface of the aggregates since it lessens the adherence of cement. One should avoid aggregates containing reactive silica (e.g. opal-containing flint). This type of silica may react with the alkalis (Na+ and K+) in the hardened cement and cause serious cracks.

Humus

Clay

Clay particles on aggregates

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Typical alkali-silica damages

Porous flint with a high content of opal BJO, BYG

Cement + water + sand + stone + (admixtures)

Danish terminology
BJO, BYG

Term Singels (shingles) Nddesten (nut stones) rtesten (pea stones) Perlesten (pearl stones)

Type stones stones stones stones

Sizes 32-64 mm 16-32 mm 8-16 mm 4-8 mm 0-4 mm <0.25 mm

Betonsand (concrete sand) sand Filler* (filler) sand

*Also lime, stone powder, fly ash One distinguishes between smaterialer and bakkematerialer (lake and hill materials, respectively)

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Bakkematerialer

Cement + water + sand + stone + admixtures A CHEMICAL ADMIXTURES

Surface-active admixtures
1. Air-entraining agents To avoid frost damages 2. Water-reducing agents Improves the fluidity of fresh concrete Air bubble Aggregate

Setting- and hydration-regulated admixtures

1. Accelerators For example winter casting 2. Retarding agent Casting of thick constructions Massive construction

Tunnel element

Winter casting

The new water-reducing agents made it possible to develop the 30 so-called high-strength concrete and self-compacting concrete.

Cement + water + sand + stone + admixtures B MINERAL ADMIXTURES Fly ash and 1.0 0 silica fume
SiO 2
0.58 0.5 Silica fume = by-product from silicon alloys Fly ash = by-product from burning coal

0.30

0.5

Al 2O3

Portland cement 1.0 1.0 0.5 0.12 0

CaO
Fly ash and silica fume give improvements of some properties of concrete
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Cement + water + sand + stone + admixtures

Effect of plasticizers (water-reducing agents) and fly ash
Very fluid-like fresh concrete

Fly ash 2000

The spherical shape of the fly ash particles promotes the fluidity of fresh concrete

Hardened concrete with fly ash and silica fume can obtain a compression strength as high as 200 MPa!
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Cement + water + sand + stone + admixtures + Reinforcement = Reinforced concrete

Prestressed cables
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BJO, BYG

Concrete and reinforcement

Remember: no structural concrete without reinforcement!

The concrete and the reinforcement have the same temperature expansion coefficient. This is a necessary condition for avoiding cracking of reinforced concrete structures
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About 15 % of volume is reinforcement

BJO, BYG

Volume portions of constituents in concrete

Water

Cement Air Sand

Stone

BJO, KKH, BYG

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Fresh concrete is a mixture of:

2030 vol% cement and water 7080 vol% aggregates 12 vol% air

possibly: admixtures

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BJO, BYG

The most important mixture parameter is the weight ratio between BJO, water and cement in mix BYG

Low water-cement ratio

High strength Low permeability

High water-cement ratio

Low strength High permeability
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Composition of stone sizes for concrete aggregates

The total composition of the aggregates should be such that it is optimally packed
Good mixture of aggregates of different size Bad mixture of aggregates too many big stones

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BJO, BYG

Outline
Basic properties of concrete Composition of concrete mixes Workability of fresh concrete Hydration mechanisms (hardening) Treatment after casting Concrete durability

Description of the layout of the course

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BJO, BYG

Workability of fresh concrete

Slump (Danish: Stmlsprvning)
Danish terminology: (jordfugtig konsistens) (stiv konsistens) (plastisk konsistens) (tyktflydende konsistens) (flydende konsistens) Slump: 030 mm 3060 mm 60100 mm 100150 mm >150 mm

BJO, BYG

Slump test

Casting of concrete with fluid properties (flydende konsistens)

Very fluid concrete

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Normal concrete

In some cases a low slump value is desirable

BJO, BYG

Slump measurement

Casting of concrete with low slump (030 mm slump)

030 mm Slump (jordfugtig beton)

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Casting - Workability

Casting and vibration of concrete Casting the vibration is performed when the concrete has been placed

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BJO, BYG

Result of improper compacting of fresh concrete

Concrete surface

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BJO, BYG

Outline
Basic properties of concrete Composition of concrete mixes Workability of fresh concrete Hydration mechanisms (hardening) Treatment after casting Concrete durability

Description of the layout of the course

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BJO, BYG

Cement and water reactions

Alite hydration gives early strength
2C3S
(Tricalcium silicate)

7H
(Water)

C3S2H4 +
(C-S-H)

3Ca(OH)2
(Calcium hydroxide)

~ 100 KJ/mol

BJO, BYG

Belite hydration
2C2S
(Dicalcium silicate)

5H
(Water)

C3S2H4 + Ca(OH)2
(C-S-H) (Calcium hydroxide)

~ 50 KJ/mol

Aluminate hydration
2C3A
(Tricalcium aluminate)

21H
(Water)

C4AH13 + C2AH8
(Calcium aluminate hydrate 1) (Calcium aluminate hydrate 2)

~ 400 KJ/mol

Normally unwanted!

The tricalcium aluminate content should be low in a sulfate-resistant cement

C = CaO; S = SiO 2 ;

A = Al2 O 3 ;

F = Fe 2 O 3 ; H = H 2 O

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Gypsum is almost always added to cement to curb the reaction speed

Aluminate hydration
2C3A
(Tricalcium aluminate)

21H
(Water)

C4AH13 + C2AH8
(Calcium aluminate hydrate 1) (Calcium aluminate hydrate 2)

~ 400 KJ/mol

Too fast reaction, too much heat

Aluminate and gypsum hydration

C3A + 3CS*H2
(Gypsum)

+ 26H
(Water)

* C6AS3H32
(Ettringite)

Gypsum

(Tricalcium aluminate)

CaSO 4 2H 2 O

C = CaO; S = SiO 2 ;

A = Al2 O 3 ;

46 F = Fe 2 O 3 ; H = H 2 O; S* = SO 3

Hardened cement under a microscope

Cement + water = Cement paste Calcium Hydroxide (Plates) Ettringite (Needles) C-S-H (Amorphous ~ no shape)

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BJO, BYG

Cement with admixtures fly ash and silica fume

Gives high strength and low permeability

The concrete in the resund Link contains both fly ash and silica fume

STEP 1

Alite hydration
2C3S
(Tricalcium silicate)

7H
(Water)

C3S2H4 +
(C-S-H)

3Ca(OH)2
(Calcium Hydroxide) Silica fume Fly ash

STEP 2

puzzolan

Ca(OH)2
(Calciumhydroxid from the normal cement reaction)

SiO2

C-S-H
New formed (C-S-H) due to the puzzolan

Silicon oxide from fly ash and/or silica fume

OBSERVE: SiO2 present as sand (as quartz) is not the same as SiO2 present as silica. Sand is inert with respect to cement while silica is not (it reacts with CH)

The silica fume has a so-called micro-filler effect. The silica fume particles are about 100 nm in diameter (same size as cigarette smoke particles) 48

Outline
Basic properties of concrete Composition of concrete mixes Workability of fresh concrete Hydration mechanisms (hardening) Treatment after casting Concrete durability

Description of the layout of the course

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BJO, BYG

Treatment after casting Efterbehandling

Avoid early drying using membranes High risk of cracking!

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Setting and Bleeding: fresh concrete

Setting: defined as the onset of rigidity in fresh concrete Hardening: describes the development of useful and measurable strength BJO, BYG

Bleeding (a special form of segregation) may be defined as the upward movement of water after concrete has been consolidated but before it has set (undesirable phenomena). Can be avoided using cement with high fineness.

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Plastic shrinkage

BJO, BYG

When the evaporation rate exceeds the rate of bleeding and the free settlement period is ended, a hydrostatic tension begins to develop throughout the mass owing to the formation of menisci at the water surfaces in the capillaries. This results in vertical as well as lateral compressive forces and may be manifested in a slab (thick plate) by pattern cracking. It is called plastic shrinkage cracking. 52

Approximate method of calculating the rate of evaporation from a fresh concrete surface

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Outline
Basic properties of concrete Composition of concrete mixes Workability of fresh concrete Hydration mechanisms (hardening) Treatment after casting Concrete durability

Description of the layout of the course

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BJO, BYG

Concrete durability
Chlorides from seawater cause reinforcement corrosion Water (with very few ions) - leaching

Sulfate attacks the concrete Frost damages - deicing agents

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Process of carbonation
Lowers the pH-value in concrete pore solution INCREASING RISK OF REINFORCEMENT CORROSION

STEP 1

Alite hydration
2C3S
(Tricalcium silicate)

7H
(Water)

C3S2H4 +
(C-S-H)

3Ca(OH)2
(Calcium hydroxide) Silica fume Fly ash

STEP 2

Carbonation of Ca(OH)2 in concrete

Ca(OH)2
(Calciumhydroxid in the hardened cement)

CO2
Carbone dioxide In the air

CaCO3 + H2O
Calcium carbonate Water

Not wanted
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Salt-frost damages on surfaces together with reinforcement corrosion

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BJO, BYG

Outline
Basic properties of concrete Composition of concrete mixes Workability of fresh concrete Hydration mechanisms (hardening) Treatment after casting Concrete durability

Description of the layout of the course

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BJO, BYG

Lectures 1 - 7

Table 1: Schedule part I, Concrete Technology 11563, fall 2012, Aud. 306/34. Lecture Date Time Title 1 05-09-2012 8:00-10:00 Introduction, Repetition 2 12-09-2012 8:00-10:00 History of concrete, General practice 3 19-09-2012 8:00-10:00 Raw materials of concrete 26-09-2012 8:00-10:00 Concrete mix design, Hydration 4 5 03-10-2012 8:00-10:00 Chemical equilibrium 1 basics 10-10-2012 8:00-10:00 Chemical equilibrium 2 application 6 Vacation 7 24-10-2012 8:00-10:00 Pore structure development

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BJO, BYG

Lectures 8 - 13

Table 2: Schedule part II, Concrete Technology 11563, fall 2012, aud. 306/34. Lecture Date Time Title 8 31-10-2012 8:00-10:00 Moisture fixation 07-11-2012 8:00-10:00 Moisture transport 9 10 14-11-2012 8:00-10:00 Corrosion 11 21-11-2012 8:00-10:00 Mechanical properties 12 28-11-2012 8:00-10:00 Durability 13 05-12-2012 8:00-10:00 Repetition

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Exercises After each lecture it is time to exercise! Time set aside: from after lecture until 12:00

ROOMS: 116/025

116/44

116/45

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Literature:
Notes provided (250 DKK) Powerpoint slides provided

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Exam:
Written exam 20-12-2012.

E5A

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