CEMENT AND CONCRETE MATERIALS materials fundamentals + mix design

CEMENT Materials fundamentals Sources of information Cement manufacture + composition Cement hydration Microstructure Concrete mixes Properties: strength
permeability durability

Information/texts Jackson & Dhir: Civil Engineering Materials, 5th edn, 1997 Mindess, Young & Darwin: Concrete, 2002 Neville & Brooks: Concrete Technology, 1987 Neville: Properties of Concrete 4th edn, 1995 Bensted & Barnes: Structure and Performance of Cements, 2nd edn, 2001

Information/journals Cement and Concrete Research Magazine of Concrete Research American Concrete Institute Journal ACI Journal Materials and Structures [RILEM]

Information/online Virtual Cement & Concrete Testing Laboratory: includes Electronic Monograph from Bentz at NIST http://ciks.cbt.nist.gov/vcctl/ See also Microstructure Images Library from Lange at UIUC: http://sftp.cee.uiuc.edu/research/dlange/micro/

Cement Manufacture Raw materials limestone + clay on firing, produces a complex mixture of synthetic minerals, principally calcium silicates and calcium aluminates

Manufacture

CEMENT World production 2001 1.6 billion tons Steel production 900 million tons

CEMENT World production 2001 1.6 billion tonnes 2--5 % total CO2 emission Energy intensive manufacture
Various figures Various figures are quoted. are quoted. The energy cost The energy cost of manufacture of manufacture is around 3500 is around 3500 kJ/kg cement kJ/kg cement

CEMENT World production 2001 1.6 billion tonnes EU production 2002 194 million tonnes For each tonne cement produced 0.800 tonne CO2 is also produced
0.525 tonne from decalcination of limestone 0.335 tonne from combustion of fuel in the kiln 0.050 tonne from electricity production

CEMENT

In EU, cement industry produces 3 per cent of total anthropogenic CO2

Source: Cembureau

Civil Engineering: Materials

Cement manufacture Some facts Cement is the industrial material produced in by far the largest tonnage: 1.6 billion tonnes worldwide 2001 (compare steel 900 million tonnes). Most of this cement is combined with about four times that weight of aggregate to make concrete. Large-scale industrial plants: typical output of a modern cement plant is 3000 tonnes/day. Low unit cost and large production volumes mean that it is uneconomic to transport cements over long distances, for example between countries. Therefore cement is produced in virtually every country in the world. Much of the worlds production capacity is owned by a small number of major industrial business conglomerates. For example, the Holcim Group (formerly the Swiss company Holderbank) operates in 70 countries with technical centre in Zurich. Lafarge is another massive group. British companies include RMC and Castle (owned by the Heidelberg group). The trend towards large multinational conglomerates helps to ensure a good technical level in cement manufacture worldwide.

Sustainability issues Cement manufacture is an important source of anthropogenic CO2 emissions (see overheads). Information A useful source of information about the European cement industry is http://www.cembureau.be/

Cement standards The long-serving British Standard for cement, BS 12, is being replaced by Euro-Norm EN 197 Cement Part 1: Composition, specifications and conformity criteria for common cements *Check out this document on-line via UoE Library ...needs ATHENS registration See also BCA: Information sheet on Eurocements on course website

Euro-Cements Five families CEM I CEM II CEM III CEM IV CEM V Portland cement Portland-composite cement Blastfurnace cement Pozzolanic cement Composite cement

Euro-Cements Other main components of composite cements Blastfurnace slag Silica fume Pozzolana Fly ash Burnt shale Limestone

Table 22. Mineralogical Composition of Classic Cement Clinker

Oxide Composition 3CaO SiO 2 2CaO SiO 2 3CaO Al 2 O 3 4CaO Al2 O 3 Fe 2O 3 Cement Notatiion C 3S C 2S C 3A C 4AF Common Name a lite belite aluminate brownmillerite 5565 1525 814 812

Concentration (wt%

Clinker microstructure
150 micron

C3 S C2 S C2 A C4AF

Clinker microstructure C3S, C2S, C 3A, C4AF

200 micron

Cement grinding Gypsum additions (strictly sulphate) Particle size distribution

Images from Lange UIUC http://cee.ce.uiuc.edu/lange/micro

Particle size Powder surface area Mean particle diameter 15-20 micron Direct measurement of cement particle size distribution is used for quality control in modern cement manufacture But a traditional measurement of cement particle size is the Blaine surface area typically 350 m2/kg [200-650 range]

Cement hydration 1 Heat evolution Induction period

Cement hydration 2 Chemical reaction with water All minerals involved

115 micron

Cement hydration 2 Principal reaction which develops strength C3S + water ---> C-S-H

Cement hydration 2 Principal reaction which develops strength C3S + water ---> C-S-H + Ca(OH)2

Ca(OH)2 Hydrated lime or portlandite

Cement hydration 3 Chemical reaction with water All minerals involved Formation of lime (calcium hydroxide) pH of pore water

Cement hydration 4 Water requirement about 30% by wt cement for complete reaction

Cement hydration 5
Four stages of hydration in a microstructural model of C3S hydration. The degrees of hydration are: top left--0% top right--20%, bottom left--50% bottom right--87% Red=unreacted cement blue=CH yellow=C-S-H black= porosity
from Bentz, NIST

Computational materials science Cellular automaton model of cement and concrete

D Bentz and E Garboczi NIST

Cement hydration 6

Synchrotron X-ray view

Summary of setting and hardening Workability Development of continuous network of hydrate material Strength development Porosity and permeability Timescale

Strength and strength development

Cement Based Materials Mortars Concrete Manufactured cement based materials Autoclaved aerated concrete

Transport properties Permeability

Sorptivity

see Hall & Hoff: Water Transport in Brick, Stone and Concrete 2002

PERMEABILITY property

Darcys law: u = Q/A = - kp /L k permeability Q volume rate of flow

B A