07:30 - 08:30 08:30 - 09:30

Registration Introduction; Different types of cements, hydration and early age property development of concrete; Concrete admixtures Compressive strength of concrete; Tensile and flexural strength Tea break Behaviour under load; Deformation principles; Elastic properties Shrinkage and creep Lunch break Concrete deterioration mechanisms Concrete durability Tea break Special concretes: SCC, HSC Sponsors presentations on concrete technology Discussion and closure

Workshop, May 2010

09:30- 10:30 10:30 - 11:00 11:00 - 12:00 12:00 - 13:00 13:00 - 14:00 14:00 - 14:30 14:30 - 15:00 15:00 - 15:30 15:30 - 16:00 16:00 - 16:30 16:30

Concrete Technology for Structural Engineers

Professor Mark Alexander, Dr. Hans Beushausen Concrete Materials and Structural Integrity Research Group University of Cape Town

Concrete: Constituent Materials and Properties

Professor Mark Alexander Dr. Hans Beushausen
Concrete Technology for Structural Engineers May 2010

Concrete Technology for Structural Engineers Workshop, May 2010

Concrete Technology for Structural Engineers Workshop, May 2010

Concrete Technology for Structural Engineers Workshop, May 2010

Contents
Constituent materials for structural concrete Cements
cement/binder types portland cements hydration microstructure SA cement types

Hydraulic Cements/Binders
Cements or binders which, when mixed with water, set or harden in air or water by a process of hydration, forming compounds which are volumetrically stable, durable, and increase in strength with age. Basic constituents are oxides of Ca, Si, Al, Fe

CEMENTING MATERIALS (Binders)

Ca0/Si02 ratio 2,6 3,6, typically 2,8 Implies excess of calcium in the system

Aggregates not dealt with

explicitly here

Admixtures brief
- further lecture

Concrete Technology for Structural Engineers Workshop, May 2010

Concrete Technology for Structural Engineers Workshop, May 2010

Concrete Technology for Structural Engineers Workshop, May 2010

Most common example: Portland Cement

Latent Hydraulic Binders

Binders which, when mixed with water, will harden very slowly (generally too slowly for engineering purposes), and therefore require an activator to accelerate the hydration. Comprise same basic oxides as hydraulic binders, but in different proportions. Ca0/Si02 ratio 0,92 1,05, typically 1,02 therefore a deficiency of calcium to form calcium silicates

Most common example: ground granulated blast furnace slag or GGBS Also Corex slag (GGCS) (W. Cape)
Table : Chemical composition of South African GGBS (From Fulton 9) Oxide SiO2 CaO Al2O3 MgO FeO MnO K2O S TiO2 % by mass 34 40 32 37 11 16 10 13 0.3 0.6 0.7 1.2 0.8 1.3 1.0 1.7 0.7 1.4

Table : Composition of Portland cement clinker (From Fulton 9) Oxide CaO SiO2 Al2O3 Fe2O3 MgO Na2O + 0.658 K2O % by mass 63 69 19 24 47 1-6 0.5 3.6 0.2 0.8

Formation of hydrated calcium silicates

Concrete Technology for Structural Engineers Workshop, May 2010

Concrete Technology for Structural Engineers Workshop, May 2010

Concrete Technology for Structural Engineers Workshop, May 2010

Pozzolanic Materials
Materials which are siliceous or alumino-siliceous and in themselves possess little or no cementitious properties, but can react with lime in the presence of water to form stable hydrated cementitious compounds. Examples: Volcanic ashes and earths; calcined shales and clays; fly ash (FA); condensed silica fume (CSF). In common use in concrete in SA: FA (CSF rarely used).

For FA: Ca0/Si02 ratio 0,09 to 0,13, but can vary widely. For CSF: Ca0/Si02 ratio 0,01, very low Ca0 content. Table : Chemical composition of South African FA (ex Matla, Lethabo & Kendal) and CSF (From Fulton 9) Oxide FA SiO2 Al2O3 CaO Fe2O3 MgO Na2O + 0.658 K2O 48 55 28 34 47 24 12 1-2 % by mass CSF 92 96 1.0 1.5 0.3 0.6 1.0 1.6 0.6 - 0.8 0.8 1.3

PORTLAND CEMENTS

In South Africa, we often refer to slag, fly ash and CSF collectively as Cement extenders. They are also called Supplementary cementitious materials

Concrete Technology for Structural Engineers Workshop, May 2010

Concrete Technology for Structural Engineers Workshop, May 2010

Concrete Technology for Structural Engineers Workshop, May 2010

Manufacture
PC manufactured in a large rotary kiln high temperature process (1400-1450 C). Raw materials mainly limestone, shale/clay - milled to form raw meal, which is then calcined to produce clinker. Raw meal: oxides of Ca, Si, A and Fe, (compositions given previously.) Clinker: milled with small amount of gypsum to make Portland Cement.

Cement chemistry shorthand notation

C = CaO S = SiO2 A = Al2O3 F = Fe2O3

Compound composition of S.A. Portland cements

Table : Compound composition of South African CEM I cements From Fulton
9

Compound Tricalcium silicate Dicalcium silicate Tricalcium aluminate Tetracalcium alumino-ferrite Magnesia Gypsum Free lime

Formula 3CaO.SiO2 2CaO.SiO2 3CaO.Al2O3 4CaO.Al2O3.Fe2O3 MgO Raw material CaO

Abbrev. C3S C2S C3A C4AF M -

% by mass in cement 60 73 8 30 5 12 8 16 1.9 3.2 4.4 6.7 0.2 2.5

Primary clinker compounds are C3 S Tricalcium silicate C2 S Dicalcium silicate Tricalcalcium aluminate C3 A Tetracalcium aluminoferrite C4AF E.g. C3S = 3CaO.SiO2

Concrete Technology for Structural Engineers Workshop, May 2010

Concrete Technology for Structural Engineers Workshop, May 2010

Concrete Technology for Structural Engineers Workshop, May 2010

Hydration of Portland Cements

Hydration is the formation of a compound by the combination of water with some other substance (i.e reaction with water), in this case with clinker minerals. The main strength forming compounds in PC are the calcium silicates (C3S & C2S). The primary reaction products are calcium silicate hydrates and calcium hydroxide. Thus:

Rates of strength gain of various clinker minerals

Example (C3S hydration)

2C3S + 6H C3S2H3 + 3CH (calcium hydroxide).

CH is calcium hydroxide, CaOH2 Together with the metal alkalis (Na and K), these give concrete its high alkalinity (pH = 12.5 - 13.0) - essential for durability of embedded reinforcing steel

CS

H
water

CSH
calcium silicate hydrates

Calcium silicate

Concrete Technology for Structural Engineers Workshop, May 2010

Concrete Technology for Structural Engineers Workshop, May 2010

Concrete Technology for Structural Engineers Workshop, May 2010

Influence of main hydration components on concrete properties

Early-age development of hydration products and micro-structure

Component CSH

Strength
Provides cohesive and adhesive properties of conc. Reduces porosity, but may cause cleavage and strength reduction. Not significant. Reduces total porosity. Significant only in low-porosity pastes.

Deformations
Gel pores influence shrinkage and creep through water loss. Dimensionally stable. Restrains CSH deformations. Minor effect.

Durability
Gel insoluble. Generally low permeability. Blocks capillary pores and lowers permeability. Leached by water. Attacked by acids. Carbonates. Ettringite (if formed from sulphate attack) is expansive. Renewed hydration gives autogenous healing of internal cracking.

Hydration of Cement Extenders

Slag (GGBS) and Fly Ash (FA) Recall: hydration of PC produces excess CaOH2 and an alkaline pore solution

Calcium Hydroxide

Ettringite

Unhydrated

cement Capillary Pores

Restrains CSH deformations

Cement extenders require an alkaline environment to induce hydration (Activators)

Capillary porosity is Fine pores and gel Porosity influences a major factor pores contribute to permeability and diffusivity. influencing strength. shrinkage and creep. Large pores increase permeability.

Concrete Technology for Structural Engineers Workshop, May 2010

Concrete Technology for Structural Engineers Workshop, May 2010

Concrete Technology for Structural Engineers Workshop, May 2010

Hydration of Cement Extenders

GGBS: Once activated, hydrates to form CSH but does not consume CaOH2 FA: Activated by alkalis, then hydrates by consuming excess CaOH2 (from hydration of PC) to form CSH. In general, hydration products produced by GGBS and FA are similar to those produced by hydration of PC. However, extended cement concretes have lower CaOH contents - generally an advantage.
2

E.g. (1) Strength performance of different slag concretes

w/b 0.60 1.4 1.2 fc, slag concrete / fc, PC 1.0 0.8 0.6 0.4 0.2 0 20 40 Age (days) 60

E.g. (2) w/c required for a Grad 30 concrete as function of different binders

GGBS GGCS GGAS

Concrete Technology for Structural Engineers Workshop, May 2010

Concrete Technology for Structural Engineers Workshop, May 2010

Concrete Technology for Structural Engineers Workshop, May 2010

Heat of Hydration Hydration of Portland cements and cement

extenders produces substantial amounts of heat (heat of hydration)
Graph below shows rate of heat evolution in early stages
Stage 1: Early rapid heat evolution mainly C3A Stage II: Induction or dormant period Stage III: Initial set 2-4h, followed by accel. period to max. heat rate (4-8h) C3S hydration Stage IV: Reaction slows Stage V: steady state

Heat of Hydration (contd)

Total heats of hydration of PC and other binders CEM I Range for SA CEM I: 270-320 kJ/kg Proportion of the above for typical blended binders 50% GGBS: 60% 30% FA: 55% 5% CSF: 90% But note: there is large variability in the above need for specific testing in critical cases

Heat rate curves for typical SA cement blends in concrete (From Ballim et al)

0.1

10

100

Concrete Technology for Structural Engineers Workshop, May 2010

Concrete Technology for Structural Engineers Workshop, May 2010

Concrete Technology for Structural Engineers Workshop, May 2010

Total heat curves for SA cement blends in concrete

Heat rate curves for GGBS, FA, CSF cement blends (From Ballim et al)

Powers Model for Hydration

Has the advantage that it can predict porosity which is key to understanding behaviour of PC concretes

low heat PC clinker (From Ballim et al)

Schematics of Powers Model

GGBS FA

CSF

Concrete Technology for Structural Engineers Workshop, May 2010

Concrete Technology for Structural Engineers Workshop, May 2010

Concrete Technology for Structural Engineers Workshop, May 2010

Features of Powers Model

The formation of the rigid cement gel (i.e. CSH) is always the same regardless of the stage of hydration, type of PC, w/c. Characteristic feature of CSH is porosity gel pores and capillary pores. Gel has a characteristic porosity of 28% (i.e. gel pores very tiny, 0.0010.003 m). Capillary pores are much larger (0.01 1.0 m). Remnants of original water-filled space. The combined water (water of hydration) is a constant proportion by mass of the cement with which it combines wn/c = constant = 0.23 Densities: unhydrated cement = 3.14 - 3.17 g/cm3; gel solids = 2.51 g/cm3 ; gel including pores = 1.80 g/cm3 The gel expansion factor relates the volume of gel (including pores) to the volume of unhydrated cement from which it is formed 2,2

Schematic of volume relationships during hydration (after Addis)

Limits of Hydration
1. 2.

The Condition of Limiting Space water-cured concrete. The Condition of Limiting Water sealed concrete (e.g. large members, mass concrete). These lead to a critical w/c of approx. 0.40 (range 0.36 - 0.42) Below this critical w/c: capillary porosity is minimised Above this critical w/c: the system increasingly is governed by capillary porosity

Concrete Technology for Structural Engineers Workshop, May 2010

Concrete Technology for Structural Engineers Workshop, May 2010

Concrete Technology for Structural Engineers Workshop, May 2010

The Condition of Limiting Space (water-cured concrete) gives:

Role of capillary pores

Capillary porosity is a major factor influencing strength Fine pores and gel pores contribute to shrinkage and creep Porosity influences permeability and diffusivity. Large pores increase permeability

Concrete Technology for Structural Engineers Workshop, May 2010

Concrete Technology for Structural Engineers Workshop, May 2010

Concrete Technology for Structural Engineers Workshop, May 2010

Concept of degree of hydration

This is the degree to which the cement has hydrated at any given time - critically influenced by curing. Curing is the combination of temperature, moisture, and time effects coupled with the type of binder (e.g. fast or
slow hydration)

Degree of hydration (contd)

Temperature of curing is also important influences rate of hydration and therefore rate of strength development

EXTENDED CEMENTS/BINDERS
Ground granulated blastfurnace slag GGBS Fly Ash FA Condensed Silica Fume CSF

In essence, time and temperature are interchangeable

(see later lecture on concrete strength the Maturity Concept)

This means that at lower curing temperatures, one needs to cure for longer This is also true for blended cements due to their slower hydration characteristics

Concrete Technology for Structural Engineers Workshop, May 2010

Concrete Technology for Structural Engineers Workshop, May 2010

Concrete Technology for Structural Engineers Workshop, May 2010

Table: Effects of extenders on properties of concrete (from Table 1.5, Fulton 9).
Extender Effects Suitability for use in Mass Marine ASR concrete exposure GGBS particularly suited to High marine GGBS conditions; contents provides > 50%) substantial help resistance to reduce risk chloride of thermal ingress and cracking. controls reinf. corrosion.

Table: Effects of extenders on properties of concrete (from Table 1.5, Fulton 9).
Exten- Effects der Fresh concrete Improves workability and reduces water content Slightly retards setting Hardened concrete Slower strength development Improved long term strength Refines pore structure, reduces permeability Prevents or retards ASR Binds chlorides and reduces chloride ingress Lower heat of hydration rate Suitability for use in Mass Marine ASR concrete exposure

Table: Effects of extenders on properties of concrete (from Table 1.5, Fulton 9).
Extender Effects Mass concrete Fresh concrete Reduces workability Increase cohesiveness Significantly reduces bleeding CSF Hardened concrete Increases strength Reduces permeability Substantially refines pore structure Suitability for use in Marine exposure ASR

Fresh concrete May improve workability Slightly retards setting Hardened concrete Slower strength development Improved long term strength Reduced permeability Prevents or retards ASR Binds chlorides and reduces chloride ingress Lower heat of hydration rate

GGBS

Requires > 40% GGBS content to control potential ASR for susceptible aggregate types.

FA

Fly Ash Requires content of FA 30% content of FA content of enhances 30% > 20% to resistance control significantly to chloride reduces risk potential ingress and of thermal ASR for reinf. cracking. suscep. corrosion agg. due to types. chlorides.

CSF significantly Requires reduces physical CSF permeability, but content of Not does not bind > 15% to suitable chlorides control for use in effectively. potential mass Nevertheless can ASR for concrete. improve susceptible resistance to aggregate chloride ingress. types.

Concrete Technology for Structural Engineers Workshop, May 2010

Concrete Technology for Structural Engineers Workshop, May 2010

Concrete Technology for Structural Engineers Workshop, May 2010

In general, cement extenders:

o Reduce cost of concrete o Enhance durability of concrete o Reduce industrial waste o Improve physical microstructure and chemical resistance of concrete

SA CEMENT TYPES
SA cements are manufactured according to SANS 50197-1 The Table that follows gives Common cements i.e cements for concrete that are based on Portland cement technology The next slide interprets the symbols given in the Table

Cement Notation
(a) CEM (b) I, II, III (c) A, B, C (d) 32.5 42.5 52.5 R
(a) Type (b) Clinker of Cement content category
CEM Denotes a common cement, i.e. for concrete I - > 95% clinker II - may contain up to 35% extender (except CSF)

(c) Proportion and type of (d) 28-day extender in cements strength class
In CEM II: A 6-20% extender B 21-35% extender In CEM II: 2nd capital letter indicates type of extender: D CSF L Limestone S GGBS V or W - FA Number indicates 28 day strength class. Lower boundary of a window for strength 32.5 32.5R 42.5 42.5R 52.5 52.5R R denotes high early strength cement

In CEM III: A 36-65% III may extender contain > 35% B 66-80% GGBS extender C 81-95% extender

Concrete Technology for Structural Engineers Workshop, May 2010

Concrete Technology for Structural Engineers Workshop, May 2010

Concrete Technology for Structural Engineers Workshop, May 2010

Important to understand that concrete can be made to most strength grades with most of the common cements irrespective of the strengthen class of the cement (within certain limits) The controlling factor will be w/c ratio in the mix design

Strength vs w/c for a range of SA binder types

Strength class 52.5

Strength class 32.5 Strength class 42.5

Concrete Technology for Structural Engineers Workshop, May 2010

Concrete Technology for Structural Engineers Workshop, May 2010

SA CEMENT TYPES various cement companies

Cement Afrisam Type
CEM I CEM II 52.5 N

Thank you and questions

Lafarge
-

NPC
-

PPC
42.5 N/R 52.5 N

A-M(V-L) 42.5N A-V 52.5 N A-L 32.5 R A-L 32.5 R A-M (L) 42.5 N A-M(V-L) 42.5 N B-S 42.5 N B-M (L-S) 32.5 R B-L 32.5 N A-V 42.5 N B-L 32.5 N B-V 32.5 R B-L 32.5 R A-V 32.5 R B-V 32.5 R A 32.5 N Corex slag in bulk
(not available at present)

CEM IIIA CEM IV CEM V A (S-V) 32.5 N

BULK OF CEMENTS LIE HERE