CONCRETE TECHNOLOGY

Concrete is the most widely used material in the world apart from water and it is the
most commonly used man made construction material.
• Concrete is a composite material composed of coarse granular material (the aggregate
or filler) embedded in a hard matrix of material (the cement or binder) that fills the
space among the aggregate particles and glues them together.

• Alternatively, concrete can be defined as a composite material that consists essentially

of a binding medium in which are embedded particles or fragments of aggregates

• Depending on what kind of binder is used, there are different types of concrete
e.g:

• Concrete in made with non-hydraulic cement, it is called non-hydraulic cement

concrete; (non-hydraulic cements used in early history were gypsum and lime;
they are non-hydraulic cement because cannot gain strength in water)

Concrete made of hydraulic cement, it is called hydraulic cement concrete

because it gains strength in water

• Concrete is made of asphalt, it is called asphalt concrete;

• Concrete is made of polymer, it is called polymer concrete.

 Typical Raw Materials

Depending on the chemistry of each material, the

following raw materials are used.
• Limestone
• Clay (shale, schist)
• Sand
• Iron ore (laterite)
 Basic Raw Materials of Portland cement

Limestone Clay Shale

Sand Iron Ore

Cement production process
 2000 T/H 165,000 MT
Fuller
Mixing bed
Roller
Mill
Raw material mining Silo

2x25,800 MT
2X450 T/H

400 T/H
2x75,000 MT
Cement
Silos

Clinker
Silo
4X10,000 MT

4X140 T/H

ILC Pre-calciner Kiln

Rotor
Packers

2X5,000 TPD

15,000 TPD
Auto
Packers OK MILL
Typical chemical composition of cement clinker with
Minor constituents

The maximum permitted amounts of these minor constituents are laid down in the various
standard specifications and are strictly controlled
Hydration of cement
• The hydration of Portland cement involves the
reaction of the anhydrous calcium silicate and
aluminate phases with water to form hydrated
phases.

• These solid hydrates occupy more space than the

anhydrous particles and the result is a rigid
interlocking mass whose porosity is a function of the
ratio of water to cement (w/c) in the original mix.

• Provided the mix has sufficient plasticity to be fully

compacted, the lower the w/c, the higher will be the
compressive strength of the hydrated cement
paste/mortar/concrete and the higher the resistance
to penetration by potentially deleterious substances
from the environment
• Cement hydration is complex and the reactions of the
silicate phases (C3S and C2S) and the aluminate phases
(C3A and C4AF)

• Both C3S and C2S react with water to produce an

amorphous calcium silicate hydrate known as C–S–H
gel which is the main ‘glue’ which binds the sand and
aggregate particles together in concrete.

• C3S is much more reactive than C2S and under

‘standard’ temperature conditions of 20°C
approximately half of the C3S present in a typical
cement will be hydrated by 3 days and 80% by 28
days. However, hydration of C2S does not normally
proceed to a significant extent until ~14 days.
• C3S reacts very fast at the early stage, releases
more hydration heat, and contributes most to
early age strength of concrete.

• C2S reacts very slowly, releases less heat, and

contributes minimally to early age strength of
concrete. C2S contributes the most to the long-
term strength of concrete.

• C3A and C4AF phases

Reaction of C3A with water in the presence of a
of gypsum is
C3A + 3(CSH)2+ 26H →C6A3H32
This is called calcium sulfoaluminate hydrate
and more commonly ettringite

• If ettringite is formed before the paste has

hardened and gained strength due to hydration
of C3S. It will contribute to the early strength
development of concrete

• If ettringite is formed after the concrete has

hardened and free space has been occupied by
other hydration products, it will cause breakage
of hardened hydration products and hence
create cracks and volume instability
A typical calorimetric curve of Portland cement
Simplified illustration of hydration of cement paste
 ADMIXTURES

What is an admixture in concrete?

• Admixtures are chemicals which are added to concrete at the

mixing stage to modify some of the properties of the mix.

• Admixtures should never be regarded as a substitute for good mix

design, good workmanship, or use of good materials
Uses of admixtures
The most common reasons for using admixtures in
concrete are:
• To increase workability without changing water content.

• To reduce water content without changing workability.

• To effect a combination of the above.

• To adjust setting time.

• To reduce segregation and/or bleeding.

• To improve pumpability.
• To accelerate the rate of strength development at
early ages.

• To increase strength.

• To improve potential durability and reduce permeability.

• To reduce the total cost of the materials used in the

concrete.

• To compensate for poor aggregate properties.

Chemical admixtures are usually classified according to the intended
specific functions:
⮚ water-reducing admixtures

⮚ set modifiers (retarders, accelerators)

⮚ air-entraining agents

⮚ anti-bleeding/segregation admixtures

⮚ corrosion inhibitors

⮚ curing and shrinkage (drying) reducing admixtures

⮚ water-proofing admixtures

⮚ anti-freezing admixtures
Air entrainers
Uses
• It enhance resistance of hardened concrete to damage from
freezing and thawing

• For improved workability, in stiff concrete mixes.

• It reduces bleeding and segregation, when a mix lacks fines.

Superplasticizers
Uses
• It allows for a flowable concrete in areas of congested
reinforcement.

• It facilitate consistency in self-levelling concrete placing.

• It is used in In high-strength concretes, to increase the flow though
water:cement ratio is reduced
 Mechanism of action of Admixtures
Admixtures work by one or more of the following actions:
• Chemical interaction with the cement hydration process, typically
causing an acceleration or retardation of the rate of reaction of one
or more of the cement phases.

• Adsorption onto cement surfaces, typically causing better particle

dispersion (plasticizing or superplasticizing action).

• Affecting the surface tension of the water, typically resulting in

increased air entrainment.

• Affecting the rheology of the water, usually resulting in an

increased plastic viscosity or mix cohesion.

• Introducing special chemicals into the body of the hardened

concrete that can affect specific properties such as corrosion
susceptibility of embedded steel or water repellence.
Mining water can cause problems due to the presence of salts,
acids, oil, sugar, and organic matter.

Mixing and curing with sea water is not allowed

The pH value of water to be used in mixing and curing shall not be

less than 6
 Advantages of low water cement ratio

• Increase in strength

• Lower permeability

• Increased resistance to weathering

• Better bond between concrete and reinforcement

• Reduced drying shrinkage and cracking

• Less volume change from wetting and drying

Aggregates (sand and Stone)
 binding medium
(mortar)
⮚ Portland Cement Concrete
relatively inert
filler materials
(aggregates)

⮚ In concrete mixtures the proportions of cement paste

& aggregates is controlled by the following factors:
1) Suitable workability & placeability of fresh mass.
2) Adequate strength & durability of hardened product.
3) Minimum cost of the final product
⮚The aggregate occupies ~70-75% of the
volume of concrete, so its quality is of great
importance.

⮚Aggregates may affect the following

properties of concrete:
– Strength
– Durability
– Structural Performance
– Economy
⮚ Aggregates have 3 main functions in
concrete:
1) To provide a mass of particles which are suitable
to resist the action of applied loads & show
better durability then cement paste alone.
2) To provide a relatively cheap filler for the
cementing material.
3) To reduce volume changes resulting from setting
& hardening process & from moisture changes
during drying.
⮚ The properties of concrete are affected by the
properties of aggregate:
1. The mineral character of aggregate affects the
strength, durability, elasticity of concrete.
2. The surface characteristics of aggregate affects
the workability of fresh mass & the bond between
the aggregate & cement paste in hardened
concrete. If it is rough, workability decreases &
bond increases.
3. The grading of aggregate affects the workability,
density & economy.
4. The amount of aggregate in unit volume of
concrete
Coarse Aggregate
Retained on #4 Sieve
Igneous, Sedimentary and
Metamorphic rock
Granite
Limestone
River gravel

Fine Aggregate
Passing #4 Sieve
Natural Siliceous and Crushed
Limestone
 Properties of fresh Concrete

• Fresh concrete is defined as a fully mixed concrete in a rheological

state that has not lost its plasticity.

• The fresh concrete stage covers the cement hydration stages I and
II. The plastic state of fresh concrete provides a time period for
transportation, placing, compaction, and surface finishing
A typical calorimetric curve of Portland cement
 Factors Affecting Workability
• Method and duration of transportation

• Quantity and characteristics of cementing

materials
• Aggregate grading, shape and surface texture

• Quantity and characteristics of chemical admixtures

• Amount of water

• Amount of entrained air

• Concrete & ambient air temperature

The properties of fresh concrete are short-term requirements in
nature, and should satisfy the following requirements:

1. It must be easily mixed and transported.

2. It must be uniform throughout a given batch, and between
batches.
3. It must keep its fluidity during the transportation period.
4. It should have flow properties such that it is capable of
completely filling the forms.
5. It must have the ability to be fully compacted without
segregation.
6. It must set in a reasonable period of time.
7. It must be capable of being finished properly, either against the
forms or by means of
troweling or other surface treatment.
 WORKABILITY

• Workability is the most

important property of freshly
mixed concrete.
• There is no single test method
that can simultaneously
measure all the properties
involved in workability.
• It is determined to a large
extent by measuring the
“consistency” of the mix.
 CONSISTENCY

⮚ Consistency is the fluidity or degree of wetness

of concrete.
⮚ It is generally dependent on the shear
resistance of the mass.
⮚ It is a major factor in indicating the workability
of freshly mixed concrete.
 • Slump Test is related with the ease with which
concrete flows during placement

The slump cone is filled in 3 layers. Every

layer is evenly rodded 25 times.

Measure the slump by determining the vertical difference

between the top of the mold and the displaced original center
of the top surface of the specimen.
 Vebe test
For the test, a standard cone is cast. The mould is removed, and a
transparent disk is placed on the top of the cone. Then it is vibrated
at a controlled frequency and amplitude until the lower surface of
the disk is completely covered with grout. The time in seconds for
this to occur is the Vebe time. The test is probably most suitable for
concrete with Vebe times of 5 to 30s. The only difficulty is that
mortar may not wet the disc in a uniform manner, and it may be
difficult to pick out the end point of the test.
Vebe
aparatus
Compaction factor test
The upper hopper is completely filled
with concrete, which is then successively
dropped into the lower hopper and then
into the cylindrical mould.

The excess of concrete is struck off, and

the compacting factor is defined as the
weight ratio of the concrete in the
cylinder, mp, to the same concrete fully
compacted in the cylinder (filled in four
layers and tamped or vibrated), mf (i.e.,
compacting factor = mp/mf).
For the normal range of concrete the
compacting factor lies between 0.8 to
0.92 (values less than 0.7 or higher
than 0.98 is regarded as unsuitable).
This test is good for very dry mixes.