Concrete 1

University of Liverpool
February, 18th 2020
CEV 233, Concrete
marco-broccardo.com
CIVE233 Structural Engineering in the Built Environment
Outline, Syllabus
๏February, 18th 2020 ๏February, 26th 2020

‣ Motivation ‣ Recap
‣ Intro to concrete ‣ Strength tests
‣ Cement ‣ Casting tests
‣ Intro to mix design ‣ History of Concrete
‣ Quiz ‣ Quiz
slide-2 marco-broccardo.com
‣ Motivation
‣ Introduction to concrete
‣ Cement
‣ Intro to mix design
‣ Quiz
Facts about concrete
๏II most used commodity

๏Concrete is “cheap,” ~0.05$/lb
๏ ~6.5-7 billions [m3] concrete per year
๏7-8% global CO2 is directly related to concrete
~1 [m3] concrete per person per year
๏II most used commodity

๏Concrete is “cheap,” ~0.05$/lb (steel is about 1$/lb)
๏ ~6.5-7 billions [m3] concrete per year
๏7-8% global CO2 is directly related to concrete
Agricolture
9%
Transportation
29%
Electricity
28% CO2
Comm. & Res.

Concrete 12%
8% Industry
14%
30
29
22.5
CO2 per country

15
14
7.5
8
6
0
China U.S. Concrete India
5000
3750
millions tons
2500
1250
0
1970 1978 1986 1994 2002 2010 2014 2018
Years
Good facts about concrete
๏Shape flexibility
๏Long history
๏Is made of local materials
๏It uses a lot of recycle materials
Challenges of Concrete
๏ Lowering the CO2 footprint

๏Making the material more robust and durable
๏Making the material more efficient and economical
๏Including more waste materials
US National Academy of Engineering Challenges
๏Providing access to clean water

๏Developing Carbon Sequestration
๏Restoring and improving urban infrastructures
๏Providing energy from nuclear fusion
๏…
‣ Motivation
‣ Cement
‣ Quiz
Concrete ingredients
Rock Sand Cement Water
Cement paste
Mortar
Concrete
Example of other composite materials
Concrete is a composite material!
Plywood Concrete Fiber composite
‣ Cement ๏Most expensive ingredient

๏Binder
‣ Aggregate
Fine Agg.
๏To make a more durable material
๏Restrain shrinkage
Coarse Agg. ๏To make a cheaper material
‣ Additive
๏Fibers, minerals, chemical products, etc.
Aggregate (70% of the volume)&Water
๏Fine Aggregate: A. smaller than #4 sieve (4 openings per inch~0.2”)
๏Coarse Aggregate: A. larger than #4 sieve. Typical size: 0.2”~1”

๏Water MUST free of chlorides and clean. (E.g., potable water)
steel corrosion
Fibers
๏Microfibers
‣ fresh concrete (to control plastic shrinkage)
‣ To control the crack size
‣ Plastic (polypropylene) contributes in the fresh state (prevent cracking)
๏Macrofibers
‣ Steel & plastic Fibers contributes in the hard state
‣ Can be used as reinforcement and to hold concrete after cracking
Micro Fibers
Source: Contec fiber Source: Sigma Plantfinder blog
Macro Fibers
Source: Dena World Source: TU Chemnitz
Fibers
๏When?
‣ Complicate shapes (e.g., shells str., very thin str., concrete pavements)
‣ To control the crack size
๏To increase ductility NOT to increase the strength
Source: Structural Synthetic Fibers in Thin Concrete Overlays: Keep Cracks Tight, Increase Load Transfer, & Reduce Slab Displacement, Amy M. Dean
Fibers
load
deformation
no fibers fibers
Type of concrete (density)
๏Lightweight ~<1800[kg/m3]
‣ light natural egg. (pumice, casting air inside concrete)
‣ to reduce the dead load of the structure
๏Normal weight ~2300-2500[kg/m3]

๏Heavy weight ~3000[kg/m3]
‣ Heavy natural aggr. (barytes, magnetite), manufactured agg. (iron)
‣ Used for radiation shielding (medical or nuclear).
Compressive strength, Fc
๏Low strength concrete ~ < 20 [MPa]

๏Moderate strength concrete ~20-40 [MPa]
๏High strength concrete ~>40 [MPa]
US EU
Source: fhwa.dot.gov/publications/research/infrastructure/structures/06103/chapt3.cfm blog
Compressive strength
๏Strength(w/cm)
water
~ 0.4-0.6
cement
Other strengths
๏Tensile ~ 10% of compressive str. E.g.,

๏Flexural ~0.63 Fc units in [Mpa]
๏Shear ~ 6 times the tensile strength
๏Example
30 [MPa]
‣ Tensile 3.00[Mpa]
‣ Flexural 3.45[Mpa]
‣ Shear 18.00[Mpa]
Tensile strength
Source: Ince, R. (2017). The fracture mechanics formulas for split-tension strips. Journal of Theoretical and Applied Mechanics, 55(2), 607-619.
Tensile strength
P P
P Mmax P
Strength envelope
We can increase the compressive strength !
‣ Motivation
‣ Cement
‣ Quiz
Calcination
๏Production of cement uses 6% of World Energy

๏ Cement industry produce 5% of CO2 emissions
๏ Calcining CaCO3 +heat CaO + CO2
Calcium Carbonate >1400 OC Calcium Oxid Carbone dioxine
+ +
Calcination
Mine
Heat
Grind Material
40%
CO2
Calcination
60%
1 [kg] cement ~ .9 [kg] CO2
Cement production
๏Raw materials (limestone&clay) crushed and mixed with ash iron

๏Heated in a rotating kiln to obtain the calcination
๏The“clinker” is extracted, cooled, & mixed with gypsum and limestone
๏Cement is transported to ready-mixed companies
rotating kiln
60% >1400 OC
Limestone Hot hair

Clay
Ash+Iron Clinker
Source: Carbon Brief, Chatham House
Ordinary Portland Cement (OPC) Manufacture
๏Dry Process
‣ Input: raw materials
‣ Process: Crusher > Grinder > Compressed Air Blenders
‣ Output: raw materials+15% Water (“kiln feed”)
๏Wet Process
‣ Input: raw materials
‣ Process: Crusher > Grinder > Wash mill
‣ Output: raw materials+35-50% of Water (“slurry”)
>1400 OC
Hot hair
Clinker
Source: Carbon Brief, Chatham House
Ordinary Portland Cement (OPC) Manufacture
๏Dry Process lower quality cement

‣ Mixing materials in dry state
‣ Kiln needed for manufacturing of cement is smaller than wet process
‣ Difficult to obtain a homogenous mix
‣ Energy consumption is “low” (100kg of coal per tonne of cement)
‣ Low production cost
‣ High capital cost due to blenders
๏Wet Process (better quality cement)
‣ Wet mixing of raw materials (in wash mill with 35-50%)
‣ Kiln needed for manufacturing of cement is bigger than dry process
‣ Easy to obtain a homogenous mix
‣ Energy consumption is high (350kg of coal per tonne of cement)
‣ High production cost
‣ High capital cost is lower than dry
Type of cements
๏Ordinary Portland Cement (OPC)

attacked by sulfate
‣ Type I — General use
‣ Type II — Moderate Sulfate Resistance, (limit the C3A<8%)
‣ Type III — High Early strength, (grind Clinker finer)
‣ Type IV — Low Heat (not common), massive structures
‣ Type V — High Sulfate Resistance, (limit the C3A<5%)
๏White cement—OPC with minimal content of iron & manganese
Type of cements
Jubilee church, Rome, Richard Meier
Source: Guy Nordenson and associates
Type of cements
Source: Davide Cherubini
Type of cements
๏Blended Portland cements

‣ OPC combined w/other materials (additive) to obtain a desired property
‣ Blend a-posteriori not by the producer (e.g., on site)
๏Performance based cements

‣ OPC blended with fly ash, silica fume, slag, etc.
‣ Processed by the procedures with high optimization standard
‣ GU General Use
‣ MS Moderate Sulfate resistance
‣ MH Moderate Heat
‣ HE High Early
‣ HS High Sulfate resistance
Type of cements
๏Masonry Cements
‣ In masonry construction you usually produce the mixture at site
‣ The Masonry cement provide an ad-hoc mixture for masonry constructions
๏Expansive Cements
‣ Compensate for shrinkage of OPC (important for large slabs)
‣ Reduce the cracking due to dry shrinkage
๏Calcium Aluminate Cements (CAC)

‣ They gain strength more rapidly then OPC
‣ Extremely resistant to corrosive chemicals (Acid& Basis)
‣ Microstructure is not stable! Loss of resistance to 20-50% after 20-40 days
‣ Motivation
‣ Cement
‣ Quiz
Mix design goals
๏Set a goal or very few goals!

‣ High strength/low strength
‣ Set fast/slow
‣ Reduce creep
‣ Low/high shrinkage
‣ Fluid
‣ ….
Mix design fundamentals WSDE
๏Workability
‣ Is it “easy” to use in a construction site?
๏Strength
‣ Does it have the desired strength?
๏Durability
‣ Does it perform for the entire service life and beyond?
๏Economy
‣ Does it cost effective?
Workability
๏Viscosity of the paste

‣ W/cm ratio (the most important parameter)
‣ Addmixtures
‣ Aggregate size, gradation, shape, and texture
‣ Weather condition
Strength
๏W/cm ratio (the most important parameter)

‣ higher W/cm ratio lower strength
‣ Aggregate size, and strength, shape (if they are elongate there stress conc)
‣ Quality of the paste
Durability
๏W/cm ratio
๏Chemical resistance of the paste
๏Air void system
๏ Secondary Cementation Materials, SCM, (fly ash, slags, furnace fume)
๏Cracking, chemical penetration resistance
Economy
๏Cement is the most expensive element

‣ Reduce the use of cement by increasing SCMs
๏Reduce the construction labor

๏Minimize special equipments
Concrete Mixture Proportions (Typical ranges)
Slump test
Low work. High work.
Coarse aggr. 42% -3% 39%
% of Volume
Fine aggr. 28% -3% 25%
Paste 24% +6% 30%
Air 6% 6%
Air
6%
Paste
24% Coarse aggregate
42%
%Volume
Fine aggregate
28%
Low workability
Air
6%
Coarse aggregate
Paste
39%
30%
%Volume
Fine aggregate
25%
High workability limit
Concrete Mixture size distribution
Only the size distribution is different!
Deficient Excessive High High Good

fine sand fine sand intermediate coarse mixture
Source: Tyler Ley: www.tylerley.com, based on Daniel Cook Ph.D. investigations
Segregation
Larger/intermediate
coarse aggregate
High past
content
Segregation
Shape aggregate
~8-10cm slump
4 ml/kg addmix. 0.0 ml/kg addmix. 1.8 ml/kg addmix.
Crushed limestone A Crushed limestone B Crushed A

Flat shape Cubic shape Rounded shape
Medium texture Medium texture Low texture
Medium Angular Medium Angular Low Angular
Source D., Ghaeezadeh, A., & Ley, T. (2013). Investigation of optimized graded concrete for Oklahoma (No.
OTCREOS11. 1-39-F). Oklahoma Transportation Center.
Mineralogy and Gradation
๏Mineralogy
‣ Type of rock: limestone, granite, sandstone, etc.
‣ Density (special gravity), strength, and hardness
๏Gradation
‣ Size distribution, & shape
‣ Depend on how the rock is processed
‣ The sand gradations depend on where they are removed from the river
‣ The manufactured sand gradation depend on processing coarse aggregate
Sieve analysis
๏% passing through the sieve or as the precent retained
Sieve analysis, Percentage passage
4 ml/kg addmix.
48%
Source 52%
Source Ley, T., Cook, D., & Fick, G. (2012). Concrete pavement mixture design and analysis (MDA):
Effect of aggregate systems on concrete properties (No. Part of DTFH61-06-H-00011 Work Plan 25).
Sieve analysis
28%
Sieve analysis
‣ Motivation
‣ Cement
‣ Quiz
Source: Steve Bartlett, https://www.flickr.com/photos/31381944@N07/

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University of Liverpool

February, 18th 2020

CEV 233, Concrete

๏February, 18th 2020 ๏February, 26th 2020

Facts about concrete

๏II most used commodity

Facts about concrete

~1 [m3] concrete per person per year

Facts about concrete

๏II most used commodity

Facts about concrete

Comm. & Res.

Facts about concrete

CO2 per country

Facts about concrete

Good facts about concrete

๏ Lowering the CO2 footprint

US National Academy of Engineering Challenges

๏Providing access to clean water

Rock Sand Cement Water

Rock Sand Cement Water

Rock Sand Cement Water

Rock Sand Cement Water

Example of other composite materials

Concrete is a composite material!

Plywood Concrete Fiber composite

‣ Cement ๏Most expensive ingredient

Aggregate (70% of the volume)&Water

๏Fine Aggregate: A. smaller than #4 sieve (4 openings per inch~0.2”)

๏Coarse Aggregate: A. larger than #4 sieve. Typical size: 0.2”~1”

‣ To control the crack size

‣ Plastic (polypropylene) contributes in the fresh state (prevent cracking)

Source: Contec fiber Source: Sigma Plantfinder blog

Source: Dena World Source: TU Chemnitz

‣ To control the crack size

๏To increase ductility NOT to increase the strength

Type of concrete (density)

๏Normal weight ~2300-2500[kg/m3]

‣ Used for radiation shielding (medical or nuclear).

๏Low strength concrete ~ < 20 [MPa]

Source: fhwa.dot.gov/publications/research/infrastructure/structures/06103/chapt3.cfm blog

๏Tensile ~ 10% of compressive str. E.g.,

We can increase the compressive strength !

๏Production of cement uses 6% of World Energy

Calcium Carbonate >1400 OC Calcium Oxid Carbone dioxine

1 [kg] cement ~ .9 [kg] CO2

๏Raw materials (limestone&clay) crushed and mixed with ash iron

Limestone Hot hair

Ordinary Portland Cement (OPC) Manufacture

Ordinary Portland Cement (OPC) Manufacture

๏Dry Process lower quality cement

๏Ordinary Portland Cement (OPC)

๏White cement—OPC with minimal content of iron & manganese

Jubilee church, Rome, Richard Meier

Source: Guy Nordenson and associates

Source: Davide Cherubini

๏Blended Portland cements

๏Performance based cements

๏Calcium Aluminate Cements (CAC)

Mix design goals

๏Set a goal or very few goals!

Mix design fundamentals WSDE

๏Viscosity of the paste

๏W/cm ratio (the most important parameter)