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Concrete Technology: 18CV44 Sem:IV
Concrete Technology: 18CV44 Sem:IV
18CV44
Sem:IV
By
Mrs Snehalata Hiremath
Assistant professor
Civil Engineering
Department
Tontadarya College of
Engineering
Contents
Concrete Ingredients-Cement
Manufacturing process, Chemical
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Lime- excess will decrease the strength.
Deficiency will make it set quickly.
Silica- higher silica increases the
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LIMESTONES
◦ Originate from the biological deposition of shells and
skeletons of plants and animals.
◦ Massive beds accumulated over millions of years.
◦ In the cement industry limestone includes calcium
carbonate and magnesium carbonate.
◦ Most industrial quality limestones is of biological
origin.
◦ The ideal cement rock 77 to 78% CaCO3, 14% SiO2,
2.5% Al2O3, and 1.75% FeO3.
◦ Limestone with lower content of CaCO3 and higher
content of alkalis and magnesia requires blending
with high grade limestone
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SOURCES OF ARGILLACEOUS MINERALS
Argillaceous mineral resources:
◦ Clay and shale for alumina and silica Iron ore for iron
◦ Other natural sources of silica and alumina are:
Loess, silt, sandstone, volcanic ash, diaspore,
diatomite, bauxite
◦ Shales, mudstones, and sandstones are typically inter
bedded with the limestone and were deposited as the
inland waters and oceans covered the land masses.
◦ Clays are typically younger surface deposits
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Manufacture of Portland cement
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Raw materials
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Preparation of Materials
Crush the materials and store them
Blend the materials and grind them
Store them and do final blending
Blending – assure constant composition and
predictable properties.
Wet, dry, and semi-dry processes
Burn the materials
Grind, blend, and store the materials
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Cement Manufacturing Process
WET PROCESS
Raw materials are homogenized by crushing, grinding
and blending so that approximately 80%of the raw
material pass a No.9 sieve.
The mix will be turned into form of slurry by adding
30 - 50%of water.
It is then heated to about 2750ºF (1510ºC) in
horizontal revolving kilns (76-153m length and 3.6-
4.8min diameter.
Natural gas, petroleum or coal are used for burning.
High fuel requirement may make it uneconomical
compared to dry process.
Wet process is obsolete
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DRY PROCESS
◦ Raw materials are homogenized by crushing, grinding
and blending so that approximately 80%of the raw
material pass a No.200 sieve.
◦ Mixture is fed into kiln & burned in a dry state
◦ This process provides considerable savings in fuel
consumption and water usage but the process is
dustier compared to wet process that is more efficient
than grinding.
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DRY PROCES & WET PROCESS
In the kiln, water from the raw material is driven
off and limestone is decomposed into lime and
Carbon Dioxide.
limestone = lime + Carbon Dioxide
In the burning zone, portion of the kiln, silica
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Burning process
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Four processes take place in the kiln: Evaporation 240 to 450°C
Calcination 600 to 1100°C
Clay decomposes (600°C)
Limestone decomposes (700°C) – CO2 driven off
Formation of initial compounds (1000°C)
Initial formation ofC2S (1200°C), formation of calcium
aluminates and Ferrites
Formation of melt (flux compoundsmelt) (1350°C)
Clinkering – charge temperature is 1400 to 1600°C
Formation of C3S
Cooling
Rate of cooling significantly affects the reactivity of the final
cement
Klinker
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The rotation and shape of kiln allow the blend
to flow down the kiln, submitting it to gradually
increasing temperature.
As the material moves through hotter regions
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Cement Clinkers
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The cement clinkers are cooled to about
150ºF (51ºC) and stored in clinker silos.
When needed, clinker are mixed with 2-5%
dry place
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Cement Manufacturing
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KILN
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Cement Silos
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Ordinary Portland Cement (OPC)
Chemical composition of Portland Cement:
Tri-calcium Silicate (50%)
Di-calcium Silicate (25%)
Tri-calcium Aluminate (10%)
Tetra Calcium Aluminoferrite (10%)
Gypsum (5%)
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Role of various ingredients of Cement
FUNCTION :TRICALCIUM SILICATE
◦ Hardens rapidly and largely responsible for initial set &
early strength
◦ The increase in percentage of this compound will cause
the early strength of Portland Cement to be higher.
◦ A bigger percentage of this compound will produces
higher heat of hydration and accounts for faster gain in
strength.
FUNCTION :DICALCIUM SILICATE
◦ Hardens slowly
◦ It effects on strength increases occurs at ages beyond
one week
◦ Responsible for long term strength
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FUNCTION :TRICALCIUM ALUMINATE
◦ Contributes to strength development in the first few days
because it is the first compound to hydrate .
◦ It turns out higher heat of hydration and contributes to
faster gain in strength.
◦ But it results in poor sulfate resistance and increases the
volumetric shrinkage upon drying.
FUNCTION :TRICALCIUM ALUMINATE
◦ Contributes to strength development in the first few days
because it is the first compound to hydrate .
◦ It turns out higher heat of hydration and contributes to faster
gain in strength.
◦ But it results in poor sulfate resistance andincreases the
volumetric shrinkage upon drying.
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Cements with low Tricalcium Aluminate
contents usually generate less heat, develop
higher strengths and show greater resistance
to sulfate attacks.
It has high heat generation and reactive with
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FUNCTION : TETRACALCIUMALUMINOFERRITE
◦ Assist in the manufacture of Portland Cement by
allowing lower clinkering temperature.
◦ Also act as a filler
◦ Contributes very little strength of concrete even though
it hydrates very rapidly.
◦ Also responsible for grey color of Ordinary Portland
Cement
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Cement Properties and Tests
1. Fineness
95% of cement particles are smaller than 45 micrometer
hydration.
More is the fineness of cement more will be the rate of
hydration.
Thus the fineness accelerates strength development
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2. Soundness
Soundness is the ability of a hardened paste to retain
following tests:
Le-Chatelier accelerated test (BS 4550: Part 3)
Autoclave-expansion test (ASTM C 151)
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3. Consistency- IS:4031-1988(part 4)methods of physical
tests for hydraulic cement
Consistency refers to the relative mobility of a freshly
cement paste.
Setting time is to determine if a cement sets according
apparatus.
In actual construction dealing with cement, mortar or
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Setting Time
Initial setting Time:Initial setting time is
regarded as the time elapsed between the
moment that the water is added to the cement
and the time at which the needle penetrates to a
depth of 33 to 35 mm from top is taken as
initial setting time.
Final setting time: It is the period elapsed
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The standard sand(Ennore sand) to be used in the test shall
conform to IS: 650-1991 or sand passing 100 percent through
2 mm sieve and retained 100 percent on 90 micron IS sieve.
2mm to 1mm -33.33 percent
1mm to 500 microns -33.33 percent
500mm to 90 microns-33.33 percent
The material for each cube shall be mixed separately and the
(100 + 21 = 99 + 22 )
C3A + 6H = C3AH6
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Heat of Hydration
The heat of hydration is the heat generated
when water and Portland cement react. Heat of
hydration is most influenced by the proportion
of C3S and C3A in the cement, but is also
influenced by water-cement ratio, fineness and
curing temperature. As each one of these
factors is increased, heat of hydration increases.
For usual range of Portland cements, about
composition of cement.
Fine aggregate
Functions
1. It fills the voids existing in the coarse aggregate.
2. It reduces shrinkage and cracking of concrete.
3. By varying the proportion of sand concrete can be
prepared economically for any required strength
4. It helps in hardening of cement by allowing the
water through its voids.
5. To form hard mass of silicates as it is believed that
some chemical reaction takes place between silica
of sand and constituents of cement
Requirements
1. Fine aggregate should consist of coarse angular
sharp and hard grains.
2. It must be free from coatings of clay and silt.
3. It should not contain any organic matter.
4. It should be free from hygroscopic salt.
5. It should be strong and durable and chemical inert.
6. The size of sand grains should pass through
4.75mm IS sieve and should be entirely retained on
75 micron IS sieve
7. Fineness modulus limits-
fine sand-2.2-2.6
Medium sand-2.6-2.9
Coarse sand-2.9-3.2
Grading limits
Very coarse sand (Zone I) and very fine sand
(Zone IV) is unsatisfactory for concrete
making.
Coarse sand results in harshness, bleeding
and seggregation
Fine sand results in more demand of water to
produce fluidity.
Most suitable grading required to produce