25-08-2014

CVL 141
IIT DELHI
CIVIL ENGINEERING MATERIALS.

( Lecture 7)
Concrete Introduction

B. Bhattacharjee
CIVIL ENGINEERING DEPARTMENT
IIT DELHI

B. Bhattacharjee
DEPARTMENT OF CIVIL ENGINEERING, IIT DELHI

General Outline

U
U
U

Concrete Material.
Components of concrete.
Concrete as a composite.
Cement :
U Production.
U Composition

B. Bhattacharjee
DEPARTMENT OF CIVIL ENGINEERING, IIT DELHI

25-08-2014

What is CONCRETE?
Cement-sand
Mortar
Aggregate

In normal concrete

Aggregates forms
the skeleton matrix
60-75% by volume.
25-40% Paste
1-2% Voids.

Aggregate shall be inert and strong.

B. Bhattacharjee

DEPARTMENT OF CIVIL ENGINEERING, IIT DELHI

CONCRETE INGREDIENTS
Ordinarily concrete
is made by mixing an
inorganic material
known as cement
with water together
with natural sand or
stone dusts and
natural stones which
may be uncrushed or
crushed.

Cement

Sand/
Fine Aggregate

Stone /
Coarse Agg.

B. Bhattacharjee
DEPARTMENT OF CIVIL ENGINEERING, IIT DELHI

25-08-2014

COMPONENTS OF CONCRETE
Modern concrete invariably have additional
ingredients other than the four components
mentioned earlier.
Chemical Admixture: accelerators,
set retarders, water reducers etc.
Mineral Admixture: Fly ash, silicafume,
rice husk ash and other pozzolana.
B. Bhattacharjee

DEPARTMENT OF CIVIL ENGINEERING, IIT DELHI

ADMIXTURES
Chemical Admixture: Used for specific
Property/performance enhancement.
Mineral Admixture: Used for improvement
of long term strength and durability
performance.
Using above admixtures together, high
Strength and high performance concrete
Materials can be designed.
B. Bhattacharjee

DEPARTMENT OF CIVIL ENGINEERING, IIT DELHI

25-08-2014

ADVANTAGES AND
DISADVANTAGES OF CONCRETE
Lower life cycle cost
Mould-ability
Robustness.
Can be designed for desired property
Low tensile strength.
Lower ductility (brittle)
Concrete is most popular construction
material.
B. Bhattacharjee

DEPARTMENT OF CIVIL ENGINEERING, IIT DELHI

CONCRETE & COMPOSITES

Normal strength Concrete
High strength/performance concrete
Ultra high strength concrete
Fiber Reinforced Concrete.
Densified with small particle (DSP)
Macro Defect Free (MDF) Matrix
Reactive Powder Concrete (RPC)
Polymer Concrete (PC)
Polymer cement concrete
B. Bhattacharjee

DEPARTMENT OF CIVIL ENGINEERING, IIT DELHI

25-08-2014

CONCRETE COMPOSITES

A
Reinforcement

Matrix
Binder

B. Bhattacharjee

DEPARTMENT OF CIVIL ENGINEERING, IIT DELHI

LIME & SILICA

First use of lime as a construction material may
Date back to pre-historic time as reported.
Lime and volcanic ash was used in Roman
Times .
In medieval India Lime and Surkhi
Calcinations of lime together with silica was
next step

B. Bhattacharjee

10

DEPARTMENT OF CIVIL ENGINEERING, IIT DELHI

25-08-2014

CEMENT
Most commonly used cement is called Portland
Cement patented in 1824 in England, when mixed
with water, hardens, hence hydraulic cement .
Basic raw materials used in the manufacture
of cement are calcium carbonate found in lime
Stone or chalk, and silica, alumina and iron
oxide found in clay or shale.

B. Bhattacharjee

11

DEPARTMENT OF CIVIL ENGINEERING, IIT DELHI

CEMENT
Wet process means better homogeneity at the
expense of energy.
Modern Practice is dry process.
Grinding depends on raw material & Fineness
typically 10-30% retained on 90 micron sieve.
Homogenized raw meal is introduced in to
top of a pre-heater tower and passes through
A series of cyclones to precalciner vessel.

B. Bhattacharjee

12

DEPARTMENT OF CIVIL ENGINEERING, IIT DELHI

25-08-2014

CEMENT

Raw meal suspended in gas stream is

de-carbonated in precalciner by flash heating
at 900C
The meal in the rotary kiln is heated to 1500 C
partial melting & tumbling action converts in to
granular material called clinker .
The clinker is cooled and grinded with Gypsum
To obtain Portland Cement.
1T of OPC= 1 T of CO2 .

B. Bhattacharjee

13

DEPARTMENT OF CIVIL ENGINEERING, IIT DELHI

Production process
Clay/
Shale
Grinding/
Blending

Grinding/
Blending
Storage/
Final blend
Pre heater
Burning [Kiln]

B. Bhattacharjee
DEPARTMENT OF CIVIL ENGINEERING, IIT DELHI

14

25-08-2014

Production

TEMP

B. Bhattacharjee
DEPARTMENT OF CIVIL ENGINEERING, IIT DELHI

15

Cement
Cement is produced burning calcium carbonate found
in Lime Stone or chalk, and silica, alumina and iron
oxide found in clay or shale at about 1500 C.
The materials sinter and partially fused to form
Clinker
The clinker is cooled and ground to a fine powder
with some gypsum, resulting in Ordinary Portland
Cement (OPC)
India is the second largest producer of cement after
China at the moment.
B. Bhattacharjee
DEPARTMENT OF CIVIL ENGINEERING, IIT
DELHI

25-08-2014

Oxide composition
CO2 from Lime stone is liberated while burning
leaving CaO, SiO2, etc.
Approximate composition limits of Portland cement
Oxide
CaO
SiO2
AL2O3
Fe2O3
MgO
Alkalis
SO3

Content , percent
60-67
17-25
3-8
0.5-6.0
0.1-4.0
0.2-1.3
1-3

B. Bhattacharjee
DEPARTMENT OF CIVIL ENGINEERING, IIT
DELHI

Compound Composition
Oxides forms solid solutions of compounds:
3CaO SiO2 , 2CaO SiO2 , 3CaOAl2O3 and 4CaO Al2O3
Fe2O3 etc
Main compounds & abbreviations
Oxide/Compounds
CaO
SiO2
AL2O3
Fe2O3
3CaO SiO2
2CaO SiO2
3CaOAl2O3
4CaO Al2O3 Fe2O3

Abbreviations
C
S
A
F
C 3S
C 2S
C 3A
C4AF

B. Bhattacharjee
DEPARTMENT OF CIVIL ENGINEERING, IIT
DELHI

25-08-2014

Compound Composition
Main compounds in Portland cement
Name of compound

Oxide composition

Abbreviation

Tricalcium silicate (Alite)

3CaO.SiO2

C3S

Dicalcium Silicate (Belite)

2CaO.SiO2

C2S

3CaO.Al2O3

C3A

4CaO.Al2O3.Fe2O3

C4AF

Tricalcium aluminate
Tetracalcium
aluminoferrite

B. Bhattacharjee
DEPARTMENT OF CIVIL ENGINEERING, IIT
DELHI

Compound Composition
Control Ratio: Lime saturation factor (LSF)
Silica ratio (SR) & Alumina ratio(AR)
C
LSF =
100%
2.8S + 1.2 A + 0.65 F LSF>100 results in free
S
lime , hence 95-98%
SR =
S+F
Higher SR means more
C3S and less C3A & Higher
A
AR =
AR means higher C3A
F
Compound composition can be obtain from Oxide
Composition By Bogues equation
B. Bhattacharjee
DEPARTMENT OF CIVIL ENGINEERING, IIT
DELHI

10

25-08-2014

Compound Composition
C3S = 4.07C 7.60S - 6.72A - 1.43F - 2.85 S
C 2S = 2.87S - 0.754C3S
C3 A = 2.65A - 1.69F
C 4 AF = 3.04F ; S = SO 3
Calculated compound composition (percent)
C 3A
C 3S
C 2S
C4AF
Minor compounds

10.8
54.1
16.6
9.1
-

B. Bhattacharjee
DEPARTMENT OF CIVIL ENGINEERING, IIT
DELHI

Production

B. Bhattacharjee
DEPARTMENT OF CIVIL ENGINEERING, IIT DELHI

22

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25-08-2014

Production

B. Bhattacharjee
DEPARTMENT OF CIVIL ENGINEERING, IIT DELHI

23

Heat of Hydration
Heat of hydration of pure
compounds
Compound

Heat of hydration
J/g

C3S
C2S
C3A
C4AF

502
260
867
419

Cal/g
120
62
207
100

B. Bhattacharjee
DEPARTMENT OF CIVIL ENGINEERING, IIT
DELHI

12

25-08-2014

Schematic representation
Schematic representation of the formation
and hydration of Portland cement
Component elements

Component oxides
Fe2O3

O2

Si

Ca

Al

Fe

CaO Si O2 Al2O3

Cement compounds

Portland cements

Hydration products

C3S

C2 S

C3A C4AF

Various types

C-S-H gel

Ca(OH)2

B. Bhattacharjee
DEPARTMENT OF CIVIL ENGINEERING, IIT
DELHI

SUMMARY

Concrete Material.
V Natural aggregates, cement or cementitious
and water and; also admixtures.
V Concrete composites.
V Cement Production.
V Composition of cement.

B. Bhattacharjee
DEPARTMENT OF CIVIL ENGINEERING, IIT DELHI

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25-08-2014

THANK YOU
FOR
HEARING

DEPARTMENT OF CIVIL ENGINEERING, IIT DELHI

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