13-05-2014

NPTEL PROJECT
IIT DELHI
Concrete Technology

Module 1 ( Lecture 1)
Cement: Production and Composition
B. Bhattacharjee

CIVIL ENGINEERING DEPARTMENT

IIT DELHI

DEPARTMENT OF CIVIL ENGINEERING, IIT DELHI

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General Outline

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

B. Bhattacharjee
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DEPARTMENT OF CIVIL ENGINEERING, IIT DELHI

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What is CONCRETE?

In normal concrete

Cement-sand
Mortar
Aggregates forms
Aggregate the skeleton matrix
60-75% by volume.
25-40% Paste
1-2% Voids.
¾Aggregate shall be inert and strong.

B. Bhattacharjee
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DEPARTMENT OF CIVIL ENGINEERING, IIT DELHI

CONCRETE INGREDIENTS

– Ordinarily concrete
is made by mixing an Cement
inorganic material
known as cement
with water together Sand/
with natural sand or Fine Aggregate
stone dusts and
natural stones which Stone /
may be uncrushed or Coarse Agg.
crushed.

B. Bhattacharjee
DEPARTMENT OF CIVIL ENGINEERING, IIT DELHI 4

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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
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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.
¾ Using above admixtures together, high
Strength and high performance concrete
Materials can be designed.

B. Bhattacharjee
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DEPARTMENT OF CIVIL ENGINEERING, IIT DELHI

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ADVANTAGES AND
DISADVANTAGES OF CONCRETE
™ Lower life cycle cost
™ Mould-ability
™ Robustness.
™Can be designed for desired property
™ Low tensile strength.
™Lower ductility (brittle)
¾ Concrete is most popular construction
material.

B. Bhattacharjee
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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
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DEPARTMENT OF CIVIL ENGINEERING, IIT DELHI

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CONCRETE COMPOSITES

A
Reinforcement

Matrix
Binder

B. Bhattacharjee
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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
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DEPARTMENT OF CIVIL ENGINEERING, IIT DELHI

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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
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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
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DEPARTMENT OF CIVIL ENGINEERING, IIT DELHI

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CEMENT
Raw meal suspended in gas stream is
de-carbonated in precalciner by flash heating
at 900°C
™ 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
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DEPARTMENT OF CIVIL ENGINEERING, IIT DELHI

Production process
Clay/
Shale

Grinding/
Grinding/ Blending
Blending

Storage/
Final blend
Pre heater
Burning [Kiln]

B. Bhattacharjee
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DEPARTMENT OF CIVIL ENGINEERING, IIT DELHI

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Production

TEMP

B. Bhattacharjee
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DEPARTMENT OF CIVIL ENGINEERING, IIT DELHI

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 1500̊ C.

¾The materials sinter and partially fused to form

Clinker

¾ The clinker is cooled and ground to a fine powder

with some gypsum, resulting in Ordinary Portland
Cement (OPC)

¾ India is the second largest producer of cement after

China at the moment.
B. Bhattacharjee
DEPARTMENT OF CIVIL ENGINEERING, IIT
DELHI

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Oxide composition
CO2 from Lime stone is liberated while burning
leaving CaO, SiO2, etc.

Approximate composition limits of Portland cement

Oxide Content , percent
CaO 60-67
SiO2 17-25
AL2O3 3-8
Fe2O3 0.5-6.0
MgO 0.1-4.0
Alkalis 0.2-1.3
SO3 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 Abbreviations
CaO C
SiO2 S
AL2O3 A
Fe2O3 F
3CaO SiO2 C 3S
2CaO SiO2 C 2S
3CaOAl2O3 C 3A
4CaO Al2O3 Fe2O3 C4AF

B. Bhattacharjee
DEPARTMENT OF CIVIL ENGINEERING, IIT
DELHI

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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
Tricalcium aluminate 3CaO.Al2O3 C3A
Tetracalcium 4CaO.Al2O3.Fe2O3 C4AF
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
A C3S and less C3A & Higher
AR = AR means higher C3A
F

Compound composition can be obtain from Oxide

Composition By Bogue’s equation

B. Bhattacharjee
DEPARTMENT OF CIVIL ENGINEERING, IIT
DELHI

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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 10.8
C 3S 54.1
C 2S 16.6
C4AF 9.1
Minor compounds -
B. Bhattacharjee
DEPARTMENT OF CIVIL ENGINEERING, IIT
DELHI

Production

B. Bhattacharjee
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DEPARTMENT OF CIVIL ENGINEERING, IIT DELHI

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Production

B. Bhattacharjee
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DEPARTMENT OF CIVIL ENGINEERING, IIT DELHI

Heat of Hydration

Heat of hydration of pure

compounds

Compound Heat of hydration

J/g Cal/g
502 120
C3S
C2S 260 62
C3A 867 207
C4AF 419 100

B. Bhattacharjee
DEPARTMENT OF CIVIL ENGINEERING, IIT
DELHI

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

Component elements O2 Si Ca Al Fe

Component oxides CaO Si O2 Al2O3

Fe2O3

Cement compounds C3S C2 S C3A C4AF

Portland cements Various types

Hydration products 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
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DEPARTMENT OF CIVIL ENGINEERING, IIT DELHI

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THANK YOU
FOR
HEARING

DEPARTMENT OF CIVIL ENGINEERING, IIT DELHI

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