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Materials and Structures (2009) 42:15–24

DOI 10.1617/s11527-008-9363-0

ORIGINAL ARTICLE

Hydration monitoring of cement-based materials


with resistivity and ultrasonic methods
Jie Zhang Æ Lei Qin Æ Zongjin Li

Received: 24 June 2007 / Accepted: 17 January 2008 / Published online: 12 March 2008
Ó RILEM 2008

Abstract Two test setups, the electrical resistivity Keywords Electrical resistivity  Ultrasonic 
and ultrasonic techniques, were used to monitor the Hydration  Cement  Non-destructive test (NDT)
hydration process of cement-based materials. In the
electrical resistivity method, a non-contacting device
was used. In the ultrasonic method, a wave was
transmitted and measured by the embedded piezo- 1 Introduction
electric ultrasonic transducers, which had good
coupling with the surrounding materials. The focus Chemical reaction between compound of hydraulic
of the study was to detect the setting and hardening cement and water yields ceramic products that
behaviors of cement paste during the first 7 days of achieve the binding property after hardening. This
hydration using the above techniques. Immediate complex process or reaction between cement and
after placing the cement paste into the mould, the water is called hydration. The cement hydration
measurement started and continued throughout the reaction varying in time involves the change from the
hydration process. The obtained resistivity and ultra- suspension state to the solid with pore state. Solid
sonic data were used to interpret the hydration hydration products form both at the surfaces of the
process of the specimens. The correlation of two cement particles and in the pore solution by nucle-
techniques was also studied. The results illustrated ation and aggregation. As a result, the solid phase
that both electrical resistivity and ultrasonic tech- becomes highly connected and the material trans-
niques were effective to accurately monitor the forms from a viscous suspension of irregularly-
hydration of cement pastes. The resistivity method shaped cement particles into a porous elastic solid.
was able to study both the chemical reaction and The connectivity of the solid phase is responsible for
physical change during hydration, while ultrasonic the setting and hardening behaviours and load-
method was sensitive to physical change of cement bearing capacity of cement. The pore structure has
only. significant implications for the transport property and
further the durability of cement-based materials.
The physical setting, strength gain and lifetime of
cements are accompanied by a series of mineralogical
J. Zhang (&)  L. Qin  Z. Li and microstructural changes during the hydration.
Department of Civil Engineering, The Hong Kong Such hydration process has attracted a considerable
University of Science and Technology, Clear Water Bay,
Kowloon, Hong Kong attention and has been studied by many methods, like
e-mail: zhangjie@ust.hk the commonly used Vicat needle, universal testing
16 Materials and Structures (2009) 42:15–24

machine, scanning electronic microscope (SEM), cement that exist in traditional resistivity measure-
X-ray diffraction (XRD) and so on. However, the ments. With this new method, accurate, reliable, and
thus measured setting time and strength parameters re-producible results have obtained. It provides a base
cannot directly show the materials and the micro- for correctly interpreting the nature of the hydration
structural changes in hydration process. For example, of cement-based materials.
the setting time defined by penetration values of By using the ultrasonic measurement, as the
Vicat needles (ASTM C191) correspond to two hydration goes on, ultrasonic pulse propagation path
particular practical points, which are loosely defined in the cement system switches from the liquid phase
as the limit of handling and the beginning of to the solid phase. At early times the observed wave
mechanical strength development, respectively. And involves essentially motion of the fluid phase while at
also the test’s accuracy depends largely on the skill longer times it involves essentially motion of the
and experience of the person performing it [1]. SEM solid frame. The UPV reveals a significant increase
and XRD need to stop the hydration process and do after the appearance of the connectivity of solid
the certain sample pretreatments. Such methods phase, as already shown by Krautkraemer and
cannot provide the continuous information about Krautkraemer [11] and Sayers and Dahlin [12].
hydration and moreover the sample will be influenced Ultrasonic waves are therefore sensitive to the point
by the drying and cutting preparation. Therefore, at which the solid phase becomes interconnected.
alternative techniques, which are accurate and non- This point is of practical significance since the
destructive, are highly needed to monitor the hydra- connectivity of the solid phase is responsible for the
tion process of cement-based material. Thus, the load bearing capacity of set cement. Because of its
details about the complex hydration can be clarified. non-destructive and reproducible benefits, ultrasonic
During the last decade, non-destructive testing (NDT) technique has been employed to monitor the hydra-
techniques have attracted increasing attention for the tion process. Different from the conventional
characterization of the behavior of concrete at early measurement using the surface contact commercial
age. These techniques include electrical properties ultrasonic transducers, in this study the embedded
measurements [2–5] and ultrasonic pulse velocity home-made piezoelectric sensors are used. The
(UPV) tests [6–9]. In this paper, the combinative embedded ultrasonic system has several advantages.
utilization of the non-contacting electrical resistivity First, the home-made cement sensors are water and
measurement and embedded piezoelectric ultrasonic noise proof; second, it has good coupling with
system will be presented and discussed. They concern cement-based matrix; third, sensing system is good
the continuous monitoring of the setting and harden- for in-situ measurement. Moreover, the new sensor is
ing of the fresh cement paste and have proper control inexpensive and suitable for any-scale structures [13].
by reliable and more objective for the advanced The principle aim of this study is to use the
process technology. characterization of changes in the electrical resistivity
In the electrical resistivity method, the electrical and UPV, respectively to follow cement hydration
conduction of cement-based media relies on ionic and monitor the development of the microstructure at
conduction through water-filled pores. The factors early age.
influencing electrical conduction for porous media
are mainly controlled by microstructure and liquid
solution conductivity. The research had shown that 2 Experimental
electrical measurement can be applied to provide
useful information of the hydration process of the 2.1 Non-contacting resistivity measurement
cement-based materials. To overcome the contacting
problem between the sample with the electrodes The electrical resistivity of the specimen was mea-
commonly used in the traditional measurement, a sured by a non-contacting electrical resistivity
non-contacting electrical resistivity device was measurement device, CCR-II (BCT, Hong Kong).
invented recently [10]. This approach performs like Its work mechanism is schematically shown in Fig. 1.
a transformer and eliminates all the problems asso- This system adopts a transformer principle and the
ciated with the contact between electrodes and device has no electrode. There is no contacting with
Materials and Structures (2009) 42:15–24 17

Fig. 1 Schematic diagram


and equivalent circle of the
non-contacting electrical
resistivity measurement
device (CCR-II)

the specimen. Around 3,200 g cement paste mixture


was cast into the ring-shaped mould, with size
770 mm (perimeter) 9 55 mm (height) 9 42 mm
(width). Two thermocouples with accuracy of
±0.5°C were embedded into the sample to detect
the specimen’s temperature change during the whole
testing process. Based on the mutual inductance, the
wire-wound coil acted as the primary and the ring-
shaped cement specimen acted as the secondary coil
of the transformer. After an AC with 1 kHz fre-
quency sine wave was applied on the primary, a Fig. 2 Schematic arrangement of the piezoelectric ultrasonic
toroidal current was inducted in the secondary. The measurement setup and cement paste container with transduc-
ers embedded
resulting parameter was pure resistivity which was
attributed to ion immigration in the pore solution.
This apparatus completely eliminated the problems and effective for any-scale structures. For construc-
introduced by electrodes commonly occurred in tion of a concrete structure, early-age performance
traditional methods, such as the polarization effect monitoring can be performed by the new system to
and contact problems caused at the electrode–con- provide guidance for construction control. After the
crete interface. Therefore, this method can accurately concrete is cured and the strength is fully developed,
monitor the electrical resistivity of cement-based the system can be used to conduct structural health
materials. Data readings were taken over a period monitoring to detect the damage accumulation or
from casting, usually about 10 min after the mixing, even disaster evolving. It meets all the requirements
to 7 days. The sampling interval was 1 min and of concrete structure health monitoring from fresh
operation was continuous. stage to hardened stage.
In this study, the transducers were fixed at the
2.2 Embedded piezoelectric ultrasonic method bottom of a plastic box of 250 9 320 9 100 mm3 to
monitor the early-hydration of cement paste. Cement
In this research, a new ultrasonic measurement paste was poured into the box and vibrated to remove
system, which uses home-made embedded piezoelec- the entrapped air bubbles. An electrical pulse was first
tric composites as the ultrasonic transducers, is generated by an Agilient 33120A functional generator.
adopted (Fig. 2). The working principle is that the After amplifying by a power amplifier, the input
piezo-composite vibrates when an electrical pulse is electrical pulse excited the transmitter, and then
applied on it, and then the ultrasonic wave propagates vibrated in its resonance modes, emitting ultrasonic
along the direction of vibration. The ultrasonic waves waves. A longitudinal ultrasonic wave was received by
are received by other piezoelectric composites sensor, the receiver through changing mechanical energy into
working as receiver. Comparing with traditional electrical energy. The voltage of the receiver could be
ultrasonic non-destructive methods, which have con- measured and recorded by the oscilloscope though a
ventional commercial ultrasonic transducers fixed on pre-amplifier. The oscilloscope was a 12 bit Agilent
the surfaces, the new method eliminates the coupling 5462A one with a sampling frequency of 1 MHz.
and surface contacting problems and is inexpensive After casting the fresh sample, the measurement was
18 Materials and Structures (2009) 42:15–24

immediately started. It should be pointed out that the resistivity. On first contact with water, the mobile ions
two setups may experience different temperatures due are rapidly released from the surface of each cement
to the different cross sections of the specimens. grains; the pH values rise to over 12 within a few
Subsequently, the maturity transformation in two minutes. This process is hydrolysis. Because of ion
setups may be influenced slightly. However, the dissolution, the conductivity of cement–water mixture
temperature developments in the two setups should will increase and the resistivity decreases inversely.
have the same trends. After reaching the saturation, this initial hydrolysis
slows down quickly, which is corresponding to the
2.3 Specimens (materials and mix proportion) minimum point in the resistivity and also the zero
value of the differential resistivity. The first peak in
In this study, the cement-based specimen used was Fig. 4 is related to the first small increase of resistiv-
ordinary Portland cement (OPC) paste with ity. Then, in the next 3 h, near zero values in
0.4 water/cement ratio (w/c). The specimens for both differential of resistivity indicate that the mixture is
resistivity and ultrasonic tests were from the same relatively inactive which refers to a competition
mixing batch and cast at the same time. The between the dissolution and precipitation, identified
specimens were covered by plastic lids and put to as a dynamic balance, or called competition period
environmental chamber with 100% humidity and [14] (stage II). The dissolving and consuming ions
constant temperature for curing and testing. Testing compete to reach a balance. As the hydration contin-
continues for 7 days without any breakage and ues, the thickness of the hydrate layer increases and
hydration cease. The traditional Vicat method was forms a barrier through which water must flow to
also applied in this study to measure the setting times. transport the free ions and through which ions must
diffuse to conduct the electricity. The resulting rapid
increase of differential resistivity corresponding to the
3 Result and discussion accelerated increase of resistivity is the third stage
(stage III), which is observed from 3 to 10 h. At about
3.1 Electrical resistivity result 10 h of hydration, the differential resistivity reaches
the maximum, showing the fastest increase of resis-
Figure 3a, b show the bulk electrical resistivity tivity. After that, a decelerated increase of resistivity
development with time up to 1 day (24 h) and 7 days continues for longer than 7 days (stage IV). With
(168 h), respectively. The resistivity–time curve hydration degree increase, the resistivity of the sample
begins with a small decline corresponding to the increases due to the growing solid phase and their
dissolution of ions from cement into water. After interconnection, which will block the way of trans-
reaching the minimum point at half an hour after portation of the ionic conductors in the pore solution.
mixing time, the resistivity of the specimen increases Eventually, movement through the C–S–H layer
a little for several minutes and then shows a nearly determines the rate of reaction and hydration becomes
level development at very low value and keeps this diffusion controlled. The resistivity increases much
level process for 3 h. In this flat stage, the initial slowly. The resistivity and its differential develop-
hydration products form in solution, which reduces ments detected in this study bear noticeable
the ion concentration and allows additional ions from resemblance to the conductivity evolution observed
cement particles dissolved. After 3 h of hydration, the by Sant et al. [15]. The dissolution, induction and
resistivity increases gradually due to the growth of hardening periods were also reported in their work.
hydrates. This increase continues through the whole
test period. 3.2 UPV result
From the plot of rate change of resistivity with time
shown in Fig. 4, the hydration process stages can be Figure 5 shows the development of UPV in fresh
easily identified. There are four stages can be divided cement paste measured by the embedded piezoelectric
in the first 7 days hydration. In the first stage (stage I), ultrasonic method. In the first three hours, the UPV
the differential of resistivity is below zero. This remains nearly constant around 1,500 m/s. This period
negative value correlates with the initial decline of (period 1) is related to the stage I and II of cement
Materials and Structures (2009) 42:15–24 19

Fig. 3 Electrical resistivity (a) 3


development during the first
(a) 1 day and (b) 7 days of
hydration
2.5

Resistivity (Ω.m)
2

1.5

0.5
0.1 1 10 100
Time (h)

(b) 12

10

8
Resistivity (Ω.m)

0
0.1 1 10 100 1000
Time (h)

hydration in Fig. 4. It is considered the paste in this Fig. 4. When a critical quantity of hydration product is
period as an emulsion with dispersed solid particles reached, the percolation of solid phase seems to occur
uniformly. In this measurement, it was observed that and UPV starts to increase. In this period, more and
the velocity started from about 1,550 m/s, and more hydration products continues to be intersected,
decreased slightly before the rapid rise in velocity. stiffness or modulus of material increases rapidly. As a
The average value of 1,500 m/s is very close to result, the UPV increases notably. Period 3 in UPV
1,490 m/s, the wave velocity in water. Based on the corresponds to period 4 in resisting measurement,
property of emulsion-like cement paste in this stage, implying that the hydration process of cement pro-
the velocity value looks very reasonable. A period of ceeds into diffusion control and the hydration products
rapid increase (period 2) in the UPV, which corre- growing rate slows down. The UPV thereafter
sponds to the rapid development of hydration increases only slightly. High hydration degree is
products, appears after the flat velocity period. This reached and further hydration becomes minimal. Thus,
period started at the similar time as that of stage III in the velocity development reaches the plateau.
20 Materials and Structures (2009) 42:15–24

Fig. 4 Rate of electrical 0.003


resistivity development
during the first 7 days of 0.002 I II III IV
hydration

Differential resistivity (Ω .m/h)


0.001

0
0.1 1 10 100 1000
-0.001

-0.002

-0.003

-0.004

-0.005
Time (h)

Fig. 5 Velocity 3500


development during the first
7 days of hydration 1 2 3
3000
velocity (m/s)

2500

2000

1500

1000
0.1 1 10 100 1000
Time (h)

3.3 Comparison 3.3.1 Stage I: dissolution stage (0–0.7 h)

If we put the plots of velocity, resistivity, differential In stage I, upon mixing cement with water, ions are
resistivity and temperature together and make a rapidly released from the surface of the cement grains
comparison, we can find the curves’ characteristic and dissolve into the solution. Hydration reactions
points correspond very well. Four stages of hydration start to take place. The electrical resistivity decreases
can be identified as shown in Fig. 6. Namely: the due to the increase of ionic concentrations and the
dissolution stage (I), the competition stage (II), the mobility of these ions, such as Ca2+, OH-. After the
acceleration stage (III) and the deceleration stage initial solubilization, the formation of the solid hydra-
(IV). The physical and chemical meanings of these tion products occurs from the solution phase or at a
stages are discussed in the following. solid–solution interface. The two most important
Materials and Structures (2009) 42:15–24 21

with the other clinker minerals exist in the following


hydration reactions. The hydration of C3S has the
following reactions involved [17] during the various
stages of hydration:
H
C3 S ! ‘‘C2 S’’+ Ca2þ + OH ð1Þ

H 
‘‘C2 S’’!2Ca2þ + H2 SiO2
4 + 2OH ð2Þ

2H2 SiO2 6
4 + 2OH ! Si2 O7 + 3H2 O ð3Þ
C3A is the most active phase of cement. The main
reactions which C3A goes through in the presence of
gypsum ðCSH 2 Þ are as follows:
 2 ! 6Ca2þ +2Al(OH)
C3 A + 6H + 3CSH 4

ð4Þ
+ 3SO2
4 + 4OH

 2 ) + 26H ! C6 AS
C3 A þ 3ðCSH 3 H32 (ettringite)
ð5Þ
C3A reacts with the sulphate ions in the solution
dissolved from the gypsum. The hydration product,
hexagonal crystals ettringite (AFt) as stubby rods,
starts to appear on the surface of cement grains.
As the water within the pore system becomes
saturated with the ions, the resistivity reaches the
minimum point, showing the end of the dissolution
period. Therefore, it may be well concluded that the
resistivity development during this stage is dominated
by the ions dissolution. There are also chemical
reaction occurrences and the products were detected
by Xiao [14].
In this stage, ultrasonic wave propagates through
the water-like viscous suspension. Previous study
[12] considered the system in this period as a
dispersion of solid particles in a liquid. Cement
particles are isolated from each other, while the
capillary pore water is connected. The observed
ultrasonic wave involves essentially motion of the
Fig. 6 Velocity, resistivity, rate of resistivity and temperature emulsion phase. The UVP remains constant at a very
in resistivity test developments during the first 7 days of low value close to the wave velocity in water.
hydration

components of Portland cements in this stage are 3.3.2 Stage II: competition stage (0.7–3 h)
tricalcium aluminate (C3A) and tricalcium silicate
(C3S) (Abbreviation used in this paper: CaO = C, Studies show that at high dilutions a gel layer or
SiO2 = S, Al2O3 = A, Ca(OH)2 = CH, H2O = H, membrane forms over the surfaces of the grains soon
SO3 ¼ S) because their hydration reactions are the [18]. Short rods of ettringite are probably more
initial driving force in building up chemical bonded abundant near to the surfaces of the aluminate phase,
cementitious materials [16]. We assume no interaction and appear to nucleate in the solution and on the outer
22 Materials and Structures (2009) 42:15–24

surface of a layer of gel. The ions in the solution are layer around the cement grains which engulfs and
readily absorbed by the formation of a thin layer of perhaps nucleates on the ettringite rods. The CH
hydration products. The initial hydration reaction forms massive crystals in the originally water-filled
consumes a few ions so that the resistivity of the space. Nucleation sites appear to be relatively few in
specimen shows a small increase. This small increase number, and the growing crystals may engulf some of
detected by the sensitive and accurate non-contacting the smaller cement grains. Small isolated clusters of
resistivity measurement is the first discovery on the solid substance are formed. These small isolated
resistivity study of the fresh cement-based materials. clusters are the basis of the solid network. The solid
The initial hydrates form an envelope around the network continues to develop until it becomes
unhydrated cement grains. These effects reduce the connected throughout the material. At this critical
ion concentration and meanwhile allow additional time, a solid percolation formed, which is the start of
ions from cement particles dissolved. Therefore, this setting. As the hydration going on, more and more
competition of consuming and releasing ions leads to hydrates form the solid network. The shells grow
a dynamic balance in the resistivity–time curve and a outwards and those surrounding adjacent grains are
slow increase of the temperature curve as well. beginning to coalesce. At this stage, fracture through
In this stage, ultrasonic waves also propagate the shells begins to supplant fracture between them. It
through the viscous suspension. There is no obvious coincides with the maximum rate of heat evolution
change in UPV curve compared with the value in and corresponds approximately to the completion of
stage I. UPV keeps very low, though a slight decrease setting. Thus, the stage III completes.
caused by an increasing tortousity of the pore solution The structure of interconnected shells has been
due to the formation of hydration products. This result considered to play an important part in determining
is similar as the previous studies [6, 8, 19]. There is no the mechanical and other properties, which thus
significant change in UPV curve in stage I and II, depend on the particle size distribution of the cement.
showing that the ultrasonic method is not sensitive at In this stage, the rapid increase of resistivity is related
the very beginning of the hydration because during to a relatively small but significantly decrease in the
these two stages the chemical reaction plays an number of ionic species. The pores inside the
important role in the cement hydration process. specimen are likely to be filled with a highly
concentrated or colloidal solution, and the shells are
evidently sufficiently porous at this stage that ions
3.3.3 Stage III: acceleration stage (3–10 h) can readily migrate through them. The temperature in
the samples increases rapidly to reach the maximum
In stage III, the rate of cement hydration increases mainly due to the hydration of the tricalcium silicate
sharply because of the growth of hydrates, leading to and the tricalcium aluminate. The UPV propagates
hardening. In this stage, C3S reaction dominates through the solid phase instead of through the liquid
hydration. C–H continues to crystallize from solution phase; this fact leads to a steep increase in UPV
with the concomitant development of C–S–H (Fig. 6). This critical degree of hydration, when the
(C3S2H8) from the surface of C3S to form a coating system changes from a suspension of cement particles
covering grain and the reaction of C3S proceeds in water into an interconnected solid phase, can be
rapidly. During this period, which begins at about 3 h considered as the percolation threshold [20]. From
and ends at about 10 h, some 30% of the cement Fig. 6, we find that the stage III superposes with the
reacts [17]. It coincides with that of strong heat period 2 in UPV curve, which begins at the time as
evolution and is characterized by the rapid formation the minimum quantity of hydration products required
of C–S–H, ettringite and CH. At the beginning of for a sharp climb of UPV is achieved. An increase is
stage III, the following reactions occur: found both in the resistivity development of the
2C3 S + 11H ! C3 S2 H8 + 3CH ð6Þ hydrating specimen and in the UPV. As discussed
before, more and more cement grains continue to
2C2 S + 9H ! C3 S2 H8 + CH ð7Þ
become connected in this stage, and the percolation
Studies show that the undried C–S–H has a filmy, of solid phase seems to occur in the early part of
foil-like morphology. The C–S–H forms a thickening stage III, after which shear waves can propagate. In
Materials and Structures (2009) 42:15–24 23

stage III, the water-saturated porous solid structure 4 Conclusions


becomes more and more connected as newly formed
hydration products fill in the pores. Due to this rapid The non-contacting resistivity device and the embed-
increase of connected solid, the ultrasonic pulse can ded piezoelectric ultrasonic measurement used in this
propagate through more connected solid volume; study provide two alternative ways to accurately
thus, the UPV increases. The UPV is more sensitive monitor the hydration process of cement-based mate-
to detect the solid percolation threshold and setting rials. The two systems are effective, accurate, non-
process of cement-based materials. destructive and in-situ. By utilizing the critical points
Two dots in Fig. 6 represent the initial and final on resistivity curve, four stages can be identified,
setting times measured by the standard Vicat method. which are the dissolution stage, the competition stage,
Setting refers to the stiffness change of the paste. the acceleration stage and the deceleration stage. Both
Setting corresponds to a noticeable formation of resistivity and UPV can detect the commencement of
hydration products. The beginning of solidification is acceleration period. This point corresponds to the
called the initial set. Further buildup of hydration threshold of solid percolation.
products is followed by start of the fully rigid state, The resistivity measurement reflects both chemical
responsible for the strength of concrete, which is and physical change in cement paste. It is sensitive to
known as the final set [21]. Setting times are the conductivity change of the pore solution. The
commonly defined arbitrarily by a Vicat needle. In early-time decrease in resistivity results is due to the
this apparatus, weighted needles of standard design ion dissolution from the cement to the water. The
are allowed to sink into the paste, and initial and final resistivity plateau is caused by competition of ions,
set defined as the times when the degree of penetra- and the resistivity increase with different rate results
tion falls below specified levels. However, using this from the increasing tortuosity of the pore structures.
method, setting times are loosely defined as the fixed Nevertheless, the ultrasonic results involve essen-
penetration values that do not fully reflect the tially in physical change of cement paste, the motion
chemical and microstructural developments of the of the solid phase. It is sensitive to the point at which
cement hydration. The skill and experience of handler the solid phase becomes interconnected.
also limit its accuracy and reproducibility. In this
study, the resistivity and ultrasonic methods have Acknowledgement The financial support from Hong Kong
Research Grant Council under projected HKUST6272/03E is
been applied as the alternative methods for deter- greatly acknowledged.
mining the setting behavior of cement-based
materials. In the stages derivation here, we can use
the start time of stage III as the initial setting and the
end time as the final setting. References

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