CONCRETE MAKING

MATERIALS

Concrete
Rocklike Material

Ingredients
– Portland Cement
– Course Aggregate
– Fine Aggregate
– Water
– Admixtures (optional)
 Concrete Properties

Versatile
Pliable when mixed
Strong & Durable
Does not Rust or Rot
Does Not Need a Coating
Resists Fire

Type III - High Early Type IV - Low Heat of Hydration

Type I - Normal Type I - Normal

Composition of concrete
Cement

Aggregates

Water

Chemical Admixtures

Mineral Admixtures
http://www.bu.edu/sjmag/scimag2008/images/Texture__Concrete
_Cracked_by_ivelt_resources.jpg

Towards Modern cement….

• John Smeaton, while planning the building

of Eddystone lighthouse tower in 1756,
discovered that the best limes for mortar
contained a high degree of clayey matter

• Ultimately, such a lime was used along with

pozzolana in equal quantities
 Eddystone Lighthouse Tower

•Completed in 1759

•72 feet tall; 93 steps

•Newer lighthouse
constructed in 1882;
Smeaton’s tower
was moved stone-by-
stone to Plymouth,
where it is still the
most major
landmark

CEMENT

Crystalline compound of calcium silicates and other calcium

compounds having hydraulic properties.
Considered hydraulic because of their ability to set and harden
under or with excess water through the hydration of the
cement’s chemical compounds or minerals

http://img.alibaba.com/photo/11654315/Portlan
d_Cement_42_5_N_R.jpg
 Cement
The grey colour of the final mixture is a result of Fe and
Mg additions, much like the colour of a mineral is
darkened by the presence of these elements. Ingredients
are superheated (up to 1480°C) in large cement kilns, and
the cooled pellets are crushed to a powder and gypsum is
added.
Although the final product - concrete - is cost-effective and
non-polluting in its final form, the production of cement is
one of the most energy intensive of all industrial
manufacturing processes and generates undesirable
emissions (CO2, SO2, nitrous oxides, sulfur compounds,
dioxins) and highly alkaline wastewater. Cement kilns
are a major pollution problem in many regions

CONSTITUENT MATERIALS AND PROPERTIES (Cont’d)

Types of cement
Standard Portland cement - Used for general purposes; air entrained (50% C3S;
24% C2S; 11%C3A; 8% C4AF; 72% passing 45 µm sieve)

Modified Portland cement - Used when sulphate resistance and/or generation

of moderate heat of hydration are required; air entrained (42% C3S; 33% C2S;
5% C3A; 13% C4AF; 72% passing 45 µm sieve)

High early strength Portland cement - Used for early strength and cold weather
operations; air entrained (60% C3S; 13% C2S; 9% C3A; 8% C4AF; ….)

Low heat Portland cement - Used where low heat of hydration is required;
air entrained (26% C3S; 50% C2S; 5% C3A; 12% C4AF; …….)

High sulphate-resistant concrete - Used where sulphate concentration is very

high; also used for marine and sewer structures; air entrained (40% C3S; 40 %
C2S; 3.5 % C3A; 9% C4AF; 72% passing 45 µm sieve)
 CONSTITUENT MATERIALS AND PROPERTIES (Cont’d)

Portland Pozzolan Cement (P.P.C.) - By grinding & blending P.C.

Clinker+Pozzolan+Gypsum

Portland Blast Furnace Slag Cement (P.B.F.S.C.) - By intergrinding

B.F.S.+P.C. Clinker+Gypsum
This cement is less reactive (rate of gain of strength & early strength is
less but ultimate strength is same)

White Portland Cement - W.P.C. İs made from materials containing a little

iron oxide & manganese oxide.
Fe2O3 + MnO ≤ 0.8%

High Alumina Cement - The raw materials for H.A.C. is limestone and
Bauxite (Al2O3 & Fe2O3)

11

PORTLAND CEMENT

Physical Properties of Portland Cements

1) Fineness,
2) Soundness
3) Consistency
4) Setting time
5) Compressive strength
6) Heat of hydration
7) Loss of ignition
Cement
Manufactured using a combination of raw
materials mined from a quarry near the cement
plant. Production requires a source of calcium,
silicon, and small amounts of aluminum, iron,
and gypsum.
Which rocks and sediments could provide
these elements? Typically
limestone, shells or chalk (for Ca)
shale (for Si)
clay minerals (for Si)
quartz sand (for Si)
iron ore
aluminum ore (bauxite)
gypsum evaporite deposits

CONSTITUENT MATERIALS AND PROPERTIES

Components, types and properties

Component materials required for cement making

Limestone, shale, slate, clay, chalk - Lime (~ 60%), silica (~ 20%),
alumina (~ 10%) - Others : Iron oxide, magnesium oxide, sulphur
trioxide, alkalies, carbon-di-oxide

Manufacturing process
Wet and dry methods - In both methods raw materials are homogenized
by casting, grinding and blending - Approximately 80% of the ground
materials pass through #200 sieve - Primary and Secondary crushers;
wet and dry grinding mills
 Blending of raw materials
• Choice of blending process
- Wet or dry - When moisture content of raw
materials is > 15%, wet blending and when
MC < 8%, dry blending
• Wet process – more uniform mixing
• Dry process – higher output, lower power
consumption
• Dry process with precalciners are the order
of the day

A cement plant,
showing a
precalciner and
rotary kiln
AGGREGATES

Aggregates occupy 60 to 80 percent of the

volume of concrete.

Sand, gravel and crushed stone are the

primary aggregates used.

All aggregates must be essentially free

of silt and/or organic matter.
http://www.bondedaggregate.co.uk/images/select-aggregate-
driveway.jpg

AGGREGATE ORIGINS AND

PRODUCTION
Can either be natural or manufactured
I. Natural aggregates are generally extracted from larger rock
formations through an open excavation
II. Manufactured rock typically consists of industrial
byproducts such as slag (byproduct of the metallurgical
processing – typically produced from processing steel, tin
and copper)
Specialty rock that is produced to have a particular physical
characteristic not found in natural rock (such as the low
density of lightweight aggregate).
 Aggregates are obtained from rocks, which,
in turn, are composed of minerals (either a
single mineral, or a mixture of minerals).
Types of rocks
• Igneous, sedimentary, and metamorphic
• 95% of the outer 10 miles of the earth’s
crust is composed of igneous and
metamorphic rocks, but 75% of the rocks
exposed on the surface of the earth are
sedimentary

Igneous rocks
1.Intrusive: when the molten matter cools slowly under
the earth’s surface, and results in the formation of
large rocks with typically large crystals, e.g., Granite,
gabbro, pegmatite.
2. Extrusive: when the molten matter cools rapidly on
the earth’s surface, resulting in the formation of rocks
with smaller crystals, e.g., Basalt, andesite, rhyolite.
3. Pyroclastics: these are formed due to the
cementation of extremely fine ash deposits which
cool very rapidly resulting in an amorphous rock, e.g.,
volcanic tuff, pumice, breccia (generally light weight)
Sedimentary rocks
• Sedimentary rocks are deposited in a fluid medium
due to lithification of weathered sediments.
• Lithification can occur as a result of cementation
(common cements being iron oxide, calcite, or
quartz), crystallization, or compaction (due to the
application of high pressure).
• Shale, sandstone, and limestone make up 46, 32,
and 22 % of all sedimentary rocks, respectively.

Metamorphic rocks
• Metamorphic rocks are formed when pre-
existing rocks are subjected to heat and
pressure.
• Recrystallization often occurs, and the
resulting rocks have typically large crystals
with a well-defined cleavage.
• Examples - marble, gneiss, schist, phyllite,
slate, etc.
 Role of aggregates in concrete

60 – 80% volume occupied by aggregates

Main significance:

• Cost
• Dimensional stability
• Strength & Stiffness
• Abrasion resistance

Aggregate classification
Bulk density < 1120 kg/m3 – light weight
> 2080 kg/m3 – heavy weight
Apparent Sp.Gravity for common aggregates – 2.6 to 2.7

Natural light weight aggregates – by crushing igneous volcanic

rocks such as pumice, scoria or tuff.
Synthetic aggregates are manufactured by thermal
treatment of clays, shale, slate, pearlite, vermiculite,
blast furnace slag, fly ash
Heavy weight aggregate – primarily used for making nuclear
radiation shields.
- Natural rocks suited consist predominantly barium
mineral, iron ores and titanium ore
Engineering considerations of using various
rocks as concrete aggregate

Crushing strength and modulus of elasticity - Higher the better;

should be considerably higher than the values expected for
concrete
Unsoundness - volume changes in aggregate induced by
weather resulting in deterioration of concrete.
A pore size distribution that allows the aggregate particles to get
saturated on wetting (or thawing in frost attack), but prevent easy
drainage on drying (or freezing) is capable of causing high hydraulic
pressure within the aggregate

19SC702 Course material – Dr.K.B.Anand

Fineness Modulus – used as an index of the fineness of

aggregate. Higher the FM, the coarser the aggregate

Shape – elongated, blade-shaped aggregate particles should

be avoided or limited (even manufactured sand with
elongated grain) as it produce harsh concrete.

Deleterious substances – organic impurities, clay & other

fines, salt contamination

Alkali-Aggregate Reaction: Reaction of alkalis in concrete

with certain specific types of aggregates

Alkalis could come from cement, admixtures, water, or from

aggregates themselves!
 AGGREGATE PHYSICAL
PROPERTIES
Toughness and abrasion resistance. Aggregates should be
hard and tough enough to resist crushing, degradation and
disintegration from activities such as manufacturing,
stockpiling, production, placing and compaction.
Durability and soundness. Aggregates must be resistant to
breakdown and disintegration from weathering
(wetting/drying) or else they may break apart and cause
premature distress.

WATER

Good water is essential for quality concrete.

Should be good enough to drink--free
of trash, organic matter and excessive
chemicals and/or minerals.
The strength and other properties of
concrete are highly dependent on the
amount of water and the water-cement ratio.
http://pure-perfection.net/custom/Water-Droplet-1039X761.jpg
 WATER

shall be free form injurious amounts

of oils, acids, alkalis, salts, sugar,
organic materials that may be
deleterious to concrete or steel

WATER – Contd..

potable water is generally

considered satisfactory

pH value of water shall not be

less than 6
 WATER – Contd..

sea water is not recommended

because of harmful salts in sea water

water found satisfactory for mixing is

also suitable for curing concrete

Permissible Limit for Solids

Sl.N Tested as Permissible Limit, Max
o. per
1.
IS 3025
Organic 200 mg/l
(Part 18)
2.
IS 3025
Inorganic 3000 mg/l
(Part 18)
3.
Sulphates IS 3025
400 mg/l
(as SO3) (Part 24)

4. 2000 mg/l
Chlorides IS 3025 for concrete not containing embedded steel and 500 mg/l
(as Cl) (Part 32) for reinforced concrete work
5. 2000 mg/l
Suspended IS 3025
matter (Part 17)
CHEMİCAL ADMİXTURES

Materials in the form of powder or fluids that are added to the

concrete to give it certain characteristics not obtainable with
plain concrete mixes.

In normal use, admixture dosages

are less than 5% by mass of cement,
and are added to the concrete at the
time of batching/mixing. http://www.cca.org.nz/images/admixtures1.jpg
CONCRETE CHEMICALS

WHY?
Strong
Durable
Water proof structures
Based on use – 4 types

ADMIXTURES

Materials added to the concrete besides

cement, water and aggregate.
Why??
To improve the properties of the concrete
required.
Admixtures can be divided in 2 groups that
is:
a) Chemical admixtures
b) Mineral admixtures
TYPES OF CHEMICAL ADMIXTURES
Accelerators
Retarders
Plasticizers
Super Plasticizers
Air entrainment agents
Damp proofing and water proofing admixtures
Bond admixtures
Corrosion inhibitors
Fungicidal insecticidal and germicidal
admixtures

CHEMİCAL ADMİXTURES

The most common types of admixtures are:

Accelerators :
- Speed up the hydration (hardening) of the concrete.
- Typical materials used are CaCl2 and NaCl.
Acrylic retarders :
-Slow the hydration of concrete, and are used in large or
difficult pours.
- Typical retarder is table sugar, or sucrose (C12H22O11).
CHEMICAL ADMIXTURES
Air Entraining agents:
-The most commonly used admixtures for agricultural
concrete.
-Produce microscopic air bubbles throughout the concrete.
-Entrained air bubbles:
Improve the durability of concrete exposed to
moisture and freeze/thaw action.
Improve resistance to scaling from deicers and
corrosive agents such as manure or silage.

CHEMICAL ADMIXTURES
Water-reducing admixtures
-Increase the workability of plastic or "fresh" concrete,
allowing it be placed more easily, with less consolidating
effort.
-High-range water-reducing admixtures are a class of
water-reducing admixtures
Increase workability
Reduce the water content of a concrete.
Improves its strength and durability characteristics.
Mineral admixtures
Very fine-grained materials which are added to
the concrete mix to improve the properties of
concrete.
These inorganic materials have pozzolanic
property
Benefits
Higher early strength
Reduced permeability
Control of alkali-aggregate reactivity
Reduced costs.

COMMONLY USED MINERAL ADMIXTURES

Fly ash,
Silica fume,
Ground granulated blast-furnace slag.
Metkaolin
Types of concrete
Regular concrete Glass concrete
High-strength concrete Asphalt concrete
Stamped concrete Rapid strength concrete
High-performance concrete Rubberized concrete
Self-consolidating concretes Polymer concrete
Vacuum concretes Geopolymer or green concrete
Shotcrete Limecrete
Pervious concrete Refractory Cement
Cellular concrete, Concrete cloth
Cork-cement composites Innovative mixtures
Roller-compacted concrete

Concrete production
This process develops physical and chemical properties like
mechanical strength, low moisture permeability, and chemical
and volumetric stability.
A properly proportioned concrete mix will provide
Mixing concrete
Workability
Curing
 Mixing concrete
Essential for
I. The production of uniform concrete,
II. High quality concrete.
Equipment and methods should be capable
of effectively mixing

http://en.yujianjx.com/upload/Concrete-Mixing-Plants-HZS50.jpg

Workability

The ease with which freshly mixed concrete can be placed and
finished without segregation.
Difficult to measure but ready-mix companies usually have
experience in determining the proper mix.
Important to accurately describe what the concrete is to be
used for, and how it will be placed.
Curing

Concrete that has been specified, batched, mixed, placed, and

finished "letter-perfect" can still be a failure if improperly or
inadequately cured.
Usually the last step in a concrete
project and, unfortunately,
is often neglected even by professionals.

http://www.eagleind.com/piclib/324.jpg

Curing

Curing has a major influence on the properties of hardened

concrete such as durability, strength, water-tightness, wear
resistance, volume stability, and resistance to freezing and
thawing.
Proper concrete curing for agricultural and residential
applications involves keeping newly placed concrete moist and
avoiding temperature extremes (above 90°F or below 50°F)
for at least three days.
A seven-day (or longer) curing time is recommended.
Curing
The best curing method depends on:
Cost,
Application equipment required,
Materials available,
Size and shape of the concrete surface.
Prevent the loss of the mixing water from concrete by sealing
the surface.
Can be done by:
Covering the concrete with impervious paper or plastic
sheets,
Applying membrane-forming curing compounds.

Curing

Begin the curing as soon as the concrete has hardened

sufficiently to avoid erosion or other damage to the freshly
finished surface.
Usually within one to two hours after placement and finishing.

http://epg.modot.mo.gov/files/thumb/b/b2/1055.jpg/400px-
1055.jpg
Properties of concrete

Strength
Elasticity
Cracking
Shrinkage cracking
Tension cracking

General test methods

Compaction Factor Test (Compacting Factor Test, Glanville)
Compaction Test
Free Orifice Test (Orimet Test)
K-Slump Tester
Free Flow Test Methods
Slump Test
Modified Slump Test
Slump Rate Machine
Kelly Ball Test
Ring Penetration Test
Cone Penetration Test
Moving Sphere Viscometer
Flow Trough Test
Delivery-Chute Torque Meter
Delivery-Chute Depth Meter
Surface Settlement Test
GYPSUM
Occurs in nature as :
- flattened
- often twinned crystals
- transparent cleavable masses
called selenite.
May also occur in a silky, fibrous
form, in which case it is commonly
called satin spar.
Finally may also be granular or quite
compact. http://www.warmtec.co.nz/mediac/400_0/media/variotherm3.JPG

In hand-sized samples.
Can be transparent or opaque.

OCCURRENCE GYPSUM

A common mineral, with thick

and extensive evaporite beds in
association with sedimentary
rocks.
Gypsum is deposited in lake and
sea water.
Hydrothermal anhydrite in veins
is commonly hydrated to gypsum
by groundwater in near surface
exposures.
Often associated with the
minerals halite and sulfur.
http://en.wikipedia.org/wiki/Gypsum
USES OF GYPSUM

Gypsum Board primarily used as a finish for walls and

ceilings; known in construction slang as Drywall
Plaster ingredient.
A component of Portland cement used to prevent flash setting
of concrete.

Quality control
• Lot of variation in quality of
cements (between brands, in the
same brand, sometimes in batches
produced on the same day!)
• Sampling and evaluation to be performed:
after excavation from the quarry,
before and after blending the feedstock,
after formation of clinker,
after intergrinding clinker with gypsum,
before packaging in the bags and drums
REFERENCES
WEB,http://www.cement.org/basics/concretebasics_aggregate.asp
Standard specification for portland cement (AASHTO M 85-89). 1986. AASHTO standard
specification for transportation materials. Part I, Specifications. 14th ed.
Powers, T. C., L. E. Copeland, J. C. Hayes, and H. M. Mann. 1954. Permeability of portland
cement paste. ACl Journal Proceedings 51 (3):285-98.
Whiting, D. 1988. Permeability of selected concretes. ACI special publication. Permeability
of concrete SP-108: 195-222.
Tsuji, Y., and N. Miyake. 1988. Chemically prestressed precast concrete box culverts.
Concrete International: Design and Construction 10 (5):76-82 (May).
Ramachandran, V. S., and R. F. Feldman. 1984. Cement science. In Concrete admixtures
handbook: Properties, science, and technology, ed. V. Ramachandran, 1-54. Park Ridge, N.J.:
Noyes Publications.
Concrete Technology : M.S.Shetty
Concrete chemicals : A.R.Santhakumar
Concrete Technology :Gambhir
Subramaniam . B.V : Concrete chemicals ,a course note on concrete mix
design and construction practice
Accelarators and chemicals for concrete construction” Literature from Symons corporation,
USA

Thank you for your attention☺

Assignment - 01
1. What are the composition of concrete and its percentage in
normal concrete?
2. What is the purpose of curing?
3. List down the types of cements and Bogue’s Compound and
its proportions?
4. Enumerate the importance of usage of rounded and angular
aggregate?
5. List down the types of chemical admixtures and its purpose.