CVEN 3304 Concrete Structures

Introduction to
Concrete Materials
Lecture 1: Introduction and Cement Production
By Taehwan Kim, Lecturer in the UNSW
25/07/2016
School of Civil and Environmental Engineering

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 1 /79

CVEN 3304 - Concrete Structures

Introduction of
Course
Concrete
History of
Concrete

Dr. Taehwan Kim, Lecturer

Office: Room 704 (CVEN)
Contact: [email protected]

Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 2 /79

Books
Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 3 /79

Assessment
Introduction of
Course
Concrete
History of
Concrete
Concrete
Component

Formal Exam in November:

Class Marks
1 Assignment issued on 9th Aug.
1 Quiz on during the last tutorial class
on 24th Aug. (1 hour)

16.7%
16.6%
8.3 %
8.3%

Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability
Photo: Mr. bean Video

No begging or Cheating
CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 4 /79

Personal Background
Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production

B.Sc and M.Sc

Civil and Envir. Engineering
Structure of concrete

Cement
Properties
Current Trend:
Sustainability

CVIE 3304, Week 1: Concrete and Cement hydration

Lecturer
Civil and Envir. Engineering
Materials and Structures

July 25th , 2016

Ph.D.
Civil Engineering
Concrete materials

Post Doc
Civil and Envir. Engineering
Materials of concrete

Slide 5 /79

Whats in this part of the class?

Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

Concrete as Composite
Constituent Materials Cement, Water,
Aggregate, Supplementary Cementitious
Materials (Waste Materials)
Chemical Reactions and Microstructure
Concrete Mixing, Placing and Finishing
Properties of Fresh and Hardened Concrete
Durability Performance
Sustainable Materials

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 6 /79

What you will learn from this course?

Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

This is a introductory course that summarize

one semester course.
However, Concrete Materials part will cover
basic conceptual understanding of concrete.
We will understand the importance of concrete
manufacture on the performance of structures
and their service-life.
We will learn various terminologies and
phenomenon related to concrete materials.
We will understand what factors can related
and how they can influence the concrete
properties.

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 7 /79

What is Concrete?
Introduction of
Course
Concrete
History of
Concrete
Concrete
Component

From Latin Concretus To Hold Together or To

Grow Together
Formable Rock
Composite: Binder + Filler

Cement
Cement
Production

Binder: Cement

Cement
Properties

Filler: aggregate

Current Trend:
Sustainability

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 8 /79

What is Concrete?
Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

A composite material that consists of a

binding medium (typically cement)
within which are embedded fine and
coarse aggregates.
The present consumption of concrete in
the world is of the order of 33 billion
tones every year.
Humans consumes no material except
water in such tremendous quantities.
The largest volume used in the world
except for water.

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 9 /79

Bridges
Introduction of
Course

Captain Cook Bridge,

Brisbane, QLD, 1972

Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

Pre-cast, Pre-stressed
Concrete free-cantilever
bridge
Captain Cook Bridge, Sydney,
NSW, 1965

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

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Bridges
Introduction of
Course

Hoover dam Bypass

Bridge, Time span:
2005 to 2010

Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 11 /79

Bridges
Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability
Hoover dam Bypass Bridge, Time span: 2005 to 2010
CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 12 /79

Pavements
Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 13 /79

Structures
Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability
The Gordon river dam, Tasmania, Australia
http://www.spiritland.net/tas-southwest.htm

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 14 /79

Structures
Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

Stamp House by Charles Wright Architecture,

QLS, Australia
http://wrightarchitects.com.au/projects-2/contact/stamphouse/#prettyPhoto

Self-sustaining, solar-powered, carbon neutral, cyclone shelter

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

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Materials in Construction
Introduction of
Course
Concrete
History of
Concrete
Concrete
Component

Environmental Concern
Energy Consumption
Cost
Performance

Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 16 /79

Environment and Energy

Introduction of
Course
Concrete

GD>1: eco-friendly
GD=1: almost theoretical process
GD<1: pollutant emission process

History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

Comparison of GD of different industries of China (D. Xu et al., 2015)

GD =

Theoretical usage of natural resources for unit qualified product

Actual usage of materials for unit qualified product

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

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Comparison with Building Materials

Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 18 /79

Pros and Cons of Concrete

Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

ADVANTAGE
Durable
Economical
Formed on Site
Energy Efficient
Inflammable
Thermal Resistance
Water Resistant
Aesthetics

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

DISADVANTAGE
Brittle
Slow Material
Development
Low Strength to
Weight Ratio
Formed on Site
Volume Instability

Slide 19 /79

History of Concrete
Introduction of
Course
Concrete

~3000 BC, Egyptians made Pyramid with

gypsum mortars as a binding agent

History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 20 /79

History of Concrete
Introduction of
Course

~300 BC to 200 AD, Romans

Concrete

Colossseum, 70 AD

History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

Mortars by mixing Volcanic

ash and Lime
Concrete is mainly in
compression
"Pantheon, 120 AD" by Giovanni Paolo Panini
https://commons.wikimedia.org/wiki/File:Pantheonpanini.jpg#/media/File:Pantheon-panini.jpg

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

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Modern Concrete
Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties

It is almost Impossible to find the material

which replace the concrete as concrete
actually has low environmental impact.
But, Engineers and Scientists keep working to
develop better concrete
Reduce the environmental impact (CO2 emission)
Increase the efficiency of energy consumption
Control property of concrete even on the
nanoscale

Current Trend:
Sustainability

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

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Modern Concrete
Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

Mechanical Properties
Fiber Reinforced Concrete
Ultra High Performance Concrete

Workability
Self-Compacting Concrete
Roller-Compacted Concrete

Durability and Environmental Concern

Self Healing Concrete
Alkali Activated Material based Concrete
Self-Cleaning Concrete (photocatalytic concrete)

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

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Bridging Length Scales

Introduction of
Course

Macro

K. L. Scrivener et al., CCR, Vol. 78, 2015

Tricalicum
Silicate

Concrete
History of
Concrete

Meso

Concrete
Component
Cement

Micro

Cement
Production
Cement
Properties

Nano

500 m

Coarse Aggregate

In near future,
we might be
able to change
the properties
of concrete on
nanoscale

Mortar (sand + cement)

Current Trend:
Sustainability
Fine Aggregate
Paste (cement)
CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

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Components of Concrete
Introduction of
Course
Concrete
History of
Concrete

CONCRETE
= Cement + Fine & Coarse Aggregate + Water
Fine
aggregate

Concrete
Component
Cement

Coarse
aggregate

Cement

Cement
Production
Cement
Properties
Current Trend:
Sustainability

Water

Component of Concrete (by the courtesy of PCA

http://www.cement.org/cement-concrete-basics/how-concrete-is-made)

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 25 /79

Mixture Proportions
Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production

Concrete Mixing is like Making Cookies:

Proportions, Combining Materials, Mixing,
Placement, and Curing.
Just Concrete Ingredients are Cement,
Aggregates, and Water.
The Mixing Proportion is important to produce
a good quality of concrete..

Cement
Properties
Current Trend:
Sustainability

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 26 /79

Mixture Proportions
Introduction of
Course

Concrete Proportions

Concrete

Mortar

History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

Coarse Aggregate

Concrete

Concrete taken from I-465 outside Indianapolis, Courtesy by J. W. Weiss

Mortar = Cement + Water + Fine Aggregate

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 27 /79

Mixture Proportions
Introduction of
Course

Concrete Proportions

Concrete

Paste

History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

Concrete

Fine Aggregate

Concrete taken from I-465 outside Indianapolis, Courtesy by J. W. Weiss

Paste = Cement + Water

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 28 /79

Proportions By Volume
Introduction of
Course
Concrete
History of
Concrete

10%

Paste

Concrete
Component

14%

32%

Cement
Cement
Production

40%

Cement
Properties
Current Trend:
Sustainability

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Cement

Water

Coarse Aggregate

Fine Aggregate

Slide 29 /79

Proportions By Weight
Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

We can simply
determine how
much each of these
materials weigh by
utilizing density
relations
Weights are used for
Batching.
Cement 3.15 X water
Agg 2.6 X water

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

13%
6%

38%

42%

Cement

Water

Coarse Aggregate

Fine Aggregate

Slide 30 /79

Comparing the Proportions

Introduction of
Course
Concrete

Volume

History of
Concrete

Weight

10%

Concrete
32%
Component

13%
6%

14%

Cement
Properties

59%
42%

40%
Cement

22%

38%

Cement
Cement
Production

Cost

Water

Current Trend:
Property
Sustainability

Relationships

CVIE 3304, Week 1: Concrete and Cement hydration

Coarse Aggregate

Weight (Key for

Batching)
July 25th , 2016

19%

Fine Aggregate

Cost (Important
for Profits)
Slide 31 /79

Standard and Specification

Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

There is a rules and direction to ensure the

quality of concrete.
Standard and Specification: To give as a
direction to be followed; authoritative rules or
directions.
Australian Standards

AS 3972
General purpose and blended cements
AS/NZC 2350 Methods of testing Portland and blended cements
AS/NZS 2350.1 Method of sampling Portland and blended cements
AS 2350.2
Chemical composition of Portland cement
AS 2350.3
Normal consistency of Portland and blended cements
AS/NZS 2350.4 Setting time of Portland and blended cements
AS/NZS 2350.5 Determination of soundness of Portland and blended cements
AS 2350.7
Determination of temperature rise during hydration of Portland and
blended cements
AS/NZS 2350.8 Fineness index of Portland cement by air permeability
AS 2350.9
Determination of residue on a 45 micron sieve
AS 2350.10
Calcium oxide content of blended cement

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 32 /79

Cement
Introduction of
Course
Concrete
History of
Concrete

CEMENT

Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 33 /79

Cement
Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

Cement: a Powder Binder to bind other materials

together. Particularly, a substance made of lime
and clay, mixed with water and aggregates to make
concrete. It is like a Glue!!!
Early cement starts from Pyramids (3000 BC):
Gypsum mortar.
Portland Cement
has been the most
popular and well
proven binder for
more than one
century.

CVIE 3304, Week 1: Concrete and Cement hydration

Cement

July 25th , 2016

Slide 34 /79

Inventor of Portland Cement

Introduction of
Course
Concrete
History of
Concrete

Joseph Aspdin took

out a patent for his
Portland cement in
1824

Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability
Aspdins Beehive Kiln (by the
courtesy of Dartford museum)
CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

British Mason, Joseph Aspdin

Slide 35 /79

Cement Kiln: Vertical to Horizontal

Introduction of
Course
Concrete

Rotary Kilns: Current cement kilns, horizontal

kiln that can be rotated.

History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

British rotary kiln, the first successful rotary kiln, 1901

Vertical Cement Kiln, Pennsylvania, US

In the 1876, Tomas Millen and two sons burned the

cement in a sewer pipe horizontally.
Greater capacity, burning raw materials thoroughly
and uniformly.
Replace the older vertical kilns rapidly.

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 36 /79

Rotary Cement Kiln

Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 37 /79

Cement Production
Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production

Ordinary Portland
Cement (OPC)
Raw Materials
Heating and Cooling
Clinker
Grinding
Cement

Cement Plant

Cement
Properties
Current Trend:
Sustainability

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 38 /79

Cement Production
Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 39 /79

Raw Materials of OPC

Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

Lime (CaO):
Limestone, Calcite,
Shale, Marl
Iron (Fe2O3): Clay, Iron
ore
Silica (SiO2): Clay,
Shale, Marl, Fly ash
Alumina (Al2O3): Clay,
Shale, Fly ash,
Aluminum ore

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 40 /79

Raw Materials of OPC

Introduction of
Course

Cement Chemistry Notation

Concrete

Oxide Form

Notation

Concrete
Component

CaO

SiO2

Cement

Al2O3

Fe2O3

Cement
Properties

SO3

Current Trend:
Sustainability

H2O

History of
Concrete

Cement
Production

While this system has advantages, it takes some time to get

used to these notation, since, for example, C normally stands
for Carbon, and H normally stands for hydrogen in chemistry.

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 41 /79

Mining and Conveying

Introduction of
Course
Concrete

Mining to Get Limestone and Shale

Crushing Limestone and Shale

dumper

History of
Concrete
Concrete
Component
Cement
Cement
Production

TRANSPORT

Cement
Composition

Crushing (primary
and secondary
crushers)

Storage at the
cement plant
transport

LIMESTONE CRUSHING PROCESS and TRANSPORT

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 42 /79

Limestone Quarry
Introduction of
Course
Concrete

Limestone Quarry typically determine the

Plant Location

History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 43 /79

Mixture of Raw Materials

Introduction of
Course

Grinding, Mixing, Homogenization, and Storage

Concrete
History of
Concrete

Dust collection

Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

From Japan Cement Association

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

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Cement Production
Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 45 /79

Clinker Production: Rotary Kiln

Introduction of
Course
Concrete
History of
Concrete
Concrete
Component

Before feeding materials to the Rotary Kiln

Crushed Limestone
(Quarried)

Other Raw Materials

Grinding/Storage

Clay and Shale

(Quarried)
Grinding/Storage

Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

Storage,
Homogenization,
Final Grinding

Preheaters

Burning Kiln

Material is ready to be processed further

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 46 /79

Clinker Production: Preheater

Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

Preheater
And Precalciner
De-carbonating raw materials,
and reduce the size and length
of kiln

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

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Clinker Production: Rotary Kiln

Introduction of
Course

Chemical Reactions among Components

Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production

CaO
SiO2

Ca3SiO5
1300-1450 C

Al2O3

Ca2SiO4
Ca3Al2O3

Fe2O3

Ca2AlFeO5

Cement
Properties

4 Main
Compounds
of Clinker

Current Trend:
Sustainability

http://www2.cement.org/basics/images/flashtour.html

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 48 /79

What is Happening in the Kiln?

Introduction of
Course
Concrete
History of
Concrete

Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

Mass distribution

Concrete
Component

Pre-heating

Limestone
CaCO3
Limestone
(Sand)
(Sable)

Up to
750oC

CLAY
Iron Oxydes

CRU

TIME

Dehydration Zone ( up to ~500 C)

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 49 /79

What is Happening in the Kiln?

Introduction of
Course
Concrete
History of
Concrete

Preheating

Concrete
Component
Cement
Production
Cement
Properties
Current Trend:
Sustainability

Mass distribution

Cement

Limestone
CaCO3

Calcination
Calcination: CaCO3
Preheating
Free lime
(CaO)
Ca2SiO4
Belite

Quartz, SiO2
Clay
Iron oxide

CaO + CO2

Up to
950oC

Calcium
Aluminates

Time

Calcination Zone ( 500 C to 950 C)

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 50 /79

What is Happening in the Kiln?

Introduction of
Course
Concrete
Preheating

Concrete
Component

Limestone
CaCO3

Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

Mass distribution

History of
Concrete

Quartz, SiO2
Clay
Iron oxide

Calcination

Up to
1350oC
Ca2SiO4
Belite
Calcium

Time

Free lime (CaO) reacts with silica and aluminum and produce belite and
calcium aluminate Solid-State reaction Zone (900 C to 1350 C)
CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 51 /79

What is Happening in the Kiln?

Introduction of
Course
Concrete
History of
Concrete

Preheating

Concrete
Component
Cement
Production
Cement
Properties
Current Trend:
Sustainability

Limestone
CaCO3
Mass distribution

Cement

Up to
1450oC

Calcination

Quartz, SiO2
Clay
Iron oxide

Ca2SiO4
Belite

Ca3SiO5
Alite

Calcium

Time

Clinkering Zone (1350C to 1500 C)

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

C3A = Ca3Al2O6, C4AF = Ca2AlFeO5

Slide 52 /79

Cooling
Introduction of
Course

About 1300-1400oC
Duration: Few minutes

Concrete
History of
Concrete
Concrete
Component

Stabilisation of the Alite

Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability
About 80oC
CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 53 /79

Clinker
Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production

The melt phases

causes the particles
to agglomerate into
large nodules (5 to
25 mm)
Like Walnuts or Golf
Balls
Photo courtesy by P. Stutzman

Cement
Properties
Current Trend:
Sustainability

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 54 /79

Clinker Composition
Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

Chemistry of Clinker
Cement Chemistry Notation
Compound

Chemical
Formula

Oxide
Composition

Cement
Notation

Mineral
Name

Content

Tricalcium
Silicate

Ca3SiO5

3CaO.SiO2

C3S

Alite

~65%

Dicalcium
silicate

Ca2SiO4

2CaO.SiO2

C2S

Belite

~15%

Tricalcium
aluminate

Ca3Al2O6

3CaO.Al2O3

C3A

Aluminate

~7%

C4AF

Ferrite

~8%

Tetracalcium
Ca2AlFeO5 4CaO.Al2O3.Fe2O3
Aluminoferrite

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 55 /79

Clinker: Microscopic Images

Introduction of
Course
Concrete

Polished Section SEM image

C3S

from Understanding Cement, Nicholas B.

Winter

C2S

History of
Concrete

C2S

Concrete
Component

C2S
C2S

Cement

Epoxy resin

250 um

Cement
Production
Cement
Properties
Current Trend:
Sustainability

Polished Section Optical

Microscopy image

C3S

from Understanding Cement, Nicholas

B. Winter
C2S

C4AF and C3A

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 56 /79

Cement Production
Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 57 /79

Cement Grinding
Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production

Addition of Gypsum: Mandatory to prevent

flash set of concrete
Gypsum = hydrated calcium sulfate
(CaSO42H2O => CSH2)
Ball Mill Cement Grinding: Fineness
influences performance of cement

Cement
Properties
Current Trend:
Sustainability
http://www2.cement.org/basics/images/flashtour.html
CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 58 /79

Cement Production
Introduction of
Course
Concrete
History of
Concrete
Concrete
Component

SUMMARY
Crushed Limestone
(Quarried)

Other Raw Materials

Grinding/Storage

Clay and Shale

(Quarried)
Grinding/Storage

Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

Storage,
Homogenization,
Final Grinding
Distribution
/Storage

CVIE 3304, Week 1: Concrete and Cement hydration

Preheaters

Finish Grinding

July 25th , 2016

Burning Kiln

Gypsum (other mtl.)

Slide 59 /79

Cement Storage
Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production

Moisture Sensitive: therefore keep it dry.

This also applies to relative humidity
Can be stored in silos or in bags on pallets
(keep from outside walls)
If stored for a long time, it may develop
wharehous pack can break lumps but do
not use if lumps do not break

Cement
Properties
Current Trend:
Sustainability

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 60 /79

Cement Composition
Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

Be familiar with Cement Notation!!!!

Cement Chemical Oxide Composition
Oxide Name

Oxide
Formula

Cement
Notation

Weight %

Calcium Oxide, Lime

CaO

60 66

Silicon Dioxide, Silica

SiO2

18 24

Aluminum Oxide, Alumina

Al2O3

26

Ferric Oxide

Fe2O3

16

Magnesium Oxide, Magnesia

MgO

0.5 5

Sulfur Trioxide

SO3

1.5 5

Water

H2O

Sodium Oxide

Na2O

Potassium Oxide

K2O

0.05 1.2
(Na2Oeq)

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 61 /79

Cement Composition
Introduction of
Course
Concrete
History of
Concrete
Concrete
Component

These Oxides in Cement do exist in the cement as Four main

forms and Gypsum.
Simple Estimate of phase composition: Bogue Calculation
Compound

Chemical
Formula

Oxide
Composition

Cement
Notation

Mineral
Name

Content

Tricalcium
Silicate

Ca3SiO5

3CaO.SiO2

C3S

Alite

~50%

Cement
Production

Dicalcium
silicate

Ca2SiO4

2CaO.SiO2

C2S

Belite

~25%

Cement
Properties

Tricalcium
aluminate

Ca3Al2O6

3CaO.Al2O3

C3A

Aluminate

~12%

4CaO.Al2O3.Fe2O3

C4AF

Ferrite

~3.5%

CaSO42H2O

CSH2

Gypsum

3.5%

Cement

Current Trend:
Sustainability

Tetracalcium
Ca2AlFeO5
Aluminoferrite
Dihydrate
Calcium
Sulfate

CVIE 3304, Week 1: Concrete and Cement hydration

CaSO42H2O

July 25th , 2016

Slide 62 /79

Cement Fineness
Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties

Grinding Final step in the Production

Two Measures for Fineness
Specific Surface
Particle Size Distribution

Blaine Fineness: Measure of Permeability

Typical Surface Area
Normal ~ 350 m2/kg
High Early Strength ~500m2/kg

Current Trend:
Sustainability

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 63 /79

Cement Fineness
Introduction of
Course
Concrete
History of
Concrete
Concrete
Component

Finer = More Surface Area

Finer generally indicates Faster
Reaction rate is a function of the surface
area.

Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 64 /79

Cement Fineness
Introduction of
Course
History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties

Concrete

Here we consider
the same volume
or weight of
cement
Observe how
surface area
increases as
particle size
decreases

Current Trend:
Sustainability
Plot from J. Weiss

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 65 /79

Cement Types
Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

Australian Standard AS3972-2010

7 standard Cements in Australia

General Purpose Cement

Type GP General
Purpose Cement
Type GB Blended
Cement
Type GL General
Purpose Limestone
Cement

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Special Purpose Cement

Type HE High Early
Strength Cement
Type LH Low Heat
Cement
Type SR Sulfate
Resisting Cement
Type SL Shrinkage
Limited Cement

Slide 66 /79

Mill Report or Mill Certificate

Introduction of
Course

Information required
from producers
Based on production
averages
Can be useful for
tracing changes
Should be recorded

Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 67 /79

Mill Report or Mill Certificate

Introduction of
Course

Chemical Oxide
Composition

Concrete
History of
Concrete
Concrete
Component

Bogue Calculation

Cement
Cement
Production
Cement
Properties

Cement Compound

Current Trend:
Sustainability

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 68 /79

Mill Report or Mill Certificate

Introduction of
Course

Physical

Concrete
History of
Concrete
Concrete
Component

Strength

Cement
Cement
Production

Fineness

Cement
Properties
Current Trend:
Sustainability

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 69 /79

Sustainability
Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

It can be defined as any practice of

maintaining the process of productivity
by replacing resources used with
resources of equal or greater value
without degrading natural biotic
system and eco-footprints.
The goal of Sustainability is to achieve
indefinite human survival on Earth by
maintaining healthy environmental
system.

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 70 /79

Sustainability
Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production

Action Toward Global Sustainable

Development
1997: Kyoto Protocol
2007 in Bali: Failed to reach agreement
2009 in Copenhagen: Failed to reach agreement
2012 in Doha: Prolong the Kyoto protocol until 2020

2015 in Pairs: Paris Agreement

2021~: Implementation of Paris Agreement

Cement
Properties
Current Trend:
Sustainability
2015 Paris Climate Conference, http://newclimate.org/2015/12/14/whatthe-paris-agreement-means-for-global-climate-change-mitigation/

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 71 /79

Sustainability
Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production

Long term Goals of Paris Agreement in 2015

Limiting global temperature increase by the
end of the century to a maximum of 2C
Zero or Net-Zero global greenhouse gas
emission within this century.
Greenhouse gas: CO2 is dominant

Cement
Properties
Current Trend:
Sustainability

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 72 /79

Environmental Point of View of Concrete

Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties

5~ 8 % of total global CO2 emission

Most of this emission come from the
production of cement
Is concrete really Bad Material to avoid to
Use? The Answer is NO!!!
Actually, low impact material for carbon
footprint. Just simply Concrete is the most
used material in the world except for water.

Current Trend:
Sustainability

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 73 /79

Environmental Point of View of Concrete

Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production

Keep trying to reduce

the environmental
impact.
Big things have small
beginnings. from
Prometheus, 2012

Cement
Properties
Current Trend:
Sustainability

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 74 /79

Supplementary Cements
Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

Reuse industry by-product

Types of Supplementary Materials

Fly Ash
Silica Fume (Expensive)
Slag
Natural Pozzolans
Rice Husk Ash
Metakaolin

Energy Efficient, Reduced CO2 emissions

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 75 /79

Supplementary Cementitious Materials

Introduction of
Course

How SCMs looks like?

Concrete
History of
Concrete

Metakaolin

Silica Fume

Class F Fly Ash

Slag

Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

Class C Fly Ash

CVIE 3304, Week 1: Concrete and Cement hydration

Calcined Shale
July 25th , 2016

Slide 76 /79

Blended Cements
Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

Partially replace Portland cement with SCMs

Type GP Cement (General Purpose)

AS3972 permits manufacturers to add up 7.5 % of

Mineral Additions to reduce the clinker content in
cement

TYPE GB Cement (Blended Cement)

Fly ash and/or slag more than 7.5%
Amorphous Silica (<10%)

Advantages

Reduction of carbon footprint

Lower heat of hydration
Increased durability
Energy Saving
Higher long term strength

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 77 /79

Alternative Cements
Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production

To replace clinkers with more environmental

friendly materials
Alkali Activated Materials (fly ash/slag):
LC3: Limestone and Calcined clay
Calcium Sulfoaluminate Cement
CO2 cured cement: It consumes CO2 to cure
the cement

Cement
Properties
Current Trend:
Sustainability

CVIE 3304, Week 1: Concrete and Cement hydration

Durable
Concrete
Environmental
Economical
Impact
Production

July 25th , 2016

Slide 78 /79

Summary
Introduction of
Course
Concrete
History of
Concrete
Concrete
Component
Cement
Cement
Production
Cement
Properties
Current Trend:
Sustainability

Brief History of Concrete

What is Concrete? Mixture of cement,
aggregates, and water
Main components of cement: L, I, S, A
Cement Production, Kiln heats up materials
to drive off water, CO2, and change to
Cement
Calcium Silicates, Calcium Aluminates,
Ferrites, and Gypsum
Sustainability to maintain human life, SCMs,
alternative cements.

CVIE 3304, Week 1: Concrete and Cement hydration

July 25th , 2016

Slide 79 /79