Weathering of cement and concrete

Deterioration of structures

Deterioration of structures
Weathering is due to long term exposure to corrosive environmental conditions Constituents of cement are attacked by water, salt solutions and acids Concrete consisting of cement mortar (a mixture of Portland cement, fine aggregates, sand & water) with coarse aggregate such as gravel or crushed stone is also susceptible to deterioration due to long term exposure Tensile strength of concrete is increased by reinforcement with steel rods for use in beams, pillars etc. where tensile stresses occur
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Effect of acidity & protection

Attack of cement & concrete by acidic solutions of CO2, inorganic acids increases with greater acidity Acidic water leach out the lime and also hydrolyses aluminates and silicates and dissolve the liberated Ca(OH)2 This attack may be impaired by coating different protective agents like linseed oil, chlorinated rubber or epoxy ester paints and SiF4 which forms a protective coating of CaF2 and hydrated alumina and silica This treatment is useful for sewage pipes
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Attack by sulphate solutions

Cement & concrete structures are susceptible to a serious deterioration due to attack by sulphate solutions sulphate solutions react with Ca(OH)2 to form gypsum (Ca sulphate dihydrate) C3A phase of hardened cement reacts with Ca sulphate and other sulphates to form Ca-sulphoaluminate with a huge increase in volume (227%) This volume expansion leads to disruption of cement and concrete structures
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Cement with greater resistance

Effect due to attack by sulphate solutions may be overcome by increasing C4AF content and by superheated steam Superheated steam converts the free Ca(OH)2 into the more hydrated mono-ca-silicate (CSH). Cements with greater resistance to sulphate attack are: (i)- Superheated Cement, and (ii) high alumina cement
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Admixtures for concrete

These are added to improve the properties of concrete These are:
Air entraining agents-Surfactants such as oleic acid, caprylic acid, pdodecyl benzenesulphonic acid These agents resists spalling & cracking Water decreasing agents-lignosulphonate, melamine formaldehyde resin sulphonates etc., plasticity improves Setting accelerators-like CaCl2 & Ca formate acclerate the hydration of C2S and C3S phases (contributing to the strength of the cement) and retard the hydration of C3A. The optimum amount of CaCl2 is about 1.5% by wt and any excess promotes corrosion of the reinforcing steel.
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Ceramics (Gk. Keramos=burnt matter)

Ceramic materials consist of a combination of metallic & non-metallic elements Ceramics include- Bricks, tiles, glass, abrasives, refractories which are mostly produced from naturally occurring minerals of silica and alumina Highly refractory carbides, borides, nitrides are also called ceramics Properties-ceramics have desirable mechanical properties such as good tensile and compressive strengths, resistance to weathering, chemical attack, capability to withstand high temp as well as good electrical resistance
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Sand, calcite (CaCO3), diamond-abrasives

Three major components of ceramics

A plastic component which imparts plasticity e.g. clay
Dry clay is not plastic but the incorporation of water makes it plastic, making it amenable to be shaped

A refractory non-plastic component- it is silica Contributes to the mechanical strength of the products Quartz is mostly used as the refractory component in ceramics A flux or glassy material- which improves the workability and provides the bonding of ingredients The flux component of the ceramic is feldspar- a constituent of igneous rock. Naturally occuring albite (sodium feldspar-Na2O.Al2O3.6SiO2), orthoclase (sodium feldspar-K2O.Al2O3.6SiO2) and anorthite (lime feldspar-CaO.Al2O3.6SiO2 are used as flux material
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Method of Ceramics production

It involves following steps: Fabrication or formation of ceramic body Drying Firing

Ceramics production
First step-Fabrication

or formation of ceramic body

By throwing soft mud (or raw material mix) on a potters hand wheel

Other methods
Stiff mud process- The mix containing 10-20% water is forced through a steel die of the desired shape in a pug mill Slip casting- An aqueous suspension of the mix having pourable consistensy is poured ito a mould of PoP. PoP absorbs the water and a uniform deposit is obtained Dry pressing- for making floor & wall tiles (from dry mix containing 5-15% water) Hot pressing- for making dense refractory oxides & carbides 10

 Second step is Drying in Kilns at controlled humidity & rates of drying to prevent cracking of the product Last step is firing of dried ceramic ware in Kilns over a range of temp. 800-2000 C depending on the composition of the mix

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Three Major Groups of Ceramic Materials

Three Groups Clay Products Glass Refractories all of which find extensive use in a variety of industries

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Clay Products
May be classified into three major groups White wares or white pottery or china such as porcelain ware, table ware or dinner ware Stoneware such as sanitary fixtures, drainage pipes etc. Structural clay products like tiles & bricks

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White Wares
White products with a refractory body & glossy coating called glaze
Constituents of Glaze are: quartz, feldspar, boric oxide (B2O3) & lead oxide The raw materials used in the manufacture of white wares are kaolin, feldspar and silica free from iron oxide and other colored impurities Manufacturing steps(i)Prep of body, (ii)Glazing, (iii)Decoration Fine powder of raw material blended in the required proportion is mixed with water to form a plastic mass Desired article is shaped by hand moulding, slip casting or pressing Now the body is carefully dried and fired in a buscuit oven (buscuit firing)
http://www.pillivuyt.fr/en-pillivuyt-fabrication.php
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Porous material

Biscuit oven

Bisque of soft-paste porcelain

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