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Outline
Concrete History of Cement Raw Materials Manufacturing process Quality Control
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What is Concrete?
Cement Concrete Cement Paste Phase
(OPC, PPC....)
Cement+Admixtures+Water
SP, VMA, SRA...
Mineral + Chemical River Msand Synthetic Natural Recycled Pozzolanic + Inert Fillers FA, slag, silica fume, Metakaolin Light wt. Normal wt. Heavy wt.
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Why Concrete?
5.5 billion tonnes of concrete per year (~ 1 tonne per human being) Excellent water resistance Ease of moulding in to any shape and size Availability of raw materials Economy (~ Rs 5-6) Less energy consumption (relatively with steel) Sustainable Durable
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Pantheon
World's largest unreinforced concrete dome
Rome - 126 AD
Colosseum
Elliptical amphitheatre Rome - 80 AD
History of Cement
Lime mortar - Hydraulic Cement - Portland Cement John Smeaton (Civil Engineer) -1756 - Eddystone Lighthouse - discovered that the best limes for mortar contained a high degree of clayey matter Ultimately, this kind of lime was used in equal quantities with pozzolana for the construction of Light house
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Portland Cement
L. J. Vicat: Prepared artificial hydraulic lime by calcining an intimate mixture of limestone (chalk) and clay principal forerunner to Portland Cement 1824 Joseph Aspdin, while obtaining a patent for his hydraulic cement, termed it as Portland cement, due to the resemblance of hardened cement in appearance and quality of Portland stone (limestone from Dorset, UK)
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Cement Production-Schematic
800C 1400C
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When moisture content of raw materials is > 15%, wet blending (in slurry form) is preferred When moisture content < 8%, dry blending is done For 8% < moisture content < 15%, dry blending with precalciners used
Process Kiln length (m) Output (tons/day) Fuel consumption (kcal/kg clinker) Wet 40 232 100 3350 1000 2200 Dry Preheater Precalciner 40 95 200 3500 800 950 54 110 1500 8500 800 95
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Cement kiln
Only rotary kilns used nowadays Typical kilns are long ~ 30 40 m Length and diameter of kiln also depends on blending process, output required and energy Temperature inside kiln varies from 850 (at inlet) to 1450C (at the outlet) Reactions are not completed inside kiln; some require cooling to occur The material comes out of kiln is called clinker
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Cement Clinker
3 to 25 mm
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Of greater importance despite minor amount present are deposits of soluble crystalline components (alkali sulfates and calcium alkali sulfates) on the surfaces of clinkers
Hewlett, 2001
Appearance of clinker
Typical PC clinker is composed of - large irregular crystals that are grains of alite (C3S), - more rounded smaller crystals that are belite (C2S), and - groundmass consisting of the flux phases (mixture of ferrite and C3A solid solutions)
Clinker
Clinkers viewed under reflected light in optical microscope
These figures show the important phases of alite (C3S, generally angular), belite (C2S, generally rounded), interstitial material (C3A and C4AF, light colour regions) and epoxy resin in clinker pores.
Clinker showing in left fig. has Typical C3S (alite) structure with Relatively high proportion of aluminate phases (white areas)
Clinker
In the Right fig. fine grained, nested C2S zone with much porosity in clinker
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Other issues
Cement manufacture today is a highly controlled process Closed circuit grinding is preferred However, there is lot of variation in quality of cements (between brands, in the same brand, sometimes in batches produced on the same day!) Quality control during cement manufacture at every stage in the process done
Quality control
Sampling and evaluation should be performed after excavation from the quarry before and after blending the feedstock after formation of clinker after intergrinding clinker with gypsum finally before packaging in the bags and drums
Some informations
UK 50 kg US 42.6 kg* Environmental impact 1 tonne of cement = 1 tonne of CO2 ( ) Depletion of natural resources
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Acknowledgments
The instructor is indebted to Dr. Manu Santhanam from Indian Institute of Technology Madras for providing some of the images and illustrations
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