Beginning of the Industry. Portland, Blended, and Other Hydraulic Cements

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1 and Other Hydraulic Oldest Concrete Found To Date dates around 7000 BC a lime concrete floor found during the construction of a road at Yiftah El in Galilee, Israel. Beginning of the Industry Portland was first patented in 1824 Named after the natural limestone quarried on the Isle of Portland in the English Channel Portland Cement First Produced North America 1871 Coplay, Pennsylvania Canada 1889 Hull, Quebec Primary Components of Raw Materials Necessary for Portland Cement Manufacture Calcium Silica Alumina Iron

2 Calcium Iron Alkali waste Aragonite Calcite Cement-kiln dust Cement rock Chalk Clay Fuller s earth Limestone Marble Marl Seashells Shale Portland, Slag Blended, Blast-furnace flue dust Clay Iron ore Mill scale Ore washings Pyrite cinders Shale Silica Calcium silicate Cement rock Clay Fly ash Fuller s earth Limestone Loess Marl Ore washings Quartzite Rice-hull ash Sand Sandstone Shale Slag Traprock Alumina Aluminum-ore refuse Bauxite Cement rock Clay Copper slag Fly ash Fuller s earth Granodiorite Limestone Loess Ore washings Shale Slag Staurolite Sulfate Anhydrite Calcium sulfate Gypsum Quarry Traditional Manufacture of Portland Cement 1. Stone is first reduced to 125 mm (5 in.) size, then to 20 mm (3/4 in.), and stored. 2. Raw materials are ground to powder and blended. or 2. Raw materials are ground, mixed with water to form slurry, and blended. 3. Burning changes raw mix chemically into clinker. 4. Clinker with gypsum is ground into portland and shipped.

3 Dry Process Manufacture of Portland Cement 2. Raw materials are ground, to powder and blended. 3. Burning changes raw mix chemically into clinker. Note four stage preheater, flash furnaces, and shorter kiln. 1. Stone is first reduced to 125 mm (5 in.) size, then to 20 mm (3/4 in.), and stored.

4 Clinker Gypsum 4. Clinker with gypsum is ground into portland and shipped Process of Clinker Production (1) (2) (3)

5 Portland Cement Types of Portland Cement ASTM C 150 (AASHTO M 85) By definition a hydraulic produced by pulverizing clinker consisting essentially of hydraulic calcium silicates, usually containing one or more of the forms of calcium sulfate as an interground addition. I Normal IA Normal, air-entraining II Moderate sulfate resistance IIA Moderate sulfate resistance, airentraining III High early strength IIIA High early strength, air-entraining IV Low heat of hydration V High sulfate resistance Performance of Concretes Made with Different in Sulfate Soil Performance of Concretes Made with Different W/C-Ratios in Sulfate Soil Type II & Type V Sulfate Resistant

6 Outdoor Sulfate Test Type V Cement W/C-ratio = 0.65 Type V Cement W/C-ratio = 0.39 Moderate and Low Heat Type III High Early Strength White Portland Cement Blended Hydraulic Cement ASTM C 595 General a hydraulic consisting of two or more inorganic constituents, which contribute to the strength gaining properties of. Blended Clinker Gypsum Portland Fly ash Slag Silica Fume Calcined Clay

7 Blended Hydraulic ASTM C 595 (AASHTO M 240) Type IS Type IP Type P Type I(PM) Type S Type I(SM) Portland blast-furnace slag Portland-pozzolan Portland-pozzolan Pozzolan-modified portland Slag Slag-modified portland Hydraulic ASTM C 1157 First performance specification for hydraulic s meet physical performance test requirements rather than prescriptive restrictions on ingredients or chemistry as in other specifications. Provides for six types Hydraulic Cement ASTM C 1157 Type GU Type HE Type MS Type HS Type MH Type LH General use High early strength Moderate sulfate resistance High sulfate resistance Moderate heat of hydration Low heat of hydration Cement specification ASTM C 150 (AASHTO M 85) portland s ASTM C 595 (AASHTO M 240) blended hydraulic s General purpose IS IP I(PM) I(SM) S, P Portland, ASTM C 1157Blended, and hydraulic Other Hydraulic GU s I Moderate heat of hydration II (moderate heat option) IS(MH) IP(MH) I(PM)(MH) I(SM)(MH) MH Cement Applications High early strength III HE Low heat Moderate of sulfate hydration resistance IV P(LH) LH II IS(MS) IP(MS) P(MS) I(PM)(MS) I(SM)(MS) MS High sulfate resistance V HS Resistance to alkali-silica reactivity (ASR) Low alkali option Low reactivity option Option R Special s White portland s, ASTM C 150 White masonry s, ASTM C 91 Masonry s, ASTM C 91 Mortar s, ASTM C 1329 Plastic s, ASTM C 1328 Expansive s, ASTM C 845 Oil-well s, API-10 Water-repellent s Regulated-set s I, II, III, V M, S, N M, S, N M, S, N M, S Type E-1(K), E-1(M), E-1(S) Shrinkage compensating concrete A, B, C, D, E, F, G, H Application White or colored concrete, masonry, mortar, grout, plaster, and stucco White mortar between masonry units Mortar between masonry units, plaster, and stucco Mortar between masonry units Plaster and stucco Grouting wells Tile grout, paint, and stucco finish coats Early strength and repair Special s with functional additions, ASTM C 595 (AASHTO M 240), ASTM C 1157 Finely ground (ultrafine) Calcium aluminate Magnesium phosphate Geopolymer Ettringite s Sulfur s Rapid hardening hydraulic Type VH, MR, GC Application General concrete construction needing special characteristics such as; water-reducing, retarding, air entraining, set control, and accelerating properties Geotechnical grouting Repair, chemical resistance and high temperature exposures Repair and chemical resistance General construction, repair, waste stabilization Waste stabilization Repair and chemical resistance General paving where very rapid (about 4 hours) strength development is required

8 Masonry Stucco using Masonry or Plastic Finely-Ground Type N for Type O and Type N mortars and with portland for mortar Types S and M Grout penetration in soil Type S for Type S mortar Type M for Type M mortar Expansive Cement Concrete Drinking Water Applications Chemical Compounds of Portland Cement

9 Hydration Products Portland Cement Compound Hydration Reactions (Oxide Notation) 2 (3CaO SiO 2 ) Tricalcium silicate 2 (2CaO SiO 2 ) Dicalcium silicate 3CaO Al 2 O 3 Tricalcium aluminate 2 (3CaO Al 2 O 3 ) Tricalcium aluminate 3CaO Al 2 O 3 Tricalcium aluminate + 11 H 2 O Water + 9 H 2 O Water 4CaO Al 2 O 3 Fe 2 O H 2 O and Tetracalcium Other Hydraulic Water aluminoferrite + 3 (CaO SO 3 2H 2 O) Gypsum + 6CaO Al 2 O 3 3SO 3 32H 2 O Ettringite + CaO H 2 O Calcium hydroxide = 3CaO 2SiO 2 8H 2 O Calcium silicate hydrate (C-S-H) = 3CaO 2SiO 2 8H 2 O Calcium silicate hydrate (C-S-H) + 26 H 2 O Water + 4 H 2 O Water + 12 H 2 O Water + 2 (CaO H 2 O) Calcium hydroxide + 3 (CaO H 2 O) Calcium hydroxide + CaO H 2 O Calcium hydroxide = 6CaO Al 2 O 3 3SO 3 32H 2 O Ettringite = 3 (4CaO Al 2 O 3 SO 3 12H 2 O) Calcium monosulfoaluminate = 4CaO Al 2 O 3 13H 2 O Tetracalcium aluminate hydrate = 6CaO Al 2 O 3 Fe 2 O 3 12H 2 O Calcium aluminoferrite hydrate SEMs of Hardened Cement Paste Type of portland SiO 2 Chemical composition, % Al 2 O 3 Fe 2 O 3 CaO MgO SO 3 Na 2 O eq I (mean) II (mean) III (mean) IV (mean) V (mean) 21.9 White (mean)

10 Type of portland I (mean) II (mean) Potential compound composition,% C 3 S C 2 S C 3 A 10 6 C 4 AF 8 11 Blaine fineness m 2 /kg Reactivity of Cement Compounds Nonevaporable Water Contents Hydrated compound C 3 S hydrate C 2 S hydrate Nonevaporable (combined) water content (g water/g compound) III (mean) IV (mean) V (mean) 54 White (mean) C 3 A hydrate C 4 AF hydrate Free lime (CaO) Scanning-Electron Micrograph of Powdered Cement Fineness of Cement ASTM C 204 ASTM C 115

11 Cement Fineness Particle Size Distribution Soundness Test ASTM C 151 (AASHTO T 107 ) Consistency of Cement Paste ASTM C 187 (AASHTO T 129) Vicat plunger Consistency of Mortar ASTM C 230 (AASHTO M 152) and ASTM C 1437 Flow table Setting Time ASTM C 191 (AASHTO M 131) Vicat apparatus

12 Setting Time ASTM C 266 (AASHTO M 154) Setting Times for Portland Mortar Cubes ASTM C 109 (AASHTO T 106) Gillmore needle Strength Development of Mortar Cubes Strength Development Type I and II Strength Development Type III, IV, and V

13 Heat of Hydration at 7 Days % of Type I Type I 100 Type II 99 Type II Moderate heat 75 Type III 106 Type IV 67 Type V 89 Heat Evolution Density of Cement Le Chatelier flask ( ASTM C 188 or AASHTO T 133) Helium pycnometer

14 Bulk Density Bulk density of varies between 830 kg/m 3 (52 lb/ft 3 ) and 1650 kg/m 3 (103 lb/ft 3 ). Thermal Analysis Thermogravimetric analysis (TGA) Differential Thermal Analysis (DTA) Differential Scanning Calorimetry (DSC) Differential Scanning Calorimetry Thermogram of a Cement Paste after (a) 15 min and (b) 24 h of Hydration Virtual Cement Testing Transporting Cement Packaging and Storage

15 Videos 1/7 Videos 2/7 Videos 3/7 Manufacturing Cement Cement Types Cement Hydration I Cement Hydration II Cement Hydration Soundness Videos 4/7 Videos 5/7 Videos 6/7 Setting Time False Set Cement Fineness Cement Strength Cement Hydration Simulation

16 Videos 7/7 Cement Delivery Storage