PORTLANDCEMENTnamedforlimestoneandchalkcliffs.Mostprevalentinconstruction.

CementPaste=cement+water
CPbondsaggregatestogether.Mortar=cementpaste+sand.Concrete=cement+water+sand+aggregates:7.5%15%PC,Water,6075%Agg.,115%Airvoids,Sometimes
admixtures.CEMENTPRODUCTION:Crushingandgrindingrawmaterials(CalciumOxideiscalcareousmaterial(limestone,chalk,oystershells))andSilica&Alumina
(argillaceousmaterial(clay,shale,blastfurnaceslug).Heatandmeltinakilnat14001650C(25003000F)toformcementclinker.GYPSUMdelaysthesettime,addgypsumto
clinkerandpulverizetofinepowder(7e11particles/lb)Smallparticlesproducelargesurfaceareaformorecompletehydration.RAWMATERIALS:65%Lime(Calcium)
[Limestone,shale],3%Iron[Clay,ironore,basicoxygenfurnaceslag],21%Silica[Clay,sand,shale,flyash],6%Alumina,and3%Gypsum(sulfate)toregulatesetting
(improvesshrinkageandstrengthdevelopment).ROTARYKILN(FURNACE):Inclinedandturnsat12rpm,Longforwetprocess,shortfordryprocess.Burningchangesraw
mixchemicallyintoclinker.Sulfate(gypsum)addedduringgrindingofclinker.Nogypsum,flashsettingoccurs.ClinkerwithgypsumisgroundintoPCandshipped.BallMill
forgrinding.C=Lime,F=FerricOxide,S=Silica,A=Alumina,H=Water,S=SulfurTrioxide.CHEMICALCOMPOSITION:90%:4560%TricalciumsilicateC3S,1530%
DicalciumsilicateC2S,612%TricalciumaluminateC3A,68%TetracalciumaluminoferriteC4AFMinorcompoundsincludeMagnesiumOxide,TitaniumOxide,
ManganeseOxide,SodiumOxide,PotassiumOxide.Alkalis(Na2O,K2O)reactwithsilicacausingdisintegrationandexpansion.Aluminaandironproducetricalciumaluminateand
tetracalciumtoreducetemperaturetoproducetricalciumsilicateSavemoney.REACTIONRATEC3A,C3S,C4AF,C2S(descending)
C3S
4255%
Earlystrengthdevelopment,responsibleforinitialset(70%reactsby28days)
C2S
1732%
Hydratesandhardensslowly.Contributestostrengthbeyond7days.(30%reactsby28days)
C3A
410%
Earlyheatgeneratedinhydration.Gypsumrequiredtoslowdown,Cementshigharenotresistanttosulfateattack.Littlecontributiontolong
termstrength
C4AF
815%
Governscolor(Lessthan1%inwhitecement)Littlecontributiontostrength
Classification
Characteristics
Applications
Type
C3S
C2S
C3A
C4A
Blain
TypeI
GeneralPurpose
FairlyhighC3Scontentforgoodearly
Generalconstruction(buildings,bridges,pavements,precast)
F
e
strengthdevelopment
Finen
TypeII
Moderatesulfateresist
LowC3Acontent(<8%)
Structuresexposedtosoilorwatercontainingsulfateions
ess
Type3
Highearlystrength
Groundmorefinely,slightlymoreC3S
Rapidconstruction,coldweather
TypeIV
Lowheatofhydration(slow
LowcontentC3S(<50%)andC3A
Massivestructuressuchasdams(rare)
I
55
19
10
7
370
react)
TypeV
Highsulfateresistance
VerylowC3A(<5%)
Exposuretohighlevelssulfate
II
51
24
6
11
370
White
Whitecolor
NoC4AF,lowMgO
Decorative(otherwisesimilartoTypeI)
III
56
19
10
7
540
Earlystrengthconcreteisalmostidenticaltonormalstrengthconcreteexceptthatthecementisfiner.Lowand
IV
28
49
4
12
380
highresistancecementuseslowconcentrationofC3AandC4AFtoreduceettringiteandmonosulfoaluminate
formation(expansiveagents)LowheatofhydrationhaslowconcentrationofC3SandC3Awhichlessenstheheat
V
38
43
4
9
380
produced.
Initialsetoccurswithdevelopmentofaweakskeletoninwhichcementgrainsareheldinplace.Finalset
skeletonbecomesmorerigid,cementparticleslockedinplace,spacingbetweencementgrainsincreasesduetovolumereduction.Methods:VicatNeedleandGillmoretest.False
setisexposedtohumidityduringstorage.Remixcementpaste.
TypeI:highwaypavements,Floors,bridges,buildings
TypeIIandV:Pipe,slabs,posts(sulfateresistant)
LowHeatCement:Largebridgepiers,Hooverdam
TypeIII:Coldweather,fasttrack,rapidform
HydrationofPortlandCement:chemicalreactionofcementwithwater
HARDENINGisnotsettingordrying
Drying=evaporation=nowater(stopsreaction,stopsstrengthgain)
Throughsolution:dominatesearlystageofhydration
Topochemical:solidstatereactionatcementsurface
Hydrationrate:aluminates>silicatesneedsbalance
Gypsumusedtoslowreactiondown.
CSH(calciumsilicatehydrate)isverystronganddenseCH(CalciumHydroxide)isweakandsoluble
CSHisprinciplehydrationproduct(5060%ofvolymeofsolidsinhydratedconcretepaste.Noncrystalline.Poorlydefined,hardtodefineC/Sratio=1.52.0(strongand
durable,highsurfacearea)Mostimportanthydrationproduct.CH:2025%volume,pH=1212.5(highlyalkaline)Crystalline(largeplatelikeprisms)lowstrength,Weaklink,
watersoluble,rducedbyusingpozzolans.CALCIUMSULFOALUMINATEHYDRATES:1520%ofvolume(littlecontributiontostrength)Affects:Setting,rateofhardening,
longtermstability.Twomainforms:Ettringite:needleshapedMonosulfatehydrate:platelikecrystals(susceptibletosulfateattack)
WATERCEMENTRATIO:mostimportantpropertyofhydratingcement.Waterneededforhydration,w/c=0.220.25
Extrawaterisneededforworkability,butcausesvoidsDecreasesstrength,durability,bondbetweensuccessivelayers,bondbetweenconcreteandrebar,increasespermeability
andvolumechangefromwettinganddrying.VOIDSinHydrated:Interlayerhydrationspace(spacebetweenlayersofCSH,doesntaffectstrength/Affectsporosityandamount
ofshrinkage(ifRHislessthan11%)Capillaryvoids(Dependentoninitialwaterparticleseparation,governedstronglybyw/cratio(Goodhydration/lowwc:voids1050nm)
(Poorhydration,highwc:voidsbetween35mm)(Capillaryvoidsgreaterthan50nmreducestrengthTrappedvoids(largepocketscausedbyhandlinganddecreasestrength,
increasepermeability)andEntrainedair(microscopicbubblescausedbyadmixtures(increasesdurabilityexpansiveagentswillfillupvoidsandinternalstressesremain
constant)
SPECIFICGRAVITYGCEMENT=3.15Measuredforcementparticleswithoutairvoids.Bulkunitweightishighlyvariable.Cementnotmeasuredbyvolume.
MIXING:someimpuritiesallowed.Average7daycomp.strengthofmortarcubes>=90%ofstrengthofthosemadewithfreshwater.
ADMIXTURES:
Airentrainer
Producetinydispersedairbubbles(waterexpandsasfreezes)Improveworkability,decreasestrengthby20%butcompensatedwithloww/c
Waterreducer
Increasesmobilityofcementparticles,improvesworkability(slumptest)PLASTICIZER:increaseslumpfrom39reducewaterby1230%
Retarder
Delayorretardinitialset(increasesettime)hotweatherforlowheatofhydration,longhaultime,specialfinishes,reduceearlystrength,
doesntreducefinalsettimemuch
Hydrationcontroller
Abilitytostop&reactivehydrationprocessSTABILIZER:stopsupto72hoursACTIVATOR:reestablishes.Extendsreadymix,longhaul
Accelerator
Speeduporaccelerateinitialandfinalset(decreasesettime).Reduceamountoftime,reducecuringtime,increaserateofstrength,plugleaks
underhydraulicpress.(Calciumchloridemostcommon
SupplementaryCementingMaterial(SCM)contributetohardenedpropertiesthroughHydraulic(Cementing)and/orPozzolanicactivity.
MostSCMsarebyproducts,byusing,lessPortlandcementisused.Generallylowerheatofhydration,increasestrength,reducaecalciumhydroxide,reducepermeability,mitigate
effectsofASR.
Pozzolanisasiliceousofaluminasiliceousmaterialwhichopsseseslittleornocementitiousvaluebutinfinelydividedformandinpresenceofmoisturewillchemicallyreact
withCaOHatorginarytempstoformcompoundspossessingcementitiousproperties.
SCMs:Flyash(ClassC,ClassF),Metakaolin(calcinedclay),Silicafume,Slagcement,calcinedshale.
Cementmixesrequireexcessmoisture.

HEATOFHYDRATIONCURVE(rapidheat,dormant,acceleration/deceleration,steadyDecreasestrength,increaseperm.
Differencebetweenhydrauliccementandpozzolan:
Silicafumeincreasesstrength,decreaseworkability.

Slagcement:3070%ofcementitiousmaterial(50%istypicallylimitfor
mostapps)Verydarkinitially(3545%CaO,3238%Silica,816%)Slagcementisnotapozzolan(latenthydraulicmaterial).
Silicafume:verypozzolanicmaterialcomposedofamorphoussilica.Smokebyproduct.Powder,waterbasedslurrypelletized,densified(mostcommoninUS,particlesare
agglomerated.Benefits:finenesscontributestoearlyandlateagestrength.Idealtoproduceconcretewithlowperm,highstrength..
PORTLANDCEMENTCONCRETEQualitydependsonchem.Comp.,agg,water,admix,proportions,mix,transport,hydration,placing,vibrating,curing.
MixDesign:Volumetric:1.Strengthrequirements2.DetermineW/C3.Estimatecoarseagg.Mass4.Airentrainmentrequirements5.Workabilityneeds6.Estimatewatercontent
7.Determinecementcontentrequirements.8.Evaluateadmixtureneeds9.Estimatefineagg.Mass10.Determinemoisturecorrections11.Trialmix.
Step1.fcstrengthofconcretefcraveragestrengthformixdesignfcr=fc+1.34s(whens<500psi)fcr=fc+2.33s500(whens>500psi)(s=std.dev.)
1/5minimumclearistance(middepth),min.clearspace(betweenreinforcement/tendons),min.clearspace(betweenreinforcementandform)usesmallestformin.
CA:givenFMandDryroddedunitweigh,Nom.MaxMassCA=DryUnit*(NominalmaxvsFM)multiplyby27togettoyd^3.CAadjustment(increaseCAvol.by10%to
reduceslump(pavementconstruction).decreaseby10%toincreaseslump(placementforpumping)
Airentrainmentrequirements.GivenNom.Maxandexposure,usetable.Workability:
WaterContent:Table7.8forangularshapedCAforgivenslump,dependsonmax.sizeandshapeofagg.CEMENTCONTENTW cement=Wwater/(w/c)
FA:Vconcrete=Vwater+Vcement+Vair+VCA+VFA(assumeVconcrete=1eitherm^3oryd^3ofconcrete)soVFA=1or27
Vwater=weight/62.4Vcement=weight/(3.15???*62.4)Vair=%*27VCA=weight/(BulkSG???*62.4)VFA=formulaaboveMFA=VFA*2.705?*62.4
MoistureCorrections:CA:Volume*1.01for1%MC,FA:Volume*1.04(if4%MC)WaterReducefreewater:ApproxmixwaterFA(MCAbs)CA(MCAbs)
ORDER:Mixdesign,trialmixesandtesting,batching,mixing,transporting,pouring,vibrating,initialset,finishing,finalset,curing,maintenance.
Mixuntiluniformappearance.Readymixed(centralplant,deliveredinagitatortruck(26rpm)Shrinkmixed(partiallymixedinplant(416rpm)Truckmixed(416rpm)
TestSlumpandAirContentonsite.Preparecylindersandbeams.Slumptest(3layers,25rods)(measuresworkability)Aircontentmethods:Pressure,Volumetric,Gravimetric,
ChaseAirIndicatorCylinders6X12standards,3lifts,rod25times.Cureonsite24hours(Temp,humidity)
Finishingconcrete(smoothingandimprintingsurfacewithdesiredtexture.Mustbecompletebeforefinalset.
Curingconcrete:maintainmoistureandtemperatureintheconcretetopromotecontinuedhydrationandstrengthgain.Hydrationwillresumeifcuringisstoppedandresumed.
CURINGAFFECTS:durability,strength,watertightnes,abrasionresistance,volumetricstability,resistancetofreezingandthawing,resistancetodeicing.
CuringApproaches:Maintainingpresenceofwaterinconcrete.SealtheSurfacesomixwatercantescape.Heatandadditionalmoisture.
Maintainpresenceofwater:Waterperiodically.Providescooling.
Methods:Ponding:smallerjobsflatwork(floorsandpavement)andlabSprayingorfogging:expensive,alotofwaterWetcoverings:burlap,cotton,rugs.
Sealsurfaceimperviouspaperorplasticsheetsmembraneformingcompounds,leaveformsinplaceHEAT:insulate,steam(goodforearlystrengthgainandinfreezing
weather)Heatingcoils,electricallyheatedformsorpads.
PropertiesofHardenedconcrete:1.EarlyVolumeChange(plasticshrinkage,dryingshrinkage,wetcont.slightsweeling,curlingfromnonuniformdrying2.Creep(longterm,
gradualdeformationsmallstainbuttransfersloadfromconcretetosteelinbeams.3.Permeabilityw/c=0.30.7,coefofperminc.to1000causedbyvoids.Allowswaterand
chemicalstopenetrate,reducesdurab.Andresisttofrost.4.StressStrainrelat.Increasew/cdecreasesstrengthandstiffness.Strongerconcretemorebrittle.
Compressivefctest.Mostcommontest.Cylinderscastin3layers7day=60%of28dayand28day=80%ultimate.Typicalcomp.=30006000psi.
Ecchordmodulus20006000ksi)Poissonsrationn=0.110.21Ec=4731sqrt(fc)MPaEc=57000sqrt(fc)psi6inchdiameterby12inchlong
SplitTensiontestT=2P/(piLd)FlexuralStrength(R=Mc/I=PL/bd^2
Nondestructive:Rebound(SchmidtHammer)Penetrationresistance(Windsorprobe)UltrasonicPulseVelocity,MaturityTest.
Alt.Conc.SelfConsolidatingConcrete,FlowableFill,Shotcrete,LightweightConcrete(suchasfloatingconcrete(ASCEconcretecanoe)costsmorebutneedlessbecauseof
reducedweight.Heavyweightusedformassivewallsfornuclear,medical,etc.Highstrength:6000psistrength,veryloww/csuperplasticizersupto20000psi)Polymer
Concrete(quicksetof1hrorsuperhighstrength(>20000psi)Shrinkagecompensating.Fiberreinforcedconcrete,Rollercompactedconcrete,Selfhealingconcreate,High
performance.
W/CTable7.1andupdependingonrequirements,CoarseAgg.Table7.5AirContent7.6,Workability7.7WaterContent7.8
ConcreteCuring:Ponding/Immersion,Spraying/Fogging,WetCoverings,ImperviousPapers,MembraneExtrawaterleavesairvoids.Thirdpointloadingvscenterpoint
loadingRequiredisgreatestthanspecifiedstrength.