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MATERIALS TESTING AND QUALITY CONTROL SEMINAR for Philippine Rural Development Program January 12 – 16, 2015 BY ENG’R. ABNER GEORGE S. LOMIBAO THE UNIVERSAL CONSTRUCTION MATERIALS INSPECTION AND LABORATORY
POZZOLANIC PHILS, INC.
TECHNICAL STANDARD SPECIFICATIONS
DEPARTMENT OF PUBLIC WORKS AND HIGHWAYS (DPWH) STANDARD SPECIFICATIONS OF HIGHWAYS , BRIDGES , AND AIRPORTS, 1995 ASTM (AMERICAN SOCIETY OF TESTING MATERIALS) AASHTO (AMERICAN ASSOCIATION OF STATE HIGHWAY TRANSPORTATION OFFICIAL) ACI (AMERICAN CONCRETE INSTITUTE)
TECHNICAL STANDARDS SPECIFICATIONS
NRMCA (NATIONAL READY MIXED CONCRETE ASSOCIATION) AI (ASPHALT INSTITUTE) BS (BRITISH STANDARDS) DIN (EUROPEAN STANDARDS
AGGREGATES THE TERMS “ CONCRETE AGGREGATES”, ROCK AGGREGATES OR GRAVEL AND SAND REFERS TO THE METRIC OR PRINCIPAL STRUCTURE OF CONRETE AND ASPHALT , CONSISTING OF RELATIVELY INERT AND COARSE MATERIAL USUALLY STONE
AGGREGATES Coarse Aggregates – are predominantly retained on the No. 4 (4.76mm) Sieve Fine Aggregates – are aggregates passing the 3/8 inch (9.50mm) Sieve and predominantly retained on the No. 200 Sieve
AGGREGATES I. BY TYPE OF PROCESS • SALANDRA METHOD (Manual Screening) – River bed aggregates • MECHANICAL SCREENING – Processed River Bed Aggregates • MECHANICAL CRUSHING/SCREENING –Quarried Aggregates (Mountain Quarry)/100 % crushed
AGGREGATES II. COMMERCIAL FORMS OR SIZES • 1 ½ “ (37.50 MM) MSA OR G-1
• ¾” (19.00MM) MSA • ½” (12.50MM) MSA
• 3/8” (9.50mm) MSA OR PEA GRAVEL • S-1 (CRUSHED OR MANUFACTURED SAND)
Properties of Aggregates • Hardness –to resist surface wear by rubbing and friction • Strength and Toughness – to resist weathering without deterioration. • Cleanness-free from excessive amounts of deleterious substances such as clay, silt, coal, lignite, and organic matter. • Gradation – particle size distribution
AGGREGATES II. COMMERCIAL FORMS OR SIZES • WASHED SAND
• BALLAST AGGREGATES • EMBANKMENT MATERIALS
• SUB BASE COURSE MATERIALS • BASE COURSE MATERIALS
TEST METHODS FOR AGGREGATES I. COARSE AGGREGATES • • • • • • •
GRADATION ANALYSIS % WASH SPECIFIC GRAVITY AND ABSORPTION UNIT WEIGHT ABRASION LOSS SOUNDNESS LOSS CLAY LUMPS AND FRIABLE PARTICLES
TEST METHODS FOR AGGREGATES II. FINE AGGREGATES • • • • • • •
GRADATION ANALYSIS % WASH SPECIFIC GRAVITY AND ABSORPTION UNIT WEIGHT SOUNDNESS LOSS MORTAR STRENGTH ORGANIC IMPURITIES
ASTM C-33 GRADING REQUIREMENTS FOR AGGREGATES No
Nominal Size Openings
4 inch (100 mm)
3 1/2 inch (90m m)
3 inch (75 mm)
2 1/2 inch (63mm)
2 inch (50m m)
11/2 (37.50 mm)
1 inch (25.0m m)
¾ inch (19.0 mm)
½ inch (12.50 mm)
3/8 inch (9.50 mm)
No. 4 (4.75m m)
No. 8 (2.36mm)
No. 16 (1.18 mm)
No. 30 (0.60 mm)
No.50 (0.30 mm)
No.10 0 (0.15 mm)
25 60
10 30
2 - 10
Amounts Finer than Each Laboratory Sieve (Square Openings), Weight Percent 1
31/2 to 1 ½ (90 to 37.50mm)
2
2 ½ to 1 ½ (63 to 37.50mm)
3
357
100
90 100
25 - 60
100
0 - 15
0-5
0-5
90 - 100
35 70
0 - 15
2 to 1 inch (50 to 4.75mm)
100
90 100
35 - 70
2 inches to No. 4 (50 to 4.75mm)
100
95 100
4
1 ½ to ¾ inch (37.5 to 19.0mm)
100
90 100
467
1 ½ to No. 4 (37.5 to 4.75mm)
100
95- 100
0 - 15
0-5
35 - 70
10 30
20 - 55
0-5
0 - 15
0-5
35 70
10 30
5
1 to ½ inch (25 to 12.50mm)
100
90 100
20 55
0 - 10
0-5
56
1 to 3/8 inch (25 to 9.50mm)
100
90 – 100
40 85
10 40
015
57
1 to No. 4 (25 to 4.75mm)
100
95 100
6
¾ to 3/8 inch (19.0 to 9.50mm)
100
90 100
67
¾ to No. 4 (19.0 to 4.75mm)
100
90 100
7
½ to No.4 (12.5 to 4.75mm)
8
3/8 to No. 8 (9.50 to 2.36mm)
Sand
Fine Aggregates
25 60
100
20 55
0-5
0-5
0 - 10
0-5
015
0-5
20 55
0 - 10
0-5
90 100
40 70
0 - 15
0-5
100
85 100
10 - 30
0 - 10
0-5
100
95 100
80 - 100
50 85
Mineral Aggregates Blending Sieve Size
AGG. # 1 AGG. # 1 1½” 3/4” MSA, % MSA, % Passing Passing
Blending Proportion
Results
Required Specificatio ns
AGG#1 60%
AGG #2 40%
% Passing
% Passing
2” (50mm)
100
100
60
40
100
100
1 ½” (37.50mm)
95
100
57
40
97
95 – 100
1” (25mm)
35
100
21
40
61
¾” 19mm
10
96
6
38
44
35 – 70
3/8” (9.5mm)
3
40
2
16
18
10 – 30
#4 (4.75mm)
1
5
0.60
2
2.6
0-5
#8 (2.36mm)
1
3
0.60
1
1.6
AGGREGATES FUNCTION OF AGGREGATES
PROVIDE ECONOMICAL FILLER REDUCE SHRINKAGE IMPROVE ABRASION RESISTANCE REDUCE OR INCREASE UNIT WEIGHT
PORTLAND CEMENT
PORTLAND CEMENT It is the product obtained by finely pulverizing clinker which is produced by calcining to incipient fusion a properly proportioned mixture of argillaceous and calcareous materials.
RAW MATERIALS FOR PORTLAND CEMENT ARGILLACEOUS MATERIALS ( At 1500ºC or 2700ºF) • SILICA • ALUMINA • IRON OXIDE
CALCAREOUS MATERIALS • LIME
DIFFERENT TYPES OF PORTLAND CEMENT TYPE I USED FOR GENERAL CONCRETE CONSTRUCTION TYPE II USED WHEN MODERATE HEAT OF HYDRATION AND MODERATE SULFATE RESISTANCE IS NEEDED CHARACTERIZED BY LOW PERCENTAGE OF TRICALCIUM SULFATE. TYPE III USED FOR HIGH EARLY STRENGTH CONCRETE. IT HAS A HIGH PERCENTAGE OF C3S.
DIFFERENT TYPES OF PORTLAND CEMENT TYPE IV USED WHEN LOW HEAT OF HYDRATION IS NEEDED LIKE THE CONSTRUCTION OF MASSIVE STRUCTURES LIKE DAM. IT IS CHARACTERIZED BY HIGH PERCENTAGE OF C2S AND C4AF AND LOW PERCENTAGE OF C3S AND C3A. TYPE V USED WHEN HIGH SULFATE RESISTANCE IS NEEDED.
PHYSICAL COMPOUND OF PORTLAND CEMENT TRI-CALCIUM SILICATES (C3S) Controls the strength development of cement
DI--CALCIUM SILICATE (C2S) Controls the strength development of cement
TRI-CALCIUM ALUMINATE (C3A) Controls the volume change in concrete
TETRA CALCIUM ALUMINA FERRITE (C4AF) Reduces the clinkering temperature during manufacturing process.
Approximate composition and fineness ranges for the standard types of portland cements ASTM TYPE
TRICALCIUM SILICATE (C3S), %
DICALCIUM SILICATE (C2S), %
TETRACAL CIUM ALUMINAT E(C3A)
TETRACAL CIUM ALUMINA FERRITE (C4AF)
AIR PERMEABI LITY SPECIFIC SURFACE, M²/KG
I
41 - 65
10 – 30
0 - 17
6 – 18
300 - 400
II
35 - 60
15 – 35
0-8
6 – 18
280 - 380
III
45 - 70
10 – 30
0 - 15
6 – 18
450 - 600
IV
20 - 30
50 – 55
3-6
8 - 15
280 - 320
V
40 - 60
15 - 40
0-5
10 - 18
290 - 350
PHYSICAL COMPOUND OF PORTLAND CEMENT
GYPSUM Retards the setting time of cement (usually added during the pulverizing stage)
TEST METHODS FOR PORTLAND CEMENT 1.
Compressive Strength of Hydraulic Cement Mortar using 2” x 2” Cube
2.
Normal Consistency
3.
Time of Setting
4.
Fineness / Blend
TEST METHODS FOR PORTLAND CEMENT 1.
Chemical Analysis
Aluminum Oxide Ferric Oxide Magnesium Oxide Sulfur Trioxide Silicon Dioxide Loss on Ignition Insoluble Residue Free Lime
TEST METHODS FOR PORTLAND CEMENT 6.Tri-calcium Silicate (C3S) 7. Di-calcium Silicate (C2S) 8. Tri-calcium Aluminate (C3A) 9.Tetra-calcium Alumina-Ferrite (C4AF)
CEMENT SAMPLING AND TESTING SCHEDULE Sample Location
Sample
Test
Frequency
1
Limestone being fed to raw mill
COз Content
1 per shift
2
Clay being fed to raw mill
H2O Content (If wet process) Percent finer than 75µm (No. 200) Sieve
1 per shift
3
Raw mill discharge and blending tank
CO3 Content H2O Content (if wet process)
2 per shift 2 per shift
4
Kiln feed (from blending silo or tank)
CO3 Content H2O Content (If wet process) Percent finer than 300µm (No. 50) Sieve Percent finer than 75µm (No. 200) Sieve
2 per shift 2 per shift 2 per shift 2 per shift
5
Clinker
Free CaO, Complete chemical analysis
2 per shift 1 per day
6
Cement
Free CaO, SOз Fineness (Air permeability) Complete chemical analysis Complete physical tests
1 per shift 4 per shift 4 per shift 1 per day 1 per day
7
Cement
Retain sample for 120 days
MISCELLANEOUS OR SPECIAL PURPOSE Type
Description or purpose
ASTM Specification
White Cement
White architectural cement
None
Buff Cement
Buff architectural cement
C 845
Expansive cement Type E-1
Expansive hydraulic cement
None43 43 43
Regulated set cement
For use where rapid setting and moderate early strength development are needed
None
Oil well cements Types A through H, J
Hydraulic cements used for oil well casings and linings
None
Masonry cement types M, S, and N
For use in mortar for masonry, brick, and block construction, and stucco
C 91
Plastic cement
For use in exterior stucco applications
None
High Alumina Cement
For use in refractory, high early strength, and moderately acid resistant concretes
None
Block cement
For use in making concrete masonry units
None
Magnesium phosphate cement
Non portland cement for use where rapid hardening is needed
None
ADMIXTURE A material other than water, aggregates and portland cement (including air entraining portland cement and portland blast furnace slag cement) that is used as an ingredient of concrete and is added to the batch immediately before or during its mixing.
MINERAL ADMIXTURE
MINERAL ADMIXTURES
FLY ASH Fly ash is also known as pulverized fuel ash (pfa) which is a pozzolanic material which is capable of combining with lime to form cementitious compounds.
MINERAL ADMIXTURES TWO TYPES OF FLY ASH 1. TYPE F Produced when anthracite, bituminous or sub- bituminous coal is burned. Low lime content.
2. TYPE C Normally comes from lignite or subbituminous coal.High lime content.
MINERAL ADMIXTURES ADVANTAGES OF FLY ASH 1. 2. 3. 4. 5. 6. 7. 8.
REDUCE HEAT OF HYDRATION IMPROVE WORKABILITY OF FRESH CONCRETE DECREASE PERMEABILITY INCREASE DURABILITY INCREASE STRENGTH REDUCE CHLORIDES AND SULPHATES ATTACK REDUCE BLEEDING AND SEGREGATION REDUCE AGGREGATE ALKALI REACTION (AAR)
MINERAL ADMIXTURES FLY ASH DOSAGE IS ABOUT 5 TO 40% BY MASS OF THE CEMENT
ASTM C-618 TEST REQUIREMENTS FOR FLY ASH
CHEMICAL SO3 MOISTURE CONTENT LOSS ON IGNITION
PHYSICAL FINENESS + 325 MESH POZZOLANIC ACTIVITY/CEMENT WATER REQUIREMENT AUTOCALVE EXPANSION
MINERAL ADMIXTURES
SILICA FUME It is the by product of the manufacture of silicon, ferrosilicon, from quartz and carbon in electric arc furnaces.
MINERAL ADMIXTURES Mineral Admixtures Silica Fumes A very fine particles with size smaller than one micrometer (average diameter is 0.1 micrometer) or 100 times smaller than the average cement particle. Specific Gravity – 2.2 to 2.5 Normal content – 5 to 15% of the portland cement content Bulk density of 160 to 320 kg/m³, densified
MINERAL ADMIXTURES ADVANTAGES OF SILICA FUME 1. 2. 3. 4. 5. 6. 7. 8.
ACHIEVE HIGH STRENGTH INCREASE DURABILITY IMPROVE WORKABILITY INCREASE COHESION DECREASE BLEEDING AND SEGREGATION REDUCE HEAT OF HYDRATION REDUCE CHLORIDES AND SULPHATES ATTACK REDUCE PERMEABILITY
MINERAL ADMIXTURES BLAST FURNACE SLAG It is commonly known as ground granulated blast furnace slag (GGBFS) which is the by product of the production of iron
MINERAL ADMIXTURES
BLAST FURNACE SLAG The non metallic product consisting essentially of silicates and alumino-silicates of calcium and of other bases that is developed in a molten condition simultaneously with iron in a blast furnace.
GRANULATED BLAST FURNACE SLAG The glassy granular material formed when molten blast furnace slag is rapidly chilled as bay immersion in water.
MINERAL ADMIXTURES
BLAST FURNACE SLAG Main constituents arw calcium, magnesium, silicon, aluminum, and oxygen. Very effective with cements with higher contents of alkali and C3A and higher fineness. It must conform to the requirements of ASTM C 989
MINERAL ADMIXTURES ADVANTAGES OF BLAST FURNACE SLAG 1. 2. 3. 4.
INCREASE STRENGTH IMPROVE RESISTANCE TO CHEMEICAL ATTACK IMPROVE RESISTANCE TO BLEEDING AND SEGREGATION DECREASE PERMEABILITY
CHEMICAL ADMIXTURE
TYPES OF CHEMICAL ADMIXTURES ASTM C –494
-Chemical Admixtures for Concrete
TYPE A
- Water reducing Admixtures
TYPE B
- Retarding Admixtures
TYPE C
- Accelerating Admixtures
TYPE D
- Water Reducing and Retarding Admixtures
TYPES OF CHEMICAL ADMIXTURES ASTM C – 494
- Chemical Admixtures for Concrete
TYPE E
- Water Reducing and Accelerating Admixtures
TYPE F
- Water Reducing, High Range Admixtures
TYPE G
- Water Reducing , High Range Retarding Admixtures
ASTM-260
-Air Entraining Admixtures For Concrete
Chemical Admixtures for Concrete Chemical Admixtures Raw Materials Lignosulfonates Hydroxylated carboxylic acids Carbohydrates Melamine Napthalene condensates Organic and inorganic accelerators
TEST METHOD FOR CHEMICAL ADMIXTURES PH NO. SPECIFIC GRAVITY SOLID CONTENT CHEMICAL ANALYSIS
USES OF ADMIXTURES
Usually an admixture is used to modify the properties of the concrete in such a way to make it more suitable for the work in hand such as: Improvement of workability
Acceleration of the rate of strength development at early age.
Retardation of initial stiffening or too rapid.
Retardation or reduction of heat evolution.
USES OF ADMIXTURES
Increase in bond to steel reinforcement.
Reduction in bleeding.
Increase in durability.
Increase and decrease in the permeability to liquid.
Production of cellular concrete.
POZZOLANIC PHILS, INC.
TECHNICAL STANDARD SPECIFICATIONS
DEPARTMENT OF PUBLIC WORKS AND HIGHWAYS (DPWH) STANDARD SPECIFICATIONS OF HIGHWAYS , BRIDGES , AND AIRPORTS, 1995 ASTM (AMERICAN SOCIETY OF TESTING MATERIALS) AASHTO (AMERICAN ASSOCIATION OF STATE HIGHWAY TRANSPORTATION OFFICIAL) ACI (AMERICAN CONCRETE INSTITUTE)
TECHNICAL STANDARDS SPECIFICATIONS
NRMCA (NATIONAL READY MIXED CONCRETE ASSOCIATION) AI (ASPHALT INSTITUTE) BS (BRITISH STANDARDS) DIN (EUROPEAN STANDARDS
AGGREGATES THE TERMS “ CONCRETE AGGREGATES”, ROCK AGGREGATES OR GRAVEL AND SAND REFERS TO THE METRIC OR PRINCIPAL STRUCTURE OF CONRETE AND ASPHALT , CONSISTING OF RELATIVELY INERT AND COARSE MATERIAL USUALLY STONE
AGGREGATES Coarse Aggregates – are predominantly retained on the No. 4 (4.76mm) Sieve Fine Aggregates – are aggregates passing the 3/8 inch (9.50mm) Sieve and predominantly retained on the No. 200 Sieve
AGGREGATES I. BY TYPE OF PROCESS • SALANDRA METHOD (Manual Screening) – River bed aggregates • MECHANICAL SCREENING – Processed River Bed Aggregates • MECHANICAL CRUSHING/SCREENING –Quarried Aggregates (Mountain Quarry)/100 % crushed
AGGREGATES II. COMMERCIAL FORMS OR SIZES • 1 ½ “ (37.50 MM) MSA OR G-1
• ¾” (19.00MM) MSA • ½” (12.50MM) MSA
• 3/8” (9.50mm) MSA OR PEA GRAVEL • S-1 (CRUSHED OR MANUFACTURED SAND)
Properties of Aggregates • Hardness –to resist surface wear by rubbing and friction • Strength and Toughness – to resist weathering without deterioration. • Cleanness-free from excessive amounts of deleterious substances such as clay, silt, coal, lignite, and organic matter. • Gradation – particle size distribution
AGGREGATES II. COMMERCIAL FORMS OR SIZES • WASHED SAND
• BALLAST AGGREGATES • EMBANKMENT MATERIALS
• SUB BASE COURSE MATERIALS • BASE COURSE MATERIALS
TEST METHODS FOR AGGREGATES I. COARSE AGGREGATES • • • • • • •
GRADATION ANALYSIS % WASH SPECIFIC GRAVITY AND ABSORPTION UNIT WEIGHT ABRASION LOSS SOUNDNESS LOSS CLAY LUMPS AND FRIABLE PARTICLES
TEST METHODS FOR AGGREGATES II. FINE AGGREGATES • • • • • • •
GRADATION ANALYSIS % WASH SPECIFIC GRAVITY AND ABSORPTION UNIT WEIGHT SOUNDNESS LOSS MORTAR STRENGTH ORGANIC IMPURITIES
ASTM C-33 GRADING REQUIREMENTS FOR AGGREGATES No
Nominal Size Openings
4 inch (100 mm)
3 1/2 inch (90m m)
3 inch (75 mm)
2 1/2 inch (63mm)
2 inch (50m m)
11/2 (37.50 mm)
1 inch (25.0m m)
¾ inch (19.0 mm)
½ inch (12.50 mm)
3/8 inch (9.50 mm)
No. 4 (4.75m m)
No. 8 (2.36mm)
No. 16 (1.18 mm)
No. 30 (0.60 mm)
No.50 (0.30 mm)
No.10 0 (0.15 mm)
25 60
10 30
2 - 10
Amounts Finer than Each Laboratory Sieve (Square Openings), Weight Percent 1
31/2 to 1 ½ (90 to 37.50mm)
2
2 ½ to 1 ½ (63 to 37.50mm)
3
357
100
90 100
25 - 60
100
0 - 15
0-5
0-5
90 - 100
35 70
0 - 15
2 to 1 inch (50 to 4.75mm)
100
90 100
35 - 70
2 inches to No. 4 (50 to 4.75mm)
100
95 100
4
1 ½ to ¾ inch (37.5 to 19.0mm)
100
90 100
467
1 ½ to No. 4 (37.5 to 4.75mm)
100
95- 100
0 - 15
0-5
35 - 70
10 30
20 - 55
0-5
0 - 15
0-5
35 70
10 30
5
1 to ½ inch (25 to 12.50mm)
100
90 100
20 55
0 - 10
0-5
56
1 to 3/8 inch (25 to 9.50mm)
100
90 – 100
40 85
10 40
015
57
1 to No. 4 (25 to 4.75mm)
100
95 100
6
¾ to 3/8 inch (19.0 to 9.50mm)
100
90 100
67
¾ to No. 4 (19.0 to 4.75mm)
100
90 100
7
½ to No.4 (12.5 to 4.75mm)
8
3/8 to No. 8 (9.50 to 2.36mm)
Sand
Fine Aggregates
25 60
100
20 55
0-5
0-5
0 - 10
0-5
015
0-5
20 55
0 - 10
0-5
90 100
40 70
0 - 15
0-5
100
85 100
10 - 30
0 - 10
0-5
100
95 100
80 - 100
50 85
Mineral Aggregates Blending Sieve Size
AGG. # 1 AGG. # 1 1½” 3/4” MSA, % MSA, % Passing Passing
Blending Proportion
Results
Required Specificatio ns
AGG#1 60%
AGG #2 40%
% Passing
% Passing
2” (50mm)
100
100
60
40
100
100
1 ½” (37.50mm)
95
100
57
40
97
95 – 100
1” (25mm)
35
100
21
40
61
¾” 19mm
10
96
6
38
44
35 – 70
3/8” (9.5mm)
3
40
2
16
18
10 – 30
#4 (4.75mm)
1
5
0.60
2
2.6
0-5
#8 (2.36mm)
1
3
0.60
1
1.6
AGGREGATES FUNCTION OF AGGREGATES
PROVIDE ECONOMICAL FILLER REDUCE SHRINKAGE IMPROVE ABRASION RESISTANCE REDUCE OR INCREASE UNIT WEIGHT
PORTLAND CEMENT
PORTLAND CEMENT It is the product obtained by finely pulverizing clinker which is produced by calcining to incipient fusion a properly proportioned mixture of argillaceous and calcareous materials.
RAW MATERIALS FOR PORTLAND CEMENT ARGILLACEOUS MATERIALS ( At 1500ºC or 2700ºF) • SILICA • ALUMINA • IRON OXIDE
CALCAREOUS MATERIALS • LIME
DIFFERENT TYPES OF PORTLAND CEMENT TYPE I USED FOR GENERAL CONCRETE CONSTRUCTION TYPE II USED WHEN MODERATE HEAT OF HYDRATION AND MODERATE SULFATE RESISTANCE IS NEEDED CHARACTERIZED BY LOW PERCENTAGE OF TRICALCIUM SULFATE. TYPE III USED FOR HIGH EARLY STRENGTH CONCRETE. IT HAS A HIGH PERCENTAGE OF C3S.
DIFFERENT TYPES OF PORTLAND CEMENT TYPE IV USED WHEN LOW HEAT OF HYDRATION IS NEEDED LIKE THE CONSTRUCTION OF MASSIVE STRUCTURES LIKE DAM. IT IS CHARACTERIZED BY HIGH PERCENTAGE OF C2S AND C4AF AND LOW PERCENTAGE OF C3S AND C3A. TYPE V USED WHEN HIGH SULFATE RESISTANCE IS NEEDED.
PHYSICAL COMPOUND OF PORTLAND CEMENT TRI-CALCIUM SILICATES (C3S) Controls the strength development of cement
DI--CALCIUM SILICATE (C2S) Controls the strength development of cement
TRI-CALCIUM ALUMINATE (C3A) Controls the volume change in concrete
TETRA CALCIUM ALUMINA FERRITE (C4AF) Reduces the clinkering temperature during manufacturing process.
Approximate composition and fineness ranges for the standard types of portland cements ASTM TYPE
TRICALCIUM SILICATE (C3S), %
DICALCIUM SILICATE (C2S), %
TETRACAL CIUM ALUMINAT E(C3A)
TETRACAL CIUM ALUMINA FERRITE (C4AF)
AIR PERMEABI LITY SPECIFIC SURFACE, M²/KG
I
41 - 65
10 – 30
0 - 17
6 – 18
300 - 400
II
35 - 60
15 – 35
0-8
6 – 18
280 - 380
III
45 - 70
10 – 30
0 - 15
6 – 18
450 - 600
IV
20 - 30
50 – 55
3-6
8 - 15
280 - 320
V
40 - 60
15 - 40
0-5
10 - 18
290 - 350
PHYSICAL COMPOUND OF PORTLAND CEMENT
GYPSUM Retards the setting time of cement (usually added during the pulverizing stage)
TEST METHODS FOR PORTLAND CEMENT 1.
Compressive Strength of Hydraulic Cement Mortar using 2” x 2” Cube
2.
Normal Consistency
3.
Time of Setting
4.
Fineness / Blend
TEST METHODS FOR PORTLAND CEMENT 1.
Chemical Analysis
Aluminum Oxide Ferric Oxide Magnesium Oxide Sulfur Trioxide Silicon Dioxide Loss on Ignition Insoluble Residue Free Lime
TEST METHODS FOR PORTLAND CEMENT 6.Tri-calcium Silicate (C3S) 7. Di-calcium Silicate (C2S) 8. Tri-calcium Aluminate (C3A) 9.Tetra-calcium Alumina-Ferrite (C4AF)
CEMENT SAMPLING AND TESTING SCHEDULE Sample Location
Sample
Test
Frequency
1
Limestone being fed to raw mill
COз Content
1 per shift
2
Clay being fed to raw mill
H2O Content (If wet process) Percent finer than 75µm (No. 200) Sieve
1 per shift
3
Raw mill discharge and blending tank
CO3 Content H2O Content (if wet process)
2 per shift 2 per shift
4
Kiln feed (from blending silo or tank)
CO3 Content H2O Content (If wet process) Percent finer than 300µm (No. 50) Sieve Percent finer than 75µm (No. 200) Sieve
2 per shift 2 per shift 2 per shift 2 per shift
5
Clinker
Free CaO, Complete chemical analysis
2 per shift 1 per day
6
Cement
Free CaO, SOз Fineness (Air permeability) Complete chemical analysis Complete physical tests
1 per shift 4 per shift 4 per shift 1 per day 1 per day
7
Cement
Retain sample for 120 days
MISCELLANEOUS OR SPECIAL PURPOSE Type
Description or purpose
ASTM Specification
White Cement
White architectural cement
None
Buff Cement
Buff architectural cement
C 845
Expansive cement Type E-1
Expansive hydraulic cement
None43 43 43
Regulated set cement
For use where rapid setting and moderate early strength development are needed
None
Oil well cements Types A through H, J
Hydraulic cements used for oil well casings and linings
None
Masonry cement types M, S, and N
For use in mortar for masonry, brick, and block construction, and stucco
C 91
Plastic cement
For use in exterior stucco applications
None
High Alumina Cement
For use in refractory, high early strength, and moderately acid resistant concretes
None
Block cement
For use in making concrete masonry units
None
Magnesium phosphate cement
Non portland cement for use where rapid hardening is needed
None
ADMIXTURE A material other than water, aggregates and portland cement (including air entraining portland cement and portland blast furnace slag cement) that is used as an ingredient of concrete and is added to the batch immediately before or during its mixing.
MINERAL ADMIXTURE
MINERAL ADMIXTURES
FLY ASH Fly ash is also known as pulverized fuel ash (pfa) which is a pozzolanic material which is capable of combining with lime to form cementitious compounds.
MINERAL ADMIXTURES TWO TYPES OF FLY ASH 1. TYPE F Produced when anthracite, bituminous or sub- bituminous coal is burned. Low lime content.
2. TYPE C Normally comes from lignite or subbituminous coal.High lime content.
MINERAL ADMIXTURES ADVANTAGES OF FLY ASH 1. 2. 3. 4. 5. 6. 7. 8.
REDUCE HEAT OF HYDRATION IMPROVE WORKABILITY OF FRESH CONCRETE DECREASE PERMEABILITY INCREASE DURABILITY INCREASE STRENGTH REDUCE CHLORIDES AND SULPHATES ATTACK REDUCE BLEEDING AND SEGREGATION REDUCE AGGREGATE ALKALI REACTION (AAR)
MINERAL ADMIXTURES FLY ASH DOSAGE IS ABOUT 5 TO 40% BY MASS OF THE CEMENT
ASTM C-618 TEST REQUIREMENTS FOR FLY ASH
CHEMICAL SO3 MOISTURE CONTENT LOSS ON IGNITION
PHYSICAL FINENESS + 325 MESH POZZOLANIC ACTIVITY/CEMENT WATER REQUIREMENT AUTOCALVE EXPANSION
MINERAL ADMIXTURES
SILICA FUME It is the by product of the manufacture of silicon, ferrosilicon, from quartz and carbon in electric arc furnaces.
MINERAL ADMIXTURES Mineral Admixtures Silica Fumes A very fine particles with size smaller than one micrometer (average diameter is 0.1 micrometer) or 100 times smaller than the average cement particle. Specific Gravity – 2.2 to 2.5 Normal content – 5 to 15% of the portland cement content Bulk density of 160 to 320 kg/m³, densified
MINERAL ADMIXTURES ADVANTAGES OF SILICA FUME 1. 2. 3. 4. 5. 6. 7. 8.
ACHIEVE HIGH STRENGTH INCREASE DURABILITY IMPROVE WORKABILITY INCREASE COHESION DECREASE BLEEDING AND SEGREGATION REDUCE HEAT OF HYDRATION REDUCE CHLORIDES AND SULPHATES ATTACK REDUCE PERMEABILITY
MINERAL ADMIXTURES BLAST FURNACE SLAG It is commonly known as ground granulated blast furnace slag (GGBFS) which is the by product of the production of iron
MINERAL ADMIXTURES
BLAST FURNACE SLAG The non metallic product consisting essentially of silicates and alumino-silicates of calcium and of other bases that is developed in a molten condition simultaneously with iron in a blast furnace.
GRANULATED BLAST FURNACE SLAG The glassy granular material formed when molten blast furnace slag is rapidly chilled as bay immersion in water.
MINERAL ADMIXTURES
BLAST FURNACE SLAG Main constituents arw calcium, magnesium, silicon, aluminum, and oxygen. Very effective with cements with higher contents of alkali and C3A and higher fineness. It must conform to the requirements of ASTM C 989
MINERAL ADMIXTURES ADVANTAGES OF BLAST FURNACE SLAG 1. 2. 3. 4.
INCREASE STRENGTH IMPROVE RESISTANCE TO CHEMEICAL ATTACK IMPROVE RESISTANCE TO BLEEDING AND SEGREGATION DECREASE PERMEABILITY
CHEMICAL ADMIXTURE
TYPES OF CHEMICAL ADMIXTURES ASTM C –494
-Chemical Admixtures for Concrete
TYPE A
- Water reducing Admixtures
TYPE B
- Retarding Admixtures
TYPE C
- Accelerating Admixtures
TYPE D
- Water Reducing and Retarding Admixtures
TYPES OF CHEMICAL ADMIXTURES ASTM C – 494
- Chemical Admixtures for Concrete
TYPE E
- Water Reducing and Accelerating Admixtures
TYPE F
- Water Reducing, High Range Admixtures
TYPE G
- Water Reducing , High Range Retarding Admixtures
ASTM-260
-Air Entraining Admixtures For Concrete
Chemical Admixtures for Concrete Chemical Admixtures Raw Materials Lignosulfonates Hydroxylated carboxylic acids Carbohydrates Melamine Napthalene condensates Organic and inorganic accelerators
TEST METHOD FOR CHEMICAL ADMIXTURES PH NO. SPECIFIC GRAVITY SOLID CONTENT CHEMICAL ANALYSIS
USES OF ADMIXTURES
Usually an admixture is used to modify the properties of the concrete in such a way to make it more suitable for the work in hand such as: Improvement of workability
Acceleration of the rate of strength development at early age.
Retardation of initial stiffening or too rapid.
Retardation or reduction of heat evolution.
USES OF ADMIXTURES
Increase in bond to steel reinforcement.
Reduction in bleeding.
Increase in durability.
Increase and decrease in the permeability to liquid.
Production of cellular concrete.
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