BM01-Lecture 7

Non-hydraulic binders
part II

Building materials
Lecture 7

Strength of gypsum

Gypsum fire resistance

moisture content
with increasing moisture the strength
decreases
water/gypsum ratio
with increasing w/g the strength decreases
Conditioning

Moisture in
gypsum
gyp

Compressive
strength
g

MPa

Dried at 35 40 C

13,8

100

In air with 65
% RH

0,04

In air with 90
% RH

0,15

Immersed in
water

17,50

13,6
12,9
6,4

98,5
93,5
46,5

Bulk density

Compressive
t
th
strength

kg.m-3

MPa

w/g

calcium sulphate binders:

gypsum
anhydrite
(non-hydraulic)
(non
hydraulic) lime
water glass
magnesium binder

0 50
0,50

1410

14 6
14,6

0,55

1300

13,0

0,60

1230

11,4

0,65

1170

10,8

0,75

1040

9,5

non flammable
fl
bl (class
( l
A1)
contains water of crystallization (17 % of its weight)
exposed
d to
t the
th fire,
fi the
th chemically
h i ll combined
bi d water
t iis
released in the form of water vapor the
y
((calcination)) of gyp
gypsum occurs
dehydration
calcined gypsum adheres to the uncalcined material
and retards the calcination process
until all the water of crystallization has been liberated,
the temperature on the unexposed side will not
exceed 100C
100 C

the gypsum can serve as a fire retardant

with ability to delay the spread of fire up to 4 hours

protection of wood and steel elements against fire
1

BM01-Lecture 7

Gypsum after fire test (Mokrsko)

Gypsum use

Lime - gypsum plaster

gypsum sets quickly, lime is slow to set
combination of lime and gypsum plasters sets
at a medium speed
g gy
gypsum plaster expands slightly
g y
while setting,
and lime contracts slightly
the plaster does not crack
better workability

plasters in interior
blocks
floor screeds
gypsum boards ((drywall)
gyp
y
)
gypsum fiberboards

Gypsum board (drywall)

panel made of a paper liner wrapped around
an inner core made from gypsum with fibers
(cellulose and/or fiberglass)

BM01-Lecture 7

Special gypsum boards

Gypsum board types

Gypsum plasterboard - type A
G. p. with control density - D
Gypsum sheathing board - E
iin external
t
l walls.
ll reduced
d
d water
t absorption
b
ti
rate with a minimum water vapor permeability

G. p. with improved core adhesion

at high temperatures - F
mineral fibers and / or other additives in the
gypsum core

G. p. with reduced water absorption

rate - H1 H3
G. p. with enhanced surface hardness - I
G. baseboard - P
G.
G p. with
i h enhanced
h
d strength
h-R

fire proof (F)

glass fibre and other
additives in the core
acoustic (D)
high density core
special
dimensional
p
configuration
thermal insulating
bonded to an expanded
polystyrene

Gypsum board use

standard boards to 65%RH
impregnated boards
permanently to 75 %RH
for a short term to 100 %

Gypsum fiberboards
gypsum (80%) + cellulose
ll l
fib
fibers (20 %)

no paper on surface
higher bulk density
higher strength
better fire resistance
in the higher humidity

Basement,
showers
3

BM01-Lecture 7

Anhydrite
anhydrous
anh dro s CaSO4 + acti
activator
ator
activators: lime, cement, sulphates
slow setting even with activator
self-leveling
leveling screeds
used for self

Air lime

Self-leveling screeds
contains gypsum or anhydrite + plasticizer +
sand (1:1 1:2)
very good
d ffor under-floor
d fl
h
heating
ti
used only in interiors

Building limes classification

EN 459
Building lime

Air lime

calcium oxide CaO or calcium hydroxide

Ca(OH)2 with different purity

Calcium lime

Dolomitic
lime

Hydraulic lime

Hydraulic
lime HL

Natural
hydraulic
lime NHL

known from ancient days

y (Assyrians,
(
y
,
Egyptians, Greeks, Romans.....)
4

BM01-Lecture 7

Air lime manufacturing

Air lime manufacturing

Raw material:
limestone calcite
calcite, chalk (CaCO3)
limestone,
dolomitic limestone (CaCO3+MgCO3)
dolomite (CaCO3MgCO3)

Pieter van Laer (1599 1642)

Air lime manufacturing

step 1 burning (decarbonation)
quicklime CaO
q
crushed, ground, pulverized
unstable in the presence of
moisture and CO2

step 2 slaking (hydration)

hydrated lime Ca(OH)2
lime slurry, putty, milk of lime
powder

Air lime burning

900 - 1200
1200C
C decarbonation in
kilns
CaCO3 + heat CaO + CO2
CaCO3MgCO3 + heat CaO + MgO + 2CO2
lower temperature - soft-burned lime more reactive, porous, suitable for mortars
higher
hi h temperature hard-burned
h db
d lime
li

less reactive, denser, suitable for AAC

too
t high
hi h ttemperature
t
overburned
b
d lime
li
5

BM01-Lecture 7

Lime kiln

Quicklime CaO
large lump lime
crushed lime 25 mm
Crypta Balbi
Roma

2 5 mm
ground lime 2,5
pulverized lime 0,2 mm
pelletized lime

Pacold lime kiln

Velk Chuchle

Quicklime hydration
Reaction between quicklime and water:
CaO + H2O Ca(OH)2 + heat
highly exothermic process

Types of hydration:
dry hydration Ca(OH)2 in powder

Quicklime slaking
CaO reacts with the amount of water
much higher than the quantity, necessary
for the reaction
240-320 l of water /100 kg of quicklime
lime putty
putty, slurry
slurry, milk of lime
a great quantity of heat is released
material can splatter
danger of burns!

slaking Ca(OH)2 in suspension

( l
(slurry,
putty,
tt milk
ilk off lime)
li )
6

BM01-Lecture 7

Quicklime slaking
the volume expansion (due to absorbed
water) - the greater the expansion, the better
lime
min. 2,6 l slurryy from
1 kg of quicklime

Quicklime slaking
Factors affecting
g the slaking
g process:
p
quality of quicklime
specific surface
temperature (slightly under 100 C)
amount of water added
to much water drowning (killing) the lime

the lime putty has to mature from a few hours

to many days (to allow the slaking of all
particles)
historically lime was slaked over a period
of at least six months (even 10 years)

Imperfect slaking:
uneconomical (unskillful slaking may reduce
the paste to less than two volumes)
the unslaked particles may slake later in
the mortar

Dry hydration of quicklime

Setting
g and hardening
g of air
lime

adding water under controlled conditions

reaction with just the right amount of water
65 70 l of water /
100 kg of quicklime
powder hydrated
lime
special equipment - lime hydrator
lime putty (powder + water) has to mature

Setting physical reaction (drying out of

colloid gel)
Hardening carbonation
Ca(OH)2 + CO2 + nH2O CaCO3 + (n+1)H2O
slow
depends
and
d
d on CO2 concentration
i
d RH
and air temperature
Lime plasters should be left min. 1 month
without painting !

BM01-Lecture 7

Lime cycle
Carbonation
(hardening)
+ CO2
+ H2O

Drying

Air lime use

Limestone

CaCO3

Burning
- CO2

Lime
mortar

+ H2O

prepared in-situ
ready-made mixtures

C O
CaO

Ca(OH)2

Using

mortars
t
and
d plasters
l t

Quick
lime

Slaking

Ca(OH)2

sand lime bricks

autoclaved aerated concrete
lime wash white or color paint
disinfectant
di i f t t

Hydrated lime
Lime slurry, lime putty

Water glass
Sodium silicate aqueous solution or solid
compound of sodium oxide (Na2O) and silica
(silicon dioxide
dioxide, SiO2)
sodium, potassium, lithium
produced by burning of soda ash (Na2CO3) and silica
sand ((SiO2) in a furnace ((1000 - 1400 C)) or
dissolving silica sand under pressure in a heated
aqueous solution of soda (NaOH)

hardening: adding of the weak acids (CO2,

organic esters)

Water glass
Properties:
soluble in water alkaline solution
stable in neutral and alkaline solutions
in acidic solutions reacts and hardens glassy
gel
hard
adg
assy ge
good resistance to high temperatures
(int mescent)
(intumescent)

usually mixed with fine sand

8

BM01-Lecture 7

Water glass use

timber treatment wood
preservation
binders exposed to heat
or fire
concrete and masonry
treatment reducing of
their porosity
refractory use - with
light eight aggregates
lightweight
water treatment
soil stabilization

Magnesia binder use

floorings (cast floors)
Xylolith
y

fire protection products

f
fiber
boards
grinding wheels,
abrasive stones

Magnesia binder
Sorel cement
g and MgCl
g 2
based on MgO
prepared by mixing burned magnesia
(MgO) with magnesium chloride
hardening formation of magnesium
oxychlorides
high strength
good fire resistance
good resistance to abrasion
high elasticity

Xylolith
mixture of magnesia
g
cement, sawdust, and
wood flour, with an addition of finely
dispersed
p
mineral substances ((talc, asbestos,
marble flour) and alkali-resistant pigments
the seamless floors in residential and public
buildings

Villa Tugendhat, Brno

Ludwig Mies van der Rohe, 1930
9

BM01-Lecture 7

Geopolymers
synthetic aluminosilicate polymers formed in
alkaline environment at normal temperature
raw material
t i l e.g. thermal
th
l activated
ti t d clays
l
(metakaolin, fly ash) + strong alkali activator
fire-resistant, blast-resistant and acid-resistant

Geopolymers
Prof. Joseph Davidovits

349,- /1kg
399,- /1kg
http://www.youtube.com/watch?v=znQk_yBHre4

Geopolymer concretes

Concrete

+ high strength
- price !!
+ fire resistant
- efflorescence
+ lower energy
- difficult preparation
consumption
ti
chemically
+c
e ca y resistant
es sta t
+ durability

10

BM01-Lecture 7

Concrete
EN 206
206-1
1 Concrete - Part 1
1: Specification
Specification,
performance, production and conformity:
material formed by mixing cement,
coarse and fine aggregate and water
water,
with or without the incorporation of
d i t
d additions,
dditi
hi h
admixtures
and
which
develops its properties by hydration of
the cement

Terms (EN 206-1)

206 1)

Concrete components
binder
bi d (cement)
(
t)
aggregates
mixing water
admixtures (up to 5 % of cement
mass)
additions (in powder)
reinforcement (steel bars, grids,
fibers)

Terms (EN 206-1)

206 1)

fresh concrete - concrete which

hich is ffully
ll
mixed and still in a condition that is
capable of being compacted by the
chosen method

designed concrete - concrete for which

the required properties and additional
characteristics are specified to the
producer who is responsible for providing
a concrete conforming
g to the required
q
properties and additional characteristics

h d
d concrete
t - concrete
t which
hi h is
i
hardened
in a solid state and which has
developed a certain strength

prescribed concrete - concrete for which

the composition of the concrete and the
constituent materials to be used are
specified to the producer who is
responsible for providing a concrete with
the specified composition
11

BM01-Lecture 7

Concrete types
yp according
g the
bulk density
normal weight concrete
2000 2600 kg.m-3
light-weight
light weight concrete
800 2000
000 kg.m
g -3
heavy-weight concrete
> 2600 kg.m-3

Concrete works

Concrete types according the

place of manufacture
site-mixed concrete - concrete produced
on the construction site by the user of the
concrete for his own use
ready-mixed concrete - concrete delivered
in a fresh state by a person or body who is
not
concrete
also:
ot the
t e user.
use Readyeady mixed
ed co
c ete is
sa
so
concrete produced off site by the user
concrete produced on site, but not by the user

precast concrete product - concrete

product cast and cured in a p
place other than
p
the final location of use

On site mixed concrete

mixing
t
transport
t
p
placing
g
compacting
f
k
formwork
removal
curing

12

BM01-Lecture 7

On site mixed concrete

Ready mixed concrete

mobile concrete
batching plant

Concrete transport
p

Concrete consolidation
To get rid of the air voids:
statical compacting
rodding,
g, tamping,
p g, ramming
g

dynamical
vibrating (immersion
or surface vibrators)

combined
pressure and jolting

selfself compacting
plasticizers

13

BM01-Lecture 7

Segregation of concrete

the separation of the

constituent materials
of concrete usually
by over-vibration
over vibration

Concrete curing
any procedure that maintains proper
moisture and temperature of the concrete to
ensure continuous hydration
if the water is allowed to evaporate the
h d ti ceases and
hydration
d the
th concrete
t shrinks
hi k
cracks occur !

- the denser aggregates

settle
ttl to
t the
th bottom
b tt
while
hil
the lighter cement paste
tends to move upwards

Concrete curing methods

Minimal time of curing

ponding
pp g in p
plastic or wet cloth
wrapping
spraying on temporary curing
membrane

14

BM01-Lecture 7

Cement
Concrete constituents

binder mixing
mi ing with
ith water
ater cement
paste cement stone
has to conform with EN 197-1
most expensive part of the concrete
as Iittle cement as possible should be
used

Other binders

Cement dosage
Minimal:
unreinforced concrete:
200 kg /1 m3
of finished concrete
reinforced concrete :
- sheltered:
240 kg/1 m3
3
- unsheltered:
260 kg/1m
g
- watertight constructions: 300 kg/1 m3
Strength increases to the amount
g m3 higher
g
dosage
g is not
450 kg/1
economical !

polymers

h lt
asphalts
gypsum
clays

+ high strength
strength, good
resistance against
aggressive environment
environment, fast
setting and hardening
- demanding production
production, price ,
fire resistance
d
roads
- only inside of the building
- low strength, volume
instabilityy
15

BM01-Lecture 7

Aggregates
gg egates

A
t
Aggregates

granular mineral material suitable for use

in concrete.
aggregates may be natural, artificial or
recycled
y
from material previously
y used in
construction
gravels, stone and sands form the granular
structure, which must have its voids filled as
completely as possible by the binder glue
approximately 80 % of the weight and 70
75% of the volume of the concrete

Standards for aggregates

EN 12620 Aggregates
A
t for
f concrete
t
- normal and heavy-weight aggregates
EN 13055-1 - Lightweight
g
g aggregates.
gg g
Lightweight aggregates for concrete,
mortar and grout
EN 13043 Aggregates for bituminous
mixtures and surface treatments
EN 13055-2 Lightweight aggregates for
bituminous mixtures and surface treatments

Standard and special aggregates

Bulk

Bulk

Bulk

Bulk

Bulk
16

BM01-Lecture 7

Origin of aggregates
natural aggregate - aggregate from mineral
sources which has been subjected to nothing
more than mechanical processing
manufactured aggregate - aggregate of
mineral origin res
resulting
industrial
lting from an ind
strial
process involving thermal or other
modification
recycled aggregate - aggregate resulting
from the processing of inorganic material
recovered aggregate - aggregate recovered
from wash water or fresh concrete

Gradation
ideal
id l filli
filling off space

Aggregates properties
Required for mix design:
grading
durability
particle shape
p and surface texture
p
rounded aggregates - more workable mix
angular aggregates - harder to place, work and
compact concrete ,but c. is stronger

abrasion and skid resistance

unit weights and voids
b
ti and
d surface
f
i t
absorption
moisture

Aggregates gradation
Particle-size distribution has an impact on:
b lk d
it and
d strength
t
th off concrete
t
bulk
density
y ((consolidation,, finishability,
y,
workability
and pumpability)
cost

Apollonius from Perga

(262-190 p.n.l.)

17

BM01-Lecture 7

Ideal gradation
g
Fuller equation

yi 100

di
Dmax

Bolomey, EMPA, Kenedy, Hummel, Valete

minimally
i i ll two
t
fraction,
f
ti
better
b tt
three

F : C = 1: (1,5 2)

Physical properties (EN 12620)

resistance to fragmentation of coarse
aggregate
Los Angeles coefficient
resistance to impact

resistance to wear - micro-Deval

resistance to polishing and abrasion
particle density
p
y and water absorption
p
bulk density
durability
y
freeze/thaw resistance
volume stability - drying shrinkage
alkali-silica reactivity

Chemical properties (EN 12620)

chlorides
g compounds
p
sulfur containing
acid-soluble sulfate
total sulfur

other constituents
constituents which alter the rate of setting and
hardening of concrete organic substances
constituents which affect the volume stability
of air-cooled blastfurnace slag

carbonate content of fine aggregates for

concrete pavement surface courses
18

BM01-Lecture 7

Organic impurities in aggregates

h
humus content
t t (decaying vegetation), fulvo
f l
acids (humic acids)
retarding effect on cement
colorimetric tests (NaOH, KOH)
comparison with standard color

sugars - influence on setting and hardening

decrease of strength
bo ate co
te t
carbonate
content
ca

Sulfur content in aggregates

total sulfur content - expressed as
percentage by mass of the aggregate
max 1% (2 % for blastfurnace slag)
max.

sulfides
lfid (FeS
(F S2, PbS) - source off sulfates
lf t
sulfates (CaSO4, PbSO4 ) - sulfate corrosion

lignite and coal particles may cause brown stains

and/or p
popouts
to appear
at the surface
p
pp

Chlorides in aggregates

Alkali - silica reaction

chlorides may dissolve in the mixing water

and promote corrosion of steel
maximum
i
chloride
hl id content
t t is
i expressed
d as
percentage of water-soluble chloride ion
content
t t by
b mass off combined
bi d aggregate
t

certain aggregates can react with alkaline

hydroxides present in the pore fluids of
concrete
under adverse conditions and in the presence
of moisture this can lead to expansion and
subsequent cracking or disruption of the
concrete - ASR
less common is alkali-carbonate reaction

plain concrete 0,15 %

0 06 %
reinforced concrete 0,06
prestressed concrete 0,03 %

19

BM01-Lecture 7

Alkali-silica reaction - ASR

occurs over time in concrete between the
highly alkaline cement paste and reactive
non-crystalline
non
crystalline (amorphous) silica
formation of a swelling gel of calcium silicate
hydrate
y
((CSH g
gel))

Water
mixing water
for hydration
for workability
curing water

Water

Mixing water - EN 1008

p
potable water
suitable for use in concrete without testing

water recovered from processes in the concrete

industry
normally suitable for use in concrete, but shall conform
to the requirements of standard

water from underground sources

natural surface water and industrial waste water
both suitable for use in concrete, but shall be tested

sea water or brackish water

may be used for concrete without
reinforcement or other embedded metal
not suitable for the production of
reinforced or prestressed concrete

sewage water
not suitable for use in concrete
20

BM01-Lecture 7

Admixtures

Admixtures
EN 934-2:
material added during the mixing
process of concrete in small quantities
related to the mass of cement (0
(0,2
25
%) to modify the properties of fresh or
hardened concrete
mostly liquid

Admixture types (EN 934-2)

934 2)

water reducing/plasticizing
high-range water reducing/superplasticizing
water
a e retaining
ea
g
water resisting
air entraining
g
set accelerating
hardening
g accelerating
g
set retarding
dual function admixtures
set retarding/water reducing/plasticizing
set retarding/high-range water
reducing/superplasticizing
d i /
l ti i i
set accelerating/water reducing/plasticizing

Plasticizing
g and
superlasticizing admixtures
Enables the water content of a given concrete
mix to be reduced without affecting the
consistence, or increases the workability
without changing the water content, or
achieves both effects
reduction 5%
(plasticizer)
reduction 12%
(superplasticizer)

21

BM01-Lecture 7

Plasticizing/Water reducing
admixtures
d i t
admixture is adsorbed on to the cement
particles and lowers the inter particular
attraction so that flocs of cement break up
p

Superplasticizers
increased fluidity
flowing, self-leveling, self-compacting concrete
t ti and
d compaction
ti round
d dense
d
penetration
reinforcement

reduced
d
d W/C ratio:
ti

lignosulphonate
hydrocarbolic acids salts
carbohydrates

very high early strength,

very high later age strengths >100 MPa
reduced shrinkage (especially if combined with
reduced cement content
improved durability by removing water to reduce
permeability
bilit and
d diff
diffusion
i

Superplasticizers
Sulphonated melamine formaldehyde
condensates (SMF)
1625%
16 25% water reduction,
reduction little or no retardation
very effective at low temperatures

Sulphonated
p
naphthalene
p
formaldehyde
y
condensates (SNF)
1625% water reduction.
tend to increase the entrapment
of larger, unstable air bubbles

Polycarboxylate ether
superplasticizers (PCE)
20 35% water
t reduction
d ti
2035%+
relatively expensive
22