composite material
A composite material (also called a composition material or shortened to composite, which is the common name) is a material which is produced from two or more constituent materials. These constituent materials have notably dissimilar chemical or ...
composed of fine and coarse aggregate bonded together with a fluid
cement
A cement is a binder, a chemical substance used for construction that sets, hardens, and adheres to other materials to bind them together. Cement is seldom used on its own, but rather to bind sand and gravel ( aggregate) together. Cement mix ...
(cement paste) that hardens (cures) over time. Concrete is the second-most-used substance in the world after
water
Water (chemical formula ) is an inorganic, transparent, tasteless, odorless, and nearly colorless chemical substance, which is the main constituent of Earth's hydrosphere and the fluids of all known living organisms (in which it acts as a ...
, and is the most widely used building material. Its usage worldwide, ton for ton, is twice that of steel, wood, plastics, and aluminum combined. Globally, the ready-mix concrete industry, the largest segment of the concrete market, is projected to exceed $600 billion in revenue by 2025. This widespread use results in a number of
environmental impacts
Environmental issues are effects of human activity on the biophysical environment, most often of which are harmful effects that cause environmental degradation. Environmental protection is the practice of protecting the natural environment on t ...
. Most notably, the production process for cement produces large volumes of
greenhouse gas emissions
Greenhouse gas emissions from human activities strengthen the greenhouse effect, contributing to climate change. Most is carbon dioxide from burning fossil fuels: coal, oil, and natural gas. The largest emitters include coal in China and lar ...
, leading to net 8% of global emissions. Other environmental concerns include widespread
illegal sand mining
Sand theft or unauthorised or illegal sand mining leads to a widely unknown global example of natural and non-renewable resource depletion problem comparable in extent to global water scarcity. Beach theft is illegal removal of large quantities ...
, impacts on the surrounding environment such as increased
surface runoff
Surface runoff (also known as overland flow) is the flow of water occurring on the ground surface when excess rainwater, stormwater, meltwater, or other sources, can no longer sufficiently rapidly infiltrate in the soil. This can occur when th ...
or
urban heat island effect
An urban heat island (UHI) is an urban area, urban or metropolitan area that is significantly warmer than its surrounding rural areas due to human impact on the environment, human activities. The temperature difference is usually larger at nigh ...
, and potential public health implications from toxic ingredients. Significant research and development is being done to try to reduce the emissions or make concrete a source of
carbon sequestration
Carbon sequestration is the process of storing carbon in a carbon pool. Carbon dioxide () is naturally captured from the atmosphere through biological, chemical, and physical processes. These changes can be accelerated through changes in land ...
, and increase recycled and secondary raw materials content into the mix to achieve a
circular economy
A circular economy (also referred to as circularity and CE) is a model of production and consumption, which involves sharing, leasing, reusing, repairing, refurbishing and recycling existing materials and products as long as possible. CE aims ...
. Concrete is expected to be a key material for structures resilient to climate disasters, as well as a solution to mitigate the pollution of other industries, capturing wastes such as
coal fly ash
Fly ash, flue ash, coal ash, or pulverised fuel ash (in the UK) plurale tantum: coal combustion residuals (CCRs)is a coal combustion product that is composed of the particulates (fine particles of burned fuel) that are driven out of coal-fired b ...
Portland cement
Portland cement is the most common type of cement in general use around the world as a basic ingredient of concrete, mortar, stucco, and non-specialty grout. It was developed from other types of hydraulic lime in England in the early 19th c ...
and
water
Water (chemical formula ) is an inorganic, transparent, tasteless, odorless, and nearly colorless chemical substance, which is the main constituent of Earth's hydrosphere and the fluids of all known living organisms (in which it acts as a ...
, the mixture forms a fluid
slurry
A slurry is a mixture of denser solids suspended in liquid, usually water. The most common use of slurry is as a means of transporting solids or separating minerals, the liquid being a carrier that is pumped on a device such as a centrifugal pu ...
that is easily poured and molded into shape. The cement reacts with the water through a process calle concrete hydration that hardens over several hours to form a hard matrix that binds the materials together into a durable stone-like material that has many uses. This time allows concrete to not only be cast in forms but also to have a variety of tooled processes preformed. The hydration process is
exothermic
In thermodynamics, an exothermic process () is a thermodynamic process or reaction that releases energy from the system to its surroundings, usually in the form of heat, but also in a form of light (e.g. a spark, flame, or flash), electricity (e ...
, which means ambient temperature plays a significant role in how long it takes concrete to set. Often, additives (such as
pozzolan
Pozzolans are a broad class of Silicon_dioxide, siliceous and aluminium oxide, aluminous materials which, in themselves, possess little or no cementitious value but which will, in finely divided form and in the presence of water, react chemically ...
s or
superplasticizer
Superplasticizers (SPs), also known as high range water reducers, are additives used in making high strength concrete. Plasticizers are chemical compounds that enable the production of concrete with approximately 15% less water content. Superplast ...
s) are included in the mixture to improve the physical properties of the wet mix, delay or accelerate the curing time, or otherwise change the finished material. Most concrete is poured with reinforcing materials (such as
rebar
Rebar (short for reinforcing bar), known when massed as reinforcing steel or reinforcement steel, is a steel bar used as a Tension (physics), tension device in reinforced concrete and reinforced masonry structures to strengthen and aid the concr ...
) embedded to provide
tensile strength
Ultimate tensile strength (UTS), often shortened to tensile strength (TS), ultimate strength, or F_\text within equations, is the maximum stress that a material can withstand while being stretched or pulled before breaking. In brittle materials t ...
, yielding
reinforced concrete
Reinforced concrete (RC), also called reinforced cement concrete (RCC) and ferroconcrete, is a composite material in which concrete's relatively low tensile strength and ductility are compensated for by the inclusion of reinforcement having hig ...
.
In the past,
lime
Lime commonly refers to:
* Lime (fruit), a green citrus fruit
* Lime (material), inorganic materials containing calcium, usually calcium oxide or calcium hydroxide
* Lime (color), a color between yellow and green
Lime may also refer to:
Botany ...
based cement binders, such as lime putty, were often used but sometimes with other
hydraulic cement
A cement is a binder, a chemical substance used for construction that sets, hardens, and adheres to other materials to bind them together. Cement is seldom used on its own, but rather to bind sand and gravel ( aggregate) together. Cement mix ...
s, (water resistant) such as a calcium aluminate cement or with Portland cement to form Portland cement concrete (named for its visual resemblance to
Portland stone
Portland stone is a limestone from the Tithonian stage of the Jurassic period quarried on the Isle of Portland, Dorset. The quarries are cut in beds of white-grey limestone separated by chert beds. It has been used extensively as a building sto ...
). Many other non-cementitious
types of concrete
Concrete is produced in a variety of compositions, finishes and performance characteristics to meet a wide range of needs.
Mix design
Modern concrete mix designs can be complex. The choice of a concrete mix depends on the need of the project ...
exist with other methods of binding aggregate together, including
asphalt concrete
Asphalt concrete (commonly called asphalt, blacktop, or pavement in North America, and tarmac, bitumen macadam, or rolled asphalt in the United Kingdom and the Republic of Ireland) is a composite material commonly used to surface roads, parkin ...
with a
bitumen
Asphalt, also known as bitumen (, ), is a sticky, black, highly viscous liquid or semi-solid form of petroleum. It may be found in natural deposits or may be a refined product, and is classed as a pitch. Before the 20th century, the term a ...
binder, which is frequently used for
road surface
A road surface (British English), or pavement (American English), is the durable surface material laid down on an area intended to sustain vehicular or foot traffic, such as a road or walkway. In the past, gravel road surfaces, hoggin, cobbles ...
s, and polymer concretes that use polymers as a binder. Concrete is distinct from mortar. Whereas concrete is itself a building material, mortar is a bonding agent that typically holds
brick
A brick is a type of block used to build walls, pavements and other elements in masonry construction. Properly, the term ''brick'' denotes a block composed of dried clay, but is now also used informally to denote other chemically cured cons ...
s,
tile
Tiles are usually thin, square or rectangular coverings manufactured from hard-wearing material such as ceramic, stone, metal, baked clay, or even glass. They are generally fixed in place in an array to cover roofs, floors, walls, edges, or o ...
s and other masonry units together.
Etymology
The word concrete comes from the Latin word "''concretus''" (meaning compact or condensed), the perfect passive participle of "''concrescere''", from "''con''-" (together) and "''crescere''" (to grow).
History
Ancient times
Mayan concrete at the ruins of
Uxmal
Uxmal (Yucatec Maya: ''Óoxmáal'' ) is an ancient Maya city of the classical period located in present-day Mexico. It is considered one of the most important archaeological sites of Maya culture, along with Palenque, Chichen Itza and Calakmul i ...
(850-925 A.D.) is referenced in ''Incidents of Travel in the Yucatán'' by John L. Stephens. "The roof is flat and had been covered with cement". "The floors were cement, in some places hard, but, by long exposure, broken, and now crumbling under the feet." "But throughout the wall was solid, and consisting of large stones imbedded in mortar, almost as hard as rock."
Small-scale production of concrete-like materials was pioneered by the
Nabatean
The Nabataeans or Nabateans (; Nabataean Aramaic: , , vocalized as ; Arabic: , , singular , ; compare grc, Ναβαταῖος, translit=Nabataîos; la, Nabataeus) were an ancient Arab people who inhabited northern Arabia and the southern Lev ...
traders who occupied and controlled a series of oases and developed a small empire in the regions of southern Syria and northern Jordan from the 4th century BC. They discovered the advantages of
hydraulic lime
Hydraulic lime (HL) is a general term for calcium oxide, a variety of lime also called quicklime, that sets by hydration. This contrasts with calcium hydroxide, also called slaked lime or air lime that is used to make lime mortar, the other common ...
, with some self-cementing properties, by 700 BC. They built
kiln
A kiln is a thermally insulated chamber, a type of oven, that produces temperatures sufficient to complete some process, such as hardening, drying, or chemical changes. Kilns have been used for millennia to turn objects made from clay int ...
s to supply mortar for the construction of
rubble masonry
Rubble stone is rough, uneven building stone not laid in regular courses. It may fill the core of a wall which is faced with unit masonry such as brick or ashlar. Analogously, some medieval cathedral walls are outer shells of ashlar with an inn ...
houses, concrete floors, and underground waterproof
cistern
A cistern (Middle English ', from Latin ', from ', "box", from Greek ', "basket") is a waterproof receptacle for holding liquids, usually water. Cisterns are often built to catch and store rainwater. Cisterns are distinguished from wells by t ...
s. They kept the cisterns secret as these enabled the Nabataeans to thrive in the desert. Some of these structures survive to this day.
Roman
Roman or Romans most often refers to:
*Rome, the capital city of Italy
*Ancient Rome, Roman civilization from 8th century BC to 5th century AD
*Roman people, the people of ancient Rome
*''Epistle to the Romans'', shortened to ''Romans'', a letter ...
eras, builders discovered that adding
volcanic ash
Volcanic ash consists of fragments of rock, mineral crystals, and volcanic glass, created during volcano, volcanic eruptions and measuring less than 2 mm (0.079 inches) in diameter. The term volcanic ash is also often loosely used t ...
to the mix allowed it to set underwater.
Concrete floors were found in the royal palace of
Tiryns
Tiryns or (Ancient Greek: Τίρυνς; Modern Greek: Τίρυνθα) is a Mycenaean archaeological site in Argolis in the Peloponnese, and the location from which the mythical hero Heracles performed his Twelve Labours. It lies south of Myce ...
, Greece, which dates roughly to 1400–1200 BC. Lime mortars were used in Greece, Crete, and Cyprus in 800 BC. The
Assyria
Assyria (Neo-Assyrian cuneiform: , romanized: ''māt Aššur''; syc, ܐܬܘܪ, ʾāthor) was a major ancient Mesopotamian civilization which existed as a city-state at times controlling regional territories in the indigenous lands of the A ...
n Jerwan Aqueduct (688 BC) made use of waterproof concrete. Concrete was used for construction in many ancient structures.
The Romans used concrete extensively from 300 BC to 476 AD. During the Roman Empire,
Roman concrete
Roman concrete, also called , is a material that was used in construction in ancient Rome. Roman concrete was based on a hydraulic-setting cement. It is durable due to its incorporation of pozzolanic ash, which prevents cracks from spreading. B ...
(or ''
opus caementicium
Roman concrete, also called , is a material that was used in construction in ancient Rome. Roman concrete was based on a hydraulic-setting cement. It is durable due to its incorporation of pozzolanic ash, which prevents cracks from spreading. B ...
'') was made from
quicklime
Calcium oxide (CaO), commonly known as quicklime or burnt lime, is a widely used chemical compound. It is a white, caustic, alkaline, crystalline solid at room temperature. The broadly used term "''lime''" connotes calcium-containing inorganic ma ...
,
pozzolana
Pozzolana or pozzuolana ( , ), also known as pozzolanic ash ( la, pulvis puteolanus), is a natural siliceous or siliceous- aluminous material which reacts with calcium hydroxide in the presence of water at room temperature (cf. pozzolanic reactio ...
and an aggregate of
pumice
Pumice (), called pumicite in its powdered or dust form, is a volcanic rock that consists of highly vesicular rough-textured volcanic glass, which may or may not contain crystals. It is typically light-colored. Scoria is another vesicular vol ...
. Its widespread use in many Roman structures, a key event in the
history of architecture
The history of architecture traces the changes in architecture through various traditions, regions, overarching stylistic trends, and dates. The beginnings of all these traditions is thought to be humans satisfying the very basic need of shelt ...
termed the Roman architectural revolution, freed Roman construction from the restrictions of stone and brick materials. It enabled revolutionary new designs in terms of both structural complexity and dimension. The
Colosseum
The Colosseum ( ; it, Colosseo ) is an oval amphitheatre in the centre of the city of Rome, Italy, just east of the Roman Forum. It is the largest ancient amphitheatre ever built, and is still the largest standing amphitheatre in the world to ...
in Rome was built largely of concrete, and the
Pantheon
Pantheon may refer to:
* Pantheon (religion), a set of gods belonging to a particular religion or tradition, and a temple or sacred building
Arts and entertainment Comics
*Pantheon (Marvel Comics), a fictional organization
* ''Pantheon'' (Lone S ...
has the world's largest unreinforced concrete dome.
Concrete, as the Romans knew it, was a new and revolutionary material. Laid in the shape of
arch
An arch is a vertical curved structure that spans an elevated space and may or may not support the weight above it, or in case of a horizontal arch like an arch dam, the hydrostatic pressure against it.
Arches may be synonymous with vaul ...
domes
A dome () is an architectural element similar to the hollow upper half of a sphere. There is significant overlap with the term cupola, which may also refer to a dome or a structure on top of a dome. The precise definition of a dome has been a m ...
, it quickly hardened into a rigid mass, free from many of the internal thrusts and strains that troubled the builders of similar structures in stone or brick.
Modern tests show that ''opus caementicium'' had as much compressive strength as modern Portland-cement concrete (ca. ). However, due to the absence of reinforcement, its
tensile strength
Ultimate tensile strength (UTS), often shortened to tensile strength (TS), ultimate strength, or F_\text within equations, is the maximum stress that a material can withstand while being stretched or pulled before breaking. In brittle materials t ...
was far lower than modern
reinforced concrete
Reinforced concrete (RC), also called reinforced cement concrete (RCC) and ferroconcrete, is a composite material in which concrete's relatively low tensile strength and ductility are compensated for by the inclusion of reinforcement having hig ...
, and its mode of application also differed:
Modern structural concrete differs from Roman concrete in two important details. First, its mix consistency is fluid and homogeneous, allowing it to be poured into forms rather than requiring hand-layering together with the placement of aggregate, which, in Roman practice, often consisted of
rubble
Rubble is broken stone, of irregular size, shape and texture; undressed especially as a filling-in. Rubble naturally found in the soil is known also as 'brash' (compare cornbrash)."Rubble" def. 2., "Brash n. 2. def. 1. ''Oxford English Dictionar ...
. Second, integral reinforcing steel gives modern concrete assemblies great strength in tension, whereas Roman concrete could depend only upon the strength of the concrete bonding to resist tension.
The long-term durability of Roman concrete structures has been found to be due to its use of
pyroclastic
Pyroclastic rocks (derived from the el, πῦρ, links=no, meaning fire; and , meaning broken) are clastic rocks composed of rock fragments produced and ejected by explosive volcanic eruptions. The individual rock fragments are known as pyroc ...
(volcanic) rock and ash, whereby the crystallization of strätlingite (a specific and complex calcium aluminosilicate hydrate) and the coalescence of this and similar calcium–aluminum-silicate–hydrate cementing binders helped give the concrete a greater degree of fracture resistance even in seismically active environments. Roman concrete is significantly more resistant to erosion by seawater than modern concrete; it used pyroclastic materials which react with seawater to form Al-
tobermorite
Tobermorite is a calcium silicate hydrate mineral with chemical formula:
Ca5Si6O16(OH)2·4H2O or
Ca5Si6(O,OH)18·5H2O.
Two structural varieties are distinguished: tobermorite-11 Å and tobermorite-14 Å.
Tobermorite occurs in hydrated cemen ...
crystals over time.
The widespread use of concrete in many Roman structures ensured that many survive to the present day. The
Baths of Caracalla
The Baths of Caracalla ( it, Terme di Caracalla) in Rome, Italy, were the city's second largest Ancient Rome, Roman public baths, or ''thermae'', after the Baths of Diocletian. The baths were likely built between AD 212 (or 211) and 216/217, durin ...
in Rome are just one example. Many
Roman aqueduct
The Romans constructed aqueducts throughout their Republic and later Empire, to bring water from outside sources into cities and towns. Aqueduct water supplied public baths, latrines, fountains, and private households; it also supported mining o ...
s and bridges, such as the magnificent
Pont du Gard
The Pont du Gard is an ancient Roman aqueduct bridge built in the first century AD to carry water over to the Roman colony of ''Nemausus'' ( Nîmes). It crosses the river Gardon near the town of Vers-Pont-du-Gard in southern France. The Pont ...
in southern France, have masonry cladding on a concrete core, as does the dome of the
Pantheon
Pantheon may refer to:
* Pantheon (religion), a set of gods belonging to a particular religion or tradition, and a temple or sacred building
Arts and entertainment Comics
*Pantheon (Marvel Comics), a fictional organization
* ''Pantheon'' (Lone S ...
.
After the Roman Empire collapsed, use of concrete became rare until the technology was redeveloped in the mid-18th century. Worldwide, concrete has overtaken steel in tonnage of material used.
Middle Ages
After the Roman Empire, the use of burned lime and pozzolana was greatly reduced. Low kiln temperatures in the burning of lime, lack of pozzolana, and poor mixing all contributed to a decline in the quality of concrete and mortar. From the 11th century, the increased use of stone in church and
castle
A castle is a type of fortified structure built during the Middle Ages predominantly by the nobility or royalty and by military orders. Scholars debate the scope of the word ''castle'', but usually consider it to be the private fortified r ...
construction led to an increased demand for mortar. Quality began to improve in the 12th century through better grinding and sieving. Medieval lime mortars and concretes were non-hydraulic and were used for binding masonry, "hearting" (binding
rubble masonry
Rubble stone is rough, uneven building stone not laid in regular courses. It may fill the core of a wall which is faced with unit masonry such as brick or ashlar. Analogously, some medieval cathedral walls are outer shells of ashlar with an inn ...
cores) and foundations.
Bartholomaeus Anglicus Bartholomaeus Anglicus (before 1203–1272), also known as Bartholomew the Englishman and Berthelet, was an early 13th-century Scholastic of Paris, a member of the Franciscan order. He was the author of the compendium ''De proprietatibus rerum' ...
in his ''De proprietatibus rerum'' (1240) describes the making of mortar. In an English translation from 1397, it reads "lyme ... is a stone brent; by medlynge thereof with sonde and water sement is made". From the 14th century, the quality of mortar was again excellent, but only from the 17th century was pozzolana commonly added.
The ''
Canal du Midi
The Canal du Midi (; ) is a long canal in Southern France (french: le Midi). Originally named the ''Canal royal en Languedoc'' (Royal Canal in Languedoc) and renamed by French revolutionaries to ''Canal du Midi'' in 1789, the canal is considere ...
'' was built using concrete in 1670.
Industrial era
Perhaps the greatest step forward in the modern use of concrete was
Smeaton's Tower
Smeaton's Tower is a memorial to civil engineer John Smeaton, designer of the third and most notable Eddystone Lighthouse. A major step forward in lighthouse design, Smeaton's structure was in use from 1759 to 1877, until erosion of the ledge it ...
, built by British engineer
John Smeaton
John Smeaton (8 June 1724 – 28 October 1792) was a British civil engineer responsible for the design of bridges, canals, harbours and lighthouses. He was also a capable mechanical engineer and an eminent physicist. Smeaton was the fir ...
in Devon, England, between 1756 and 1759. This third
Eddystone Lighthouse
The Eddystone Lighthouse is a lighthouse that is located on the dangerous Eddystone Rocks, south of Rame Head in Cornwall, England. The rocks are submerged below the surface of the sea and are composed of Precambrian gneiss. View at 1:50000 ...
pioneered the use of
hydraulic lime
Hydraulic lime (HL) is a general term for calcium oxide, a variety of lime also called quicklime, that sets by hydration. This contrasts with calcium hydroxide, also called slaked lime or air lime that is used to make lime mortar, the other common ...
in concrete, using pebbles and powdered brick as aggregate.
A method for producing
Portland cement
Portland cement is the most common type of cement in general use around the world as a basic ingredient of concrete, mortar, stucco, and non-specialty grout. It was developed from other types of hydraulic lime in England in the early 19th c ...
was developed in England and patented by
Joseph Aspdin
Joseph Aspdin (25 December 1778 – 20 March 1855) was an English cement manufacturer who obtained the patent for Portland cement on 21 October 1824.
Life
Aspdin (or Aspden) was the eldest of the six children of Thomas Aspdin, a bricklaye ...
in 1824. Aspdin chose the name for its similarity to
Portland stone
Portland stone is a limestone from the Tithonian stage of the Jurassic period quarried on the Isle of Portland, Dorset. The quarries are cut in beds of white-grey limestone separated by chert beds. It has been used extensively as a building sto ...
, which was quarried on the
Isle of Portland
An isle is an island, land surrounded by water. The term is very common in British English. However, there is no clear agreement on what makes an island an isle or its difference, so they are considered synonyms.
Isle may refer to:
Geography
* Is ...
in
Dorset
Dorset ( ; archaically: Dorsetshire , ) is a county in South West England on the English Channel coast. The ceremonial county comprises the unitary authority areas of Bournemouth, Christchurch and Poole and Dorset (unitary authority), Dors ...
, England. His son
William
William is a male given name of Germanic origin.Hanks, Hardcastle and Hodges, ''Oxford Dictionary of First Names'', Oxford University Press, 2nd edition, , p. 276. It became very popular in the English language after the Norman conquest of Engl ...
continued developments into the 1840s, earning him recognition for the development of "modern" Portland cement.
Reinforced concrete
Reinforced concrete (RC), also called reinforced cement concrete (RCC) and ferroconcrete, is a composite material in which concrete's relatively low tensile strength and ductility are compensated for by the inclusion of reinforcement having hig ...
was invented in 1849 by
Joseph Monier
Joseph Monier (; 8 November 1823, Saint-Quentin-la-Poterie, France – 13 March 1906, Paris) was a French gardener and one of the principal inventors of reinforced concrete.
Overview
As a gardener, Monier was not satisfied with the material ...
. and the first reinforced concrete house was built by
François Coignet
François Coignet (10 February 1814 – 30 October 1888) was a French industrialist and a pioneer in the development of reinforced concrete as the first person to use iron-reinforced concrete to construct buildings.Day, p. 284
Biography
Coign ...
in 1853.
The first concrete reinforced bridge was designed and built by
Joseph Monier
Joseph Monier (; 8 November 1823, Saint-Quentin-la-Poterie, France – 13 March 1906, Paris) was a French gardener and one of the principal inventors of reinforced concrete.
Overview
As a gardener, Monier was not satisfied with the material ...
in 1875.
Composition
Concrete is an artificial composite material, comprising a matrix of cementitious binder (typically
Portland cement
Portland cement is the most common type of cement in general use around the world as a basic ingredient of concrete, mortar, stucco, and non-specialty grout. It was developed from other types of hydraulic lime in England in the early 19th c ...
paste or
asphalt
Asphalt, also known as bitumen (, ), is a sticky, black, highly viscous liquid or semi-solid form of petroleum. It may be found in natural deposits or may be a refined product, and is classed as a pitch. Before the 20th century, the term a ...
) and a dispersed phase or "filler" of aggregate (typically a rocky material, loose stones, and sand). The binder "glues" the filler together to form a synthetic conglomerate. Many
types of concrete
Concrete is produced in a variety of compositions, finishes and performance characteristics to meet a wide range of needs.
Mix design
Modern concrete mix designs can be complex. The choice of a concrete mix depends on the need of the project ...
are available, determined by the formulations of binders and the types of aggregate used to suit the application of the engineered material. These variables determine strength and density, as well as chemical and thermal resistance of the finished product.
Aggregates consist of large chunks of material in a concrete mix, generally a coarse
gravel
Gravel is a loose aggregation of rock fragments. Gravel occurs naturally throughout the world as a result of sedimentary and erosive geologic processes; it is also produced in large quantities commercially as crushed stone.
Gravel is classifi ...
or crushed rocks such as
limestone
Limestone ( calcium carbonate ) is a type of carbonate sedimentary rock which is the main source of the material lime. It is composed mostly of the minerals calcite and aragonite, which are different crystal forms of . Limestone forms whe ...
, or
granite
Granite () is a coarse-grained (phaneritic) intrusive igneous rock composed mostly of quartz, alkali feldspar, and plagioclase. It forms from magma with a high content of silica and alkali metal oxides that slowly cools and solidifies undergro ...
, along with finer materials such as
sand
Sand is a granular material composed of finely divided mineral particles. Sand has various compositions but is defined by its grain size. Sand grains are smaller than gravel and coarser than silt. Sand can also refer to a textural class of s ...
.
Cement paste, most commonly made of Portland cement, is the most prevalent kind of concrete binder. For cementitious binders,
water
Water (chemical formula ) is an inorganic, transparent, tasteless, odorless, and nearly colorless chemical substance, which is the main constituent of Earth's hydrosphere and the fluids of all known living organisms (in which it acts as a ...
is mixed with the dry cement powder and aggregate, which produces a semi-liquid slurry (paste) that can be shaped, typically by pouring it into a form. The concrete solidifies and hardens through a
chemical process
In a scientific sense, a chemical process is a method or means of somehow changing one or more chemicals or chemical compounds. Such a chemical process can occur by itself or be caused by an outside force, and involves a chemical reaction of some ...
called
hydration Hydration may refer to:
* Hydrate, a substance that contains water
* Hydration enthalpy, energy released through hydrating a substance
* Hydration reaction, a chemical addition reaction where a hydroxyl group and proton are added to a compound
* ...
. The water reacts with the cement, which bonds the other components together, creating a robust, stone-like material. Other cementitious materials, such as
fly ash
Fly ash, flue ash, coal ash, or pulverised fuel ash (in the UK) plurale tantum: coal combustion residuals (CCRs)is a coal combustion product that is composed of the particulates (fine particles of burned fuel) that are driven out of coal-fired ...
and
slag cement
Ground-granulated blast-furnace slag (GGBS or GGBFS) is obtained by quenching molten iron slag (a by-product of iron and steel-making) from a blast furnace in water or steam, to produce a glassy phase, glassy, granular product that is then dried an ...
, are sometimes added—either pre-blended with the cement or directly as a concrete component—and become a part of the binder for the aggregate. Fly ash and slag can enhance some properties of concrete such as fresh properties and durability. Alternatively, other materials can also be used as a concrete binder: the most prevalent substitute is
asphalt
Asphalt, also known as bitumen (, ), is a sticky, black, highly viscous liquid or semi-solid form of petroleum. It may be found in natural deposits or may be a refined product, and is classed as a pitch. Before the 20th century, the term a ...
, which is used as the binder in
asphalt concrete
Asphalt concrete (commonly called asphalt, blacktop, or pavement in North America, and tarmac, bitumen macadam, or rolled asphalt in the United Kingdom and the Republic of Ireland) is a composite material commonly used to surface roads, parkin ...
.
Admixtures are added to modify the cure rate or properties of the material. Mineral admixtures use recycled materials as concrete ingredients. Conspicuous materials include
fly ash
Fly ash, flue ash, coal ash, or pulverised fuel ash (in the UK) plurale tantum: coal combustion residuals (CCRs)is a coal combustion product that is composed of the particulates (fine particles of burned fuel) that are driven out of coal-fired ...
, a by-product of
coal-fired power plants
Coal is a combustible black or brownish-black sedimentary rock, formed as rock strata called coal seams. Coal is mostly carbon with variable amounts of other elements, chiefly hydrogen, sulfur, oxygen, and nitrogen.
Coal is formed when dea ...
;
ground granulated blast furnace slag
Ground-granulated blast-furnace slag (GGBS or GGBFS) is obtained by quenching molten iron slag (a by-product of iron and steel-making) from a blast furnace in water or steam, to produce a glassy, granular product that is then dried and ground into ...
, a by-product of
steelmaking
Steelmaking is the process of producing steel from iron ore and carbon/or scrap. In steelmaking, impurities such as nitrogen, silicon, phosphorus, sulfur and excess carbon (the most important impurity) are removed from the sourced iron, and all ...
; and
silica fume
Silica fume, also known as microsilica, (CAS number 69012-64-2, EINECS number 273-761-1) is an amorphous (non-crystalline) polymorph of silicon dioxide, silica. It is an ultrafine powder collected as a by-product of the silicon and ferrosilicon a ...
, a by-product of industrial
electric arc furnace
An electric arc furnace (EAF) is a furnace that heats material by means of an electric arc.
Industrial arc furnaces range in size from small units of approximately one-tonne capacity (used in foundries for producing cast iron products) up to ab ...
s.
Structures employing Portland cement concrete usually include steel reinforcement because this type of concrete can be formulated with high
compressive strength
In mechanics, compressive strength or compression strength is the capacity of a material or structure to withstand loads tending to reduce size (as opposed to tensile strength which withstands loads tending to elongate). In other words, compre ...
, but always has lower
tensile strength
Ultimate tensile strength (UTS), often shortened to tensile strength (TS), ultimate strength, or F_\text within equations, is the maximum stress that a material can withstand while being stretched or pulled before breaking. In brittle materials t ...
. Therefore, it is usually reinforced with materials that are strong in tension, typically
steel
Steel is an alloy made up of iron with added carbon to improve its strength and fracture resistance compared to other forms of iron. Many other elements may be present or added. Stainless steels that are corrosion- and oxidation-resistant ty ...
rebar
Rebar (short for reinforcing bar), known when massed as reinforcing steel or reinforcement steel, is a steel bar used as a Tension (physics), tension device in reinforced concrete and reinforced masonry structures to strengthen and aid the concr ...
.
The '' mix design'' depends on the type of structure being built, how the concrete is mixed and delivered, and how it is placed to form the structure.
Cement
Portland cement is the most common type of cement in general usage. It is a basic ingredient of concrete, mortar, and many
plaster
Plaster is a building material used for the protective or decorative coating of walls and ceilings and for Molding (decorative), moulding and casting decorative elements. In English, "plaster" usually means a material used for the interiors of ...
s. British masonry worker
Joseph Aspdin
Joseph Aspdin (25 December 1778 – 20 March 1855) was an English cement manufacturer who obtained the patent for Portland cement on 21 October 1824.
Life
Aspdin (or Aspden) was the eldest of the six children of Thomas Aspdin, a bricklaye ...
patented Portland cement in 1824. It was named because of the similarity of its color to
Portland limestone
Portland stone is a limestone from the Tithonian stage of the Jurassic period quarried on the Isle of Portland, Dorset. The quarries are cut in beds of white-grey limestone separated by chert beds. It has been used extensively as a building sto ...
, quarried from the English
Isle of Portland
An isle is an island, land surrounded by water. The term is very common in British English. However, there is no clear agreement on what makes an island an isle or its difference, so they are considered synonyms.
Isle may refer to:
Geography
* Is ...
and used extensively in London architecture. It consists of a mixture of calcium silicates (
alite
Alite is an impure form of tricalcium silicate, , sometimes formulated as ( in cement chemist notation), typically with 3-4% of substituent oxides. It is the major, and characteristic, phase in Portland cement. The name was given by Törnebohm i ...
,
belite
Belite is an industrial mineral important in Portland cement manufacture. Its main constituent is dicalcium silicate, Ca2SiO4, sometimes formulated as 2 CaO · SiO2 (C2S in cement chemist notation).
Etymology
The name was given by Törnebohm in ...
),
aluminates
In chemistry, an aluminate is a compound containing an oxyanion of aluminium, such as sodium aluminate. In the naming of inorganic compounds, it is a suffix that indicates a polyatomic anion with a central aluminum atom.
Aluminate oxyanions
Alum ...
and ferrites—compounds which combine calcium, silicon, aluminum and iron in forms which will react with water. Portland cement and similar materials are made by heating
limestone
Limestone ( calcium carbonate ) is a type of carbonate sedimentary rock which is the main source of the material lime. It is composed mostly of the minerals calcite and aragonite, which are different crystal forms of . Limestone forms whe ...
(a source of calcium) with clay or shale (a source of silicon, aluminum and iron) and grinding this product (called '' clinker'') with a source of
sulfate
The sulfate or sulphate ion is a polyatomic anion with the empirical formula . Salts, acid derivatives, and peroxides of sulfate are widely used in industry. Sulfates occur widely in everyday life. Sulfates are salts of sulfuric acid and many ar ...
(most commonly
gypsum
Gypsum is a soft sulfate mineral composed of calcium sulfate dihydrate, with the chemical formula . It is widely mined and is used as a fertilizer and as the main constituent in many forms of plaster, blackboard or sidewalk chalk, and drywall. ...
).
In modern
cement kiln
Cement kilns are used for the pyroprocessing stage of manufacture of portland and other types of hydraulic cement, in which calcium carbonate reacts with silica-bearing minerals to form a mixture of calcium silicates. Over a billion tonnes of ...
s, many advanced features are used to lower the fuel consumption per ton of clinker produced. Cement kilns are extremely large, complex, and inherently dusty industrial installations, and have emissions which must be controlled. Of the various ingredients used to produce a given quantity of concrete, the cement is the most energetically expensive. Even complex and efficient kilns require 3.3 to 3.6 gigajoules of energy to produce a ton of clinker and then grind it into cement. Many kilns can be fueled with difficult-to-dispose-of wastes, the most common being used tires. The extremely high temperatures and long periods of time at those temperatures allows cement kilns to efficiently and completely burn even difficult-to-use fuels.
Water
Combining
water
Water (chemical formula ) is an inorganic, transparent, tasteless, odorless, and nearly colorless chemical substance, which is the main constituent of Earth's hydrosphere and the fluids of all known living organisms (in which it acts as a ...
with a cementitious material forms a cement paste by the process of hydration. The cement paste glues the aggregate together, fills voids within it, and makes it flow more freely.
As stated by
Abrams' law Abrams' law (also called Abrams' water-cement ratio law) is a concept in civil engineering. The law states the strength of a concrete mix is inversely related to the mass ratio of water to cement. As the water content increases, the strength of con ...
, a lower water-to-cement ratio yields a stronger, more
durable
Durability is the ability of a physical product to remain functional, without requiring excessive maintenance or repair, when faced with the challenges of normal operation over its design lifetime. There are several measures of durability in use, ...
concrete, whereas more water gives a freer-flowing concrete with a higher slump. Impure water used to make concrete can cause problems when setting or in causing premature failure of the structure.
Portland cement consists of five major compounds of calcium silicates and alumninates ranging from 5 to 50% in weight, which all undergo hydration to contribute to final material's strength. Thus, the hydration of cement involves many reactions, often occurring at the same time. As the reactions proceed, the products of the cement hydration process gradually bond together the individual sand and gravel particles and other components of the concrete to form a solid mass.
Hydration of tricalcium silicate
:
Cement chemist notation
Cement chemist notation (CCN) was developed to simplify the formulas cement chemists use on a daily basis. It is a shorthand way of writing the chemical formula of oxides of calcium, silicon, and various metals.
Abbreviations of oxides
The main o ...
: C3S + H → C-S-H + CH + heat
:Standard notation: Ca3SiO5 + H2O → (CaO)·(SiO2)·(H2O)(gel) + Ca(OH)2
:Balanced: 2Ca3SiO5 + 7H2O → 3(CaO)·2(SiO2)·4(H2O)(gel) + 3Ca(OH)2 (approximately; the exact ratios of the CaO, SiO2 and H2O in C-S-H can vary)
Due to the nature of the chemical bonds created in these reactions and the final characteristics of the particles formed, the process of cement hydration is considered irreversible, which makes methods of cement recycling prohibitive.
Aggregates
Fine and coarse aggregates make up the bulk of a concrete mixture.
Sand
Sand is a granular material composed of finely divided mineral particles. Sand has various compositions but is defined by its grain size. Sand grains are smaller than gravel and coarser than silt. Sand can also refer to a textural class of s ...
, natural gravel, and
crushed stone
Crushed stone or angular rock is a form of construction aggregate, typically produced by mining a suitable rock deposit and breaking the removed rock down to the desired size using crushers. It is distinct from naturally occurring gravel, which i ...
are used mainly for this purpose. Recycled aggregates (from construction, demolition, and excavation waste) are increasingly used as partial replacements for natural aggregates, while a number of manufactured aggregates, including air-cooled
blast furnace
A blast furnace is a type of metallurgical furnace used for smelting to produce industrial metals, generally pig iron, but also others such as lead or copper. ''Blast'' refers to the combustion air being "forced" or supplied above atmospheric ...
slag and
bottom ash
Bottom ash is part of the non-combustible residue of combustion in a power plant, boiler, furnace or incinerator. In an industrial context, it has traditionally referred to coal combustion and comprises traces of combustibles embedded in formin ...
are also permitted.
The size distribution of the aggregate determines how much binder is required. Aggregate with a very even size distribution has the biggest gaps whereas adding aggregate with smaller particles tends to fill these gaps. The binder must fill the gaps between the aggregate as well as paste the surfaces of the aggregate together, and is typically the most expensive component. Thus, variation in sizes of the aggregate reduces the cost of concrete. The aggregate is nearly always stronger than the binder, so its use does not negatively affect the strength of the concrete.
Redistribution of aggregates after compaction often creates non-homogeneity due to the influence of vibration. This can lead to strength gradients.
Decorative stones such as
quartzite
Quartzite is a hard, non- foliated metamorphic rock which was originally pure quartz sandstone.Essentials of Geology, 3rd Edition, Stephen Marshak, p 182 Sandstone is converted into quartzite through heating and pressure usually related to tect ...
, small river stones or crushed glass are sometimes added to the surface of concrete for a decorative "exposed aggregate" finish, popular among landscape designers.
Admixtures
Admixtures are materials in the form of powder or fluids that are added to the concrete to give it certain characteristics not obtainable with plain concrete mixes. Admixtures are defined as additions "made as the concrete mix is being prepared". The most common admixtures are retarders and accelerators. In normal use, admixture dosages are less than 5% by mass of cement and are added to the concrete at the time of batching/mixing. (See below.) The common types of admixtures are as follows:
* Accelerators speed up the hydration (hardening) of the concrete. Typical materials used are
calcium chloride
Calcium chloride is an inorganic compound, a salt with the chemical formula . It is a white crystalline solid at room temperature, and it is highly soluble in water. It can be created by neutralising hydrochloric acid with calcium hydroxide.
Ca ...
,
calcium nitrate
Calcium nitrate, also called ''Norgessalpeter'' (Norwegian salpeter), is an inorganic compound with the formula Ca(NO3)2(H2O)x. The anhydrous compound, which is rarely encountered, absorbs moisture from the air to give the tetrahydrate. Both anhyd ...
and
sodium nitrate
Sodium nitrate is the chemical compound with the formula . This alkali metal nitrate salt is also known as Chile saltpeter (large deposits of which were historically mined in Chile) to distinguish it from ordinary saltpeter, potassium nitrate. T ...
. However, use of chlorides may cause corrosion in steel reinforcing and is prohibited in some countries, so that nitrates may be favored, even though they are less effective than the chloride salt. Accelerating admixtures are especially useful for modifying the properties of concrete in cold weather.
* Air entraining agents add and entrain tiny air bubbles in the concrete, which reduces damage during
freeze-thaw
Frost weathering is a collective term for several mechanical weathering processes induced by stresses created by the freezing of water into ice. The term serves as an umbrella term for a variety of processes such as frost shattering, frost wedg ...
cycles, increasing
durability
Durability is the ability of a physical product to remain functional, without requiring excessive maintenance or repair, when faced with the challenges of normal operation over its design lifetime. There are several measures of durability in use, ...
. However, entrained air entails a tradeoff with strength, as each 1% of air may decrease compressive strength by 5%. If too much air becomes trapped in the concrete as a result of the mixing process,
defoamer
A defoamer or an anti-foaming agent is a chemical additive that reduces and hinders the formation of foam in industrial process liquids. The terms anti-foam agent and defoamer are often used interchangeably. Strictly speaking, defoamers eliminate ...
s can be used to encourage the air bubble to agglomerate, rise to the surface of the wet concrete and then disperse.
* Bonding agents are used to create a bond between old and new concrete (typically a type of polymer) with wide temperature tolerance and corrosion resistance.
*
Corrosion inhibitor
In chemistry, a corrosion inhibitor or anti-corrosive is a chemical compound that, when added to a liquid or gas, decreases the corrosion rate of a material, typically a metal or an alloy, that comes into contact with the fluid. The effectiveness ...
s are used to minimize the corrosion of steel and steel bars in concrete.
* Crystalline admixtures are typically added during batching of the concrete to lower permeability. The reaction takes place when exposed to water and un-hydrated cement particles to form insoluble needle-shaped crystals, which fill capillary pores and micro-cracks in the concrete to block pathways for water and waterborne contaminates. Concrete with crystalline admixture can expect to self-seal as constant exposure to water will continuously initiate crystallization to ensure permanent waterproof protection.
*
Pigment
A pigment is a colored material that is completely or nearly insoluble in water. In contrast, dyes are typically soluble, at least at some stage in their use. Generally dyes are often organic compounds whereas pigments are often inorganic compo ...
s can be used to change the color of concrete, for aesthetics.
*
Plasticizer
A plasticizer ( UK: plasticiser) is a substance that is added to a material to make it softer and more flexible, to increase its plasticity, to decrease its viscosity, and/or to decrease friction during its handling in manufacture.
Plasticiz ...
s increase the workability of plastic, or "fresh", concrete, allowing it to be placed more easily, with less consolidating effort. A typical plasticizer is lignosulfonate. Plasticizers can be used to reduce the water content of a concrete while maintaining workability and are sometimes called water-reducers due to this use. Such treatment improves its strength and durability characteristics.
*
Superplasticizer
Superplasticizers (SPs), also known as high range water reducers, are additives used in making high strength concrete. Plasticizers are chemical compounds that enable the production of concrete with approximately 15% less water content. Superplast ...
s (also called high-range water-reducers) are a class of plasticizers that have fewer deleterious effects and can be used to increase workability more than is practical with traditional plasticizers. Superplasticizers are used to increase compressive strength. It increases the