The Structure of Concrete

Three phases present in concrete:

(1) Aggregate particles (2) Hydrated cement paste (hcp) (3) Transition zone, which is the interfacial region between the aggregates and the hcp.

The amount, size, shape and distribution of these three phases constitute the structure of concrete. Macrostructure - the structure visible to the human eyes. Microstructure - the microscopically magnified portion of a macrostructure. The structure of concrete is highly heterogeneous and dynamic (i.e. changes with time).

Structure of the Aggregate Phase

Aggregates in concrete are usually chemically stable. Thus, the properties of concrete are influenced primarily by the physical rather than the chemical properties of the aggregate. The aggregate phase is predominantly responsible for the unit weight, elastic modulus and thermal properties of the concrete. Effects of the shape and texture of the coarse aggregate:
More angular and rougher texture gives better bonding with the cement paste, but lower consistency in the fresh concrete.

The aggregate phase is usually stronger than the other two phases of concrete, and does not affect the strength of the concrete, except in the case of weak aggregates.

Effects of flat and elongated aggregate tendency to trap bleed water.

Structure of Hydrated Cement Paste

Anhydrous Portland cement - angular particles in the size range 1 to 50 m. Calcium silicate hydrate (C3S2H3 or C-S-H)
Recall the chemical reactions:

2C3S + 6H C3S2H3 + 3CH 2C2S + 4H C3S2H3 + CH

C-S-H makes up 50 to 60% of the solids in a completely hydrated cement paste. C-S-H appear as very small fibrous crystals which fill the space formerly occupied by water and the dissolved cement particles.

Calcium hydroxide
Constitutes 20 to 25% of the volume of solids in the hydrated paste. Large prismatic crystals. Little contribution to strength of concrete. Chemically unstable. High solubility in acidic solution.

Ettringite
Recall :
C3A + 3CH2 + 26H C3A3CH32 (Ettringite) (Formed at the beginning of hydration process) C3ACH12-18 + 2CH + 2 + (10-16)H C3A3CH32 (Formed as a result of sulfate attack on monosulfate hydrate)

Needle-shaped prismatic crystals.

Monosulfate hydrate
Recall: C3A + CH2 + (10-16)H C3ACH12-18 (Monosulfate) (From hydration of C3A) C3A3CH32 + 2C3A + (4-22)H 3(C3ACH12-18 ) (From ettringite at the early stage of hydration.) Hexagonal plate crystals. Susceptible to sulfate attack.

Unhydrated clinker grain

Some unhydrated clinker grains may be found in the microstructure of hydrated cement pastes.

Interlayer space in C-S-H

This void size is small and does not have any adverse effect on the strength and permeability of the hydrated cement paste.

 Capillary voids
Space not filled by the solid components of the hcp. Range from 10 to 50 nm in size in low w/c paste, and from 3 to 5 m in high w/c paste.

Air voids
Consists of entrapped air produced during mixing, and entrained air produced as a result of addition of an airentraining admixture. They are larger than capillary voids.

Capillary water
Water present in the voids, but free from the influence of the attractive forces exerted by the solid surface. Two categories: (1) Free water in voids larger than 50 nm, whose removal does not cause any volume change. (2) Water held by capillary tension in small capillaries.

Adsorbed water
Water adsorbed onto the surface of solids in the hcp.

Interlayer water
This is the water associated with the C-S-H structure. Monomolecular water layer between layers of C-S-H. Lost only on strong drying. The C-S-H structure shrinks considerably when the interlayer water is lost.

Strength of hydrated cement paste

1 cm3 of cement produces 2 cm3 of hydration product. The hydration product will occupy the space previously occupied by the cement particles and water. Solids-to-space ratio increases as the hydration progresses. Solids-to-space ratio increases as the w/c decreases. Strength increases as the solids-to-space ratio increases (Powers equation) Compressive strength = kx3 where k = 34,000 psi x = solids-to-space ratio

Calculations in Case A
Assume volume of cement = 100 cm3 w/c = 0.63 mass of cement = 100 x 3.15 =315 g mass of water = 315 X 0.63 g = 200 g (round off) volume of water = 200 cm3 total volume of paste = 100 + 200 = 300 cm3 At 0% hydration Volume of solid = volume of cement = 100 cm3 Solid-to-space ratio = 100/300 = .33 or 33% At 50% hydration 50% of the cement (with a volume of 50 cm3) hydrates to form a hydration product with a volume of 100 cm3.

Total volume of solid = vol. of hydration product + vol. of unhydrated cement = 100 + 50 = 150 cm3 Solid-to-space ratio = 150/300 = .50 or 50% At 75% Hydration 75% of the cement (with a volume of 75 cm3) hydrates to form a hydration product with a volume of 150 cm3. Total volume of solid = 150 + 25 cm3 = 175 cm3 Solid-to-space ratio = 175/300 = .58 or 58% At 100% Hydration Total volume of solid = vol. Of hydration product = 200 cm3 Solid-to-space ratio = 200/300 = .67 or 67%

Calculations in Case B
Assume volume of Cement = 100 cm3 mass of cement = 315 g At w/c of 0.4 mass of water = 315 X 0.4 = 126 g volume of water = 126 cm3 Total volume of paste = 100 + 126 = 226 cm3 Volume of hydration production at 100% hydration = 200 cm3 Solid-to-space ratio = 200/226 = .885 or 88.5%

 Dimensional stability
When saturated hcp is held at 100% relative humidity (RH), no dimensional change will occur. When saturated hcp is held at less than 100% RH, the free water in the large cavities will escape first. There is little shrinkage at this point. When most of the free water has been lost, on continued drying, water in the small capillaries and adsorbed water will escape, causing considerable shrinkage.

Durability
The hcp is alkaline. Exposure to acidic waters is detrimental to the material. A lower permeability of the hcp will lower the exposure and thus increase the durability. Permeability is directly related to porosity. Thus, a lower porosity of the hcp will give a lower permeability, which will give a greater durability.

Transition Zone in Concrete

Structure of the Transition Zone
In freshly mixed concrete, water films form around the large aggregate particles, resulting in a higher w/c ratio closer to the larger aggregates. Owing to the high w/c ratio, the hydration products in the transition zone are relatively larger crystals, which form a more porous framework.

Strength of the Transition Zone

The volume and size of voids in the transition zone are larger than in the bulk mortar. Consequently, its strength is lower. The large calcium hydroxide crystals in the transition zone also reduce its strength. Differential movements between the aggregate and the hcp due to drying or cooling cause microcracks in the transition zone, resulting in a lower strength.

 Influence of the Transition Zone on Properties of Concrete

The transition zone is the weakest phase, and thus is the strength-limiting phase in concrete. The transition zone explains why concrete fails at a considerably lower stress level than the strength of either the aggregate or the hardened cement paste. It takes considerably more energy to propagate cracks under compression than in tension. This explains why concrete fails in a brittle manner in tension, but is relatively tougher in compression. This also explains why the tensile strength is much lower than the compressive strength.

The microcracks present in the transition zone explains why the aggregate and hcp remain elastic until fracture in a uniaxial compression test, whereas concrete shows inelastic behavior.

 Influence of the Transition Zone on Properties of Concrete (Continued)

The structure of the transition zone (with its high volume of voids and microcracks) explains why the stiffness of the concrete is less than either that of the aggregate or the hcp. The existence of microcracks in the transition zone explains why the permeability of the concrete is higher than the permeability of the hcp, or the aggregate. The w/c ratio in the transition zone affects the strength of the concrete. In general, the larger the aggregate, the higher will be the local w/c ratio in the transition zone and, consequently, the weaker and more permeable will be the concrete.