Concrete is a composite material composed of aggregate bonded together with a fluid cement that cures to a solid over time. Concrete is the second-most-used substance in the world after water,[1] and is the most widely used building material.[2] Its usage worldwide, ton for ton, is twice that of steel, wood, plastics, and aluminium combined.[3]
When aggregate is mixed with dry Portland cement and water, the mixture forms a fluid slurry that is easily poured and molded into shape. The cement reacts with the water through a process called concrete hydration[4] that hardens it over several hours to form a hard matrix that binds the materials together into a durable stone-like material that has many uses.[5] This time allows concrete to not only be cast in forms, but also to have a variety of tooled processes performed. The hydration process is exothermic, which means ambient temperature plays a significant role in how long it takes concrete to set. Often, additives (such as pozzolans or superplasticizers) 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 steel rebar) embedded to provide tensile strength, yielding reinforced concrete.
In the past, lime-based cement binders, such as lime putty, were often used but sometimes with other hydraulic cements, (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).[6][7] Many other non-cementitious types of concrete exist with other methods of binding aggregate together, including asphalt concrete with a bitumen binder, which is frequently used for road surfaces, 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 bricks, tiles and other masonry units together.[8] Grout is another material associated with concrete and cement. It does not contain coarse aggregates and is usually either pourable or thixotropic, and is used to fill gaps between masonry components or coarse aggregate which has already been put in place. Some methods of concrete manufacture and repair involve pumping grout into the gaps to make up a solid mass in situ.
Concrete floors were found in the royal palace of Tiryns, Greece, which dates roughly to 1400 to 1200 BC.[10][11] Lime mortars were used in Greece, such as in Crete and Cyprus, in 800 BC. The Assyrian Jerwan Aqueduct (688 BC) made use of waterproof concrete.[12] Concrete was used for construction in many ancient structures.[13]
Small-scale production of concrete-like materials was pioneered by the Nabatean 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, with some self-cementing properties, by 700 BC. They built kilns to supply mortar for the construction of rubble masonry houses, concrete floors, and underground waterproof cisterns. They kept the cisterns secret as these enabled the Nabataeans to thrive in the desert.[14] Some of these structures survive to this day.[14]
The Romans used concrete extensively from 300 BCE to 476 CE.[16] During the Roman Empire, Roman concrete (or opus caementicium) was made from quicklime, pozzolana and an aggregate of pumice. Its widespread use in many Roman structures, a key event in the history of architecture 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.[17] The Colosseum in Rome was built largely of concrete, and the Pantheon has the world's largest unreinforced concrete dome.[18]
Concrete, as the Romans knew it, was a new and revolutionary material. Laid in the shape of arches, vaults and domes, 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.[19]
Modern tests show that opus caementicium had as much compressive strength as modern Portland-cement concrete (c. 200 kg/cm2 [20 MPa; 2,800 psi]).[20] However, due to the absence of reinforcement, its tensile strength was far lower than modern reinforced concrete, and its mode of application also differed:[21]
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. 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.[22]
The widespread use of concrete in many Roman structures ensured that many survive to the present day. The Baths of Caracalla in Rome are just one example. Many Roman aqueducts and bridges, such as the magnificent Pont du Gard in southern France, have masonry cladding on a concrete core, as does the dome of the Pantheon.
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 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 cores) and foundations. Bartholomaeus Anglicus 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.[29]
Perhaps the greatest step forward in the modern use of concrete was Smeaton's Tower, built by British engineer John Smeaton in Devon, England, between 1756 and 1759. This third Eddystone Lighthouse pioneered the use of hydraulic lime in concrete, using pebbles and powdered brick as aggregate.[31]
A method for producing Portland cement was developed in England and patented by Joseph Aspdin in 1824.[32] Aspdin chose the name for its similarity to Portland stone, which was quarried on the Isle of Portland in Dorset, England. His son William continued developments into the 1840s, earning him recognition for the development of "modern" Portland cement.[33]
Reinforced concrete was invented in 1849 by Joseph Monier.[34] and the first reinforced concrete house was built by Franois Coignet[35] in 1853.The first concrete reinforced bridge was designed and built by Joseph Monier in 1875.[36]
Prestressed concrete and post-tensioned concrete were pioneered by Eugne Freyssinet, a French structural and civil engineer. Concrete components or structures are compressed by tendon cables during, or after, their fabrication in order to strengthen them against tensile forces developing when put in service. Freyssinet patented the technique on 2 October 1928.[37]
Concrete is an artificial composite material, comprising a matrix of cementitious binder (typically Portland cement paste or asphalt) 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.[38] Many types of concrete 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.
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, a by-product of coal-fired power plants; ground granulated blast furnace slag, a by-product of steelmaking; and silica fume, a by-product of industrial electric arc furnaces.
Structures employing Portland cement concrete usually include steel reinforcement because this type of concrete can be formulated with high compressive strength, but always has lower tensile strength. Therefore, it is usually reinforced with materials that are strong in tension, typically steel rebar.
Cement kilns are extremely large, complex, and inherently dusty industrial installations. 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.[41] The five major compounds of calcium silicates and aluminates comprising Portland cement range from 5 to 50% in weight.
As stated by Abrams' law, a lower water-to-cement ratio yields a stronger, more durable concrete, whereas more water gives a freer-flowing concrete with a higher slump.[43] The hydration of cement involves many concurrent reactions. The process involves polymerization, the interlinking of the silicates and aluminate components as well as their bonding to sand and gravel particles to form a solid mass.[44] One illustrative conversion is the hydration of tricalcium silicate:
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