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OPUS CAEMENTICIUM

Roman concrete also called Opus caementicium was a material used in construction during the late Roman Republic through the whole history of the Roman Empire. Roman concrete was based on hydraulic-setting cement with many material qualities similar to modern Portland cement. By the middle of the first century, the material was used frequently as brick-faced concrete, although variations in aggregate allowed different arrangements of materials. Further innovative developments in the material, coined the Concrete Revolution and contributed to structurally complicated forms, such as the Pantheon dome.

Vitruvius, writing around 25 BC in his Ten Books on Architecture, distinguished types of aggregate appropriate for the preparation of lime mortars. For structural mortars, he recommended pozzolana, which were volcanic sands from the sand like beds of Puteoli brownish-yellow-gray in color near Naples and reddish-brown at Rome. Vitruvius specifies a ratio of 1 part lime to 3 parts pozzolana for cements used in buildings and a 1:2 ratio of lime to pulvis Puteolanus for underwater work, essentially the same ratio mixed today for concrete used at sea.

By the middle of the first century, the principles of underwater construction in concrete were well known to Roman builders. The City of Caesarea was the earliest known example to have made use of underwater Roman concrete technology on such a large scale.

Rebuilding Rome after the fire in 64 AD, which destroyed large portions of the city, the new building code by Nero consisted of largely brick-faced concrete. This appears to have encouraged the development of the brick and concrete industries.

Shotcrete

Shotcrete and gunite are two commonly used terms for substances applied via pressure hoses. Shotcrete is concrete (or sometimes mortar) conveyed through a hose and pneumatically projected at high velocity onto a surface. Shotcrete undergoes placement and compaction at the same time due to the force with which it is projected from the nozzle. It can be impacted onto any type or shape of surface, including vertical or overhead areas.

The dry mix method involves placing the dry ingredients into a hopper and then conveying them pneumatically through a hose to the nozzle. The nozzle man controls the addition of water at the nozzle. The water and the dry mixture is not completely mixed, but is completed as the mixture hits the receiving surface. This requires a skilled nozzle man, especially in the case of thick or heavily reinforced sections. Advantages of the dry mix process are that the water content can be adjusted instantaneously by the nozzle man, allowing more effective placement in overhead and vertical applications without using accelerators. The dry mix process is useful in repair applications when it is necessary to stop frequently, as the dry material is easily discharged from the hose.

Wet-mix shotcrete involves pumping of a previously prepared concrete, typically ready-mixed concrete, to the nozzle. Compressed air is introduced at the nozzle to impel the mixture onto the receiving surface. The wet-gun procedure generally produces less rebound, waste (when material falls to the floor), and dust compared to the dry-mix procedure. The greatest advantage of the wet-mix process is that larger volumes can be placed in less time.

Mortar

Mortar is a workable paste used to bind construction blocks together and fill the gaps between them. The blocks may be stone, brick, cinder blocks, etc. Mortar becomes hard when it sets, resulting in a rigid aggregate structure. Modern mortars are typically made from a mixture of sand, a binder such as cement or lime, and water. Mortar can also be used to fix, or point, masonry when the original mortar has washed away

Portland cement mortar (often known simply as cement mortar) is created by mixing Ordinary Portland cement (OPC) with sand and water.

It was invented in 1794 by Joseph Aspdin and patented on 18 December 1824, largely as a result of various scientific efforts to develop stronger mortars than existed at the time. It was popularized during the late nineteenth century, and owing to the First World War, by 1930 it had superseded lime mortar for new construction. The main reasons for this were that Portland cement sets hard and quickly, allowing a faster pace of construction, and requires less skilled workers. However, as a general rule, Portland cement should not be used for the repair of older buildings constructed in lime mortar, which require the flexibility, softness and breathability of lime if they are to function correctly.

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