Unit-4 part 1

Cement

By
Dr. Shankar Singh Kushwaha

Civil Engineering, I-Semester

CE112 Construction Materials
Department of Civil Engineering
Maulana Azad National Institute of Technology, Bhopal
(M.P.)
 Presentation outline
 Introduction
 Types
 Indian Standard Classification of Lime
 Lime Kiln
 Why Use Lime?
 Test of Lime
 Introduction
Cement is the mixture of calcareous, siliceous, argillaceous and

other substances. Cement is used as a binding material in mortar,

concrete, etc.
 Introduction
Cement is a fine powder which sets after a few hours when

mixed with water, and then hardens in a few days into a solid,
strong material.

Cement is mainly used to bind fine sand and coarse

aggregates together in concrete.

Cement is a hydraulic binder, i.e. it hardens when water is

added.

It was first produced by a mason Joseph Aspdin in

England in 1924. He patented it as portland cement.

Lime stone mines in india
 Chemical Composition of cement

Lime 63%
Silica 22%
Alumina 06%
Iron oxide 03%
Gypsum 02 to 05%
 Function of composition of cement
(i) Lime(CaO):
Lime forms nearly two-third (2/3) of the cement.
Therefore sufficient quantity of the lime must be in the raw
materials for the manufacturing of cement.
Its proportion has an important effect on the cement.
Sufficient quantity of lime forms di-calcium silicate and tri-
calcium silicate in the manufacturing of cement.
Lime in excess, causes the cement to expand and
disintegrate.
(ii) Silica (SiO2):
The quantity of silica should be enough to form di-calcium silicate
and tri-calcium silicate in the manufacturing of cement.
Silica gives strength to the cement. Silica in excess causes the
cement to set slowly.

(iii) Alumina (Al2O3):

Alumina supports to set quickly to the cement.
It also lowers the clinkering temperature.
Alumina in excess, reduces the strength of the cement.

(iv) Iron Oxide (Fe2O3):

Iron oxide gives colour to the cement.

(v) Calcium Sulphate (or) Gypsum (Ca SO4):

 At the final stage of manufacturing, gypsum is added to increase the
setting of cement.
 MANUFACTURING OF CEMENT

(1) Mixing and crushing of raw materials

a.Dry process
b.Wet process
(2) Burning
(3) Grinding
 Conti…
(a) Dry process:
In this process, the raw materials are changed to powdered
form in the absence of water.
 In this process calcareous material such as lime stone
(calcium carbonate) and argillaceous material such as
clay are ground separately to fine powder in the absence
of water and then are mixed together in the desired
proportions.
 Water is then added to it for getting thick paste and then
its cakes are formed, dried and burnt in kilns.
 This process is usually used when raw materials are very
strong and hard.
 Cont…
(b) Wet
process:
In this process, the raw materials
are changed to powdered form in
the
 In thispresence
process, rawof water.
materials are pulverized by using a
Ball mill, which is a rotary steel cylinder with hardened
steel balls. When the mill rotates, steel balls pulverize
the raw materials which form slurry (liquid mixture).
 The slurry is then passed into storage tanks, where
correct proportioning is done. Proper composition of raw
materials can be ensured by using wet process than dry
process. Corrected slurry is then fed into rotary kiln for
burning.
 This process is generally used when raw materials are
soft because complete mixing is not possible unless
water is added.
(2) Burning:
 The raw slurry (wet Process) or raw meal (dry process), obtained by
one of wet or dry process is called charge.
 Charge is introduced into a rotary Kiln. The rotary kiln consists of a
steel cylinder about 150meters long and 4meter diameter and rotates
30 to 60 turns per hour.
 At one end of the cylinder a screw conveyer is arranged which
slowly allows the charge into the cylinder.
 In the other end of the cylinder, a burner is arranged. Coal or
burning oil is burnt at this end.
 The charge entering the cylinder slowly moves towards the hot end.
At the burning end of the kiln, the temperature is around 1600 to
1900 degrees centigrade.
 At this end some chemical reactions takes place between oxides of
calcium , aluminium and silica.
 Mixture of calcium silicates and calcium aluminates is formed.
 The resultant product consists of grey hard balls called clinker
cement.
The percentage of important compound formed in
cement is given below:
(Bogue's compound of cement)
 (3) Grinding:

• Clinker cement is cooled, ground to fine powder

and mixed with 2 to 5 percent of gypsum
(Calcium sulphate Ca SO4) .
(added for controlling the setting time of cement)
• Finally, fine ground cement is stored in storage
tanks from where it is drawn for packing.
 Hydration of cement
The chemical reactions that take place between cement and
water is referred as hydration of cement.
On account of hydration certain products are formed. These
products are important because they have cementing or
adhesive value.
Out of all cement compounds (bogue's compound of
cement), the strength of cement is contributed mainly by
silicates.
Silicates react with water and produce a gel called Calcium
Silicate Hydrate or ‘C-S-H’ gel.
This gel is initially weak and porous, but with the passage
of time it becomes stronger and less porous.
 In the order of reaction with water, C3A is the first to react with it
and imparts setting to the cement paste. Hence C3A is responsible
for setting.

 Strength contribution by C3A is negligible and therefore can very

well be neglected.

 Strength of cement is mainly contributed by silicates i.e. C3S and

C2S.

 In the category of silicates, C3S is quicker in reacting with water as

compared to C2S. Therefore the initial strength up to 7 days is
mainly given by C3S.

 After 7 days when most of C3S has already exhausted, C2S also
start reacting with water. The strength between 7 and 28 days is
contributed mainly by C2S and a part is contributed by C3S
 Which cement to use?

The choice of the cement depends upon the nature of work,

local environment, method of construction etc.

The different type of cement has been achieved by

different methods like :
Types of cement
(a) Ordinary Portland Cement (OPC):
It is the most commonly produced and used cement. It is
available in three different grades.

(b) Rapid Hardening cement (RHC):

It is also called ‘Early Strength Cement’ because its 3 days
strength is almost equal to 7 days strength of OPC. One type of this
cement is manufactured by adding calcium chloride (CaCl2) to the
O.P.C in small proportions. Calcium chloride (CaCl2) should
not be more than 02%.
In RHC, strength development is very fast. This is because of
following reasons:

 Higher fineness of cement. The specific surface of this cement is

increased to 320 m2/kg as compared to 225 m2/kg for OPC.
 Higher quantity of C3S in cement as compared to C2S. C3S is
more reactive in comparison to C2S.
The sulphate present in the soil or surrounding environment
reacts with free Ca(OH)2 available in the concrete and
CaSO4 is formed. There is no dearth of free Ca(OH)2 as it
is available in abundance in the set cement. The CaSO4 thus
produced reacts with hydrate of calcium aluminate and
form an expansive compound called calcium sulpho-
aluminate which causes expansion and cracks in the set
cement. Sulphate attack is further accelerated if it is
accompanied by alternate wetting and drying also, which
(d) Sulphate Resistant Cement (SRC):
It is modified form of O.P.C and is specially manufactured
to resist the sulphates. In certain regions/areas where water
and soil may have alkaline contents and O.P.C is liable to
disintegrate, because of un favorable chemical reaction
between cement and water, S.R.C is used. This cement
contains a low %age of C3A not more than 05%.

The quantity of C3A can be controlled

simply byblending OPC with slag cement.
Limitation:
This cement requires longer period of curing (why?). It
develops strength slowly, but ultimately it is as strong as
O.P.C.
(e) Portland slag cement:
It is produced by blending OPC clinkers with slag in
suitable proportion (20-25%) and grinding together.
The slag can be separately added to OPC while
making concrete.

Limitation of slag cement:

It develops strength slowly, but ultimately it is as
strong as O.P.C.
 (e) Portland Pozzolana
cement:
It is produced by blending OPC clinkers with
pozzolana in suitable proportion (20-25%) and grinding
together.

It develops strength slowly, but ultimately it is as

strong as O.P.C.
(f) QUICK SETTING CEMENT:
When concrete is to be laid under water, quick setting
cement is to used. This cement is manufactured by adding
small %age of aluminum sulphate (Al2SO4) which accelerates
the setting action. This cement can also be produced by not
adding gypsum to OPC The setting action of such cement
starts with in 05 minutes after addition of water and it
becomes stone hard in less than half an hour.

(h) LOW HEAT CEMENT:

In this cement the heat of hydration is reduced by tri
calcium aluminate (C3A ) content. It contains less %age of
lime than ordinary port land cement. It is used for mass
concrete works such as dams etc.
WHITE CEMENT:
This cement is called snowcrete. As iron oxide gives the
grey colour to cement, it is therefore necessary for white
cement to keep the content of iron oxide as low as possible.
Lime stone and china clay free from iron oxide are suitable
for its manufacturing. This cement is costlier than O.P.C. It
is mainly used for architectural finishing in the buildings.
 Tests on
Cement
 Field Test
 Laboratory test
Field
Test
(a)Date of Manufacture

(b)One feels cool by thrusting one’s hand in the cement bag.

(c)It is smooth when rubbed in between fingers.
(d)A handful of cement thrown in a bucket of water should
float.
 Laboratory test (IS 269–1967)

(1) Fineness Test.

(2) Consistency test.

(3) Setting Time Test.

(4) Soundness test.

(5) Compressive strength test.
 Fineness Test
It is measured in terms of percentage of weight
retained after sieving the cement through 90 micron
sieve or by surface area of cement in square centimetres
per gram of cement.
According to IS code specification weight retained on
the sieve should not be more than 10 per cent.
In terms of specific surface should not be less than
2250 cm2/gm.
 Setting Times

A period of 30 minutes as minimum setting time

for initial setting and a maximum period of 600
minutes as maximum setting time is specified by IS
code, provided the tests are conducted as per the
procedure prescribed by IS 269-1967.
Setting Times

Vicat Apparatus
 Soundness Test
Once the concrete has hardened it is necessary to
ensure that no volumetric changes takes place.
The cement is said to be unsound, if it exhibits
volumetric instability after hardening.
IS code recommends test with Le Chatelier mould
for testing this property.
At the end of the test, the indicator of Le Chatelier
mould should not expand by more than 10 mm.
Soundness Test

Le Chatelier Apparatus
 Crushing Strength Test
For this 200 gm of cement is mixed with 600 gm
of standard sand confirming to IS 650–1966.
These mortar (1:3) cubes are made with standard
size (70.6 mm or 5000 mm2) and tested in
compression testing machine as per the specification
of IS code.
Average of three cubes is reported as crushing
strength.
The compressive strength at the end of 3 days
should not be less than 11.5 N/mm2 and that at the
end of 7 days not less than 17.5 N/mm2.
 Uses of Cement
(i) Cement slurry is used for filling cracks in concrete
structures.
(ii) Cement mortar is used for masonry work, plastering and
pointing.
(iii) Cement concrete is used for the construction of various
structures like buildings, bridges.
water tanks, tunnels, docks, harhours etc.
(iv) Cement is used to manufacture lamp posts, telephone
posts, railway sleepers, piles etc.
(v) For manufacturing cement pipes, garden seats, dust bins,
flower pots etc. cement is commonly
used.
(vi) It is useful for the construction of roads, footpaths, courts
for various sports etc.