CE 8: C O N S T R U C T I O N M A T E R I A L S A N D T E S T I N G

UNIT 3:
CEMENT
 What is Cement?

How is Cement Made?

SCOPE Cement Reaction with water

Types of Cement
Ordinary Portland Cement
Blended Cement
Historical Facts
About Cement
Gypsum Limestone Volcanic ash
- Earliest use since 2000 years ago

- Egyptians used calcined gypsum

- Romans and Greeks used method of

heating limestone Process of producing
cement : firing mixture
- Romans mix volcanic ash and lime
of lime and clay
- Patent on cement was granted to
Joseph Aspdin in 1824
+

=
Joseph Aspdin
cement
 + =

What is cement? cement water Cement paste

+ +

cement water Fine aggregates

A fine power substance that reacts
=
w i t h w a t e r t o f o r m a k i n d o f b i n d e r.

mortar

+ +

cement water
Fine aggregates
+
Coarse
= concrete
Aggregates
How to Produce a
cement
Step 1 : Produce a material

Called Clinker

Step 2 : From Clinker produce a

finished product: cement

 Note that C02 (greenhouse) is

To produce Clinker emitted from coal burning as fuel and

heating of limestone (calcinating)

Compounds that influence

the property of cement
+

Limestone Silica Sand

(CaC03) (Si02)

1450 °C C02
 Note that C02 (greenhouse has) is

To produce Clinker emitted from coal burning as fuel and

heating of limestone (calcinating)

Compounds that influence

the property of cement
+

C3S – early strength

Limestone Silica Sand
((CaC03) (Si02) C2S – later strength

1450 °C C02 C3A – setting time

C4AF – color of cement

 Step 2: Produce Cement using Clinker
F r o m t h e C l i n k e r, w e c a n p r o d u c e P o r t l a n d C e m e n t

+
Grinding Portland
Clinker Gypsum Cement
( To r e g u l a t e s e t t i n g t i m e )

F r o m t h e C l i n k e r, w e c a n a l s o p r o d u c e B l e n d e d
Cement

+ + Mineral
Component Grinding Blended
Clinker Gypsum Fly Ash, Cement
Pozzolan, Slag

( To r e g u l a t e s e t t i n g t i m e )
 SUPPLEMENTARY CEMENTITIOUS MATERIALS
These materials have been used to improve some properties of concrete and to reduce
the problem of discarding them. Since these materials are cementitious, they can be
used in addition to or as a partial replacement for portland cement. In fact, two or
more of these supplementary cementitious additives have been used together to
enhance concrete properties

F LY A S H SLAG CEMENT
- a b y - p r o d u c t o f t h e c o a l i n d u s t r y. made from iron blast furnace slag.
It increases the workability of the It has been used as a cementitious
fresh concrete. In addition, fly ash
extends the hydration process
material in concrete since the
beginning of the 1900s

SILICA FUME
a by-product of the production of silicon
metal or ferrosilicon alloys. One of the
most beneficial uses for silica fume is as
a mineral admixture in concrete.
Concrete containing silica fume can have
very high strength and can be very
durable.
N AT U R A L P O Z Z O L A N S
Naturally occurring pozzolans, such
as fine volcanic ash, combined with
burned lime, were used about 2000
years ago for building construction,
and pozzolan continues to be used
t o d a y.
Process Flow: Portland Cement
Process Flow: Blended Cement
Common Plant of Cement
 Common Plant of Cement
Clinker Production

Raw Material Extraction

and Preparation

Cement Kiln

Cement Griding

Cement
Grinding
 Raw Material Mixture
Compounds that influence
Oxides Sources the property of cement

CaO Limestone C3S – early strength

Si02 Sand C2S – later strength

Ai203 C l a y, S h a l e C3A – setting time

Fe 2 0 3 Iron Oxide, C4AF – color of cement

Hematite
 H Y D R AT I O N O F P O R T L A N D

CEMENT

Hydration is the chemical reaction between

the cement particles and water. The features
of this reaction are the change in matter, the
change in energy level, and the rate of
reaction. When water is added to cement,
each of the compounds undergoes hydration
and contributes to the final concrete
product. Only the calcium silicates contribute
to strength. Tricalcium silicate is responsible
for most of the early strength (first 7 days).
Dicalcium silicate, which reacts more slowly,
contributes only to the strength at later
times.
 M I X I N G WAT E R

Any potable water is suitable for making

concrete. However, some nonpotable water
may also be suitable. Frequently, material
suppliers will use unprocessed surface or well
water if it can be obtained at a lower cost
than processed water. However, impurities in
the mixing water can affect concrete set
time, strength, and long-term durability In
addition, chloride ions in the mixing water
can accelerate corrosion of reinforcing steel
 PROPERTIES OF HYDRATED CEMENT

SETTING SOUNDNESS COMPRESSIVE STRENGTH WAT E R - C E M E N T R AT I O

O F M O R TA R

Soundness of the In 1918, Abrams found that the

refers to the Compressive strength of mortar
cement paste refers to ratio of the weight of water to the
stiffening of the is measured by preparing 50-
its ability to retain its weight of cement, water–cement
cement paste or mm (2 in.) cubes and subjecting
volume after setting. . ratio, influences all the desirable
the change from a them to compression according
The autoclave qualities of concrete. For fully
plastic state to a to ASTM C109. The mortar is
expansion test (ASTM compacted concrete made with
solid state. prepared with cement, water,
C151) is used to check sound and clean aggregates,
and standard sand (ASTM
• initial set and the soundness of the strength and other desirable
C778). Minimum compressive
final set. cement paste. properties are improved by
strength values are specified by
reducing the weight of water used
• ASTM C191 ASTM C150 for different
per unit weight of cement. This
cement types at different ages.
concept is frequently identified as
Abrams’ law.
Types of Portland Cement
Types of Portland Cement
Identifying Mark in 40 Kg Bags (PNS 07)
Types of Blended Cement
Types of Blended Cement
Identifying Mark in 40 Kg Bags (PNS 63:2005)
Portland Vs Blended Cement
More porous because of long Less porous because of shorter and not
and continuous pores connect pores
 ADMIXTURES
Admixtures are ingredients other than portland cement, water, and aggregates that
may be added to concrete to impart a specific quality to either the plastic (fresh)
mix or the hardened concrete (ASTM C494). Admixtures are classified by the
following chemical and functional physical characteristics:

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WAT E R R E D U C E R S A C C E L E R ATO R S

R E TA R D E R S S P E C I A LT Y A D M I X T U R E S