oe Comparison of Wet and Dry Process 473 advantages of Wet PTOCeSS are the low cout of 6 x ‘ ner of composition ate WORSE EF Rs dete a ek ee Sete, th slurry, and the economical utilization of fuel igh the elimination of separated drying operations. On the other hand the fonger kilns, essential in Br cess, cost THOTe and are 1eSs responsive to & vi i vet Fa be used in the dry process ariable clinker demand than the short kilns je CHEMISTRY OF SETTING AND HARDENING svhen water is added to cement, the ingredients of cement react chemically with water and form various aphcated chemical compounds. The formation of these compounds is not simultaneous. But setting “non of cement continues for long time. The mixing of cement and water results in a sticky cement wire and it goes on gradually thickening till it achieves a rock-like state. « found that ordinary cement achieves about 70% of its final strength in 28 days and about 90% nal strength in one year or so, Some important compounds formed at the time of setting action of cement: 1. Tricalcium aluminate (3CaO, Al,0,): This compound is formed within 24 hours after addition of water to the cement. Tetra-calcium alumina-ferrite (4CaO, Al,O Fe,0,): This compound is also formed within 24 hours after addition of water to the cement. 3, Tricalcium Silicate (3CaO, Si0,): This compound is formed within a week or so after addition of water to the cement and it is mainly responsible for imparting strength to the cement in early period of setting. 4. Dicalcium Silicate (2CaO, SiO,): This compound is formed very slowly and hence itis responsible for giving progressive strength to the cement. ‘The above four principle minerals in ordinary portland cement are designated in short as C,A, C,AF.C,S and C,S respectively and their relative proportions, expressed as percentages, are as follows: CA 41014 % C,AF 10 to 18 fH cs 4510 65. (alit) cs . 15 to 35 (belit) When water is added to the cement, the quickest to react with water is C,A and in order of decreasing rate are C,AF, C,S and CS. During the initial period of hardening, the gain in strength of C,S is small and its is about 15 percent of that of C,S. After 28 days, the hydration of C,S comes practically to an end and the hydration of C,S only really begins at that time. Hence, when a high-strength concrete is required at a later stage, «i case of hydraulic engineering constructions, the cement is made with a high content of C,S. The hardening of conerete is greatly speeded up by C,A and hence this property of CA is utilized ‘or producing quick-hardening portland cement. Depending upon the mineralogical composition of clinker in percentage, the portland cement can be subdivided conventionally as follows:i j } i 3 2 € « 2 2 y z St et, on pth 102 Building Materiatsand Construction a Alit, containing C,8 more than 50 to 60% in Aluminate, containing CA more than 12% i Alumoferrite, containing C,A less than 2% and C,AP more than 18% 3 Belit, containing CS more than 35% High-alit, containing C,S more than 60% 4.9 VARIOUS STANDARD TESTS ON PORTLAND CEMENT AS PER 4.9.1 Consistency Many test for cements like soundness, setting lime are to be earried out with cement to wh Fequired to produce what is called the ‘normal consistency”. Normal consistency is determina Wier ‘apparatus called Vicat’s needle. It is the consistency at which the Vi t plunger G of 10 mr, Py te and 50 mm length mill penetrate 33-35 mm within 3 to 5 minutes of mixing. The test carry out at least three trial experiments by mixing the cement with distilled water varying toi 24 10 27 percent of the weight of cement. The Vicat’s needle test apparatus is shown im Fea ae 41mm = . . Airvent i 5mm = (@) (b) (co) Fig. 4.7 Vicat apparatus with various plungers (a) 10 mm dia needle for normal consistency (b) 1 mm square needle for initial set (c) 5 mm dia needle for final set. 4.9.2 Setting Time The setting time is also determined by the Vicat’s needle on cement paste of normal consistency. For this test, we use a 1 mm square needle (needle C). For this needle, the time of penetrate 33-35 mm taken as initial setting time. ‘ For final setting time, we use special needle F (which has a diameter of 5 mm) and the time at which this needle will not penetrate more than 0.5 mm is taken as the final set, . False set happens when the ratio of the penetration of the Vicat’s C needle after 300 seconds to the Penetration in 20 seconds is less than 1/2. In such cases the test has to be repeated. The water and test room should be 27 + 2°C.Non porous plate Fig. 4.8 Vicat's Apparatus 493 Fineness iris carried out to check proper grinding of cement. The fineness of cement particles may be determined cither by sieve test or by permeability apparatus test. In sieve test, the cement weighing 100 gm is taken and it is continuously passed for 15 minutes «rough standard BIS sieve no. 9. The residue is then weighed and this weight should not be more than 10 percent of original weight. In permeability apparatus test, specific surface area of cement particles is calculated. This test is better than sieve test and it gives an idea of uniformity of fineness. The specific surface acts as a measure of the frequency of particles of average size. The specific surface of cement should not be less than 0 cm*/gm. 494 Soundness The soundness test is an indication of excess of lime caused by inadequate burning of cement or excess of magnesia or sulphates. Excess of these substances is harmful and thus not allowed in cements. The following two types of tests are used for testing for soundness. (a) Le Chatelier’s test (using Le Chatelier’s apparatus). (b) Autoclave test. 49.5 Le Chatelier’s Test This test shows unsoundness due to lime only. Unaerated cement paste at normal consistency is first tested for expansion. If the test results does not satisfy requirement of 10 mm expansion, another test shall be made after aeration of the cement by spreading of the sample to a depth of 75 mm at a relative humidity of 50 to 80% for 7 days. The expansion in this aerated cement test should not be more than Simm,The apparatus shown above is used Fig. 4.9. Cement pastes with normal c rin consi the mould. After covering both sides with glass, itis first placed in water of tomperaina * Filed ag 24 hour, Ii taken out an the distance between pointers is measured. The mould, 6° 39°C : ‘water and the water is heated to the boiling point in 30 minutes, ‘han Placed Pe Glass Plate ——— Glass Plate Split, 0.5 mm t | i= | a) f tec x -—______ i> 165 mm fond Fig. 4.9 Le Chatelier's Test | oe & 4.9.6 Autoclave Test pag Ics the another test used for soundness of cement. tis sensitive to both lime and magnesia At je 3 cement having a magnesia content more than 3 per cent is to be tested for sound: Iness by this test wit, unaerated cement, The est consists of heating bars made of cement paste with water of normal conse and measuring its expansion. Effect of unsoundness of cement does not appear inthe field for consider period of time. Hence, these accelerated tests are needed to determine them. In autoclave test, weg, higher pressure and temperature to accelerate the reactions. The autoclave expansion of unaeratedcemey should not be more than 0.8 per cent and that of cement not more than 0.6 per cent, 5 4.9.7 Strength Cement hydrates when water is added to it and cohesion and solidity is exhibited. It binds togetherihe agaregates by adhesion. The strength of mortar and concrete depends upon the type and nature of cement. So, it should develop a minimum specified strength if it is to be used in structures. Cements tested for compressive and tensile strengths. 3 Compressive strength isthe basic data required for mix design. By this tes, the quality and quai of concrete can be controlled and the degree of adulteration can be checked. ae 440 STORAGE OF CEMENT {In major construction works, it will be always necessary to keep a good stock of cement at site.1 ‘cement shall always be stored in suitable weather-tight buildings which can protect if from d may be stored as bags in sheds or in bulk in silos made of concrete or steel. When storing bags, the following guidelines should be observed.