2/14/2021

Cement: Introduction Cement : Classification

A fine powdery substance exhibiting adhesive and cohesive
According to mode of setting and hardening
properties.
Classification
M  Made by calcining Lime and Clay, mixed
M
with water to form mortar or mixed with
A sand, gravel and water to make concrete.
 It is a binder that sets hardens
A
independently and can bind other Non-hydraulic cement Hydraulic cement
N materials together. N
I https://www.slideshare.net/anshumanabhisek/intr
oduction-to-cement
I Cement that sets and hardens by
Harden alone and cannot be
hydration and is capable of doing so
T Most important use of cement is the
lime + clay + water = cement T used under water.
e.g. a) Gypsum plaster
under water
production of mortar and concrete e.g. a) Portland cement
BHOPAL cement + sand + gravel = concrete BHOPAL b) Lime mortars
bonding materials like stones, bricks, b) High alumina cement
building block etc.

Cement production in India Cement: Raw Materials

desired cement quality can

achieve the by altering the
M M amount of an ingredient
during cement production.
A A
N N
I India is second largest I
producer of cement in
T the world T
BHOPAL  270,000 thousand BHOPAL
metric tons
https://thedesignbridge.in/blog/cement-manufacturing-functions-composing-properties-application-characteristics/
 2/14/2021

Cement: raw material fucntons Gypsum

Ingredient Function Composition Gypsum is natural accruing mineral with formula CaSO4·2H2O
(%) Found in layered sedimentary deposits in association with halite, anhydrite,
Lime (CaO) Control strength. Deficiency of it cause 60- 67 sulfur, calcite, and dolomite.
M cement to set quickly M  Color: clear, white, gray, red, brown
Silica (SiO2) Gives strength. Excess amount causes slow 19-23  Uses: Used to manufacture dry wall, plaster, joint
A Alumina (Al2O3)
setting
Alumina imparts quick setting property to 2.5 – 6
A compound.
the cement. Excess alumina weakens the
N cement. N A number of materials can be produced by partial or complete dehydration of
Iron Oxide (Fe2O3) Iron oxide imparts colour to cement 0– 6
gypsum. e.g.
I Magnesia (MgO) Imparts color and hardness. In excess causes 1-5 I
crakes in mortar and concrete unsoundness
CaSO4.2H2O
150℃
 CaSO4.0.5H2O  CaSO  CaO + SO
600℃
4
800℃
3
T Calcium sulphate It slows down or retards the setting action 1.5- 4.5
T Gypsum
∆
plaster of paris
∆
anhydride
∆

BHOPAL (CaSO4) of cement BHOPAL

Sulphur (SO3) Helps in making sound cement 1-3
Alkalis Excess
Here, C3S and C3A are Alkalinesilicate
tricalcium matterand
causes efflorescence
aluminate 0.3 – 1.5

Cement: different phenomena Role of Gypsum in cement

 Heat of hydration: heat generated when water and cement react. Influenced  When cement is mixed with water due to rapid hydration of tricalcium
by the proportion of silicates and aluminates in the cement, but is also aluminate, the paste become quite rigid with in a short time :
influenced by water-cement ratio, fineness and curing temperature. As each
M one of these factors is increased, heat of hydration increases. M 3CaO.Al2O3 + 6H2O 2CaO.Al2O3.6H2O

A  Fineness: measure of the size of particles of cement and is expressed in
terms of specific surface area of cement and indirectly effect heat of
N hydration. if fineness is more then heat of hydration should be more.
Expressed in cm2/gm
A  Gypsum or plaster of paris works as a retarder delaying setting of the
cement paste by reacting with tricalcium aluminate to give insoluble calcium
N sulphoaluminate, which doesnot have quick hardening properties.

I I 3CaO.Al2O3 +
After initial set
CaSO4.H2O
gypsum
3CaO.Al2O3.xCaSO4.H2O
tri calcium sulpho-aluminate
(insoluble)
T  Soundness : he stability of the volume change in the process of setting and
hardening. If the volume change is unstable after setting and hardening, the
T
“Gypsum control the rate of hardening of the cement. If not added, the cement
BHOPAL concrete structures will crack BHOPAL
will set immediately after mixing of water leaving no time for concrete placing”.
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Cement: Types Portland Cement: classification

Cement used in construction:

M 1) Natural cement: produced by calcining natural occurring argillaceous

limestone at high temperature.
M
A 2) Portland cement : most widely used reliable cementing materials. A
Hydraulic in nature
N 3) Pozzolana cement : produced from volcanic ash. Mixed with Portland cement
N
for different purpose.
I I
4) Slag cement : produced by hydrated lime with a mixture of calcium and
T aluminium silicates in the form of slag. T
BHOPAL Slow setting compared to Portland cement. BHOPAL

Portland Cement Raw materials and Manufacturing Process

1. Calcareous materials: Supply lime, alkali waste.
It is a fine powder hydraulic type cement, produced by heating limestone and clay
minerals in a kiln to form clinker, grinding the clinker, and adding 2 to 3 percent of 2. Argillaceous materials: Supply silica, alumina and iron oxide
gypsum. Also known as magic powder.
3. Powered coal or fuel coal
M M 4. Gypsum
Types:
A 1) Ordinary Portland cement
2) Rapid hardening Portland
A Mixing
properties: cement Burning Grinding
N 1) Final setting time : 300 min 3) Extra rapid Portland cement
4) Blast furnace Portland
N
(should not be more than 600min)
cement • Crushing and grinding
I 2) Fineness: 215m3/kg 5) Low heat Portland cement I of raw mix • Mixture
• Cooling of
3) Tensile strength: 3N/mm 2
6) Sulphate-resisting Portland • Can be done by: i) Wet hot clinker
burning in
T 4) Heat of hydration > 65cal./gm cement
7) White Portland cement
T process ii) Dry
process
rotary Kiln
and grinding
with gypsum
BHOPAL 8) Colored Portland cement BHOPAL
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Wet process Grinding

Raw materials are changed to
powdered form in the presence Process:
of water
Cooled clinkers further converted into the fine particles in tube mill or ball mill
in the presence of additives.
M Raw materials are pulverized
M
by using a ball mill Following agents are used:
A A a) Retarder: gypsum, for retarding setting or cement.
b) Dispersing agent: to restrict the formation of lumps.
N The slurry in then passed into
N c) Water proofing agent: to increase water repellency tendency.
storage tanks where correct
I proportioning is done I d) Air- entrainment agent: to impart air into the cement paste.
e) Miscellaneous additives: to prevent wear and dusting and to get superior
T Proper composition of raw materials
T quality of cement.
BHOPAL can be ensured by using wet process BHOPAL
When the raw materials are soft, then the wet then dry process
process is preferable to be used.

Burning Dry process

When the available raw materials are quite hard, then this process is used. The cement by
Process : this process can be prepared by using the following operations:-
 The raw mix or slurry of desired 1. Mixing of raw materials
M compositions enters into the kiln. M 2. Burning and Grinding
 Burning fuel and air are introduced.
A  The mixture passes through the different A
https://www.topnewscorner.com/rotary-kiln-market-manufacturers-report- zones including clinking zone.
N 2019-with-future-scope-till-2025/
 Produce greyish - black pellets are formed
which known as clinker
N 1. Mixing of Raw Materials: 2. Burning and Grinding: similar to the
wet process
I Rotary kiln: cylinder which rotates
around its cylindrical axis and axis act as a
 These clinkers are send for grinding after
cooling .
I the raw materials undergo the following
stages:-
the raw materials undergo the following
stages:-
device to exchange the heat i. Crushing: . i. Raw materials mixed, fined, and then
T T ii. Drying:
iii. Reduction of size:
fed into kiln .
ii. The cooled clinkers are finely ground
BHOPAL Key chemical reaction high temperatures (>1,300 °C as belite (Ca2SiO4) combines with BHOPAL iv. Mixing in correct proportion: in ball mills or tube mills.
calcium oxide (CaO) to form alite (Ca3SiO5).
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Dry synthesis procedure of Portland cement Composition of Portland cement

The percentages composition of finished is tabulated below:
Name of compound Abbreviation Composition
(%)
M M Tricalcium silicate
(3CaO.SiO2)
C3S 45 – 48

A A Dicalcium silicate
(2CaO.SiO2)
C2S 25 – 27

Tetracalcium alumino ferrite (4CaO. Al2O3. C4AF 8–9

N N Fe2O3)
Tricalcium aluminate C3A 8 - 10
I I (3CaO. Al2O3)
Magnesium oxide - 2.5 - 4
T T (MgO)
Calcium oxide - 0.9 - 2
BHOPAL BHOPAL (CaO)
Calcium sylphate - 2.8 - 5
https://www.researchgate.net/figure/Simplified-schematic-flow-chart-of-the-dry-process-of-manufacturing-of-Portland- Here, )C3S and C3A are tricalcium silicate and aluminate
(CaSO
cement_fig2_329774921 4

Comparison of wet and dry process Setting and hardening of cement

Setting: stiffening of the original plastic mass due to gel formation.
Dry process Wet process Hardening: development of strength due to crystallization.

Useful when materials are quite hard Useful for any type of raw materials
M M Both process occur due to hydration and hydrolysis of cement
constituents which are all anhydrous.
A Slow process Faster than the dry process A  Tricalcium silicate and tricalcium aluminate mainly responsible for final
Product is of inferior quality Product is of superior quality setting and hardening
N 74% or cement produced 26% or cement produced N Unhydrated cement + water
Fuel consumption is less Fuel consumption is more
I Cost of grinding is more Cost of grinding is less
I Plastic mass

T Shorter kiln is needed Longer kiln is needed T Metastable gel Crystalline hydration products ] setting
BHOPAL BHOPAL Stable gel Crystalline products
] hardening
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Chemical reactions behind Setting and hardening of cement Soundness test for cement
Following reaction take place on hydrolysis and hydration which result in setting • The stability of the volume change in the process of setting and hardening.
and hardening: • If the volume change is unstable after setting and hardening, the concrete
structures will crack
Hydrolysis:
M (i) 3CaO.SiO2 + H2O Hydrolysis 2CaO.SiO2 + Ca(OH)2 M Le-Chatelier Test:
 Detects unsoundness due to free lime
When amount of water is less
only
A (ii) 2[2CaO.SiO2] + H2O Hydrolysis
Dicalcium silicate
3CaO.2SiO2 + Ca(OH)2
Crystallline calcium hydroxide
A  Expansion test of cement in boiling water
When water is in excess for 3 to 5 hours is measured with the
N Hydration :
N help of Le-Chatelier apparatus.
 Its is replaced by autoclave test.
I (i) 2CaO.SiO2 + 4H2O 2CaO.SiO2.H2O
I  As per Indian Standard specification, if
the content of magnesia is greater than
T (hydrated dicalcium silicate)
T 3% in cement then Autoclave Test is
performed which is sensitive to both
BHOPAL (ii) 3CaO.Al2O3 + 6H2O 2CaO.Al2O3.6H2O BHOPAL Lime and Magnesia.
(hydrated dicalcium aluminate) https://www.youtube.com/watch?v=je5ztHs9tII

Cement: Different Phenomena Expansion & Expansion Joints

 Heat of hydration: heat generated when water and cement react. Influenced by the
proportion of silicates and aluminates in the cement, but is also influenced by water-
cement ratio, fineness and curing temperature. As each one of these factors is
M increased, heat of hydration increases. M
A  Fineness: measure of the size of particles of cement and is expressed in terms of A
specific surface area of cement and indirectly effect heat of hydration. if fineness is
N more then heat of hydration should be more.
Expressed in cm2/gm
N https://www.newindianexpress.com/cities/chennai/2019/dec/17/the-case-for-concrete-roads-
2077009.html

I I
T  Soundness : The stability of the volume change in the process of setting and
hardening. If the volume change is unstable after setting and hardening, the concrete
T
BHOPAL structures will crack BHOPAL
https://www.brighthubengineering.com/building-construction-
design/64844-all-you-need-to-know-about-concrete-expansion-joints/
 2/14/2021

Special cements: Aluminous cement High early strength cement

 Calcium aluminate cement
 Manufactured from grinding the resulting clinker Characteristics
Composition:
formed by mixing limestone and bauxite.  It has high amount of C3A and C3S
Lime 60%
 It has more chemical resistance to ordinary  Attain good strength within 3 days
M cement
 Alumina content should not be less than 32
M  Heat rate is high
 Compression strength (Kg/cm3): 1 day – 103
alumina
Magnesium oxide
3 -4%
4 - 5%
percent and the ratio by weight of alumina to the 28 days - 440
A lime should be between 0.85 and 1.30.
https://civileblog.com/high-alumina-cement/
A silica
Iron oxide
17-20%
2-4%
Insoluble residue
N Characteristics of High Alumina Cement Composition: N Limitations :
a) It cannot be used in mass construction as it
Total alkali
2- 3%
1%
Silica 3 – 8% evolves great heat as it sets soon. Sulfur trioxide
 The initial and final setting time is more than 3.5
I hours and 5 hours respectively.
Alumina
Lime
37 – 41%
36 – 40%
I b) It is costly
3-4%

 It hardens rapidly Iron oxide 9 – 10% Applications

T  It evolves great heat during setting.
Titanium
Magnesium
1.5 – 2%
1%
T  rapid construction
 cold weather construction.
BHOPAL  It has high resistance to chemical corrosion. Insoluble residue 1% BHOPAL

Aluminous cement White Portland cement

Advantages:
a) Allows more time for mixing and placing
operations.
M b) Can withstand at high temperature.
A c) Not affected by frost.
d) Resists the action of acids in a better way.
N e) Its strength is more than about 40 N/mm2.
 High degree of whiteness
 No ferric oxide is added in raw material: as iron oxide
Disadvantages: give the gray sheds.
a) It cannot be used in mass
construction as it evolves great heat M  Sodium Alumino ferrite (Cryolite) Na3AlF6 Is added to
act as flux In the absence of iron oxide
as it sets soon.  Strong waterproof effect: no need of waterproof
b) It is costly
A coating.
 Applied as wall putty in order to fill the uneven
surface
N https://store.technotrade.in/blogs/painting-and-coating-
systems/why-you-may-avoid-white-cement-putty

f) Not necessary to grind it to fine powder Composition:

Properties: ~69%
I Applications:
I  Initial setting time: 100 minutes.
Lime
alumina
~2%
 Fineness of: 395 m2/kg.
 construction of water pipes, sewage pipes, factory drains, coastal constructions and in ~1%
T factory chimney T  Brightness: 87%.
 Bulk density: 110 kg/3
Magnesium oxide
~25%
 Compression strength: 1 day = 21 Mpa, silica
BHOPAL  It acts as a bonding material when added in refractory castables because it forms
BHOPAL
28 days = 74 Mpa Total alkali 1%
ceramic bond at high temperatures
Sulfur trioxide ~2%
 2/14/2021

White Portland cement: advantages and disadvantages Physical Requirement of Cement

S.No. Property Description
Advantages Disadvantages
1. Fineness (m2/kg) Not less than 225 m2/kg

Better thermal insulator Lower strength than OPC. 2. Soundness

M Good reflector to the light It is costly M (a) Lechatelier expansion (mm) Not more than 10%
Able to withstand the higher temperature. Shorter setting time (b) Auto clave expansion (%) Not more than 0.08%
A Products of white cement can be recycled Can not be used in concrete structures, A 3. Setting time (in minutes)
and reused in other products at the end of as it has less compressive tension
(a) Initial setting Not less than 30 minutes
N their useful life
N (b) Final setting Not greater than 600 minutes
Applications
I  For making tiles, mosaic etc I 4. Compressive strength (MPa)
 used for architectural works (a) After 73 +/- 1 hours Not less than 27 MPa
T  For making colored cement
T (b) After 168 +/- 2 hours Not less than 37 MPa
BHOPAL  For making decorative pastel shades for cement paints BHOPAL (c) 672 +/- 4 hours Not less than 53 MPa
https://theconstructor.org/building/chemical-and-physical-requirement-of-cement/7397/

Waterproof cement Concrete and RCC

Mixture of cement, sand and crushed stone in the ratio 1: (2 – 3.5): (4 - 7) with
 Obtained by grinding Portland cement with water water.
repellent agent.
 Water repellent agent: calcium stearate, oleic
M acid.
 Water repellent film around each grain decrease
M  High compressive strength
 Low tensile strength
the deterioration rate of cement.  Proportions of raw material may vary
A https://www.slideshare.net/dhrupal1067/hydrophobic-cement-47333072
A according to the application
 Used for constructing roads, buildings,
tanks etc.
Properties:
N  Initial setting time: 30 minutes. 
Applications:
Hydro technical construction
N
 Final setting time: 10hrs  Sewage disposal treatment work
I  Fineness of: 350 m2/kg.
 Compression strength:


Water treatment plant
Marine structure
I
after 3 days = 15.69 Mpa  Hydraulic structure: dam, retaining
T 28 days = 30 Mpa  Mass construction work like bridge footing T https://www.jlconline.com/how-to/foundations/mixing-your-
own-concrete_o
BHOPAL BHOPAL
It reduces capillary water transmission under little of no pressure but does not completely
stop water-vapor transmission
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Reinforce cement concrete (RCC)

Concrete reinforced with steel rods or heavy wire mesh.

 High the concrete on setting bonds very strongly

with the reinforcement giving high compressive and How RCC column is constructed
M tensile strength.

 Even in cracks develop, considerable reinforcement

A is maintained

 Used in floor beams, arches, bridges.

N
Advantages of RCC
I  Easy to make •Suitable arrangement of beams,
 Possesses greater rigidity columns, foundations etc.
T  Higher fire resistance •Types of loads and forces to which the
BHOPAL  Maintenance cost is very low structure is likely to be subjected to.

 Steel reinforcement prevents the formation of large •To analyze the structure and to
crakes calculate, stresses, moments and shears
etc.

M
A
N
I
T
BHOPAL https://www.honestone.com.au/10-fascinating-quotes-concrete/