LECTURE #03

Cement:
Cement is a fine grey powder which when react with water forms a rigid mass. It has the binding property in the
presence of water and holds concrete together
Composition of cement
Composition of raw materials for the manufacture of ordinary Portland cement is
Calcium oxide
=60 to 65%
Silica
=20 to 25%
Aluminum oxide
=4 to 8%
Ferrous oxide
=2 to 4%
Magnesium oxide
=1 to 3%
All the above chemicals undergo some chemical combinations during the process of burning and fusion. Main
constituents of cements are
Compound
Abbreviation
Chemical formula
Typical
concentration/%
Tri-calcium silicate
C3S
3CaO-SiO2
60-70
Di-calcium silicate
C2S
2CaO-SiO2
10-20%
Tricalcium
C3A
3CaO-Al2O3
5-10%
aluminate
Tetra calcium
C4AF
4CaO-Al2O3
3-8%
alumino-ferrate
-Fe2O3
Of these compounds, C3S and C3A are mainly responsible for the initial strength of the cement.
High percentages of C3S (low C2S) results in high early strength but also high heat generation as the
concrete sets.
The reverse combination of low C3S and high C2S develops strengths more slowly (over 52 rather than
28 days) and generates less heat.
C3A (tri calcium aluminate) causes undesirable heat and rapid reacting properties, which can be
prevented by adding CaSO4 (gypsum) usually 2-4% to the final product.
C4AF makes the cement more resistant to seawater and results in a somewhat slower reaction which
evolves less heat.
Manufacture
Cement can be manufactured by any one of the two methods.
1) Dry process
2) Wet process
1)
Dry process
In this process limestone and clay are ground separately to fine powders and are then mixed together in the
desired proportions.
Water is then added to it so as to get a thick paste of which cakes are made, dried and burnt in the kilns.
(1450C-1600C)
To the clinker obtained after burning is added 2 to 4% of gypsum and ground to very fine powder.
2)
Wet process
BY ENGR. ASGHAR HUSSAIN SHAH

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LECTURE #03
The wet process consists of the following steps
I.
Mixing
The crushed raw materials in desired proportions are fed into ball mills. A little water too is added to it, slurry is
formed. The slurry is then passed into storage tanks known as silos where their proportions are adjusted.
II.
Burning
Corrected slurry is fed into rotary kiln. Slurry on entering the kiln loses moisture and forms small lumps or
nodules.(700-1200C) The nodules gradually roll down passing through zones of high temperature until they
reach burning zone where they are finally burnt at 1500 to1650C. At this temperature nodules change to clinker.
Clinkers are then air cooled.
III.
Grinding
Grinding of clinkers is done in large tube mills which are kept cool by spraying water from outside. While
grinding 3 to 4% percent gypsum is added so as to control the setting time of cement.
Finely ground cement is stored in silios from where it is drawn for packing.
Physical properties of cements:
The physical properties of cement
a. Setting Time
b. Soundness
c. Fineness
d. Strength
a. Setting Time
Cement paste setting time is affected by a number of items including: cement fineness, water-cement ratio,
chemical content (especially gypsum content) and admixtures. Setting tests are used to characterize how a
particular cement paste sets.
For construction purposes, the initial set must not be too soon and the final set must not be too late. Normally,
two setting times are defined:
Initial set. Occurs when the paste begins to stiffen considerably.
Final set. Occurs when the cement has hardened to the point at which it can sustain some load.
Setting is mainly caused by C3A and C3S and results in temperature rise in the cement paste.
False set: No heat is evolved in a false set and the concrete can be re-mixed without adding water
Occurs due to the conversion of anhydrous/semi hydrous gypsum to hydrous gypsum(CaSO4.2H2O)
Flash Set: is due to absence of Gypsum. Specifically used for under water repair.
b. Soundness
When referring to Portland cement, "soundness" refers to the ability of a hardened cement paste to retain its
volume after setting without delayed expansion. This expansion is caused by excessive amounts of free lime
(CaO) or magnesia (MgO). Most Portland cement specifications limit magnesia content and expansion.
The cement paste should not undergo large changes in volume after it has set. However, when excessive
amounts of free CaO or MgO are present in the cement, these oxides can slowly hydrate and cause expansion of
the hardened cement paste.
Soundness is defined as the volume stability of the cement paste.
c. Fineness
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LECTURE #03
Fineness or particle size of Portland cement affects Hydration rate and thus the rate of strength gain. The
smaller the particle size, the greater the surface area-to-volume ratio, and thus, the more area available
for water-cement interaction per unit volume. The effects of greater fineness on strength are generally
seen during the first seven days.
When the cement particles are coarser, hydration starts on the surface of the particles. So the coarser
particles may not be completely hydrated. This causes low strength and low durability.
For a rapid development of strength a high fineness is necessary.
d. Strength
Cement paste strength is typically defined in three ways: compressive, tensile and flexural.
These strengths can be affected by a number of items including: water cement ratio, cement-fine
aggregate ratio, type and grading of fine aggregate, curing conditions, size and shape of specimen,
loading conditions and age.
Tests on properties of cements:
a. Setting time test.
Consistency
The consistency is measured by the Vicat apparatus using a 10mm diameter plunger.
A trial paste of cement and water is mixed and placed in the mold having an inside diameter of 70mm at
the base and 60mm at the top, and a height of 40mm.
The plunger is then brought into contact with the top surface of the paste and released. Under the action
of its weight the plunger will penetrate the paste.
The depth depending on the consistency.
When the plunger penetrates the paste to a point 5 to 7mm from the bottom of the mold, the paste is
considered to be at normal consistency. The water content of the paste is expressed as a percentage by
weight of dry cement. The usual range of values being between 26% and 33%.

Setting time
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LECTURE #03
The setting time test is conducted by using the same Vicat apparatus, except that a 1mm diameter needle is
used for penetration.
The test is started about 15 minutes after placing the cement paste (which has normal consistency) into the
mold. Trials for penetration of the needle are made.
The final setting time is defined as the length of time between the penetration of the paste and the time when
the needle(with annular ring) no longer sinks visibly into the paste.
The initial setting time is defined as the length of time between the penetration of the paste and the time when
the needle penetrates 25mm into the cement paste.
b. Soundness test
IS prescribe a Soundness Test conducted by using the Le Chatelier apparatus. The apparatus consists of a
small brass cylinder split along its generatrix. Two indicators with pointed ends are attached to the cylinder
on either side of the split. The cylinder (which is open on both ends) is placed on a glass plate filled with
cement paste of normal consistency, and covered with another glass plate.
The whole assembly is then immersed in water at 20 1oC for 24 hours. At the end of that period the distance
between the indicator points is measured. The mold is then immersed in water again and brought to a boil. After
boiling for one hour the mold is removed from the water, after cooling, the distance between the indicator points
is measured again. This increase represents the expansion of the cement paste for Portland cements, expansion
is limited to 10mm.
c. Fineness Test
There are various methods for determining the fineness of cement particles. The
Blaine air-permeability method is the most commonly used method.
In the Blaine air-permeability method, given volume of air is passed through a prepared sample of
definite density. The number and size of the pores in a sample of given density is a function of the
particles and their size distribution and determines the rate of air flow through the sample. Calculations
are made and the fineness is expressed in terms of cm2/g or m2/kg
d. Strength test
Compressive Strength
Compressive strength of Portland cement is determined by the BIS method.
The cement paste (consisting of 1 part cement+3 parts standard sand+ water, by weight) is placed in
standard molds. And the specimens are water cured for various ages for testing.
The mortar specimens taken out of the molds are subjected to compression to determine the strength.
The compressive strength test is conducted on mortar cubes.. After finding the breaking load in
compression, Pmax, Compressive Strength is calculated by the relation given below
Compressive strength = Pmax /A, where A=50cm2 .
The average of the results found by testing six specimens is the compressive strength of the mortar
cubes.
Types of cements
Following are the types of cements
1)
2)
3)
4)
5)
6)
7)

Type I: Normal cement

Type IA Normal + air entrained agents
Type II: Moderate sulphate resistant cement
Type IIA Moderate sulphate resistant cement + air entrained agents
Type III: High early strength cement
Type IIIA High early strength cement + air entrained agents
Type IV: Low heat cement

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LECTURE #03
8) Type V :High sulphate resistant cement
1)
Type I Normal cement
Characteristics

Used for general purpose

Available widely

Used where concrete is not subjected to specific exposures such as sulphate attacks from soil or water or
to an objectionable temperature rise due to heat of hydration

Suitable for all uses e.g pavement, sidewalk, R.C buildings, bridges, water tanks, culverts, sewers etc.
This type of cement reaches its design strength in 28 days.
2) Type II Moderate sulphate resistant cement

This type of cement is used where precaution against moderate sulphate attack is important. Like where
concrete will come in contact with ground or buried in ground. e.g in drainage structures, large piers, retaining
walls etc
Main difference between Type I&II is the moderate sulfate resistance of Type II cement due to relatively low
C3A content (%8).
Type II generates less heat than type I and reaches its desired strength in 45 days
3) Type IIA Moderate sulphate resistant cement + air entrained agents
It is same as Type II but just having air entraining agents
4) Type III High early strength cement
High Early Strength P.C.
Strength development is rapid.
3 days f c=7 days f c of Type I
It is useful for repair works, cold weather & for early demolding.
Its early strength is due to higher C3S & C3A content.
It is used where formwork is to be removed quickly or sufficient strength for further construction is
required. It has high heat of hydration and achieves its design strength in 7 days or less. Due to high heat
generation, it should not be used in mass concreting or large structural section. Though in cold climate it
may serve well.
5)
Type IIIA High early strength cement + air entrained agents
It is the same as Type III plus air entrained agents
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LECTURE #03
6) Type IV Low heat cement
This type of cement is used in mass concreting because it generates less heat, though sets slowly but
becomes much stronger after curing. Its initial setting time shall not be less than 60 minutes and final
setting time shall not be more than 10 hours. Its design strength is 90 days.
7)
Type V High sulphate resistant cement
When concrete is exposed to highly alkaline soil or water having high sulphate content then this
type is used. This cement has a low C3A content and is limited to 5% so as to avoid sulphate
attack from outside the concrete. Otherwise the formation of calcium sulphoaluminate and
gypsum would cause disruption of concrete due to an increase in volume of resultant
compounds.

ASTM TYPE AND

NAME OFP.C

Average compound composition

C3S

C2S

C3A

C4AF

Type-I (OPC)

49

25

12

General Purpose

Type-II (Modified)

46

29

12

For Moderate Heat Of

Hidration

Type-III (High Early

Strength)

56

15

12

C3S & C3A Increased, C2S

Decreased

Type-IV (Low Heat

Cement)

30

46

13

C2S Increased

Type V (Sulfate
Resistant Pc)

43

36

12

Limit On C3A5%
2C3A+C4AF25%

BY ENGR. ASGHAR HUSSAIN SHAH

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REMARKS