Building Materials

Cement
• A cement is a binder, a substance that sets and
hardens and can bind other materials together.
The word "cement" traces to the Romans, who
used the term opus caementicium to
describe masonry resembling
modern concrete that was made from crushed
rock with burnt lime as binder.
 Concrete
• Concrete is a composite material composed mainly
of water, aggregate, and cement. Usually there are
additives and reinforcements included to achieve the
desired physical properties of the finished material.
• When these ingredients are mixed together, they form
a fluid mass that is easily molded into shape. Over
time, the cement forms a hard matrix which binds the
rest of the ingredients together into a durable stone-
like material with many uses
Paste → P.C. + Water

Mortar → P.C. + Water + Sand

Concrete → P.C. + Water + Sand + Gravel

Manufacture of Cement
1) Calcareous Rocks (CaCO3 > 75%)
• Limestone
• Marl
• Chalk
2) Argillaceous Rocks (CaCO3 < 40%)
• Clays
• Shales
• Slates
PRODUCTION STEPS( Wet Process)
1) Raw materials are crushed, screemed & stockpiled.
2) Raw materials are mixed with definite proportions to obtain
“raw mix”. They are mixed by water ( 35-50%) (wet mixing).
3) Prepared raw mix ( slurry) is fed into the rotary kiln.
4) As the materials pass through the kiln their temperature is
rised upto 1300-1500 °C. The process of heating is named as
“burning”. The output is known as “clinker” which is 0.15-5
cm in diameter and weight 1100 to 1300gms /lt
5) Clinker is cooled & stored.

6) Clinker is grounded with gypsum (3-5%) to adjust setting

time.

7) Packing & marketting.

 CLINKER

GYPSUM
PRODUCTION STEPS( Dry Process
& semi dry)
• Raw materials are crushed dry and fed in correct proportions
into a grinding mill and reduced into fine powder.
• Dry powder called as “ Raw meal” further blended and mixed
by means of air compressor
• Aerated powder tends to behave almost like liquid.
• Blended meal further sieved and fed into rotating disc called
granulator.
• 12% of water to make the blended meal into pellets.
• This is done to permit flow of exchange of heat becomes
clinker.
• 100kg coal is needed.
• 1988 in India out 173 plants 115 plants is dry process, 49
plants wet process and 9 plants are semi-dry process.
Composition of OPC

Oxide Common Name Abbreviation Approx. Amount (%)

CaO Lime C 60-67

SiO2 Silica S 17-25
Al2O3 Alumina A 3-8
Fe2O3 Iron-oxide F 0.5-6
MgO Magnesia M 0.1-4
Na2O Soda N
0.2-1.3
K2O Potassa K
Ś
SO3 Sulfuric Anhydride 1-3
Raw Materials O2 Si Al Fe

Oxide compostition CaO SiO2 Al2O3 Fe2O3

On Burning , Clinker formed
Compound Composition C3s C2S C3A C4AF

On Grinding Clinker
Portland Cements VariousTypes

Products of Hydration C-S-H gel + Ca (OH)2

 Bouge’s Compounds

Name Chemical Formula Abbreviations

Tri Calcium Silicate 3CaO.SiO2 C3S

Di Calcium Silicate 2CaO.SiO2 C2S

Tri Calcium Aluminate 3CaO.Al2O3 C3A

Tetra Calcium Alumino

4CaO.Al2O3.Fe2O3 C4AF
Ferrite
Higher C3S→higher early strength-higher heat generation
(roads, cold environments)
Higher C2S→lower early strength-lower heat generation
(dams)

C3A: is characteristically fast reacting with water & may

lead to a rapid stiffening of the paste with a large amount
of the heat generation (Flash-Set)-(Quick-Set). In order to
prevent this rapid reaction gypsum is added to the clinker.
Gypsum, C3A&water react to form relatively insoluble
Calcium-Sulfo-Aluminates.

C4AF: The hydration of ferrite phase is not well

understand. Ferrite phase has lesser role in development
of strength. The hydration products are similar to C3A.
Alumina & iron oxide occur interchangebly in the hydration
products.
 Hydration of P.C.
Hydration: Chemical reactions with water.

As water comes into contact with cement particles,

hydration reactions immediately starts at the surface of
the particles. Although simple hydrates such as C-H are
formed, process of hydration is a complex one and results
in reorganization of the constituents of original compounds
to form new hydrated compounds.
 HEAT OF HYDRATION
Hydration process of cement is accompanied by heat
generation (exothermic).
Liberation of heat is called as Heat of hydration.
It could also be advantages for cold wheather
concreting.
About 50% of this heat is liberated within 1-3 days &
75% within 7 days.
By limiting C3S&C3A content heat of hydration can be
reduced.
 Sulphates
Aluminates
and
Sulphates

Solubility of aluminates is
depressed by gypsum
Types of Cement
• Ordinary Portland Cement
• Rapid hardening cement
• Sulphate resisting cement
• Low heat cement
• Quick setting cement
• Portland pozzalona cement
• Air entraining Cement
• Expansive cement
• Masonry cement
• High alumina cement
• Hydrophobic cement
• Coloured cement
• Ordinary Portland Cement
• 33, 43, 53 grades in OPC.
• Most important benefits is faster rate of development of strength

• Rapid hardening cement

• Higher rate of development of strength comapared to OPC.
• RHC develops at a age of 3 days, same strength in OPC
expected at 7 days.
• Used for Prefabricated, formwork removed early.

• Sulphate resisting cement

• Low C3A and C4AF and other words this cement has high silicate
content.
• Solid sulphates will not attack but sulphates in solution easily
affect the calcium , aluminates and even hydrated silicates
• Uses mainly in marine structures(wetting and drying)
• Foundation and Basements, Sewage treatment plant.
• Low heat cement
• Mainly used for construction massive dams.
• Reducing the C3S and C3A , and increasing C2S content.

• Quick setting cement

• Reducing the gypsum content at the time of clinker grinding.
• Mostly used for under water construction.

• Portland pozzalona cement

• Intergrinding of OPC clinker with 10 to 20 % of pozzolanic material(
siliceous and aluminous)
• Produces less heat of hydration and offers greater resistance to attack of
aggressive waters.
• Expansive cement
Shrinkage in OPS while settling.
Uses for grouting purposes. No overall change in volume on drying is called
expansive cement
Attained based on 8-20 parts with 100 parts of OPC

• Masonry cement
• Using for construction of masonry construction.
• Used for making of mortar.

• High alumina cement

• Alumina and calcareous materials grinded to make the product
into powder.
• Construction in Cold areas.

• Hydrophobic cement
• Can be stored for longer duration.
• Particle of cement coated with water repellant material which
protects effects of moisture during storage and transportation.
• Coloured cement : White Cement
• Either White cement or grey Portland cement is used as a base.
• Add 5-10 % of Coloured pigments
• Used for Ornamental works, tiles.

• Air entraining Cement

• Mixing of small amount of air entraining agent with OPC.
• Air entraining agents – Alkali salts, synthetic detergents, calcium
salts.( 0.025 – 0.1 by weight of clinker)
• Added at the time of mixing, changes the properties and resist to
frost action.
Testing of Cement
• Field Testing
• Laboratory testing
• Fineness test
• Setting time test
• Strength test
• Soundness test
• Heat of Hydration test
• Chemical composition test
Field testing - Cement
• Colour of the cement is Greenish Grey.
• It should not be any lumps inside the bag.
• Thrust your hand into the cement bag. It should give cool feeling
• Take a small quality of cement in your hand and thrown into a
bucket full of water, particles float for some time before they sink.
• Take a pinch of cement and feel b/w the fingers. It should give a
smooth not a gritty feeling.
• Take 100 grams of cement and a small quantity of water and make a
stiff paste. From the stiff paste, pat a cake with sharp edges. Put in a
glass plate and slowly take it under water in a bucket. See the cake
is not disturbed while taking into down. After 24 hours, it should
retains its original shape and also attains some strength.
Laboratory Testing –Cement
• Fineness Test
• Maximum No. of particles in a sample of cement should have a size less
than about 100 microns.
• The smallest particles may have a size of about 10 microns.

Fineness of cement is tested in two ways

• By sieving
• By determination of Specific Surface (Air permeability apparatus)

1. Sieving
• Take 100 grams of cement and sieve through 90 microns sieve.
• Brea down the air set lumps with fingers and give circular and vertical
motion.
• Weigh the residue left on the sieve.
• Shall not exceed 10% for ordinary cement.
2. Air Permeability Apparatus
• Specific surface = Total surface area/ gram
• Place a cement bed in permeability cell of 1cm high and 2.5cm
dia.
• Slowly pass on air through the cement bed at constant velocity.
Adjust the rate of air flow until the flow meter shows the
difference in level of 30-50cm.

• Sw = K h1/h2 k = 14 X 3A
d (1-x) CL

Where X = 0.475 porosity for cement

A = Are of the cement bed
L = Length of the cement
D = Density
C= Flowmeter
Blaine
Air Permeability Apparatus
Standard Consistency Test
• Finding out initial setting time, final setting time, soundness of cement and
strength parameter is known as Standard Consistency.
• Paste must be prepared within 3-5mins
• Standard plunger of size 10mm dia. and 50mm long is attached
• By increasing the w/c ratio , the plunger penetrate to the depth 33-35mm from
the top is known as percentage of water required to produce a cement paste of
standard consistency.

Setting Time Test:

1. IST – Time elapsed between the moment water is added to the cement to
the time that the paste starts losing its plasticity.
Now change the plunger into needle, similarly the needle should only upto
depth of 33-35mm
Period elapsing b/w the time water is added to cement and the time at which
needle penetrated the depth of 33-35mm from top is known as Initial setting time.
2. FST – Center needle does not penetrate through the paste more than 0.5mm
Period elapsing b/w the time water is added to cement and the time at which
needle penetrated the depth below 0.5mm from top is known as final setting time.
Usually IST – 30mins
FST – 10hrs
Vicat’s Apparatus
Strength Test:
Take 185gms of cement and 555gms of sand and mix it with
water of (P/4 + 3 )% of combined weight of cement and sand.
Size of the cube 7.06x7.06x7.06cm and Std no. of cubes is 3
After 24 hrs, remove the mould and keep it for curing and
after 3,7, 14 or 28 days find the compressive strength.

Soundness Test
Cement after setting shall not undergo any change in volume.
Unsoundness in cement because of inadequate burning ,
insufficient fineness and also magnesium or calcium sulphate.
30mm dia, 30mm high and 165mm arm length
Measure the distance b/w indicator points.
should not more than 10mm for OPC,RHC low heat cement
but for expansive cement is more than 10mm.
Le-Chatelier Apparatus
• Heat of Hydration
• Cement is gauged with water and placed in a thermos flask.
• 120 calories of heat is generated in the hydration of 1gm of
cement
• 50oC has been observed in the interior mass concrete.
• Low Heat Cement not more than 65cal/g at 7 days and 75cal/g at
28 days

Chemical Composition test

Ratio of percentage of lime to percentage of silica,
alumina and iron oxide

CaO – 0.7 SO3 = 1.02 < x >0.66

2.8 SiO2 + 1.2 Al2O3 + 0.65 Fe2O3

• The above is known as lime saturation factor percent.

Concrete constituents
• mixture of aggregate and paste
• paste 30 to 40%
• portland cement 7% to 15% by Vol.
• water 14% to 21% by Vol.
• Aggregates 60% to 70%
• coarse aggregates
• Fine aggregates
• Admixtures
Portland Cement
• Dry powder of very fine particles
• forms a paste when mixed with water
• chemical reaction-Hydration
• glue
• paste coats all the aggregates together
• hardens and forms a solid mass
Water
• needed for two purposes:
• chemical reaction with cement
• workability
• only 1/3 of the water is needed for chemical reaction
• extra water remains in pores and holes
• results in porosity
• Good for preventing plastic shrinkage cracking and
workability
• Bad for permeability, strength, durability.
 Water
 Municipal
 Well
 Heated
 Steam
 Chilled
 Ice
 Recycled
 Introduction
• Water is an important ingredient of concrete as it actively participates in
the chemical reaction with cement.
• Since it helps to form the strength giving cement gel, the quantity and
quality of water is required to be looked into very carefully.
• In practice, very often great control on properties of cement and
aggregate is exercised, but the control on the quality of water is often
neglected.
• Since quality of water affects the strength, it is necessary for us to go into
the purity and quality of water.
 Qualities of Water
• A popular yard-stick to the suitability of water for mixing concrete is that, if
water is fit for drinking it is fit for making concrete.
• This does not appear to be a true statement for all conditions.
• Some waters containing a small amount of sugar would be suitable for
drinking but not for mixing concrete
• And conversely water suitable for making concrete may not necessarily be
fit for drinking
Qualities of Water

• The strength of concrete or mortar made with questionable

water should be compared with similar concrete or mortar
made with pure water.
• Some specification also accept water for making concrete if
the pH value of water lies between 6 and 8 and the water is
free from organic matter.
 Qualities of Water
• Instead of depending upon pH value and other chemical
composition, the best course to find out whether a
particular source of water is suitable for concrete making or
not, is to make concrete with this water and compare its 7
days’ and 28 days’ strength with companion cubes made
with distilled water.
• If the compressive strength is upto 90 per cent, the source
of water may be accepted
• it is logical to know what harm the impurities in water do to
the concrete and what degree of impurity is permissible is
mixing concrete and curing concrete.
 Qualities of Water
• Carbonates and bi-carbonates of sodium and potassium effect the setting
time of cement.
• While sodium carbonate may cause quick setting, the bi-carbonates may
either accelerate or retard the setting.
• The other higher concentrations of these salts will materially reduce the
concrete strength.
• If some of these salts exceeds 1,000 ppm, tests for setting time and 28 days
strength should be carried out.
• In lower concentrations they may be accepted.
 Qualities of Water
• Brackish water contains chlorides and sulphates.
• When chloride does not exceed 10,000 ppm and sulphate does not exceed
3,000 ppm the water is harmless, but water with even higher salt content
has been used satisfactorily.
• Silts and suspended particles are undesirable as they interfere with setting,
hardening and bond characteristics. A turbidity limit of 2,000 ppm has been
suggested
 Use of Sea Water for Mixing Concrete
• Sea water has a salinity of about 3.5 per cent.
• In that about 78% is sodium chloride and 15% is chloride and sulphate of
magnesium.
• Sea water also contain small quantities of sodium and potassium salts.
• This can react with reactive aggregates in the same manner as alkalies in
cement. Therefore sea water should not be used even for PCC if aggregates
are known to be potentially alkali reactive.
 Use of Sea Water for Mixing Concrete

• It is reported that the use of sea water for mixing concrete

does not appreciably reduce the strength of concrete
although it may lead to corrosion of reinforcement in
certain cases
• Water containing large quantities of chlorides in sea water
may cause efflorescence and persistent dampness.
• When the appearance of concrete is important sea water
may be avoided.
• The use of sea water is also not advisable for plastering
purpose which is subsequently going to be painted.
 Use of Sea Water for Mixing Concrete
• sea water be avoided for making reinforced concrete
• The use of sea water must be avoided in prestressed concrete work
because of stress corrosion and undue loss of cross section of small
diameter wires.
• The latest Indian standard IS 456 of 2000 prohibits the use of Sea Water
for mixing and curing of reinforced concrete and prestressed concrete
work.
Questionable Water
• Water < 2000 ppm of total dissolved solids is
satisfactory for making concrete.
• Water > 2000 ppm of dissolved solids should be
tested for its effects on strength and time of set.
 Introduction
• The less water in the paste (and hence the total PCC
mixture)—in general—the better for the hardened
material.
• Less water in the PCC mixture offers the following benefits:
• Higher compressive and flexural strength
• Lower permeability and improved water tightness
• Increased resistance to weathering
• Improved bond between PCC and reinforcing steel
• Reduced drying shrinkage and cracking (which can also occur due to
construction placing and curing operations)
• Reduced volume changes due to wetting and drying.
 Introduction
• Quote: “The less water used, the better the quality of the concrete—
provided the mixture can be consolidated .”
• The course instructors could not agree more.
• Designated by water to cement ratios (weight of water divided by the
weight of portland cement). The w/c ratios range from 0.25 (very low
ratio) to 0.70 (a very high ratio).
W/C Ratio Parameters
• Aggregate size:
• Grading of Aggregate:
• Surface texture of aggregate
• Shape of aggregate
• Cement type and source
• Pozzalonas
• Air Entraining & Chemical Admixtures
• Setting Time
The Water - Cement Ratio Law
For given materials the strength of the concrete (so long
as we have a plastic mix) depends solely on the relative
quantity of water as compared with the cement,
regardless of mix or size and grading of aggregate.

Duff A. Abrams
May 1918
w/cm ratio
55
WWater 350
W 
CM W
50
45
kg
300
CementitiousMaterial 40 kg

Fc', MPa
35 250
30 kg
25
20
15
10
0.2 0.3 0.4 0.5 0.6
5 5 5 5 5
w/cm ratio
 Water in Concrete
• Increased water:
• reduced strength
• increased shrinkage and creep
• increases permeability
• reduced abrasion resistance
• reduced Freeze-Thaw resistance
Aggregates
• cheap fillers
• hard material
• provide for volume stability
• reduce volume changes
• provide abrasion resistance
Admixtures
• chemical
• set retarders
• set accelerators
• water reducing
• air entraining
• mineral
• fly ash
• silica fume
• slags
Properties of fresh concrete
• Workability
• ease of placement
• resistance to segregation
• homogeneous mass
• Consistency
• ability to flow
Concrete Grades