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Chapter: Five
Cement

Chapter: Five
Cement
Cementing Materials:
• Posses property of cohesion or adhesion with
other materials to form a strong bond for
formation of compact durable mass
• Important civil engineering material
• Used as binding materials
• Used In :cement mortar, RCC, precast RCC,
grouting,shotcrete
• Widely used in building, road, bridge, water
tank, dams, tunnel constructions etc 2

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Properties of Cement:
• It provides good strength to structures
• It is easily workable
• It is a very excellent material for building structures
• It possess good plasticity
• It sets and hardens easily.

Storage and Handling of Cement:

• It should be stored in special water-tight shed with dry
damp-proof floor and walls
• Cement bags should be placed 30 cm from walls.
• Arrange the bags for “first come first served” use.
• Bags should be stacked closely to avoid free circulation
of air
• Storing should not be done for long period of time
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Cement
• Natural cement: manufactured from stones
containing 20 to 40 % clay and remaining %
occupied by calcareous material, either CaCo3
or mixture of CaCO3 and MgCO3. The Stones
are brunt then crushed.

• Artificial cement: manufactured by burning

appropriately proportioned mixture of
calcareous material and clay material at high
temperature, resulting in formation of clinker ,
which is grinded with addition of small % of
gypsum.
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Fig:-Portland Stone quarried form Isle of

Portland, Dorset 5

Basic Ingredients of Cement (OPC)

• Lime (CaO)- 60-67%
• Silica (SiO2)- 17-25%
• Alumina (Al2O3)- 3-8%
• Calcium sulphate (CaSO4)- 3-5%
• Ferrous Oxide (Fe2O3)- 0.5-6%
• Magnesium oxides (MgO)- 0.1 - 4%
• Sulphur Trioxides (SO3)- 1.3 - 3%
• Alkalies – 0.4 – 1.3%

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Lime:
• Major constituents of cement
• Presence of lime in sufficient quantity is required to
form silicates and aluminates of calcium
• Make cement sound and strong (if in right proportion)
• Excess lime causes cement unsound, causes expansion
and disintegration
Silica:
• Major constituent of cement
• Helps in formation of di-calcium silicate and tri-calcium
silicates
• Responsible for the strength of cement
• Excess silica increases the strength
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Alumina:
• Imparts quick setting property to cements
• As flux, lowers the clinkering temperature of
cement
• Excess amount reduces the strength of cement
Calcium sulphate:
• added to the cement in the form of gypsum in
clinker during grinding
• Increases the initial setting time of cement
Ferrous oxides:
• Increases the hardness of cement
• Provides the color to the cement
• Acts as flux and helps to fuse raw materials of
cement
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Magnesium oxides:
• Imparts hardness to the cement
• Imparts color to the cement
• Excess amount causes unsoundness of the cement
Sulphur trioxides:
• Makes cement sound if in proper amount
Alkalies:
• Should be present in small quantity
• Excess alkalies causes efflorescence
• Excess amount causes alkali-aggregate reaction in
concrete, masonry works.

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Harmful ingredients of cement

• Excess alkali oxides in cement such as
potassium oxides and sodium oxides causes
cracks in mortar made from such cement.
• K2O and Na2O <1 %
• MgO < 5%

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Manufacturing the Cement

• Three distinct operations are involved in the
manufacturing of normal setting ordinary
Portland cement:
1. Mixing of raw materials

2. Burning

3. Grinding

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Flow diagram of Dry process

Calcareous Materials Argillaceous Material

Limestone Clay

crushing Crushing

Dryers Dryers
Fine Grinding in Ball Fine grinding in Ball
mills and tube mills Mills and Tube Mills

Storage (Hopper) Storage (Hopper)

Mixing in correct proportion

Storage tank for raw mix

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Cont….
Flow diagram of Dry process
To Rotary Kiln

Burning in Rotary Kiln

Complete Dehydration Formation of Clinker

Disassociation of Clinker Coolers

Carbonates
CaO , Mg0 (800-900oC) Grinding of Clinker Gypsum

Storage in SILOS
Compound Formation
C3S, C2S,C3A, C4AF Weighing and Packing

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Flow diagram of Wet process:

Calcareous Materials Argillaceous Material
Limestone Clay

crushing Washing and grinding

Storage in silos Storage in basins

Mixing

Wet Grinding
Formation of slurry
Correction of Slurry
To Rotary Kiln 19

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Cont….
Flow diagram of Wet process

Burning in Rotary Kiln

Formation of Clinker ( 1500-

1600 o C

Clinker Coolers

Grinding of Clinker

Storage in SILOS

Weighing and Packing

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Rotary Kiln

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Cont….

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Composition and Function of cement

clinker
• During manufacturing of cement, all the
ingredients except gypsum is heated up to
13000C to 15000C
• After heating fused mass of diameter about
0.3mm to 2.5cm is formed which is called as
clinker
• Grinding of clinker with gypsum is done then
is ready for packing

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Bogue’s compounds
• After all the compounds undergo some
chemical combination during manufacturing
process following end products can be realized
in cement which are called Bogue’s compounds
and these are :
• Alite – C3S - 25-50% -3CaO.SiO2
• Belite - C2S - 25-40% -2CaO.SiO2
• Celite – C3A - 5-11% -3CaO.Al2O3
• Felite - C4AF - 8-14% -4CaO.Al2O3.Fe2O3
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Tricalcium Aluminate (C3A): 3CaO.Al2O3

• On adding water it is earliest to hydrates
• Contributes to initial setting of cement
• Develop large amount of heat of hydration,
Weak against sulphate attack
• It acts as flux for the fusion of clinker and
reduces the temperature of fusion, resulting in
the saving of fuel.
• Produce C3AH6 cubical compound after
hydration.

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Tricalcium silicates (C3S): 3CaO.SiO2

• Hydrates immediately next to C3A
• Contributes to the early hardness and strength of the
cement ( 7 days strength ) paste or concrete
• High heat of hydration due to rapid hydration
• Less resistive to chemical attack
• Quality/density of C-S-H gel produced from this compound
is slightly inferior than from C2S.

Dicalcium silicates (C2S): 2CaO.SiO2

• Contributes to strength gain after one week
• At seven days no strength develops in C2S
• More resistive to chemical attack
• Hydrates and hardens slowly
• contributes to the ultimate strength.
• C-S-H gel produced from this compound is dense. 31

Tetra-calcium aluminum ferrite (C4AF):

4CaO.Al2O3.Fe2O3
• Considered as inert materials
• It acts as flux for fusing clinker at lower
temperature
• Practically it doesn’t contribute in any strength
development process
• Increase the volume of cement
• Accelerates the hydration of silicates
• Produce C3AH6 cubical compound after hydration.
• Harmful for durability as is likely to attack by
sulphur.

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Compressive strength of cement

compounds with age

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Hydration of Cement
• Chemical reaction of cement with water is termed as
hydration of cement which turns cement into the
binding material with strong adhesive property.
• Various compound present in cement reacts
individually with water to produce various hydration
products. The major compounds of hydration are C-S-
H gel & Ca (OH)2.
• Calcium Silicate Hydrate (C-S-H gel) : C-S-H gel is
the most important & major product obtained from
hydration. It covers around 50-60% solid volume in
completely hydrated paste. It exhibits the strength &
binding property to concrete.
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Hydration of Cement
Hydration C3S & C2S produce C-S-H gel & Ca(OH) 2

C-S-H gel

C-S-H gel

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Hydration of Cement
• Calcium Hydroxide (Ca(OH)2): Ca(OH)2 is not a desirable product
in concrete mass but it also covers around 20-25% solid volume. It
reacts with sulphate present in environment/water to form calcium
sulphate which reacts with C3A causing deterioration in concrete (also
called Sulphate Attack).

Sulphate attack chemistry:

• Ca(OH) 2+ Sulphur compound = CaSO4
• C3A+32H + 3CaSO4 = C6AS3H32 (tri-sulphate hydrate - “ettringite” – cause large
volume change & detoriation in harden concrete)

Hydration of C3A & C4AF

• 2C3A+6H = 2C3AH6
• C4AF + 2CH + 10H = C3AH6 + C3FH6

• Hydration of C3A in presence of gypsum:

• C3A+32H + 3CaSO4 = C6AS3H32 (tri-sulphate hydrate - ettringite”)
• C3A+ 18H + CaSO4 = C4ASH18 (mono-sulphate hydrate)
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Types of cement
• OPC (Ordinary Portland Cement)
• High Alumina Cement
• Portland Slag cement
• Rapid Hardening Cement
• Low heat Cement
• Quick Setting Cement
• White Cement
• Colored Cement
• Portland Pozzolana Cement
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Ordinary Portland cement (OPC ):

• Common type of cement having medium rate of
strength development and medium rate of heat
generation.
• Initial Setting time: 30 min
• Final setting time: 10 Hrs
• Widely accepted and used in all types of general
construction
• Grades of cement : 33 Grade, 43 Grade, 53 Grade

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Portland Pozzolana Cement ( PPC): NS-385

• Pozzolana itself has no cementing value but when
mixed with lime ( CaOH2) produces cementing
property.
• More resistant to chemical attack and aggressive water
and hardens slowly
• About 85-65% by weight of OPC clinker is mixed with
15-35% by weight of pozzolanic materials ( volcanic
ash, fly ash, powdered brunt bricks, calcined clay) and
grinded
• Has lower heat of hydration and requires long period of
wet curing for better strength, mass concreting
• Higher fineness than OPC, hence more durable and
workable
• It is cheaper than OPC 39

Rapid hardening cement ( High Early Strength

Cement)
• Gives strength faster than that of OPC
• Initial and final setting time is similar to OPC
• Contains more C3S (about 56%), grinded finer
than OPC
• Used in that place where formworks is to be
removed soon
• Curing period is also shorter than that of OPC
• Higher early strength than OPC
• Unsuitable for mass concreting
• Costlier than OPC
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Portland Slag Cement:

• Obtained by mixing slag from the blast furnace in
manufacture of pig iron with cement clinker and
gypsum
• Cement clinker grinded with 60-65 % of slag
• Has less heat of hydration , So mass concreting
works
• Better resistance to acid and other corrodent
environment, marine works
• All other properties are similar to the OPC
• cheap
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Low heat cement:

• Lesser heat of hydration
• Decrease in the % of C3S & C3A and increase in % of
C2S
• % of C3A = about 5% and C2S = about 46%
• Used in mass concrete works ,
• IST and FST= nearly same to OPC,
• Rate of strength development low
Quick setting cement:
• Amount of gypsum is reduced and Al203 increased
• IST <= 5 minute and FST <= 30 minutes
• Fineness also accelerates the setting time of cement
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White Cement:
• Same strength as that of OPC
• Greater aesthetic values
• Clear white in color due to absence of Iron
oxides and magnesium oxides in cement
• Cement is heated in the kiln where Oil is used as
fuel instead of coal to avoid the contamination
by coal ash.
• Care should be taken at grinding stage of clinker
• More expensive than OPC
• Used in finished surfacing works, tile joints,
mortar for marble, some aesthetic precast works
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Colored cement:
• For aesthetical works: floor finish, window sill,
stair treads etc
• Obtained by adding 5 to 10% of suitable
coloring compound before grinding of cement
• Iron oxides, magnesium oxides, chromium
oxides or cobalt oxide is added to obtained red,
yellow, green or blue color in cement
• More expensive than OPC

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Hydrophobic Cement:
• Stored cement tends to set by absorbing humidity
from air
• places with high rainfall and humidity
• Cement clinker mixed with water-repellent film -
forming substances like acidol, oleic acid, stearic
acid.
• Mix grind as usual
• Prevents setting of cement during storage

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High Alumina Cement:

• Manufactured by fusing the limestone and bauxite
at high temperature ( limestone bauxite cement)
• Higher resistance against sulphate attack, fire and
acid.
• Initial setting time is higher than that of OPC (2.5
to 3 hrs)
• But final setting is quick ( 4.5 hrs) due to which
heat generation is also fast
• Sets quickly in a short period
• 40 N/mm2 in 1 day and 50 N/mm2 in 3 days
• Gains higher strength in short time
• expensive than OPC 46

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Test of Cement
• Compressive strength test
• Tensile Strength test
• Consistency test
• Setting time test of cement
• Soundness test

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Consistency Test
• 300gm of cement is taken with 25% water
• Fill the mould of Vicat’s apparatus
• The interval between the addition of water to the
commencement of filling of mould is known as the time
of gauging and it should be 33/4 to 41/4 minutes
• Vicat’s apparatus is attached with plunger having
diameter and length as 10mm and 50mm respectively
• Square needle(1mm*1mm) for initial setting time,
plunger for consistency test, needle with annular collar
for final setting time
• Settlement of plunger is noted and if the penetration is
betn 5 to 7mm from bottom of mould, the water added
is correct.
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Initial Setting Time Test

• Take a cement sample of 300gm and mixed
with water (quantity from consistency test)
• Filled the Vicat’s mould with the cement paste
• Using the square needle of 1mm*1mm or
1mm2 X-sectional area try to find the
penetration of about 5 mm from bottom of the
mould.( 35 mm from top of mould)
• The initial setting time is the interval between
the addition of water to cement and the stage
when the needle ceases to penetrate
completely. This time is to be 30 minutes for
OPC.
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Final Setting Time Test

• Cement paste is prepared as above and it is filled
in the Vicat’s mould as previously done.
• The needle with annular collar is attached to the
moving rod of the Vicat apparatus. This needle has
a sharp point projecting in the centre with annular
collar.
• The needle is gently released. The time at which
the needle makes an impression on the test block
and the collar fails to do so is noted.
• The final setting time is the difference between
the time at which water was added to cement and
time as recorded when needle only penetrates the
paste. This time should be about 10 hrs for OPC. 51

Compressive strength Test

• % of water by wt of (cement + sand) = (P/4 +3),
P= % of water for normal consistency
mix proportion of cement and sand= 1:3
• 3 Moulds of either cube size 70.6mm or 76mm
• Dry mix cement and sand then mix with water for uniform colour
with in 3-4 mintues
• Rod the mortar placed in mould 20 times in about 8 secs for full
compaction
• Store specimen of cubes for 24 hours in place of relative humidity 90
% and temperature 27 +_ 2OC.
• Cubes are tested in compression testing machine at end of 3 days
and 7 days
• Load is applied uniformly at the rate of 350kg/cm2
• C.S > 115kg/cm2 (3days),
• C.S >175kg/cm2(7 days)
• Average of 3 moulds give compressive strength

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Tensile strength Test

• % of water by wt of (cement + sand)= ((P/5) +2.5),
P= % of water for normal consistency
mix proportion of cement and sand= 1:3
• 12 standard briquettes are prepared
• Six briquettes are tested after 3 days and 7 days .
Rate of loading 35kg/cm2
• X-sectional of briquette at least section is 6.45cm2
• Ultimate tensile stress = failing load/6.45
• At 3 days T.S>20kg/cm2, at 7 days T.S>25kg/cm2
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Soundness Test
• Test to detect the presence
of uncombined lime and
magnesia in cement
• Test performed with the
help of Le-Chatelier
apparatus.
• Brass mould of 30mm dia.
and 30mm height
• There is split in mould and
it doesn’t exceed 0.50mm

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Soundness Test
• On either side of split there are two indicators with pointed ends
• Thickness of mould cylinder is 0.50mm
• Cement paste is prepared (water = 0.78 P)
• Using glass plate at bottom, fill the mould with paste, then cover upper
surface of mould with glass plate along with small weight at top.
• Submerge in water for 24 hrs (250C to 290C)
• Then measure the distance between the points of indicator (Say: x1)
• Again, submerge the mould in water and apply the heat in such a way
that boiling temperature of water is reached in about 30 minutes and
boiling is continued for 3 hours.
• The mould is taken out then left for cooling, again the distance
between the points of indicators is again measured (say: X2)
• Difference between x1 and x2 must not exceed 10mm.
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Admixtures
Admixtures are the materials which are added in
cement mortar or concrete to improve upon their
quality or to achieve desired property of concrete as
required.
Purpose of admixture
• Improve the workability
• Retard setting action of the mortar and concrete
• Increase the bond strength between reinforcement and
concrete
• Improve the water proofing properties of the cement
mortar or concrete
• Reduce shrinkage during setting of mortar or concrete
• Reduce bleeding and segregation effect of concrete 58

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Admixtures
• Admixtures are mainly classified into two types:
a) Chemical Admixture
b) Mineral Admixture
• Chemical Admixture:
• These are the admixture containing basic ingredient as
various chemicals.
• Normally available in liquid / powder form.
• Used with relatively low dosage normally 0.04% to 5% by
wt. of cement.
• Normally used to increase the workability, to retard or
accelerate the setting time/hardening process, for air
entraining & water proofing etc. 59

Admixtures
• Chemical Admixture:
• TYPES:
a) Water Reducing Admixture (Plasticizer)
b) High Range Water Reducing (Super-plasticizer).
c) Retarding Admixture.
d) Accelerating Admixture.
e) Air-entraining admixture.
f) Water proofing Admixture.

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Admixtures
a) Water Reducing Admixture (Plasticizer)
• Admixture which increase the workability of fresh concrete/mortar without
increasing water content or maintain workability with reduced water.
• Can reduce water requirement by 5-15%
• Eg: (Various lignosulphonate normally derived from wood product), (synthetic raw
materials), (polyglycol esters) etc.
b) High Range Water Reducing (Super-plasticizer).
• Similar to plasticizing admixture with high water reducing capacity.
• Normally used when high degree of water reduction is desirable.
• Depending upon its type can reduce water content more than 30%.
• Due to their powerful dispersing & fluidifying effect facilitates to work with very
low W/C ratio also.
• HRWR normally available in market are:
i. Sulphonated melanie-formaldehyde (SMF),
ii. Sulphonated napthalene-formaldehyde (SNF),
iii. Carboxylate acrylic easter,
• Out of above listed HRWR Carboxylate polymer based superplasticisers are found
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more effective & powerful

c) Retarding Admixture.
• Retarding Admixture delay the setting time of concrete / mortar.
• Keep concrete workable for long period giving additional time for
mixing, placing, compacting & finishing.
• Eg: Calcium sulphate (gypsum), starch/sugar, cellulose,
lignosulphonic-acid etc.

d) Accelerating Admixture.
• Accelerating Admixture when added increase rate of hydration of
hydraulic cement, shorten setting time & increase hardening process.
• Normally used when fast setting & early strength gain is desirable (Eg,
Urgent repair work, road pavement construction etc)
• Can be used in cold climate region for rapid strength gain.
• Chloride is one of the economic/effective accelerating admixture but
due to its action on corrosion of steel its use is limited to 0.15% of
Cement for RCC & 0.06% for prestressed concrete.
• Eg; Soluble carbonates, silicates & flurosilicates, Organic compound –
triethenolamine etc. 62

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e) Air-entraining admixture.
• Induce micro-air bubble (5 to 80 µ) to concrete.
• Used to produce air entrained concrete.
• Air entraining admixture induce millions of fine uniformly distributed air
bubble to concrete.
• These micro-air bubble acts as flexible ball bearing thus increase
workability, reduce segregation & bleeding, also the harden concrete have
better resistance to freezing & thawing.
• Eg; Natural wood resin. Water soluble soap of resin acid, hydrogen
petroxide, aluminium powder, Animal & vegetable oil etc.

f) Waterproofing Admixture.

Normally used where water impermeability is desirable.

Mainly two types:
• Pore-filler: Reduce permeability by its pore-filling action. Normally used
materials are Chalk, Talc, Silicates, Aluminium power.
• Water repellent: Prevent water penetration by its water repellent action.
Normally used materials are: Resin, vegetable oil, waxes, calcium soap, soda
etc.
• Mineral admixture like silica-fume, fly-ash & air entraining admixture can63
also used to improve impermeability of concrete.

THANK
YOU

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