CEL313

Concrete Engineering

July 2023
 Cement
• Introduction
• Manufacturing of Cement
• Dry Process
• Wet Process
• Constituents of Cement
• Clinker Composition
• Types of Cement
• Field Tests for Cement
• Laboratory Tests for Cement

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 Introduction
• Joseph Aspdin: Invented
Portland Cement in U.K in
1824
• He used mixture of
Limestone, Clay and Water
in Appropriate proportion
• This mixture was heated at
high temperature
• On 21st October,1824 was
granted patent Figure: Portland Stones
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 Manufacturing of Cement
Raw Material Extraction Correction of Proportions Pulverization (Powder
and Storage Form) in Ball Mill

Pulverize Clinker and Add Formation of Clinkers and Calcination in Kiln

Gypsum Its Cooling

Storage and Packing

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 Manufacturing of Cement – Dry Process
Calcareous Material Lime Stone Argillaceous Material Clay

Crushing Crushing

Fine Grinding in Ball Mills Fine Grinding in Ball Mills

Storage Basin Mixing in Correct Proportion Storage Basin

Preheating @ 800 Degree Celsius

Fed to Rotary Kiln

Clinkers are Formed

Clinkers are grounded in Ball Mill

Figure: Clinkers Cement Silos

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 Manufacturing of Cement – Wet Process
Calcareous Material Lime Stone Argillaceous Material Clay

Crushing Crushing

Fine Grinding in Ball Mills Fine Grinding in Ball Mills

Wet Grinding Mill to Make Slurry

Blending of Slurry to Correct Proportion

Slurry to Rotary Kiln

Fed to Rotary Kiln

Clinkers are Formed

Figure: Cement Silos Clinkers are grounded in Ball Mill

Cement Silos 6
 Constituents of Cement
Constituents Functions Average Composition (%)
Lime Control Strength and Soundness 60-65
Silica Gives Strength 17-25
Alumina Responsible for Quick Setting 3-8
Iron Oxide Gives Colour and Helps in Fusion 0.5-6
of Different Ingredients
Magnesia Imparts Colour and Hardness 0.5-4
Soda + Potash Residue, Causes Efflorescence and 0.5-1
Cracks
Sulphur Trioxide Makes Cement Unsound 1-2

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 Clinker Composition
Mineral Compounds Composition (%) Basic Name Symbol
Tricalcium Silicate 25-50 Alite C3S
Dicalcium Silicate 25-40 Belite C2S
Tricalcium Silicate 5-11 Celite C3A
Tetra Calcium Alumino Ferrite 8-14 Felite C4AF

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 ASTM Classification (C 150)
Type I : General Purpose
Type II: Moderately Sulphate Resistant, and moderate heat of
hydration
Type III: High early strength
Type IV: Low heat of Hydration
Type V: Sulphate Resistant

Type IA and IIA for air entrained cements

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 Typical Composition
ASTM Type C3S C2S C3A C4AF

I 45-55 20-30 8-12 6-10

II 40-50 25-35 5-7 10-15

III 50-65 15-25 8-14 6-10

IV 25-35 40-50 5-7 10-15

V 40-50 25-35 0-4 10-20

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 BIS Classification
• Ordinary Portland Cement: IS 269-1989 (Further Classified
into 33,43 and 53 grade; the grade implies the strength
achieved by the cement mortar at 28 days)
• Portland cement, Low heat: IS 12600-1989
• Rapid Hardening Portland Cement: IS 8041-1978
• Portland Pozzolana Cement: IS1489-1976
• Portland Slag Cement: IS 455-1976

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Classification of Portland Cement in India

Minimum compressive strength after specified period of curing (MPa)

Sr. No Type of Cement 1 Day 3 Days 7 Days 28 Days
1 33 Grade - 16 22 33
2 43 Grade - 23 33 43
3 53 Grade - 27 37 53

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Important Physical Requirements of Portland
Cement in India

` Physical Requirements
Type of Fineness Le Chatelier Autoclave Initial Setting Final Setting
Cement (min) (max) Expansion time time (max)
(max) (min)
M2/kg mm % min min
1 33 Grade 225 10 0.8 30 600
2 43 Grade 225 10 0.8 30 600
3 53 Grade 225 10 0.8 30 600

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 Types of Cement
1. Ordinary Portland Cement
2. Rapid Hardening Cement
3. Extra Rapid Hardening Cement
4. High Alumina Cement
5. Sulphate Resisting Cement
6. Low Heat Cement
7. Portland Pozzolana Cement
8. Water Repellent Cement
9. Quick Setting Cement
10. White Cement
11. Air Entraining Cement
12. Super Sulphate Portland Cement 14
OPC Based Cements
 Ordinary Portland Cement (OPC)

• It is obtained by Pulverizing argillaceous and calcareous materials in correct proportion

• Portland cement is most common variety of artificial cement and most commonly it is known as OPC
• It is available in 03 grades
• OPC-33 Grade (IS 269-989)
• OPC-43 Grade (IS 8112-1989)
• OPC-53 Grade (IS 12269-1987)
• Initial setting time should be >= 30 minutes, Final Setting time <= 10Hrs
• It is used in general concrete construction where there is no exposure to sulphates in the soil or in ground
water
 Rapid Hardening Cement (RHC)

• It is finer than Ordinary Portland Cement

• It contains more C3S and less C2S than the OPC
• The 01 day strength of RHC is equals to 03 day strength
of OPC
• The main advantage of RHC is that it is used when
shuttering are to be removed much earlier, thus
saving considerable time and cost
• Cost of RHC is nearly 10-15 % more than OPC
• It can be safely exposed to frost as it matures more
quickly
 Extra Rapid Hardening Cement (ERHC)
• It is obtained by mixing calcium Chloride ( not exceeding 2% by weight of the RHC) with RHC
• Addition of Calcium Chloride imparts quick setting properties
• It is very suitable for concreting in cold weathers
• Use of Extra Rapid Hardening Cement is prohibited in Prestressed Concrete Construction
• Maximum time of Using this cement is 20 minutes for mixing, transporting, placing and compaction
 High Alumina Cement
• In this cement C3A content is very low due to which it resist Sulphur attacks and Chemical Attacks
• Composition: Al2O3 39%, Fe2O3 10%, CaO 38%, FeO 4%, SiO2 6%
• It sets quickly and attains higher ultimate strength in a short period.
• About 80% of ultimate strength develops in one day
• It is resistant to freezing and thawing
• It has an initial setting time of 3.5 Hrs and Final setting time of about 5 Hrs
 Sulphate Resisting Cement

• It is similar to OPC but in this type C3A content is

decreased
• Composition: 80% GGBFS, 10-15% Gypsum, 5% OPC
Clinkers
• It is grinded more finer than OPC
• It is mainly used in following areas
• Lining of sewers
• Canals
• Coastal areas
• Sea water construction
• Initial setting time <= 30 min
• Final setting time >=600 min
 Low Heat Cement

• It is a Portland cement obtained by reducing the more

rapidly hydrating compounds such as C3S and C3A and
increasing C2S
• As per the Indian Standard Specifications, the heat of
hydration of low heat cement shall be as follows
• 07 days – not more than 65 calories per gm
• 28 days – not more than 75 calories per gm
• It is used in massive construction works such as Dam
Construction, Retaining wall construction etc.
• It has low heat of gain of strength but the ultimate
strength of LHC and OPC are nearly the same
Non-OPC Based Cement
 Blended Cement/ Binary Cement
• PPC: Portland Pozzolana Cement
• PSC: Portland Slag Cement (IS 455:1989)
• Supplementary Cementous Material

OPC Clinkers Fly ash PPC Slag Silica fume

CaO 60 2.5 41-43 44-46 4.1
SiO2 20 52 28-32 26-30 93
Al2O3 6.3 28 7-10 9-11 0.2
Fe2O3 3.6 10 5-6 2.5-3 0.05
MgO 2.4 1.6 1-2 3.5-4 0.5
SO3 1.5 0.2 2.5 2.4-2.8 0.5
Alkalies 0.6 0.9 - - 0.5
 Portland Pozzolana Cement
• It is mixture of Portland cement + pozzolanic materials
• It is grinded much finer than OPC
• Low rate of strength development
• Low heat of Hydration
• It is mainly used for
• Mass concreting works
• Marine works
• Hydration: Ca(OH)2 + S + H C-S-H gel
 Water Repellent Cement
• It is obtained by addition of 0.1 % of oleic acid with OPC clinkers
• It is mainly used in
• Water tight structure
• In basements
 Quick Setting Cement
• In the manufacturing of this cement, gypsum content is reduced to get the quick setting properties and also
small amount of aluminium sulphate is also added
• It is grinded much finer than OPC
• It sets quickly but does not harden quickly
• Initial setting time = 05 minutes
• Final setting time = 30 minutes
 White Cement

• The process of manufacturing of white cement is the same but

the amount of iron oxide which is responsible for greyish colour
is limited to less than 01 per cent
• Sodium Alumino Ferrite (Cryolite) is added to act as flux
• Whiteness of cement measured by ISI scale or Hunters Scale
• The whiteness should not be less than 70% on ISI scale and on
Hunters Scale it is generally 90%
 Air Entraining Cement (AEC)

• This cement is made by mixing a small amount of an air

entraining agent with OPC clinkers at the time grinding
• It offers good workability due to which it is having higher initial
setting time than OPC
• It is having lesser final setting time as compared to OPC, due to
which it offers resistance to freezing and thawing effects
• Some of the air entraining agents are
• Alkali salts of wood resins
• Calcium lignosulphate
 Super Sulphate Portland Cement
• Composition of Super Sulphate Portland Cement is as follows
• 80-85 % granulated slag + 10-15 % Calcium Sulphate + 4-5 % OPC Clinkers
• It is used below 40 degree temperature
• Air resistance and frost resistance is comparatively good
• High chemical resistance
• High sulphate resistance
 Field Tests For Cement
• Cement Colour: Greenish Grey
• If rubbed between figures it should feel smooth not rough
• If hand is inserted in bag of cement it should feel cool not hot
• If thrown in bucket of water it should sink and not float on
water
• A thin paste of cement should feel sticky
• It should be free from lumps

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Testing the properties of Cement
(IS 4031Part 1-6)
• Suitability: Field tests
• Reacting surface: Particle size or fineness
(Part 1 and 2)
• Swelling property: Soundness (Part 3)
• Water requirement: Standard consistency
(Part 4)
• Working time: Setting time (Part 5)
• Strength: Compressive strength
(Part 6)

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Fineness of cement : Dry sieving

90 micron IS sieve

 Sample weight 100 gm

 Sieving for 15 minutes
 Intervals of 5 minutes each
 Residue is weighed
 Weight should not be more than 10% of weight of sample.

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Fineness of cement: Air permeability method

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 Specific surface: cm²/gm of cement
 Fineness of cement: Increases with specific surface.

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Soundness of cement: Le chatelier method

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Consistency of cement: Vicat’s test

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Setting time of cement: Vicat’s test

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Compressive strength of cement: Cube test

Cement 200 gm Sand grade I (1mm-2mm) 200gm

Sand grade II Sand grade III

(500 -1 mm )200gm (less than 500 ) 200gm
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 Compressive strength test

70.7 mm cube mould

• Blended in dry state and then water is mixed.

• Water = (p/4 + 3)% of weight of dry mix.
• Mould is oiled and mortar is filled.
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• Mechanically compacted.
• Immersion curing is done.
• Test is carried on three cubes and average is taken.
• loading rate 35N/mm2/minute.
• Load at failure is recorded.

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 IS 8112 and IS 12269
Property Effect Range for OPC 43 and
OPC 53
More fine cement is susceptible to air
Particle size set. Requires more water. Sets at Residue ≤10%
or fineness higher rate. Acts as early setting Minimum 225 m2/kg
cement
More initial setting time indicates
slow setting cement. Requires Initial minimum 30 minute
Setting time
prolonged curing. Useful for distant Final maximum 600 minutes
concreting .
Unsound cement is susceptible to
volume change in concrete and By le Chatelier 10mm
Soundness
mortar. Increase in volume in micro- By Autoclave 8 mm
structure results into cracks
3 day min 23 N/mm2 (27)
Compressive More compressive strength gives 7 day min 33 N/mm2 (37)
strength more strength to concrete. 28 day range 43-58 N/mm2
(53)
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