CE 225 Construction

Material and Testing

⚫ The word cement has come
from the roman word
‘OPUS CAEMENTICIUM'
which means Roman
concrete.
⚫ An adhesive substance of all
kinds, but, in a narrower sense,
the binding materials used in
building and civil engineering
construction.
Before the 18th century
• Cement made with lime, sand, and
gravel was used.
• Examples: Dome of Pantheon of
Rome, Baths of Caracalla
18th, 19th, and 20th centuries
• Portland cement patented by Joseph
Aspdin - 1824
• Blend of Rosendale and synthetic
cementst centuryand future…
21
• Ordinary Portland Cement most
common. Base of concrete, mortar,
grout
• Green Cement made by recycled coal, ash,
⚫ 1756-John Smeaton (England) created
hydraulic lime from lime stone.
⚫ 1796- John Parker(England) created an
improved version. Birth of natural cement
industry.
⚫ 1824-portland cement was invented by
Joseph Aspedin. It resembled the colour
of sand stone found in Portland, U.K .
 Physical Chemical
⚫ Strength to masonry ⚫ Alumina: Iron oxide ≥ 0.66
⚫ Excellent binding material ⚫ 0.66≤Lime saturation
⚫ Easily workable factor ≤1.02
⚫ Stiffens early ⚫ Sulphur content ≤ 2.75 %
⚫ Possesses good plasticity ⚫ Wt. of insoluble residue ≤
⚫ Offers good resistance to 1.5%
the moisture
⚫ Fineness:
⚫ Soundness
⚫ It is quite important to
maintain the composition LIME
63%
of cement because all the
SILICA
functions of every type of 22%

cement depends on ALUMINA 6%

individual quantity of IRON OXIDE

every component. 3%

GYPSU M
1-4 %
 Raw material

ingredient range approximate

lime 60-65% 63
Silica 17-25% 21
Alumina 4-8% 6
Iron oxide 1-6% 3
Magnesia 1-3% 1.5
Calcium sulphate 3-5% 4
(Gypsum)
Sulphur 1-3% 1
Alkalies 0.2-1% 0.5
 • Controls strength and soundness. Excess will
LIME (CaO) decrease the strength. Deficiency will make it set

quickly.
SILIC • Gives strength, higher silica increases the
A strength but setting time is prolonged.

(SiO2 )
•Quick setting, excess lowers
Alumina strength
(Al2O3)
IRON OXIDE
•Imparts color, helps in
(Fe2O3) fusion of ingredients.

Magnesium •Color and hardness,

Oxide (MgO) excess causes cracking

Sulphur •It makes the cement

Trioxide (SO3) sound.
Demerits Merits
CLASSIFICTION OF CEMENT
⚫ Ordinary portland cement
⚫ Rapid hardening cement
⚫ High alumina cement
⚫ Blast furnace slag cement
⚫ Super sulphated cement
⚫ Low heat cement
⚫ Air entraining cement
⚫ Quick setting cement
⚫ Coloured cement
⚫ White cement
⚫ Acid resistance cement
⚫ Hydrophobic cement
⚫ Ordinary portland cement
◦Most commonly used cement
◦Moderate strength
◦Less heat of hydration but does not cause any
defect.
◦Mainly used in pavements and buildings.
◦Normal setting time.(initial setting 30mins, final
setting 8hrs, hardening in 3days)
⚫ Rapid hardening cement
◦ hardens in 1 day.
◦Stronger than OPC
◦ light weight, extra fine
◦Mainly used in highways, under water structures
and in cold weather areas.
⚫ High alumina cement
◦Long setting time(initial setting time 3-
5hrs)
◦Very high compressive strength
◦High resistance to sulphate
◦Used in sea water construction.
◦High heat of hydration
◦Highly resistant to corrosion and temp.
◦Very expensive, unsuitable for massive
construction.
◦Extra care required.
⚫ Blast furnace slag cement
◦Low heat of hydration
◦Not suitable for dry acid zones
◦Less strength than other cement, need longer
curing period.
◦cheap
⚫ Quick setting cement
◦Higher aluminium sulphate content.
◦Sets in 5mins and final setting 30mins.
◦Extra care required, hardens very quickly
◦Used in running water
⚫ Coloured cement
◦Can get colours by adding
mineral pigments.

◦Green(chromium
oxide),blue(cobalt),red,
brown, yellow(iron oxides)
◦Used for decorations.
⚫ White cement
◦Raw material-pure white
chalk(lime stone)
◦Free from iron oxide and
manganese oxide.
◦Dries quickly.
◦Used for plastering or
ornamental flooring or
marking.
⚫ Hydrophobic cement
◦Hydrophobic cement is obtained by grinding
portland cement clinker with a film-forming
substance such as oleic acid in order to
reduce the rate of deterioration when the
cement is stored under unfavourable
conditions. It is also known as Hydrographic
cement.
CLASSIFICATION OF PORTLAND
CEMENT (Astm C150)
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
Type V High sulphate resistant cement
TYPES OF PORTLAND CEMENT
(ASTM C150)
Type I
Type I Portland cement is known as common or
general-purpose cement. It is generally
assumed unless another type is specified. It is
commonly used for general construction,
especially when making precast, and
precast-prestressed concrete that is not to be in
contact with soils or ground water. This type of
cement reaches its design strength in 28 days.
TYPES OF PORTLAND CEMENT
(ASTM C150)
Applications of Type I Cement:
It is a general-purpose cement used in concrete
for making pavements, floors, reinforced
concrete buildings, bridges, tanks, pipes, etc.
It is for all uses where the special properties of
other cement types are not required, such as
sulfate attack from soil and water, or to an
objectionable temperature rise.
TYPES OF PORTLAND CEMENT
(ASTM C150)
Type II (Moderate Sulphate Resistance
Cement)
Type II provides moderate sulfate resistance,
and gives off less heat during hydration.
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. Type
II generates less heat than type I and reaches its
desired strength in 45 days.
 TYPES OF PORTLAND CEMENT
(ASTM C150)
Applications of Type II Cement
It is used where precaution against moderate sulfate
attack is important, as in drainage structures, which may
be subjected to a moderate sulfate concentration from
ground waters. It has moderate sulfate resistance because
it contains no more than 8% tricalcium aluminate (C3A).
It usually generates less heat of hydration at a slower rate
than Type I cement and therefore can be used in mass
structures such as large piers, heavy abutments, and
retaining walls.
Due to less heat generation it can be preferred in hot
weather.
 TYPES OF PORTLAND CEMENT
(ASTM C150)
Type IIA
It is same as Type II but just having air entraining
agents.
 TYPES OF PORTLAND CEMENT
(ASTM C150)
Type III (High early strength cement/Rapid hardening
cement)
High C3S (Tricalcium silicate) content upto 70%
Also it has high fineness and have minimum surface area
of 325 m2/kg
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.
 TYPES OF PORTLAND CEMENT
(ASTM C150)
Applications of Type III Cements
It is chemically and physically similar to Type I cement,
except that its particles have been ground finer.
It provides high early strengths at an early period, usually
a week or less.
It is used when forms need to be removed as soon as
possible or when the structure must be put into service
quickly.
It is preferred in cold weather for reduction in the curing
period.
 TYPES OF PORTLAND CEMENT
(ASTM C150)
Type IIIA
It is the same as Type III plus air entrained agents
 TYPES OF PORTLAND CEMENT
(ASTM C150)
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 design strength is 90 days.
 TYPES OF PORTLAND CEMENT
(ASTM C150)
Applications of Type IV Cements
It is used where the rate and amount of heat generated
from hydration must be minimized.
It develops strength at a slower rate than other cement
types.
It is most suitably used in massive concrete structures,
such as large gravity dams, where the temperature rise
resulting from heat generated during hardening and must
be minimized to control the concrete cracking.
 TYPES OF PORTLAND CEMENT
(ASTM C150)
Type V (High sulphate resisting 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 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.
 TYPES OF PORTLAND CEMENT
(ASTM C150)
Applications of Type V Cements
It is used only in concrete exposed to severe sulfate action
– principally where soils or ground waters have a high
sulfate content.
Its high sulfate resistance is due to its low C3A content of
about 4%.
It is not resistant to acids and other highly corrosive
substances.
 TYPES OF PORTLAND CEMENT
(ASTM C150)
Types II(MH) and II(MH)a have a similar composition as
types II and IIa, but with a mild heat.
 Uses of Cement
Laying floors ,
roofs,
concrete,Masonry, pointing, Joints for constructing
plastering drains , pipes lintels, beams
, weather
sheds

Engineering
structures To
Foundations, For filling like bridges, manufacture
foothpaths cracks culverts , bricks
dams
 Manufacturing of cement
⚫Mixing of raw material(wet or dry)
⚫Burning
⚫Grinding
 Manufacturing of cement

Limestone is
brought
from mines Mixture is
grinded to
form Formation of
homogeneous clinker at high
mixture temperature

Limestone Some additives are

is crushed additives added and again
are added at grinded This
this stage yields
cement
WET PROCESS
When the raw materials are soft, then the wet
process is preferable to be used. The cement is
manufactured by the following procedure:-
Mixing of Raw Materials:
In the wet process, there are two raw
materials e. calcareous and argillaceous.
Initially, Calcareous materials are
crushed using crushers and argillaceous
material is washed With water in the
container.
After crossing the lime stones are stored
in silos similarly after washing the clay is
stored in basins.
The crushed materials from different
silos and basins are drawn in correct
proportions in a channel called wet
grinding mills. Both the materials are
intimately mixed in the presence of
water and to form a fine thin paste
known as slurry
Slurry is then stored in another silo may
be called as slurry silo where it is
constantly stirred. The composition of
raw materials is checked again and, if
required, corrected by adding clay or
chalk materials as desires.
DRY PROCESS
When the available raw materials are
quite hard, then this process is used. The
cement by this process can be prepared
by using the following operations:-

Mixing of raw materials

Burning and Grinding
Mixing of Raw Materials: The raw materials
i.e. argillaceous and calcareous materials
undergo the following stages:-

Crushing: The raw materials, first of all, are

broken into crushers into small fragments
that vary in size.
Drying: The crushed materials are dried by
heating at a sufficiently high temperature. It
may be done in drying kilns.
Reduction of size: The drying materials
are then ground by using ball mills and
tube mills to reduce the size of materials
to find powder.
Mixing in correct proportion: The finely
dried materials are mixed in exact
proportions. The mixing may be done
either mechanically or by pneumatic
methods(eg. pumped under pressure).
In the dry process, the raw materials
mixed, fined, and then fed into kiln
whereas, in the wet process, the raw
materials are crushed separately and
then directly mixed in correct proportion
in the presence of water to make a fine
thin paste known as Slurry.
Burning: In this operation, the slurry is directly fed into a
long inclined steel cylinder called a Rotary kiln. In this
kiln there are 3 different zones shown in fig. below

Cement Manufacturing Process Flow Chart

(i) Drying Zones: In the wet process, the drying zone is

comparatively larger than the dry process. It is because
the raw material in slurry form is directly fed into the kiln
which has more amount of water. As shown in the figure
it is the upper portion of the kiln. In this zone, water is
evaporated at a temperature of 100-400°C.
(ii) Formations of modules: As the slurry gradually
descends in the kiln, the carbon dioxide from the slurry
evaporates and small lumps formed which may be called
modules.

(iii) Burning Zone:- The modules enter this zone where

temperatures are kept about 1400-1500° C. The modules
are converted into dark greenish balls and the product
obtained in the kiln, known as clinker, is of varying size 5
to 20 mm. The clinkers are very hot when coming out of
this zone.
(iv) Cooling of Clinkers:- As shown in the figure another
rotary kiln is provided in an opposite direction which is
also inclined. It is used to cool down the clinkers up to
about 90°C.
Grinding: The cooled clinkers are finely ground in ball
mills or tube mills.

Also, the gypsum is added during grinding about 2-4%.

The gypsum acts as a retarder and so allows the cement
to mix with sand or aggregate and to be placed in
position. i.e. it increases the initial setting time of
cement.
 ACQUISITION OF RAW MATERIAL
CALCIUM SOURCE CONTROLS LOCATION OF
PLANTS
SILICA USUALLY SHIPPED TO CEMENT PLANT
PREPARATION OF RAW MATERIALS
PROCESSING TO CONTROL THE COMPOSITION AND PROPERTIES OF THE
CEMENT

Addition of gypsum
Regulatesset and clinker + gypsum=cement

BURNING
Heating in a kiln
Produces “çlinker’
 quarry

THE CEMENT
loader
dumper

Quarry face
MANUFACTU
1. BLASTING
RING 2. TRANSPORT

PROCESS crushing

conveyor
storage at
the plant

3. CRUSHING & TRANSPORTATION

1.BLASTING : The raw materials that are used to manufacture cement (mainly limestone and clay) are blasted
from the quarry.
2. TRANSPORT : The raw materials are loaded into a dumper.
3. CRUSHING AND TRANSPORTATION : The raw materials, after crushing, are
Next
transported to the plant by conveyor. The plant stores the materials before they are
homogenized.
 Raw grinding and burning

storage at
the plant
THE CEMENT Raw mill

conveyor
Raw mix

MANUFACTU
preheating
RING 1. RAW GRINDING

PROCESS kiln

cooling

clinker

2. BURNING

1. RAW GRINDING : The raw materials are very finely ground in order to produce the raw mix.
2.BURNING : The raw mix is preheated before it goes into the kiln, which is heated by a flame that can
be as hot as 2000 °C. The raw mix burns at 1500 °C producing clinker which, when it leaves the kiln, is
rapidly cooled with air fans. So, the raw mix is burnt to produce clinker : the basic material needed to
make cement.
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 THE CEMENT Grinding, storage, packing, dispatch

Gypsum and the secondary additives are added to the

clinker
storage
MANUFACTU clinker.

Finish grinding

RING
PROCESS
1. GRINDING
silos

dispatch
bags

2. STORAGE, PACKING, DISPATCH

1.GRINDING : The clinker and the gypsum are very finely ground giving a “pure cement”. Other secondary
additives and cementitious materials can also be added to make a blended cement.

2.STORAGE, PACKING, DISPATCH :The cement is stored in silos before being dispatched either in bulk
or in bags to its final destination.
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 Setting- is used to describe Hardening –it refers to the gain of
the stiffening of the cement strength of a cement paste,
paste. It refers to changes of although during setting the
cement paste from a fluid to cement paste acquires some
rigid state. Setting differs strength.
from Hardening of cement.
It includes two processes initial set and final set stages

Initial setting time indicates Final setting time is the time

the beginning of the setting elapsed between the moment water
process when the cement is added to the cement and the
paste starts losing its time when the cement completely
plasticity. lost its plasticity and can resist
certain definite pressure.
 • SHOULD BE FAVOURABLE AND
CLIMAT SUITABLE FOR THE SETTING AND
E HARDENING
• SHOULD BE EASILY AVAILABLE
LABOU AND ECONOMICAL
R
• SHOULD BE NEAR . WILL DECREASE
MARKE COST OF TRANSPORT
T
• RATES SHOULD BE ECONOMICAL.
POWER CUTS MINIMAL.

• EASILY AVAILABLE.
RAW CONTINUOUSLY AVAILABLE
MATERIALS AROUND SITE.
• EASILY AVIALBLE FOR RAW
TRANSPOR MATERIALS AND FINISHED
T MATERIALS.
Quantity of trash is Increasing in
this world day by day which has
ignited the architects to find new
ideas such as :

• Alok shetty’s concept of

recycling tin cans, plastic
bottles, etc and laying them
with very less quantity of
cement.
• GREEN CEMENT
• REASEARCH by Peter Trimble
who proposed a bacterium
based design combined with
sand producing 70% much
stronger cement.