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Cement

The document provides information about cement, including its history, chemical composition, manufacturing process, hydration, types of cement and tests conducted on cement. It begins with describing how cement is made from raw materials such as limestone, clay and iron ore through grinding, heating and cooling processes. It then discusses the chemistry and reactions involved in cement hydration. The document also lists and describes common types of cement used in construction, such as ordinary Portland cement, rapid hardening cement, white cement, as well as tests to measure cement consistency, setting time and strength.

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1 CEMENT On completion of this class, you would be able to • Know the history of cement • Know the chemical composition of cement • Describe the manufacturing process of cement (Dry process)  Define Hydration of cement  State the water requirement of Hydration of cement  State the different types of cement  State the uses of each type of cement • Know the different types of tests on cement (a) Consistency test (b) Initial and final setting time tests (c) Soundness test • Know the grades of cement and their compressive strength • Blended cement and their types
2 Property variety Low cost Plasticity Simple process Durability Bonding well with bar Hydraulicity Advantages of Cement Advantages of cement
3 • Cement is a fine, soft, powdery-type substance • It is made from a mixture of elements that are found in natural materials such as limestone, clay, sand and/or shale • When cement is mixed with water, it can bind sand and aggregates into a hard, solid mass called concrete Cement
4 History of Cement • In 1824, Joseph Aspdin, a British stone mason, heated a mixture of finely ground limestone and clay in his kitchen stove and ground the mixture into a powder to create a hydraulic cement—one that hardens with the addition of water.
5 • He took a patent for this cement • A variety of sandstone is found in abundance in Portland in England • Hence it is called as “ ORDINARY PORTLAND CEMENT “ • In India, the first cement factory was installed at Tamil Nadu (1904) by South India Industry Limited History of Cement (contd)
6 • Four essential elements are needed to make cement. They are Calcium, Silicon, Aluminum and Iron • Calcium (which is the main ingredient) can be obtained from limestone, whereas silicon can be obtained from sand • Aluminum and iron can be extracted from bauxite and iron ore, and only small amounts are needed History of Cement (contd)
7 Chemical Composition of Cement • The raw materials used for the manufacture of cement consist mainly of lime, silica, alumina and iron oxide • These oxides interact with one another in the kiln at high temperature to form more complex compounds • The relative proportions of these oxide compositions are responsible for influencing the various properties of cement, in addition to rate of cooling and fineness of grinding
8 Oxide Percent content CaO (Lime) SiO2 (Silica) Al2O3 (Alumina) Fe2O3 (Iron oxide) MgO (Magnesia) Alkalies(K2O,Na2O) SO3 (Sulphur trioxide) 60-67% 17-25% 5-8% 0.5-6% 0.1-4% 0.2-1.0% 1-3% Chemical Composition of Cement
9 Functions of Ingredients of Cement Lime (CaO) • Major ingredient of cement • Excess quantity of lime makes the cement unsound • If it is less, it decreases the strength and allows the cement to set quickly
10 Silica (SiO2) • An important ingredient which gives strength to cement • If it is in excess silica allows the cement to set slowly Functions of Ingredients Cement (contd)
11 Alumina(Al2O3) • This imparts quick setting time to the cement • If it is in excess quantity, it weakens the cement • It also lowers the temperature of clinkers Functions of Cement Ingredients (contd)
12 Iron Oxide (Fe2O3) • It helps the fusion of the raw materials during burning stage • It gives colour, strength and hardness to cement Functions of Cement Ingredients (contd)
13 Magnesium Oxide (MgO) • If present in small quantities, MgO imparts hardness and colour to cement • If becomes excess quantity, weakens the cement Functions of Cement Ingredients (contd)
14 Sulphur Trioxide (SO3) • A very small quantity is required in the manufacturing of cement • If it is in excess, SO3 makes the cement unsound Functions of Cement Ingredients (contd)
15 Alkalies • A small quantity are required • Alkalies and other impurities present in raw materials are carried by the flue gases during heating • If it is in excess quantity, efflorescence is caused Functions of Cement Ingredients (contd)
16 Manufacturing of Portland Cement • The raw materials required for manufacturing of cement are calcareous materials, such as lime stones or chalk, and argillaceous materials such as shale or clay Lime Stone Shale
17 • There are two processes known as ‘wet’ and ‘dry’ processes depending upon whether the mixing and grinding of raw materials is done in wet or dry conditions Dry Process In this process the following operations are involved 1. Mixing of raw materials 2. Burning 3. Grinding 4. Packing and Distribution Manufacturing of Portland Cement (contd)
Production and Composition of Portland Cement Process to Produce Portland Cement Grinding Iron ore powder PⅡ PⅠ Mixing materials Limestone Clay Bleeding Grinding 1450℃ Raw material Clinker Gypsum
19
20 Flow chart of the manufacture of cement
Traditional Manufacture of Portland Cement 1. Stone is first reduced to 125 mm (5 in.) size, then to 20 mm (3/4 in.), and stored.
2. Raw materials are ground to powder and blended. or 2. Raw materials are ground, mixed with water to form slurry, and blended.
3. Burning changes raw mix chemically into cement clinker.
3. Burning changes raw mix chemically into clinker. Note four stage preheater, flash furnaces, and shorter kiln.
Pyro- Processing
4. Clinker is ground with gypsum into portland cement and shipped.
Clinker Gypsum
Grinding • Clinker is ground with gypsum (calcium sulfate) to produce portland cement • Fine grinding is necessary for high early strength – 85-95% -325 mesh (45 microns) – ~ 7 trillion particles per pound • Gypsum absorbs water and prevents setting of C3A during shipment
Source: van Oss and Padovani, 2002
Process of Clinker Production
Source: Taylor, 1997
Source: MacLaren and White, 2003
40 • Limestone is taken from a quarry. It is the major ingredient needed for making cement • Smaller quantities of sand and clay are also needed • Limestone, sand and clay contain the four essential elements required to make cement • The four essential elements are oxides of calcium, silicon, aluminum and Iron Manufacturing of Cement (contd)
41 Manufacturing of Cement (contd)
42 2.) Boulder-size limestone rocks are transported from the quarry to the cement plant and fed into a crusher which crushes the boulders into pieces Manufacturing of Cement (contd)
43 • The limestone pieces then go through a blender where they are added to the other raw materials in the right proportions 3. Mixing of raw materials Manufacturing of Cement (contd)
44 • The raw materials are ground to a powder. This is sometimes done with rollers that crush the materials against a rotating platform 4. Grinding of Raw Materials Manufacturing of Cement (contd)
45 Tube Mill The tube mills are used to have preliminary grinding of raw materials or mixture of raw materials or clinkers
46 5. Sintering • Everything then goes into a huge, extremely hot rotating furnace to undergo a process called "sintering“ • Sintering means: to cause to become a coherent mass by heating without melting. In other words, the raw materials become sort of partially molten • The raw materials reach about 2700° F (1480°C) inside the furnace • This causes chemical and physical changes to the raw materials and they come out of the furnace as large, glassy, red-hot cinders called "clinker" Manufacturing of Cement (contd)
47 cooler Manufacturing of Cement (contd)
48 Rotary Kiln Manufacturing of Cement (contd)
49 • The clinker is cooled and ground into a fine powder in ball mills • A small amount of gypsum is also added during the final grinding. It is now the finished product - Portland cement • The cement is then stored in silos (large holding tanks) where it awaits distribution 6. Grinding of clinkers and storing Manufacturing of Cement (contd)
50 Ball Mill The ball mills are used to carryout final grinding of clinkers Manufacturing of Cement (contd)
51 Manufacturing of Cement (contd)
53 Cement Plant
54 Bogue Compounds • During the manufacturing of cement, various constituents combine in burning and form certain compounds • These compounds formed during burning, react with water help in setting and hardening of cement • These compounds are called bogue compounds they are Compound symbol 1.Tricalcium silicate C3S 2.Dicalcium silicate C2S 3.Tricalcium aluminate C3A 4.Tetracalcium alumino ferrite C4AF Hydration of Cement
Properties of Mineral Compounds Mineral types Tricalcium silicate Dicalcium silicate Tricalcium aluminates Tetracalcium aluminoferrite Abbreviation C3S C2S C3A C4AF Content (%) 37-60 15-37 7-15 10-18 Hydration speed fast slow fastest fast Hydration heat much little most more Strength high early low later high low low Anti- corrosion good fine poor excellent Shrinkage middle better big small
56 Hydration of Cement (contd) • When water is added to cement a chemical reaction starts between active components of cement (C4AF,C3A,C3S andC2S) and water which is exothermic in nature and liberate a significant amount of heat • This is known as hydration and the liberated heat is called heat of hydration
When mixed with water, Portland cement hydrates and forms heat 3CaO·SiO2+H2O CaO·2SiO2·3H2O+Ca(OH)2 Triealcium silicate hydrates rapidly and forms earlier strength and earlier heat of hydration. Tricalcium silicate is formed in a kiln when the charge contains an abundance of lime, and hence the greater amount of CaO in the reaction. Hydration Mechanism
Dicalcium silicate hydrates slowly and is responsible for strength increase in concrete at later ages. The heat of hydration is liberated slowly. More dicalcium silicate is formed when the raw materials contain less lime. 2CaO·SiO2+H2O 3CaO·2SiO2·3H2O+Ca(OH)2 Hydration Mechanism
Tricalcium aluminate hydrates rapidly and liberates a large amount of heat. If this reaction were not controlled, concrete would set so rapidly (flash set) that it could not be used in modern construction. 3CaO·Al2O3+H2O 3CaO·Al2O3·6H2O Hydration Mechanism
60 • About an average 23 percent of water by weight of cement is required for complete hydration of Portland cement • This water combines chemically with the cement compounds • Some quantity of water, about 15 percent by weight of cement , is required to fill the cement gel pores • A total of 38 percent of water by weight of cement is required to complete the chemical reaction Water Requirement for Hydration
61 • If excess water is present, it will lead to capillary cavities • In a month’s time 85 to 90 % of the cement gets hydrated and cement attains almost its full strength • Hydration still continues and cement grows stronger with time • Total 50% of water by weight of cement is required for complete hydration Water Requirement for Hydration (contd)
Fineness and Properties Fineness Surface area touching with water Setting and hardening speed Properties Small D < 40μ Great High Strength High Too small Easily Great Cost High Large D >100μ Low Low Low Fineness related to the surface area touching with water, so it influences the setting/hardening speed and the properties of cement. Fineness and Properties of Cement
63 1. Ordinary Portland Cement(OPC) 2. Rapid Hardening Cement 3. Sulphate Resisting Cement 4. Quick Setting Cement 5. Low heat Cement 6. Portland Pozzolana Cement 7. High Alumina Cement 8. White Cement 9. Coloured Cement etc..,
64 Ordinary Portland Cement(OPC) • It is a common variety of cement • It is suitable for the construction of all civil engineering works except under water constructions Uses of Ordinary Portland Cement • Used in all important structures where great strength is required such as heavy buildings and bridges light houses, docks, reservoirs, etc,. • Foundations in wet places, and structures subjected to the action of water such as • Retaining walls • Watertight floors • Cement mortar for plastering, pointing etc • Plain concrete
65 • For making • Reinforced cement concrete for laying floors ,roofs, lintels, beams, etc,. • Reinforced brick work • In drainage and water supply works like water storage tanks, septic, tanks, etc,. • For protecting the external faces of buildings or engineering structures from weathering action • For thin masonry works, where strength is required • Making joints for drains, pipes etc,. • Manufacturing of precast pipes, piles, garden benches, fencing posts, flower pots, etc,. • Preparation of foundations, watertight floors, footpaths, etc,. Uses of Ordinary Portland Cement (contd)
66 Quick Setting Cement • As the name indicates, it sets very fast • The early setting property is brought out by reducing the amount of gypsum during the grinding process • This cement is costlier than ordinary Portland cement • Initial setting time starts within 5 minutes, after adding water • Final setting time: within 30 minutes • It is ground much finer than OPC
67 Advantages • It is used in construction of structures under water, in water logging areas, rivers, in running water like canals and streams and pipe lines etc,. • It is also used in emergency circumstances where quick setting of cement is needed. Quick Setting Cement (contd)
68 White Cement • Raw materials like china clay and pure lime stone are used to get pure white colour • It is a variety of OPC • It is prepared from such materials which are practically free from colouring oxides of iron and manganese • For burning of this cement, the oil fuel is used instead of coal • It is white in colour
69 Uses • It is used for floor finish, plaster work, ornamental work, etc • It is also used to fill the small holes during sanitary, water supply fittings, wall tiles etc White Cement (contd)
70 Laboratory Tests on Cement 1. Consistency of cement 2. Setting times of cement 3. Soundness of cement 4. Compressive strength test 5. Fine ness of cement 6. Tests for chemical composition of cement
71 Normal consistency of cement Normal consistency is defined as the percentage of water required to produce a cement paste of standard consistency
72 VicatApparatus 1
73 Normal Consistency Test of Cement 1. Take 300gm of cement sample and place at on a non- absorbent plate 2. Take 25% of water by weight of cement as first trial and mix it thoroughly with cement using gauging trowels. Ensure that the time of gauging shall be within 3 to 5 minutes. The time of gauging shall be reckoned from the instant water is added to cement to that paste is filled in the mould
74 3. Keep mould on a non absorbent plate. Apply a thin coat of oil inside the mould 4. Fill the vicat’s mould with cement paste at a stretch and tamp the mould so as to make the cement spread uniformly in the mould. Strike off the excess cement plate and level the surface of mould with spatula 5. Fix the plunger of 10mm dia x 50mm long to the plunger holder of the apparatus. Gently lower the plunger to touch the top surface of the paste and leve it quickly. Due to the weight of header and holder the plunger penetrates in to the cement paste Normal Consistency Test of Cement (contd)
75 6. Note the plunger’ penetration reading on the scale of apparatus. The recorded penetration value is reckoned from the bottom of mould 7. Remove the plunger and cement paste from the mould 8. Take sample of cement and repeat the entire process with 27% of water and note down the plunger penetration Normal Consistency Test of Cement (contd)
76 9. Repeat the above process with varying % of water and note the penetration of plunger till the penetration value is 5 to 7 mm measured from the bottom of the mould to the tip of the plunger Note :The standard consistency of ordinary Portland cement is 30 to 35% by weight of cement Normal Consistency Test of Cement (contd)
77 Calculation Procedure Weight of cement taken = g Percentage of water added = % Initial reading on vicat scale in mm = Final reading on vicat scale in mm = Penetration of plunger measured from bottom of mould in mm = Normal Consistency Test of Cement (contd)
78 Result The standard consistency of mould = _____ %
79 Initial and Final setting time of cement
80 When water is added to cement, the paste starts stiffening and gaining strength, simultaneously loosing its plasticity. Two stiffening states identified are initial and final setting times respectively • Initial setting time is the time interval between the addition of water to cement and the stage when needle ceases to penetrate completely • This time should be about 30 minutes for ordinary cement Initial Setting Time of Cement
81 Procedure (A) Preparation of test block (paste in the mould) 1. Prepare a neat cement paste by mixing the cement with 0.85 times the water required to give a paste of standard consistency 2. Start stop watch at the instant when water is added to cement. Thoroughly mix cement and water using gauging trowels till required uniformity is attained in mixing Test for Initial Setting Time of Cement (contd)
82 3. Fill the mould completely and smoothen the surface of the paste by making it level with the top of the mould. The cement paste thus prepared in the mould is the test block Note : • Clean appliance shall be used for mixing • All apparatus shall be free from vibration during the test • Care shall be taken to keep the needle straight Test for Initial Setting Time of Cement (contd)
83 (B) Initial Setting Time 1. Place the test block with porous plate at bottom, under the rod, bearing the needle (C) as shown in the fig of Vicat Apparatus 2. Lower the needle gently until it comes in contact with the surface of test block and quickly release, allowing it to penetrate into test block Test for Initial Setting Time of Cement (contd)
84 Vicat Apparatus 1 Test for Initial Setting Time of Cement (contd)
85 3. Repeat this procedure at regular intervals of time until the needle, when brought in contact with the test block and released as above fails to pierce the block for 5 to 7 mm measured from the bottom of the mould 4. The period elapsed between the time when water is added to the cement and the time at which the needle fails to pierce the test block to a point 5 to 7 mm measured from the bottom of the mould shall be reported as initial setting time Note :The initial setting time of ordinary Portland cement is 30 minutes Test for Initial Setting Time of Cement (contd)
86 (C) Final Setting Time 1. Replace the needle ‘C’ with needle ‘F’ of the vicat apparatus attachment 2. Prepare the test block according to the procedure given above 3. The cement shall be considered as finally set when, upon applying the needle gently to the surface of the test block, the needle makes an impression there while the attachment fails to do so Test for Final Setting Time of Cement (contd)
87 4. The period elapsing between the time when water is added to the cement and the time at which the needle makes an impression on the surface of the test block while the attachment fails to do so shall be the final setting time Note :The final setting time of ordinary Portland cement is 600 minutes Test for Final Setting Time of Cement (contd)
88 Sample : Sample of OPC Water required to prepare a cement paste of standard consistency = p Weight of cement required for 1 mould = 300 g Weight of water added to cement =(0.85p x 300g ml) 100 Specimen Calculation for Initial Setting Time of Cement
89 ( A) Initial setting time Time elapsed since the water is added to cement = min Initial reading on vicat apparatus in min (a) = Final reading on vicat apparatus in mm (b) = Penetration of vicat needle measured from The bottom of mould in mm (b-a) = Specimen Calculation for Initial Setting Time of Cement (contd)
90 Result a) Initial setting time for the given cement sample = __________ min b) Final setting time for the given cement sample = __________ min Note The result of initial and final setting times shall be reported to nearest ‘five minutes’ Specimen Calculation for Initial Setting Time of Cement (contd)
91 4 Equipment for Soundness test
92 1. The apparatus (shown in previous fig) consists of a small split cylinder of spring brass or other suitable metal 2. It is 30mm in dia and 30mm high 3. On either side of the split are attached two indicator arms 165 mm long with pointed ends Soundness test (contd)
93 4. Cement Is gauged with 0.78 times the water required for standard consistency (0.78p) in a standard manner and filled into the mould and kept on a glass plate 5. The mould is covered on the top with another glass plate 6. The whole assembly is immersed in water at a temperature of 270C - 320C and kept there for 24 hrs Soundness test (contd)
94 7. The distance between the indicator points is measured 8. The mould is submerged again in water and the water is heated to boiling point in about 25-30 minutes and boiling is continued for 3hours 9. The mould is removed from the water, allowed to cool and the distance between the indicator points is measured Soundness test (contd)
95 10.The difference between these two measurements represents the expansion of cement. This must not exceed 10mm for ordinary, rapid hardening and low heat Portland cements 11.If in case, the expansion is more than 10mm as tested above, the cement is said to be unsound ( not suitable ) Soundness test (contd)
GRADES OF CEMENT AND THEIR COMPRESSIVE STRENGTH 96
97 Ordinary Portland Cement (OPC ) • It is a common variety of cement • It is suitable for the building all civil engineering works except under water constructions • Cement occupied the place of lime because of its greater strength • The OPC is classified into three grades, namely 33 grade, 43 grade, 53 grade depending upon the strength of the cement ( in N/mm2 ) at 28 days when tested as per IS 4031 – 1988
98 Properties 1. Fineness : Residue shall not be less than 10% on sieve No. 9 (90µ) when sieved 2. Soundness : Expansion of the cement should not be more than 10 mm 3. Setting time : Initial setting time should be less than 30 minutes and final setting time not more than 600 minutes 4. Compressive strength: Compressive strength values are shown in the table
99 • If the 28 days strength is not less than 33 N / mm2, it is called 33 grade cement • If the 28 days strength is not less than 43 N / mm2, it is called 43 grade cement • If the 28 days strength is not less than 53 N / mm2, it is called 53 grade cement Ordinary Portland Cement (O P C )
100 Designation of Grade of Cement Grade of Cement Strength at 28 Days 33 33 N / mm2 43 43 N / mm2 53 53 N / mm2
102 Blended Cement • Cement mixture containing Ordinary Portland Cement and at least one supplementary cementitious materials (SCMs) or puzzolanas is called blended cement • Blended cements interground or blended at cement plants are generally more uniform and produce better results than blended concrete mixtures combined at the concrete mixer
103 • The blended cement will produce stronger and more durable concrete than OPC concrete • Blended cement will reduce the overall cost of the concrete since the blends are by products available in abundance and are cheaper Blended Cement (contd)
104 sand pc pcpc pc pc pc pc pc scm Portland cement Supplementary Cementations Material or puzzolana Blended cement Note -1: When OPC hydrates a glue like calcium silicate hydrate is formed, this holds concrete together. However, gaps in calcium silicate hydrate produce pathways for moisture to penetrate and reduce strength Blended Cement (contd)
105 Note - 2 When supplementary cementitious materials (scms) or puzzolanas are added, particles pack more tightly within the voids and additional glue forms from the SCM hydration process. With fewer voids, the concrete is less permeable and stronger Blended Cement (contd)
106 Portland Pozzolana Cement • Pozzolana is derived from Puzzouli, a town in Italy where the sand available when mixed with lime was found to possess hydraulic properties. It is volcanic dust • Portland puzzolana cement is manufactured by grinding Portland cement clinker and puzzolana, or by intimately and uniformly blending Portland cement and fine puzzolana
107 Portland Pozzolana Cement (contd) • Burnt clay, Shale, or Fly Ash are such other materials which have no cementing value but have the property of combining with lime to produce a stable lime - puzzolana compound which has definite cementations properties
108 Portland Pozzolana Cement (contd) • The percentage of puzzolana should be between 10 to 30% • It possesses almost the same properties of OPC • Free lime present in the cement is thus removed hence the resistance to chemical attack increases making it suitable for marine works
109 Uses • It can resist action of sulphate • It improves workability • It imparts high degree of water, lightness, fire resistance • It offers great resistance to expansion • It is cheaper Portland Pozzolana Cement (contd)
110 Improved workability • The spherical shape of fly ash particles and the glassy nature of slag particles reduce the amount of water needed to produce workable concrete • Blended cements tend to have slower set times than OPC, which can be a benefit during the warmer months Curing • As with all concretes, proper curing is essential to achieve best performance
111 Enhanced strength • Blends can improve long-term strength development, depending on the proportions and materials used • By reducing the amount of water required, blends produce stronger concrete
112 Resistance to sulphate attack • Blends can offer superior resistance to these attacks because they contain fewer compounds that react with sulphates and due to their low permeability which keeps out sulphates- bearing moisture

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Cement

  • 1.
    1 CEMENT On completion ofthis class, you would be able to • Know the history of cement • Know the chemical composition of cement • Describe the manufacturing process of cement (Dry process)  Define Hydration of cement  State the water requirement of Hydration of cement  State the different types of cement  State the uses of each type of cement • Know the different types of tests on cement (a) Consistency test (b) Initial and final setting time tests (c) Soundness test • Know the grades of cement and their compressive strength • Blended cement and their types
  • 2.
    2 Property variety Low cost Plasticity Simpleprocess Durability Bonding well with bar Hydraulicity Advantages of Cement Advantages of cement
  • 3.
    3 • Cement isa fine, soft, powdery-type substance • It is made from a mixture of elements that are found in natural materials such as limestone, clay, sand and/or shale • When cement is mixed with water, it can bind sand and aggregates into a hard, solid mass called concrete Cement
  • 4.
    4 History of Cement •In 1824, Joseph Aspdin, a British stone mason, heated a mixture of finely ground limestone and clay in his kitchen stove and ground the mixture into a powder to create a hydraulic cement—one that hardens with the addition of water.
  • 5.
    5 • He tooka patent for this cement • A variety of sandstone is found in abundance in Portland in England • Hence it is called as “ ORDINARY PORTLAND CEMENT “ • In India, the first cement factory was installed at Tamil Nadu (1904) by South India Industry Limited History of Cement (contd)
  • 6.
    6 • Four essentialelements are needed to make cement. They are Calcium, Silicon, Aluminum and Iron • Calcium (which is the main ingredient) can be obtained from limestone, whereas silicon can be obtained from sand • Aluminum and iron can be extracted from bauxite and iron ore, and only small amounts are needed History of Cement (contd)
  • 7.
    7 Chemical Composition ofCement • The raw materials used for the manufacture of cement consist mainly of lime, silica, alumina and iron oxide • These oxides interact with one another in the kiln at high temperature to form more complex compounds • The relative proportions of these oxide compositions are responsible for influencing the various properties of cement, in addition to rate of cooling and fineness of grinding
  • 8.
    8 Oxide Percent content CaO(Lime) SiO2 (Silica) Al2O3 (Alumina) Fe2O3 (Iron oxide) MgO (Magnesia) Alkalies(K2O,Na2O) SO3 (Sulphur trioxide) 60-67% 17-25% 5-8% 0.5-6% 0.1-4% 0.2-1.0% 1-3% Chemical Composition of Cement
  • 9.
    9 Functions of Ingredientsof Cement Lime (CaO) • Major ingredient of cement • Excess quantity of lime makes the cement unsound • If it is less, it decreases the strength and allows the cement to set quickly
  • 10.
    10 Silica (SiO2) • Animportant ingredient which gives strength to cement • If it is in excess silica allows the cement to set slowly Functions of Ingredients Cement (contd)
  • 11.
    11 Alumina(Al2O3) • This impartsquick setting time to the cement • If it is in excess quantity, it weakens the cement • It also lowers the temperature of clinkers Functions of Cement Ingredients (contd)
  • 12.
    12 Iron Oxide (Fe2O3) •It helps the fusion of the raw materials during burning stage • It gives colour, strength and hardness to cement Functions of Cement Ingredients (contd)
  • 13.
    13 Magnesium Oxide (MgO) •If present in small quantities, MgO imparts hardness and colour to cement • If becomes excess quantity, weakens the cement Functions of Cement Ingredients (contd)
  • 14.
    14 Sulphur Trioxide (SO3) •A very small quantity is required in the manufacturing of cement • If it is in excess, SO3 makes the cement unsound Functions of Cement Ingredients (contd)
  • 15.
    15 Alkalies • A smallquantity are required • Alkalies and other impurities present in raw materials are carried by the flue gases during heating • If it is in excess quantity, efflorescence is caused Functions of Cement Ingredients (contd)
  • 16.
    16 Manufacturing of PortlandCement • The raw materials required for manufacturing of cement are calcareous materials, such as lime stones or chalk, and argillaceous materials such as shale or clay Lime Stone Shale
  • 17.
    17 • There aretwo processes known as ‘wet’ and ‘dry’ processes depending upon whether the mixing and grinding of raw materials is done in wet or dry conditions Dry Process In this process the following operations are involved 1. Mixing of raw materials 2. Burning 3. Grinding 4. Packing and Distribution Manufacturing of Portland Cement (contd)
  • 18.
    Production and Composition ofPortland Cement Process to Produce Portland Cement Grinding Iron ore powder PⅡ PⅠ Mixing materials Limestone Clay Bleeding Grinding 1450℃ Raw material Clinker Gypsum
  • 19.
  • 20.
    20 Flow chart ofthe manufacture of cement
  • 21.
    Traditional Manufacture of PortlandCement 1. Stone is first reduced to 125 mm (5 in.) size, then to 20 mm (3/4 in.), and stored.
  • 23.
    2. Raw materialsare ground to powder and blended. or 2. Raw materials are ground, mixed with water to form slurry, and blended.
  • 24.
    3. Burning changesraw mix chemically into cement clinker.
  • 27.
    3. Burning changesraw mix chemically into clinker. Note four stage preheater, flash furnaces, and shorter kiln.
  • 28.
  • 31.
    4. Clinker isground with gypsum into portland cement and shipped.
  • 32.
  • 33.
    Grinding • Clinker isground with gypsum (calcium sulfate) to produce portland cement • Fine grinding is necessary for high early strength – 85-95% -325 mesh (45 microns) – ~ 7 trillion particles per pound • Gypsum absorbs water and prevents setting of C3A during shipment
  • 34.
    Source: van Ossand Padovani, 2002
  • 35.
  • 38.
  • 39.
  • 40.
    40 • Limestone istaken from a quarry. It is the major ingredient needed for making cement • Smaller quantities of sand and clay are also needed • Limestone, sand and clay contain the four essential elements required to make cement • The four essential elements are oxides of calcium, silicon, aluminum and Iron Manufacturing of Cement (contd)
  • 41.
  • 42.
    42 2.) Boulder-size limestonerocks are transported from the quarry to the cement plant and fed into a crusher which crushes the boulders into pieces Manufacturing of Cement (contd)
  • 43.
    43 • The limestonepieces then go through a blender where they are added to the other raw materials in the right proportions 3. Mixing of raw materials Manufacturing of Cement (contd)
  • 44.
    44 • The rawmaterials are ground to a powder. This is sometimes done with rollers that crush the materials against a rotating platform 4. Grinding of Raw Materials Manufacturing of Cement (contd)
  • 45.
    45 Tube Mill The tubemills are used to have preliminary grinding of raw materials or mixture of raw materials or clinkers
  • 46.
    46 5. Sintering • Everythingthen goes into a huge, extremely hot rotating furnace to undergo a process called "sintering“ • Sintering means: to cause to become a coherent mass by heating without melting. In other words, the raw materials become sort of partially molten • The raw materials reach about 2700° F (1480°C) inside the furnace • This causes chemical and physical changes to the raw materials and they come out of the furnace as large, glassy, red-hot cinders called "clinker" Manufacturing of Cement (contd)
  • 47.
  • 48.
  • 49.
    49 • The clinkeris cooled and ground into a fine powder in ball mills • A small amount of gypsum is also added during the final grinding. It is now the finished product - Portland cement • The cement is then stored in silos (large holding tanks) where it awaits distribution 6. Grinding of clinkers and storing Manufacturing of Cement (contd)
  • 50.
    50 Ball Mill Theball mills are used to carryout final grinding of clinkers Manufacturing of Cement (contd)
  • 51.
  • 53.
  • 54.
    54 Bogue Compounds • Duringthe manufacturing of cement, various constituents combine in burning and form certain compounds • These compounds formed during burning, react with water help in setting and hardening of cement • These compounds are called bogue compounds they are Compound symbol 1.Tricalcium silicate C3S 2.Dicalcium silicate C2S 3.Tricalcium aluminate C3A 4.Tetracalcium alumino ferrite C4AF Hydration of Cement
  • 55.
    Properties of MineralCompounds Mineral types Tricalcium silicate Dicalcium silicate Tricalcium aluminates Tetracalcium aluminoferrite Abbreviation C3S C2S C3A C4AF Content (%) 37-60 15-37 7-15 10-18 Hydration speed fast slow fastest fast Hydration heat much little most more Strength high early low later high low low Anti- corrosion good fine poor excellent Shrinkage middle better big small
  • 56.
    56 Hydration of Cement(contd) • When water is added to cement a chemical reaction starts between active components of cement (C4AF,C3A,C3S andC2S) and water which is exothermic in nature and liberate a significant amount of heat • This is known as hydration and the liberated heat is called heat of hydration
  • 57.
    When mixed withwater, Portland cement hydrates and forms heat 3CaO·SiO2+H2O CaO·2SiO2·3H2O+Ca(OH)2 Triealcium silicate hydrates rapidly and forms earlier strength and earlier heat of hydration. Tricalcium silicate is formed in a kiln when the charge contains an abundance of lime, and hence the greater amount of CaO in the reaction. Hydration Mechanism
  • 58.
    Dicalcium silicate hydratesslowly and is responsible for strength increase in concrete at later ages. The heat of hydration is liberated slowly. More dicalcium silicate is formed when the raw materials contain less lime. 2CaO·SiO2+H2O 3CaO·2SiO2·3H2O+Ca(OH)2 Hydration Mechanism
  • 59.
    Tricalcium aluminate hydratesrapidly and liberates a large amount of heat. If this reaction were not controlled, concrete would set so rapidly (flash set) that it could not be used in modern construction. 3CaO·Al2O3+H2O 3CaO·Al2O3·6H2O Hydration Mechanism
  • 60.
    60 • About anaverage 23 percent of water by weight of cement is required for complete hydration of Portland cement • This water combines chemically with the cement compounds • Some quantity of water, about 15 percent by weight of cement , is required to fill the cement gel pores • A total of 38 percent of water by weight of cement is required to complete the chemical reaction Water Requirement for Hydration
  • 61.
    61 • If excesswater is present, it will lead to capillary cavities • In a month’s time 85 to 90 % of the cement gets hydrated and cement attains almost its full strength • Hydration still continues and cement grows stronger with time • Total 50% of water by weight of cement is required for complete hydration Water Requirement for Hydration (contd)
  • 62.
    Fineness and Properties Fineness Surfacearea touching with water Setting and hardening speed Properties Small D < 40μ Great High Strength High Too small Easily Great Cost High Large D >100μ Low Low Low Fineness related to the surface area touching with water, so it influences the setting/hardening speed and the properties of cement. Fineness and Properties of Cement
  • 63.
    63 1. Ordinary PortlandCement(OPC) 2. Rapid Hardening Cement 3. Sulphate Resisting Cement 4. Quick Setting Cement 5. Low heat Cement 6. Portland Pozzolana Cement 7. High Alumina Cement 8. White Cement 9. Coloured Cement etc..,
  • 64.
    64 Ordinary Portland Cement(OPC) •It is a common variety of cement • It is suitable for the construction of all civil engineering works except under water constructions Uses of Ordinary Portland Cement • Used in all important structures where great strength is required such as heavy buildings and bridges light houses, docks, reservoirs, etc,. • Foundations in wet places, and structures subjected to the action of water such as • Retaining walls • Watertight floors • Cement mortar for plastering, pointing etc • Plain concrete
  • 65.
    65 • For making •Reinforced cement concrete for laying floors ,roofs, lintels, beams, etc,. • Reinforced brick work • In drainage and water supply works like water storage tanks, septic, tanks, etc,. • For protecting the external faces of buildings or engineering structures from weathering action • For thin masonry works, where strength is required • Making joints for drains, pipes etc,. • Manufacturing of precast pipes, piles, garden benches, fencing posts, flower pots, etc,. • Preparation of foundations, watertight floors, footpaths, etc,. Uses of Ordinary Portland Cement (contd)
  • 66.
    66 Quick Setting Cement •As the name indicates, it sets very fast • The early setting property is brought out by reducing the amount of gypsum during the grinding process • This cement is costlier than ordinary Portland cement • Initial setting time starts within 5 minutes, after adding water • Final setting time: within 30 minutes • It is ground much finer than OPC
  • 67.
    67 Advantages • It isused in construction of structures under water, in water logging areas, rivers, in running water like canals and streams and pipe lines etc,. • It is also used in emergency circumstances where quick setting of cement is needed. Quick Setting Cement (contd)
  • 68.
    68 White Cement • Rawmaterials like china clay and pure lime stone are used to get pure white colour • It is a variety of OPC • It is prepared from such materials which are practically free from colouring oxides of iron and manganese • For burning of this cement, the oil fuel is used instead of coal • It is white in colour
  • 69.
    69 Uses • It isused for floor finish, plaster work, ornamental work, etc • It is also used to fill the small holes during sanitary, water supply fittings, wall tiles etc White Cement (contd)
  • 70.
    70 Laboratory Tests onCement 1. Consistency of cement 2. Setting times of cement 3. Soundness of cement 4. Compressive strength test 5. Fine ness of cement 6. Tests for chemical composition of cement
  • 71.
    71 Normal consistency ofcement Normal consistency is defined as the percentage of water required to produce a cement paste of standard consistency
  • 72.
  • 73.
    73 Normal Consistency Testof Cement 1. Take 300gm of cement sample and place at on a non- absorbent plate 2. Take 25% of water by weight of cement as first trial and mix it thoroughly with cement using gauging trowels. Ensure that the time of gauging shall be within 3 to 5 minutes. The time of gauging shall be reckoned from the instant water is added to cement to that paste is filled in the mould
  • 74.
    74 3. Keep mouldon a non absorbent plate. Apply a thin coat of oil inside the mould 4. Fill the vicat’s mould with cement paste at a stretch and tamp the mould so as to make the cement spread uniformly in the mould. Strike off the excess cement plate and level the surface of mould with spatula 5. Fix the plunger of 10mm dia x 50mm long to the plunger holder of the apparatus. Gently lower the plunger to touch the top surface of the paste and leve it quickly. Due to the weight of header and holder the plunger penetrates in to the cement paste Normal Consistency Test of Cement (contd)
  • 75.
    75 6. Note theplunger’ penetration reading on the scale of apparatus. The recorded penetration value is reckoned from the bottom of mould 7. Remove the plunger and cement paste from the mould 8. Take sample of cement and repeat the entire process with 27% of water and note down the plunger penetration Normal Consistency Test of Cement (contd)
  • 76.
    76 9. Repeat theabove process with varying % of water and note the penetration of plunger till the penetration value is 5 to 7 mm measured from the bottom of the mould to the tip of the plunger Note :The standard consistency of ordinary Portland cement is 30 to 35% by weight of cement Normal Consistency Test of Cement (contd)
  • 77.
    77 Calculation Procedure Weight ofcement taken = g Percentage of water added = % Initial reading on vicat scale in mm = Final reading on vicat scale in mm = Penetration of plunger measured from bottom of mould in mm = Normal Consistency Test of Cement (contd)
  • 78.
  • 79.
    79 Initial and Finalsetting time of cement
  • 80.
    80 When water isadded to cement, the paste starts stiffening and gaining strength, simultaneously loosing its plasticity. Two stiffening states identified are initial and final setting times respectively • Initial setting time is the time interval between the addition of water to cement and the stage when needle ceases to penetrate completely • This time should be about 30 minutes for ordinary cement Initial Setting Time of Cement
  • 81.
    81 Procedure (A) Preparation oftest block (paste in the mould) 1. Prepare a neat cement paste by mixing the cement with 0.85 times the water required to give a paste of standard consistency 2. Start stop watch at the instant when water is added to cement. Thoroughly mix cement and water using gauging trowels till required uniformity is attained in mixing Test for Initial Setting Time of Cement (contd)
  • 82.
    82 3. Fill themould completely and smoothen the surface of the paste by making it level with the top of the mould. The cement paste thus prepared in the mould is the test block Note : • Clean appliance shall be used for mixing • All apparatus shall be free from vibration during the test • Care shall be taken to keep the needle straight Test for Initial Setting Time of Cement (contd)
  • 83.
    83 (B) Initial SettingTime 1. Place the test block with porous plate at bottom, under the rod, bearing the needle (C) as shown in the fig of Vicat Apparatus 2. Lower the needle gently until it comes in contact with the surface of test block and quickly release, allowing it to penetrate into test block Test for Initial Setting Time of Cement (contd)
  • 84.
    84 Vicat Apparatus 1 Test forInitial Setting Time of Cement (contd)
  • 85.
    85 3. Repeat thisprocedure at regular intervals of time until the needle, when brought in contact with the test block and released as above fails to pierce the block for 5 to 7 mm measured from the bottom of the mould 4. The period elapsed between the time when water is added to the cement and the time at which the needle fails to pierce the test block to a point 5 to 7 mm measured from the bottom of the mould shall be reported as initial setting time Note :The initial setting time of ordinary Portland cement is 30 minutes Test for Initial Setting Time of Cement (contd)
  • 86.
    86 (C) Final SettingTime 1. Replace the needle ‘C’ with needle ‘F’ of the vicat apparatus attachment 2. Prepare the test block according to the procedure given above 3. The cement shall be considered as finally set when, upon applying the needle gently to the surface of the test block, the needle makes an impression there while the attachment fails to do so Test for Final Setting Time of Cement (contd)
  • 87.
    87 4. The periodelapsing between the time when water is added to the cement and the time at which the needle makes an impression on the surface of the test block while the attachment fails to do so shall be the final setting time Note :The final setting time of ordinary Portland cement is 600 minutes Test for Final Setting Time of Cement (contd)
  • 88.
    88 Sample : Sampleof OPC Water required to prepare a cement paste of standard consistency = p Weight of cement required for 1 mould = 300 g Weight of water added to cement =(0.85p x 300g ml) 100 Specimen Calculation for Initial Setting Time of Cement
  • 89.
    89 ( A) Initialsetting time Time elapsed since the water is added to cement = min Initial reading on vicat apparatus in min (a) = Final reading on vicat apparatus in mm (b) = Penetration of vicat needle measured from The bottom of mould in mm (b-a) = Specimen Calculation for Initial Setting Time of Cement (contd)
  • 90.
    90 Result a) Initial settingtime for the given cement sample = __________ min b) Final setting time for the given cement sample = __________ min Note The result of initial and final setting times shall be reported to nearest ‘five minutes’ Specimen Calculation for Initial Setting Time of Cement (contd)
  • 91.
  • 92.
    92 1. The apparatus(shown in previous fig) consists of a small split cylinder of spring brass or other suitable metal 2. It is 30mm in dia and 30mm high 3. On either side of the split are attached two indicator arms 165 mm long with pointed ends Soundness test (contd)
  • 93.
    93 4. Cement Isgauged with 0.78 times the water required for standard consistency (0.78p) in a standard manner and filled into the mould and kept on a glass plate 5. The mould is covered on the top with another glass plate 6. The whole assembly is immersed in water at a temperature of 270C - 320C and kept there for 24 hrs Soundness test (contd)
  • 94.
    94 7. The distancebetween the indicator points is measured 8. The mould is submerged again in water and the water is heated to boiling point in about 25-30 minutes and boiling is continued for 3hours 9. The mould is removed from the water, allowed to cool and the distance between the indicator points is measured Soundness test (contd)
  • 95.
    95 10.The difference betweenthese two measurements represents the expansion of cement. This must not exceed 10mm for ordinary, rapid hardening and low heat Portland cements 11.If in case, the expansion is more than 10mm as tested above, the cement is said to be unsound ( not suitable ) Soundness test (contd)
  • 96.
    GRADES OF CEMENTAND THEIR COMPRESSIVE STRENGTH 96
  • 97.
    97 Ordinary Portland Cement(OPC ) • It is a common variety of cement • It is suitable for the building all civil engineering works except under water constructions • Cement occupied the place of lime because of its greater strength • The OPC is classified into three grades, namely 33 grade, 43 grade, 53 grade depending upon the strength of the cement ( in N/mm2 ) at 28 days when tested as per IS 4031 – 1988
  • 98.
    98 Properties 1. Fineness :Residue shall not be less than 10% on sieve No. 9 (90µ) when sieved 2. Soundness : Expansion of the cement should not be more than 10 mm 3. Setting time : Initial setting time should be less than 30 minutes and final setting time not more than 600 minutes 4. Compressive strength: Compressive strength values are shown in the table
  • 99.
    99 • If the28 days strength is not less than 33 N / mm2, it is called 33 grade cement • If the 28 days strength is not less than 43 N / mm2, it is called 43 grade cement • If the 28 days strength is not less than 53 N / mm2, it is called 53 grade cement Ordinary Portland Cement (O P C )
  • 100.
    100 Designation of Gradeof Cement Grade of Cement Strength at 28 Days 33 33 N / mm2 43 43 N / mm2 53 53 N / mm2
  • 101.
    102 Blended Cement • Cementmixture containing Ordinary Portland Cement and at least one supplementary cementitious materials (SCMs) or puzzolanas is called blended cement • Blended cements interground or blended at cement plants are generally more uniform and produce better results than blended concrete mixtures combined at the concrete mixer
  • 102.
    103 • The blendedcement will produce stronger and more durable concrete than OPC concrete • Blended cement will reduce the overall cost of the concrete since the blends are by products available in abundance and are cheaper Blended Cement (contd)
  • 103.
    104 sand pc pcpc pc pc pc pc pc scm Portland cement Supplementary Cementations Materialor puzzolana Blended cement Note -1: When OPC hydrates a glue like calcium silicate hydrate is formed, this holds concrete together. However, gaps in calcium silicate hydrate produce pathways for moisture to penetrate and reduce strength Blended Cement (contd)
  • 104.
    105 Note - 2 Whensupplementary cementitious materials (scms) or puzzolanas are added, particles pack more tightly within the voids and additional glue forms from the SCM hydration process. With fewer voids, the concrete is less permeable and stronger Blended Cement (contd)
  • 105.
    106 Portland Pozzolana Cement •Pozzolana is derived from Puzzouli, a town in Italy where the sand available when mixed with lime was found to possess hydraulic properties. It is volcanic dust • Portland puzzolana cement is manufactured by grinding Portland cement clinker and puzzolana, or by intimately and uniformly blending Portland cement and fine puzzolana
  • 106.
    107 Portland Pozzolana Cement(contd) • Burnt clay, Shale, or Fly Ash are such other materials which have no cementing value but have the property of combining with lime to produce a stable lime - puzzolana compound which has definite cementations properties
  • 107.
    108 Portland Pozzolana Cement(contd) • The percentage of puzzolana should be between 10 to 30% • It possesses almost the same properties of OPC • Free lime present in the cement is thus removed hence the resistance to chemical attack increases making it suitable for marine works
  • 108.
    109 Uses • It canresist action of sulphate • It improves workability • It imparts high degree of water, lightness, fire resistance • It offers great resistance to expansion • It is cheaper Portland Pozzolana Cement (contd)
  • 109.
    110 Improved workability • Thespherical shape of fly ash particles and the glassy nature of slag particles reduce the amount of water needed to produce workable concrete • Blended cements tend to have slower set times than OPC, which can be a benefit during the warmer months Curing • As with all concretes, proper curing is essential to achieve best performance
  • 110.
    111 Enhanced strength • Blendscan improve long-term strength development, depending on the proportions and materials used • By reducing the amount of water required, blends produce stronger concrete
  • 111.
    112 Resistance to sulphateattack • Blends can offer superior resistance to these attacks because they contain fewer compounds that react with sulphates and due to their low permeability which keeps out sulphates- bearing moisture