CE-6108 Advances in Cement Technology

CE-6108 ADVANCES IN CEMENT TEHNOLOGY

LECTURE 1
PORTLAND CEMENT: INTRODUCTION

1.1 HISTORICAL BACKGROUND:

Use of cementry material is very old. In 1824, Joseph
Aspdin prepared a powder from heating a mixture of
hardened limestone and clay in a furnace until CO2
has been driven off. He called it Portland cement,
because when harden it produce a material
resembling stone from Quarries near the place
Portland in England. The prototype of modern
cement was first made in 1845 by Isaac Johnson who
burnt a mixture of clay and chalk till the formation of
clinkers. Clinkers were then ground to fine powder.

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CE-6108 Advances in Cement Technology

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CE-6108 Advances in Cement Technology

1.2 RAW MATERIALS:

Calcareous:
This refers to the material having high
contents of lime.

Agrillaceous:
This refers to the material having contents
of silica and alumina.

1.3 MANUFACTURING OF CEMENT:

Grinding of raw materials

Mixing in certain proportion

Burning in large rotary Kiln at about 1400 C

Formation of clinkers (small balls)

Cooling and grinding into fine powder

Addition of Gypsum

Portland cement

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CE-6108 Advances in Cement Technology

THE CEMENT MANUFACTURING PROCESS

quarry
dumper
loader

Quarry face
1. BLASTING

2. TRANSPORT

storage at
the plant

crushing
conveyor

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
transported to the plant by conveyor. The plant stores the materials before they are
homogenized.

Next

THE CEMENT MANUFACTURING PROCESS

Raw grinding and burning

storage at
the plant

Raw mill
conveyor

preheating

Raw mix

1. RAW GRINDING

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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CE-6108 Advances in Cement Technology

THE CEMENT MANUFACTURING PROCESS

Grinding, storage, packing, dispatch
Gypsum and the secondary additives are added
to the clinker.
clinker
storage

Finish grinding

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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1.4 MANUFACTURING PROCESSES:

There are two types of manufacturing

processes.
1) Wet process
2) Dry process

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1.4 MANUFACTURING PROCESSES: (cont.)

1. WET PROCESS:
In this process, raw materials are first washed then ground.
It is better than mixing but it is quite expensive.
Three stages are there.

Mixing (Ball Mills)

Burning (Rotary Kiln)

Grinding (Tube Mills)
Oil Requirement:
The fuel consumption for the production of one ton of
cement is up to 350 Kg coal or 150 L of oil.

1.4 MANUFACTURING PROCESSES: (cont.)

2. DRY PROCESS:
In this process, raw materials are processed as it is mixing of
raw materials and is difficult to some extent but the main
advantage is that it is economical process. Also the quality of
cement is not so good as compared to the cement by Wet
Process.
In this process limestone and clay are ground separately to
fine powders and then mixed. Water is then added to get a
thick paste of which cakes are then made, dried and burnt in
Kilns. To the clinker gypsum is added 3-4% and then ground,
cement is ready.

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1.5 OXIDE COMPOSITION OF ORDINARY

PORTLAND CEMENT AS PER ASTM TYPE I:
OXIDES
TYPICAL %AGE
Lime
(CaO)
62%
Silica (SiO2)
22%
Alumina (Al2O3)
5%
Iron (Fe2O3)
3%
Magnesia (MgO)
2%
Sulfur trioxide (SO3)
1%
Alkalies (Soda & Potash)
1%
Calcium Sulphate
4%
or Gypsum (CaSO4)

LIMIT OF %AGE
60-66%
19-25%
3-8%
1-5%
0-5%
1-3%
0.5-1%
3-5%

1.6 PERFORMANCE OR FUNCTION OF

THE INGREDIENTS
Functions of each ingredient of cement are briefly
described as follows:

1.6.1 Lime:
It is the most important ingredient of the cement and its
bulk in cement is above 60% of the total contents. Its
proportion should be carefully decided. If lime is added
unnecessarily in excess quantity, some part of it is left in
form of free lime which causes expansion and
consequently disintegration of cement at the setting and
hardening. Lesser than the required quantity will cause
decrease in the strength of the cement.

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CE-6108 Advances in Cement Technology

1.6 PERFORMANCE OR FUNCTION OF

THE INGREDIENTS (Cont.)

1.6.2 Silica:
It also combines chemically with calcium and
forms hard silicates which are responsible for
imparting strength to the cement.

1.6.3 Alumina or Clay:
Alumina is responsible for the setting action of the
cement. Larger the amount of Alumina present in
the cement, quicker it will start setting. Excess
quantity of alumina weakens the cement. Alumina
forms complex aluminates with silica and calcium
and imparts the setting property to the cement.

1.6 PERFORMANCE OR FUNCTION OF

THE INGREDIENTS (Cont.)

1.6.4 Iron Oxide:
This ingredient mainly imparts color to the cement.
Beside this, it also goes into chemical combination
and helps in increasing strength and hardness of
the cement.

1.6.5 Magnesia:
It also imparts strength and hardness to the
cement, but only, when present in small quantities.

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1.6 PERFORMANCE OR FUNCTION OF

THE INGREDIENTS (Cont.)

1.6.6 Sulfur tri-Oxide:
Small %age of sulfur renders cement sound.
Excess amount of it may make it unsound.

1.6.7 Alkalies:
Alkalies present in the raw materials used for the
manufacture of cement are mostly driven out
during burning in the form of gases. Still they may
be present in the cement, but only in very small
amount. Excess of alkalies cause efflorescence in
the cement and then act as impurity.

1.6 PERFORMANCE OR FUNCTION OF

THE INGREDIENTS (Cont.)

1.6.8 Calcium Sulfate (Gypsum):
This ingredient is used to retard or prolong the
initial setting action of the cement. Excess use of
Gypsum may result in deterioration of cement.

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CE-6108 Advances in Cement Technology

1.6 PERFORMANCE OR FUNCTION OF

THE INGREDIENTS (Cont.)
Summary:
Out of the above mentioned 8 ingredients,
Alkalies, which are oxides of potassium, sodium
and magnesium, are the predominant ingredients
which adversely affect the quantity of cement. If
amount of alkalies exceeds 1%, it causes
Unsoundness of the cement. If amount of MgO
exceeds say 5%, it causes cracks in hardened
mortar or concrete. This cracking is due to the fact
that Mgo slakes very slowly, when mixed with
water.

1.7 BASIC INGREDIENTS OF CEMENT:

There are four basic ingredients of cement which are regarded
as the major constituents of cement. They are listed below along
with their abbreviated symbols.
CEMENT COMPOUND
FORMULA ABBREVIATION

Tri Calcium Silicate
3CaO.SiO2
(C3S)
Early gain in strength is due to C3S.

Di Calcium Silicate
2CaO.SiO2
(C2S)
C2S takes 14-28 days to add to the strength.

Tri Calcium Aluminate
3CaO.Al2O3
(C3A)
Aluminate is maximum heat giving compound.

Tetra Calcium Aluminoferrite,4CaO.Al2O3.Fe2O3
(C4AF)

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1.7 BASIC INGREDIENTS OF CEMENT:

(Cont.)

C3S, C2S, C3A are responsible for stiffening and

hardening of cement.


In a properly burnt clinker Tri-Silicate should
be 40% (about). In case burning is not properly
done, there will be less of C3S and more of free
lime. After addition of water, cement sets and
hardens due to hydration and hydrolysis of above
three compounds takes place which acts as glue.
The aluminate is first to set, C3S is slower and C2S
is the slowest.

1.8 HYDRATION OF CEMENT:

Setting and hardening of cement is the result of
hydration reactions occurring between the cement
compounds and water.

Hydration may be defined as:
The reaction of cement with water as a result of
which Portland cement becomes a binding agent
is called as Hydration of cement.

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1.8 HYDRATION OF CEMENT:

(Cont.)

Explanation:
When the cement is mixed with water to form a paste, hydration
reaction begins, resulting in the formation of gel and crystalline
products.
The course of hydration reactions is illustrated by the following
chemical equations:

C2S + xh2O
C2S. xH2O (Gel)

C3S + ( x+1) H2O C2S. xH2O(Gel)+Ca (OH) 2
(Crystals)

C3A + 6H2O
C3A. 6H2O (Crystals)

C4AF + 7H2O
C3A. 6H2O (Crystals)+CF.H2O (Gel)

1.8 HYDRATION OF CEMENT:

(Cont.)

The chemical combination of cement and water

produces a very hard and strong binding medium
for the aggregate particles in concrete and is
accompanied by the liberation of heat normally
expressed as calories per gram or joules/gram.
The rate of hydration depends on the relative
properties of silicate and aluminate compounds,
the cement fineness and the ambient condition
(particularly temperature and moisture).

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1.8 HYDRATION OF CEMENT:

(Cont.)

Time taken by the main constituents of cement to

attain 80% hydration is given as:
CEMENT
COMPOUNDS

HEAT OF HYDRATION (J/g)

TIME (DAYS)

C3S
502
10

C2S
260
100

C3A
867
6

C4AF
419
50
Above table is giving heat of hydration of main
compounds of Portland cement.

1.8 HYDRATION OF CEMENT:

(Cont.)

Since the conductivity of concrete is comparatively low, it acts

as an insulator and in the interior of a large concrete mass,
hydration can result in a large rise in temperature.

The heat generated during hydration can have undesirable
effects on the properties of hardened concrete, as a result
micro-cracking of the binding medium.

It is therefore very important that heat characteristics must be
considered when determining the suitability of cement for a
given job.

In massive structures such as dams, retaining walls etc., a
large amount of heat is generated. So in such structures, we
normally use low heat cement. Heat generation has also
advantages, one of these is,in cold areas, it prevent freezing
of the water in the capillaries of freshly placed concrete.

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1.9 CLASSIFICATION OF CEMENT AS PER

ASTM:

Normal/Ordinary Portland cement (Type I)

Moderate/Modified Portland cement (Type II)
Higher Early Strength cement (Type III)
Low heat of Hydration cement (Type IV)
Sulfate Resistant cement
(Type V)

1.9 CLASSIFICATION OF CEMENT

AS PER ASTM: (Cont.)
1.9.1 Normal/Ordinary Portland cement:
It is used for general construction purposes where
special properties are not required. It is normally
used for the reinforced concrete buildings,
bridges, side walks, pavements, where soil
conditions are normal. For most concrete masonry
units and for all uses where the concrete is not
subject to special sulfate hazard or where the heat
generated by the hydration of cement is not
objectionable

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1.9 CLASSIFICATION OF CEMENT

AS PER ASTM: (Cont.)
1.9.2 Moderate Portland cement:
It has better resistance to the sulfate actions than
the normal Portland cement and is used where
sulfate concentrations in ground waters are higher
than the normal but not usually severe. It also
generates heat at a low rate than the normal
Portland cement and is used in mass concrete
work. Its use will minimize temperature rise, a
property which is particularly important when
concrete is being placed in hot weather.

1.9 CLASSIFICATION OF CEMENT

AS PER ASTM: (Cont.)
1.9.3 Higher Early Strength Portland cement:
It is used where high strengths are required at
early periods usually a week or less. It is
particularly useful where it is required to remove
the formwork (shuttering) as soon as possible or
the structure must be brought in service quickly.
High Early Strength cement makes it possible to
reduce the period of protection of concrete during
cold weather.

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1.9 CLASSIFICATION OF CEMENT

AS PER ASTM: (Cont.)
1.9.4 Low Heat of Hydration cement:
It is special cement for use where the amount and
rate of heat generated must be kept lower.
Strength is also developed at slow rate. It is
intended for use in massive concrete structures
such as large dams where the temperature rise
resulting from heat generated during hydration is a
critical factor.

1.9 CLASSIFICATION OF CEMENT

AS PER ASTM: (Cont.)
1.9.5 Sulfate Resistant cement:
It is intended for use in structures subjected to
attack by sulfate concentrations in some water.
Such as may be found in the ground water in
some areas. It is also resistant to the action of sea
water.

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1.10 APPROXIMATE RELATIVE STRENGTH OF

CONCRETE AS AFFECTED BY THE TYPE
OF CEMENT:
The rate at which the strength of concrete
increases, varies with the type of cement used.
The following table gives the approximate strength
value of concrete for each type. Concrete made
with normal Portland cement is the basis of
composition.

1.10 APPROXIMATE RELATIVE STRENGTH

OF CONCRETE AS AFFECTED BY THE
TYPE OF CEMENT: (Cont.)
ASTM
Cement
Type I

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Compressive Strength % Strength of O.P.C

1-day
Strength

7-day
Strength

28-day
Strength

3 Months
Strength

Type I

100 %

100 %

100 %

100%

Type II

75 %

85 %

90 %

100%

Type III

190 %

120 %

110 %

100%

Type IV

55 %

65 %

75 %

100%

Type V

65 %

75 %

85 %

100%

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1.11 PHSICAL PROPERTIES OF CEMENT:

1.11.1 Fineness:
It affects the rate of hydration. The finer the cement
the faster strength development takes place. The
effects of greater fineness on strength are
particularly noticeable during first seven days also
as the fineness increases the amount of water
required for constant slump concrete decreases. On
the other hand the cost of grinding to a higher
fineness is considerable. Also the finer cement
increases the shrinkage and cracking of concrete.

1.11 PHSICAL PROPERTIES OF CEMENT:

(Cont.)

1.11.2 Soundness:
It is physical property tested by determining the ability of
harden cement paste to retain its volume. It is essential
that cement concrete does not undergo large changes in
volume after setting. This change in volume is known as
soundness which may cause cracks, distortions and
disintegration of concrete. After setting due to lack of
soundness, a delayed destructive expansion is caused by
too much hard burnt free lime and magnesia in the cement.
CaSO4 is a third which causes expansion. Since
unsoundness of cement is not apparent until after a period
of months or years. So it is essential to test the soundness
of cement. Le-Chateliers test detects the unsoundness
due to free lime only.

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1.11 PHSICAL PROPERTIES OF CEMENT:

(Cont.)

1.11.3 Setting Time:

Setting time is defined as the time in which stiffening of the
cement paste takes place. It is necessary for mortar and
concrete to remain plastic long enough for finishing
operations to be carried out. Setting is caused by a
selected hydration of cement compounds.
The setting process is accompanied by temperature
changes in the cement paste. The setting time of the
cement decreases with the rise of temperature but above
30 C a reverse effect may be observed. In practical
circumstances the length during which concrete remains
plastic is usually more dependant on the amount of mixing
water used than the atmosphere temperature.

1.11 PHSICAL PROPERTIES OF CEMENT:

(Cont.)

1.11.4 False Set:

It is an abnormal or premature stiffening of the
cement paste within a few minutes of mixing with
water. In false setting no appreciable heat is
evolved and remaining of cement paste without
addition of water restores the elasticity of cement
paste until it sets in normal manner.
During storage the alkalies of cement reacts with
moisture of the air forming Ca(OH)2 which further
converts to limestone, which causes false set.

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1.11 PHSICAL PROPERTIES OF CEMENT:

(Cont.)

1.11.5 Specific Gravity:

Specific Gravity of a Portland cement is generally
about 3.15. Cement made from materials other
than limestone and clay may have some different
value. Specific Gravity is not an indication of
quality of cement but is used in mix design.

1.11 PHSICAL PROPERTIES OF CEMENT:

(Cont.)

1.11.6 Heat of Hydration:

It is the heat produced by the chemical reaction between
cement and water. The amount of heat generated depends on
chemical composition of cement. And rate of heat generated is
affected by the fineness of cement, temperature during
hydration, chemical composition. In same structure with
considerable mass the rate and amount of heat generated are
significantly large. If heat is not rapidly dissipated, an
undesirable rise in temperature may occur which may be
accompanied by thermal expansion.
A subsequent drop in temperature may then create
undesirable stresses in the structure as such. On the other
hand a rise in temperature may be beneficial in cold weather,
help to make favorable curing conditions.

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1.11 PHSICAL PROPERTIES OF CEMENT:

(Cont.)

Comparative Amount of Heat Generated During

First 7-Days:
ASTM Cement Type
Heat Generated
Type I
100 %
Type II
80-85 %
Type III
150 %
Type IV
40-60 %
Type V
60-75 %

1.12 TESTS OF CEMENT:

The various tests of cement are as follows;

Fineness of cement

Soundness of cement

Standard consistency of Cement

Initial and Final setting time

Compressive Strength Test

Tensile Strength Test

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1.12 TESTS OF CEMENT:

(Cont.)

1.12.1 Fineness of Cement:

The strength relates to the fineness of cement.
More finer is the cement, the period of gaining
strength decreases. The strength is also
noticeable because the cost of grinding to higher
fineness is considerable.
Fineness of cement is tested by two methods;

Sieve Method

By Specific Surface (With Blaine Air
Permeability Apparatus)

1.11 PHSICAL PROPERTIES OF CEMENT:

(Cont.)

Blaine Air Permeability

Apparatus

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1.12 TESTS OF CEMENT:

(Cont.)

1.12.2 Soundness of Cement:

This test is carried out by subjecting cement to an
increased rate of hydration and observing how it behaves.

This test was devised by Le-Chatelier. The apparatus
consists of a cylindrical brass mould having 30mm dia.
Cement paste of normal consistency is prepared. The
cylinder is placed on a glass plate and then it is filled with
cement paste and covered with another glass plate. The
whole assembly is then immersed in water at 20C for 24
hours. At the end of that period, the distance between the
indicators is measured.

Now the cylinder is again immersed in water and brought
to boil in 25 to 30 minutes. After boiling for one hour, and
cooling, the distance between the indicators is again
measured. For Portland cement its limit is 10mm.

1.12 TESTS OF CEMENT: (Cont.)

Le-Chatelier Apparatus

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1.12 TESTS OF CEMENT:

(Cont.)

1.12.3 Standard Consistency of cement:

For the determination of initial and final setting
times and for other test, we need a cement paste
of standard consistency. It is therefore necessary
to determine for any given cement the water
content which will produce the desired
consistency. Vicat apparatus is used to determine
Normal Consistency.

1.12 TESTS OF CEMENT: (Cont.)

According to ASTM C187-98, mix 650 g of cement with a
measured quantity of water. Quickly form the cement paste,
prepare the approximate shape of a ball with gloved hands.
Press the ball, resting in the palm of one hand, into the larger
end of the conical ring, held in the other hand, completely
filling the ring with paste. Remove the excess at the larger
end by a single movement of the palm of the hand. Then set
the movable indicator F to the upper zero mark of the scale,
or take an initial reading, and release the rod immediately.
This must not exceed 30 s after completion of mixing.

The apparatus shall be free of all vibrations during the test.
The paste shall be of normal consistency when the rod settles
to a point 10 1 mm below the original surface in 30 s after
being released. Make trial pastes with varying percentages of
water until the normal consistency is obtained. Make each
trial with fresh cement. The usual range of values is between
26-33 percent.

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1.12 TESTS OF CEMENT: (Cont.)

Vicat Apparatus

1.12 TESTS OF CEMENT:

(Cont.)

1.12.4 Initial and Final Setting Time:

Initial setting of cement is that stage in the process
of hardening after which any cracks that may
appear do not reunite. Final setting is that when it
has attained sufficient strength and hardness.

Vicat apparatus is used to find the setting time for
cement. The test should be performed in a room
with 90% humidity and at temperature between 2529C.

Initial setting of cement should not be less than 30
minutes. And Final setting time should not be more
than 10 hours.

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1.12 TESTS OF CEMENT:

(Cont.)

1.12.4.1 Test for initial Setting time:

For the determination of initial setting time a round
needle with a diameter 1.13 0.05mm is used. This
needle acting under a prescribed weight is used to
penetrate a paste of standard consistence placed in
a special mould, using Vicat apparatus. When the
paste stiffens sufficiently for the needle to penetrate
only to a point 5 1 mm from the bottom, the initial
Set is said to have taken place. Initial Set is
expressed as the time taken from mixing of water
with cement to the required penetration.

1.12 TESTS OF CEMENT: (Cont.)

Vicat Apparatus with

Accessories to determine
Setting Times

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1.12 TESTS OF CEMENT: (Cont.)

1.12.4.2 Test for Final Setting Time:

Final set is determined by a similar needle fitted
with a metal attachment hollowed out so as to leave
a circular cutting edge 5mm in diameter and set 0.5
mm behind the tip of the needle. Final set is said to
have taken place when the needle gently lowered to
the surface of the paste, makes an impression on it,
but the circular cutting edge fails to do so. The final
setting time is noted from the moment when mixing
water was added to the cement.

1.12 TESTS OF CEMENT:

(Cont.)

1.12.5 Strength of cement:

The mechanical strength of hardened cement is the
property of the material that is perhaps most
obviously required for structural use. The strength
of mortar or concrete depends on the cohesion of
the cement paste on its adhesion to the aggregate
particles and to a certain extent on the strength of
aggregate itself. Very strict conditions regarding the
selection of sand, aggregates are used for
determining the strength of cement. There are
several forms of strength tests:

Direct tension or Tensile strength test

Compression test

Flexure strength test

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1.12 TESTS OF CEMENT:

(Cont.)

1.12.5.1 Tensile Strength test:

The test for tensile strength of cement is described by ASTM
C 190-77.
Procedure:

1:3 by weight cement sand mortar with a water content
which is required for neat cement paste of normal
consistency is mixed and molded into a Briquette of the
shape shown in figure.

Sand used should be well-graded and should pass
through sieve #20 and retained on sieve #30. The
briquettes are moulded in standard manner and stored at
a temperature between 20C and 27.5 C and in an
atmosphere of 95% relative humidity and then cured in
water tanks for prescribed time.

1.12 TESTS OF CEMENT: (Cont.)

At least 6 briquettes are prepared and then tested in
direct tension. The pull is applied through special Jaws
engaging the wide ends of the briquette.

According to ASTM C 150-68, for Ordinary Portland
Cement, the minimum tensile strength should be as:
One day in moist air and 2 days in water
One day in moist air and 6 days in water
One day in moist air and 27 days in water

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150 psi
275 psi
350 psi

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1.12 TESTS OF CEMENT: (Cont.)

Briquettes for Testing Cement for Tensile strength

1.12 TESTS OF CEMENT:

(Cont.)

1.12.5.2
Compressive
strength Test:
There are two standard
methods of testing the
compressive strength of
cement, one uses mortar
and
the
other
uses
concrete.
Compression Testing
Machine

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1.12 TESTS OF CEMENT: (Cont.)

Concrete Cubes:
According to BS 4550-3.4:1978,
Make batches of six, nine or twelve
cubes of 100mm size, three for
testing at each of the specified ages.
Sieve the coarse aggregate on 10
mm and 5 mm sieves with square
holes. Half fill the cube mould as
quickly as possible. Compact each
with exactly 35 strokes of the
compacting bar uniformly distributed
over the cross-section of the mould.
Place a further quantity concrete in
each mould to form the top layer and
compact similarly.

1.12 TESTS OF CEMENT:

Cube Mould

(Cont.)

Then strike off the top of each cube and smooth with trowel
so that the surface of the concrete is level with the top of the
mould. Complete the entire operation within 15 min from the
completion of mixing. After specimens are cured, they are
tested at 3, 7 and 28 days.

According to BS 12:1978, requirements for the minimum

values of the average strength of 3 cubes are:
3 days strength
1900 psi
28 days strength
4200 psi

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1.12 TESTS OF CEMENT: (Cont.)

Mortar Cubes:
The strength of cement is also determined by Mortar cubes
of size 70.7 mm according to BS 4550-3.4:1978.
Average values of 3 cubes tested should be:
3 days strength
1800 psi
28 days strength
2800 psi

1.12 TESTS OF CEMENT: (Cont.)

Mortar Cube Mould

Vibrating Machine
For Mortar Cubes

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1.13 STORAGE OF CEMENT:

Protection of cement from atmospheric temperature and damp
conditions is very essential during storage. If proper care is
not taken then cement may set and less of its strength may
experience due to partial setting. Following precautions
should be observed for proper storage of cement:

Cement should be stored in dry, weather tight and properly
ventilated places.

Cement bags should not be placed directly on the floors but
on wooden platforms.

Cement bags should be placed at some distance away from
the walls to avoid moisture penetration.

1.13 STORAGE OF CEMENT: (Cont.)

Cement bags should be placed close to each other.

Cement in sacks should be stored on a damp proof floor
and should not be piled to a height exceeding 2m.

It is also noticeable that long storage of cement reduces
its strength even if all the cares are taken.

Duration of Storage
Reduction in Strength
3 Months
2%
6 Months
5%
12 Months
40 %

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CE-6108 Advances in Cement Technology

1.13 STORAGE OF CEMENT: (Cont.)

Stacking of cement bags

Shed for storing

cement bags at
site

1.14 SPECIAL CEMENTS:

1.14.1 White Cement:
It is used for architectural purposes such as
curtain walls and facing panels, decorating
concrete, tile grout or whenever white or colored
concrete or mortar is specified. It is very similar to
normal Portland cement except in color. It is made
from specially selected raw materials containing
negligible amount of Iron Manganese Oxide and
the manufacturing process is controlled to produce
pure white and non-staining cement.

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CE-6108 Advances in Cement Technology

1.14 SPECIAL CEMENTS:

(Cont.)

1.14.2 Rapid Hardening Cement:

This cement is similar to O.P.C. but develops
strength more rapidly. The three day strength is
equal to seven day strength of O.P.C. with same
water cement ratio.
The increased rate of gain of strength is achieved
by higher contents of C3A.
Rapid gain of strength corresponds to high rate of
heat of hydration developments. So it should not
be used in mass construction or in large structural
sections. However at low temperature areas use
of this cement may prove a safeguard against
early frost damage.

1.14 SPECIAL CEMENTS:

(Cont.)

1.14.3 Ultra High Early Strength Cement:

This cement contains no added mixture and therefore
suitable for reinforced and pre-stressed concrete. The
early strength development is due to very high
fineness of cement and for this gypsum contents are
to be very high i.e. 4% (expressed as SO3). This
cement is manufactured by separating fines from rapid
hardening Portland cement. It has low bulk density
due to high fineness. Three days strength of rapid
hardening cement is reduced to 16 hours and 7 days
strength to 24 hours. In case of Ultra High Early
Strength cement, however there is a little gain in
strength beyond 28 days.

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CE-6108 Advances in Cement Technology

1.14 SPECIAL CEMENTS:

(Cont.)

1.14.4 Masonry Cement:

It has been specially designed to produce better mortar
than that made with O.P.C. or with lime cement
combination. It is made by grinding together a carefully
proportioned mixture of O.P.C. clinkers and high calcium
limestone. To the finally ground product an air entraining
agent, plasticizing agent and retardars are added. The
mortar made with this cement has particularly good
plasticity and workability, good adhesion, good bonding
and has adequate strength to meet the requirements of
ASTM C-91.
It offers great resistance to efflorescence and has good
appearance. The strength of the masonry cement is lower
than O.P.C.; therefore it should not be used in structural
concrete.

1.14 SPECIAL CEMENTS:

(Cont.)

1.14.5 Hydrophobic Cement:

This cement is used where long storage under
unfavorable conditions is required. It is obtained
by intergrinding O.P.C. with citric acid or
pentachloro phenol. The hydrophobic properties
are due to formation of a water repellant film
around each particle of the cement. This film is
broken during mixing of concrete and normal
hydration takes place. But early strength is low.
This cement is similar to O.P.C. in appearance.

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CE-6108 Advances in Cement Technology

1.14 SPECIAL CEMENTS:

(Cont.)

1.14.6 Colored Portland Cement:

These are made by adding pigments to white cement
(sometimes pigments in O.P.C. are also added.).
Strength of colored P.C. is comparatively low than
O.P.C. and 10-15 % additional cement has to be used
to maintain the strength.

1.14 SPECIAL CEMENTS: (Cont.)

1.14.7 Blast Furnace Slag Cement:
This cement is made by adding about 30% (by weight)
blast furnace slag to O.P.C. clinkers before grinding. Slag
is a waste item in the manufacturing of pig iron, the
quantity of iron and slag obtained being of the same order.
The slag is a mixture of lime, silica and alumnina. The
same oxides are in Portland cement but not in that
proportion. Usual composition of lime is 42%; silica is 30%,
alumina 19%, magnesia 5% and alkalies 1%.
Its heat of hydration is low which is beneficial for mass
concrete construction but unsuitable for cold weather. It
has excellent sulfate resisting properties.

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CE-6108 Advances in Cement Technology

1.14 SPECIAL CEMENTS:

(Cont.)

1.14.8 Water Proof Portland Cement:

It is normally produced by adding a small amount of
stearate usually calcium or aluminum to cement clinkers
during the final grinding. It is made both in white and gray
colors. The manufacturer of these cement claim that
concrete made with this cement is more resistant to the
penetration of liquid water and some oils than O.P.C.

1.14 SPECIAL CEMENTS: (Cont.)

1.14.9 Extra Rapid Hardening Cement:
It is obtained by inter-grinding calcium chloride with rapid
hardening cement. The quantity of CaCl2 should not
exceed 2%. This cement is particularly suitable for cold
weather concreting or when a very high early strength is
required. However its use with reinforcement is not
allowed. The strength of extra rapid hardening cement is
25% high than that of rapid hardening cement at 1 or 2
days and 10-20% high at seven days. The time of setting is
from 5 to 30 minutes, so early placing is essential.

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CE-6108 Advances in Cement Technology

1.14 SPECIAL CEMENTS:

(Cont.)

1.14.10 Aluminous Cement:

In order to make a concrete (from structural hydraulic
cement) which would not be attacked by sea water and
contaminated ground water, It was discovered after many
years of research that the cement with a high contents of
alumina and with apparent equal parts of Al2O3 and CaO
would meet this requirement. This cement is now
produced commercially by completely melting a mixture of
bauxite (Aluminum ore) and Calcareous material (chalk or
limestone). The molten material is tapped from furnace
continuously and cast into pigs. The pigs are crushed and
ground to a fine powder in a ball mill. The resulting
product without addition of any other material is called
melted cement.

1.14 SPECIAL CEMENTS: (Cont.)

This cement is particularly valuable where
concrete must be put into service in a short time.
Repairs to sewerage and concrete water mains
can be made overnight. Machine foundation and
floors can be put to use the day after placing.
Airport runways can be prepared with little or no
disturbance to traffic.
This cement generates considerable heat of
hydration so much suitable in cold weather.

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CE-6108 Advances in Cement Technology

1.14 SPECIAL CEMENTS:

(Cont.)

1.14.11 Portland Pozzolana cement:

This cement is produced by grinding together a mixture of
60 to 80 % Portland cement and 40 to 20 % pozzolana.
Pozzolana may be a natural active material such as
volcanic ash or artificial product such as burnt clay. Rate
of development of strength is lower than that of normal
Portland cement, especially at low temperature.
It improves the quality of concrete. It increases the
workability, lower heat of hydration and increases water
tightness. This cement has got greater resistance against
sulfatic action and sea waters. Moreover it decreases the
cost and is useful in the mass concrete works.

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