CEMENT

Pozzolans
Pozzolan is a siliceous or siliceous and aluminous material which, in
itself, possesses little or no cementitious value but which will, in finely
divided form and in the presence of water, react chemically with calcium
hydroxide at ordinary temperature to form compounds
possessing cementitious properties
Volcanic ash, volcanic tuff, perlite, are naturally occuring pozzolans.

Pozzolanic Reaction
When finely divided pozzolans are mixed with calcium hydroxide in the
presence of moisture, some chemical reactions start to take place
Calcium hydroxide + silica + water

Calcium-Silicate-Hydrate

Calcium-Silicate-Hydrate is the hydration product in very fine state and it

has an extraordinarily high surface area.

Chemical Compositon of
Pozzolans

Uses of Pozzolans In Cement

And Concrete Production
A pozzolan may be used in three different ways for benefiting from their
binding effect:
1. By just mixing the finely divided pozzolan with calcium hydroxide,
water and aggregate to produce a kind of pozzolanic concrete
2. By intergrinding the pozzolan with portland cement clinker for
producing portland-pozzolan cements. (as an additive in cement
production)
3. By adding the finely divided pozzolan to the concrete mixture during
or before the batching operation of concrete ( as an admixture)

Portland Cements
Portland cement is a binding material produced by pulverizing a small
amount of gypsum along with the portland cement clinker that is obtained
by burning an approriate combination of calcareous and clayey materials.
The finished product (Portland cement), in powdered form is normally
grayish in color. This color comes mainly from the presence of small
amounts of iron oxide in the raw materials.
Portland cement can set and harden even under the water. Therefore it is
a hydraulic binder.

The proportions of compounds of portland cement, determine the rate of

setting and hardening.

Portland Cements
Portland cement is used in making mortars and concretes.

Mortars are obtained by inclusion o fine aggregates (sand) in the cement

paste
Concretes are made by inclusion of fine and coarse aggregate in the
cement paste
The function of the cement paste in a concrete or mortar is to cover the
surface of the aggregate particles to fill the spaces between the
aggregate particles and produce a compact mass by binding them.

Portland Cements

Portland Cements

Type Of Cements
Most common used cements are:

1) Portland Cement
2) Portland Pozzolan Type of Cement (consisting portland cement and
finely divided pozzolan)
1.Ordinary Portland Cement (OPC) is the most common cement used in
the world because of the abundance and low cost to produce it.
2.Portland Pozzolana Cement (PPC) is a variation of OPC which includes
a mixture of a pozzolanic material which can increase the strength of the
concrete and reduce the amount of OPC used.
3.OPC is produced simply by grinding to a powder limestone and
secondary materials; PPC is the result of adding pozzolan or similar
materials such as volcanic ash, clay, slag, silica, fume, fly ash, or shale
with OPC.
4.PPC can greatly reduce the amount of OPC used in concrete.

Type Of Cements
Types of Cement

Composition

Purpose

Rapid Hardening
Cement

Increased Lime content

Attains high strength in early days it

is used in concrete where form work
are removed at an early stage.

Quick setting
cement

Small percentage of aluminium Used in works is to be completed in

sulphate as an accelerator and very short period and concreting in
reducing percentage of
static and running water
Gypsum with fine grinding

Low Heat Cement

Manufactured by reducing tricalcium aluminate

It is used in massive concrete

construction like gravity dams

Sulphates resisting It is prepared by maintaining

Cement
the percentage of tricalcium
aluminate below 6% which
increases power against
sulphates

It is used in construction exposed to

severe sulphate action by water and
soil in places like canals linings,
culverts, retaining walls, siphons etc.,

Blast Furnace Slag It is obtained by grinding the

Cement
clinkers with about 60% slag
and resembles more or less in
properties of Portland cement

It can used for works economic

considerations is predominant.

Type Of Cements
Types of Cement

Composition

High Alumina
Cement

It is obtained by melting
It is used in works where concrete is
mixture of bauxite and lime
subjected to high temperatures, frost,
and grinding with the clinker it and acidic action.
is rapid hardening cement with
initial and final setting time of
about 3.5 and 5 hours
respectively

White Cement

It is prepared from raw

materials free from Iron oxide.

Coloured cement

Purpose

It is more costly and is used for

architectural purposes such as precast curtain wall and facing panels,
terrazzo surface etc.,

It is produced by mixing
mineral pigments with
ordinary cement.
Pozzolanic Cement It is prepared by grinding
pozzolanic clinker with
Portland cement

They are widely used for decorative

works in floors

Air Entraining
Cement

It is produced by adding
indigenous air entraining
agents such as resins, glues,
sodium salts of Sulphates etc
during the grinding of clinker.

This type of cement is specially suited

to improve the workability with
smaller water cement ratio and to
improve frost resistance of concrete.

Hydrographic
cement

It is prepared by mixing water

repelling chemicals

This cement has high workability and

strength

It is used in marine structures,

sewage works, sewage works and for
laying concrete under water such
as bridges, piers, dams etc.,

Manufacturing of portland
cement clinker
Limestone and clay are the two main raw materials used for
manufacturing Portland cement clinker.
The manufacturing process of portland cement clinker consists
essentially of griding the raw materials. Mixing them in appropriate
proportions, burning the raw material in a kiln at a temperature of 14001500 C until the material partially fuses into small balls know as clinker.
The mixture of raw materials is burned in a rotary kiln.
The kiln is a long steel cylinder line with refractory bricks.
Modern kilns may reach 6m in diameter and 180m in length with a
production capacity 1000 tons in a day.
It rotates about its axis at a speed of 60 to 150 tours/hour

Kiln

Manufacturing of portland
cement
The clinker, that is already cooked, is conveyed to ball mills to be
interground with the gypsum rock. (3-6%). Gypsum is added for the
purpose of preventing the too quick setting of the cement.

Manufacturing of portlandpozzolan cement

Portland-pozzolan types of cement are usually produced by intergriding a
combination of portland cement clinker and some pozzolan with a small
amount of gypsum rock. They can also be produced by thoroughly mixing
some amount of portland cement with very finely divided pozzolans.
http://www.youtube.com/watch?v=n-Pr1KTVSXo

Compound composition and

effects
Portland cement clinker is usually regarded as constituted of four major
compounds occurring as a result of chemical reactions among the major
oxides.

Compound composition and

effects
When portland cement is mixed with water, the compounds of the cement
undergo chemical reactions with the water independently, and different
products result from these reactions.

Types of Portland Cement

Type I

Classification
General purpose

Characteristics
Applications
Fairly high C3S content for good General construction (most
early strength development
buildings, bridges, pavements,
precast units, etc)

Type II

Moderate sulphate
resistance

Low C3A content (<8%)

Structures exposed to soil or

water containing sulphate ions

Type III

High early strength

Ground more finely, may have

slightly more C3S

Rapid construction, cold

weather concreting

Type IV

Low heat of hydration (slow Low content of C3S (<50%) and

reacting)
C3A

Massive structures such as

dams.

Type V

High sulfate resistance

Very low C3A content (<5%)

Structures exposed to high

levels of sulphate ions

White

White color

No C4AF, low MgO

Decorative (otherwise has

properties similar to Type I)

Hydration of Portland
Cement
Chemical reactions with water are designated as hydration. Hydration
starts as soon as the cement and water are mixed. Each compound in
the cement is assumed to react independently. So each compound
produces different products when it hydrates.
2C2S + 4H
2C3S + 6H

C3S2H3 + CH
C3S2H3 + 3CH

C2S = 2CaO.SiO2
C3S = 3CaO.SiO2
H = H2O
C3S2H3 is calcium-silicate-hydrate gels are simple called C-S-H gels.

Hydration of Portland
Cement
C-S-H is a poorly crystalline material which consist of irregular fibrous
particles in the size of colloidal material. Some of the water occurs in the
structure of the C-S-H gel is held by the surface forces of the gel particles
as absorbed water, and some of the water is held between the surfaces
of certain planes in the crystal as interlayer water.
C3S and C2S are the two compounds that contribute to the ultimate
strength as they hydrate. It is known that the production of calcium
hydroxide (CH) doesnt contribute to the strength of portland cement.

Hydration of Portland
Cement
C3A + CSH2 + 10H
C3A + 3CSH2 + 26H

C4ASH12
C4AS3H32

The reaction of C3A with water is very rapid, leading to the formation of
alumina hydrates. The rapid hydration of C3A causes immediate stiffening
of the cement paste known as quick set or flash set. So in order to
prevent flash set, a small amount of CSH2(gypsum rock) is added to the
clinker during the grinding process.

The products of reaction C4ASH12 is calcium-alumino-monosulfohydrate.

It conatins 12 molecules of water in its formation and causes great
expansion. And it isnt stable so when it finds the possibility of reacting
with more gypsum it can lead to the formation C4AS3H32 as this
C4ASH12 + 2CSH2 + 16H

C4AS3H32

Hydration of Portland
Cement
C4AS3H32 has 32 water molecule and means a very great expansion is
produced.
So if no or very little amount of gypsum is used in the production of
cement, flash setting occurs,
If too much gypsum is available, results in expansion and cracking of the
hardened cement paste or concrete.
The C3A compound doesnt make significant contribution to the ultimate
strength of cement. Its percentage should be less than 5%

Hydration of Portland
Cement
Hydration of C4AF is so similiar to C3A hydrates. Here that Al ions are
partly replaced by Fe ions.
The reactions of C4AF causes expansion and heat liberation, but these
are not as much as C3A reactions.

Heat Of Hydration
The hydration reactions of the compounds of portland cement are all
exothermic. The heats of compounds:

And the heat of portland cement is between 85-100 cal/g

Heat Of Hydration
During the setting and hardening process of the cement paste or
concrete, they are being continually warmed by the internal heat
liberated. Because of reactions. So this heat leads to the temperature
rise.
The temperature rise is vital important for the hardness of concrete.

In a large mass, such as the concrete used for a dam, the heat generated
in setting and hardening of the concrete is not readily dissipated.
Therefore, a high rise in temperature may result in expansion of the
concrete mass, after hardened concretes temperature decreases to its
normal temperature, contraction takes place which leads to the serious
cracks.
Heat liberation may have an advantageous in cold weather concreting.

Setting (Priz Alma)

Setting is used to describe the stiffening of the cement paste. Although
there is some strength development during setting, for practical purposes
setting is distinguished from hardening, which refers to gain of strength of
a cement paste that has already set.
When the cement and water are mixed the chemical reaction between
the water and compounds of the cement starts as soon as these two
materials get in touch.
The length of time starting from the mixing of the cement and water until
the cement paste sets is called the setting time.

The cement paste is shapeable only during setting time. So this time
shouldnt be so long or so short. (initial setting time > 45, final setting time
<375 minutes) (initial setting time and final setting time is determined by
test)

Setting (Priz Alma)

Two kind of quick settings:

1. Flash Setting
2. False Setting (Yalanc Priz)
Flash Setting occurs when there is an insufficient amount or no gypsum
in the cement. In flash setting the paste become rigid in a very short time
and it doesnt gain its strength and it isnt shapeable.
False Setting is the abnormal premature stiffening of the paste after a few
minutes of mixing. In false setting no heat is evolved and remixing the
paste without adding water, restores plasticity until it sets in a normal
manner without loosing its strength.

Setting (Priz Alma)

Reasons of False Setting (Yalanc Priz)

a) When the gypsum rock is interground with too hot clinker

b) If the alkali in the cement has carbonated in during the storage.
(alkali carbonets and calsium hydroxide reaction because of CO2)

Fineness (ncelik)
It refers to the average size of the cement particles obtained by
intergriding the clinker with a small amount of gypsum rock.
In a finer cement: for a given weight of cement there are more cement
particles, and the total surface area of the particles is greater. Since
hydration starts on the surface, increase in fineness leads to an increase
in the rate of strength. However, if the cement particles are too fine,
prehydration might be seen during the storage.
When the cement particles are coarse, hydration starts on the surface of
the particles but further hydration is hindered by the formation of the
reaction products. It causes uncompleted hydration and low strength and
low durability in concrete.

Soundness (Salam)
Soundness of any material is the property of being strong, safe, secure
and free from injury or defect.
Unsoundness in a hardened cement paste may take place due to the
delayed or slow hydration or other reactions of oxides and sulphates. It
is because of free lime, magnesia and calcium sulphate.

Free lime in cement occurs when the raw materials fed into the kiln
contain more amount of lime than that to combine with other oxides for
the formation of the compounds.

Soundness (Salam)
If the raw materials fed into the kiln contain some magnesia, this oxide
also takes place in a hard-burned state in the clinker and in the cement
produced. Its hydration is also rather slow. The presence of magnesia
may cause disruption and cracking of the paste.
Calcium sulphate is another material liable to cause expansion in the
hardened cement paste by leading to formation of calcium
surphoaluminates. It can be prevent by adding gypsum. But the excess
amount of gypsum causes unsoundness during the setting.

Structure of Hydrated
Cement
At the beginning of the mixing operation of cement and water, the paste
has a structure which consists of cement particles with water-filled space
between them. As the hydration proceeds, the gels are formed and they
occupy some of this space.
At any stage of hydration, the structure of the cement paste consists of:

Hydration products, referred to collectively as gel

Some cement that has not hydrated yet
Water-filled spaces, which are called capillary pores

Structure of Hydrated
Cement
Gel Pores: Gel pores are interconnected interstitial spaces within the gel
itself; they constitute a part of the gel structure. Gel pores are 1.5 x 10-6
2x10-6 in diameter. Since they are very small, the loss of water by
evopration , or gain of water from outside is not easy.
Capillary Pores: Capillary pores are relatively large pores in the
hardened cement paste. The sizes are 1.25x10-3
Capillary porosity mainly depends on the following factors:
Water/Cement raito: Higher ratio results in higher void spaces in the
cement paste.
Degree of hydration: More amount of hydration means decreases in the
capillary porosities.

Structure of Hydrated
Cement

Structure of Hydrated
Cement
The water in the capillary can be lost by evaporation, or water can get
into the pores if the hardened paste is in a wet environment. The water in
the capillary pores can be freeze and that ice leads to high internal
stresses.
So capillary porosity is dangerous for concrete.

Type of Cement Produced in

Turkey
According to the TS EN 197-1

CEM I
CEM II
CEM III
CEM IV
CEM V

Portland Cement
Portland Composed Cement
Blast Furnace Slag Cement
Pozzolanic Cement
Composed Cement

Type of Cement Produced in

Turkey
Type I: General Purpose
Type II: Moderate heat of hydration and sulphate resistance (C3A < 8%) :
general construction, sea water, mass concrete
Type III: High early strength (C3A < 15%) : emergency repairs, precast,
winter construction.
Type IV: Low heat ( C3S < 35%, C3A < 7%, C2S > 40%) :mass concrete
Type V: sulphate resistant ( C3A < 5%) : sulphate in soil, sewer

Tests on Cement
Normal(Standart) Consistency
Water content of the paste is important for setting and soundness so it is
necessary to define a water as normal standard consistency test.
Method: (Vicat apparatus)
A trial paste obtained by mixing dry cement and water is placed in a mold
(d = 60mm at the top 70mm at the base and 40mm in height) The plunger
(d = 10mm) is brought into contact with the top surface of the paste.
Under it is weight plunger will penetrate the paste. If the penetration is 5
to 7 mm from the bottom then that paste is considered to be at normal
consistency. Different trials on paste having different water content is
necessary to be tried.
The optimum rate is 26-33% by weight of dry cement.

Tests on Cement
Normal(Standart) Consistency

Setting Time
1 mm diameter needle is changed with plunger.

The test is started about 15 minutes after placing the cement paste into
the mold.
The initial setting time is defined as the length of time between the
penetration of the paste and time when the needle penetrates 25 mm into
cement paste.
The final setting time is defined as the length of time between the
penetration of the paste and the time when the needle no longer sinks
visibly into the paste.
http://www.youtube.com/watch?v=jZHf90PSaac

Soundness Test
The cement paste shouldnt undergo large changes in volume after it has set.
Soundness is defined as the volume stability of the cement paste. (Le Chatelier
Apparatus)
The apparatus consists of a small brass cylinder split along its generatrix. Two
indicator with pointed ends are attached to the cylinder on either side of split.

The cylinder is placed on a glass plate. It is filled with cement paste of normal
consistency, and covered with other glass plate. The whole assembly is then
immersed in water at 20 1 C for 24 hour. At the end of that period the distance
between the indicator points is measured. The mold is then immersed in water
again and brought to a boil. After boiling for one hour, the mold is removed form
water; after cooling the distance between the indicator points is measured again.
This increased of distance between the indicator points represents the expansion
of the cement paste. For portland cement limit is 10 mm
http://www.youtube.com/watch?v=vqxAabDdmTE

Fineness Test
The Blaine air-permeability methods the most commonly used method.
In the Blaine air-permeability method a given volume of air is passed through a
prepared sample of definite density. The number and size of pores in a sample of
given density is a function of the size of the particles and their size distribution and
determines the rate of air flow through the sample. Calculations are made and the
specific surface area of the particles present in the sample is found. This value is
the Blaine fineness value of the cement and it is expressed in terms of cm2/g.