CEMENT- a hydraulic

binder
Md. Tahmidul Islam
Mongla Cement Factory
Mongla, Bagerhat
Bangladesh
Email: tuhintahmid@yahoo.com
tuhintahmid@gmail.com
 PORTLAND CEMENT

Portland cement may be defined as in the British standard as a

product obtained by intimately mixing together calcareous and
argillaceous or other silica, alumina and iron oxide bearing
materials, burning them at a clinkering temperature, and grinding
the resulting clinker.

Calcareous materials : Lime Stone (65-80% CaCO3), Marly

limestone, Coral limestone, Chalk, Shale, Calcite
Argillaceous materials: Silica, Alumina and Iron Oxide. Clay, Marly
clay, Shale, Blast Furnace Slag, sand etc.

Gypsum CaSO4.2H2O or Plaster of Paris CaSO4.½H2O acts as

retarder to prevent quick setting. After initial setting gypsum
retards the dissolution of tricalcium aluminate by forming
tricalcium sulphoaluminate (3CaO.Al2O3.xCaSO4.7H2O). mixed
with 2-5 % gypsum (CaSO4,2H2O).
 HISTORY OF CEMENT
Dates back to the thousands of years,
the Egyptians used natural cement
made by combining limestone and
gypsum for the construction of
pyramids
Romans used a combination of slaked
lime with volcanic ash found near
Pozzuoli village near Mount Vesuvius,
Italy. Best know surviving example is
the Pantheon in Rome
In 1756 to rebuilt Eddystone Lighthouse, John Smeaton conducted a number of
experiments that led to the discovery that cement made from limestone containing a
considerable proportion of clay would harden under water.
In 1824, Joseph Aspdin, a British stone mason, obtained a
patent for Portland cement. The inventor heated a mixture of
finely ground limestone and clay in his kitchen and ground the
mixture into a powder creating a hydraulic cement. Aspdin
named the product Portland cement because it resembled a
stone quarried on the Isle of Portland, England.
PORTLAND CEMENT MANUFACTURING PROCESS

1 ton of Portland
cement required
approx. 1,6 tons
of raw materials
CEMENT PRODUCTION –A SNAPSHOT
 MAIN CHEMICAL COMPOUND OF
PORTLAND CEMENT
Name of compound Chemical Usual Reaction
composition abbreviation
Tricalcium silicate 3CaO.SiO2 C3S Quick reaction

Dicalcium silicate 2CaO.SiO2 C2S Slow reaction

Tricalcium 3CaO.A2O3 C3A Very quick

aluminate reaction

Tetracalcium 4CaO.Al2O3. C4AF Not very

aluminoferrite Fe2O3 important
 CHEMISTRY OF PORTLAND CEMENT
C3S, C2S, C3A and C4AF are the main crystalline phases of
Portland cement

Mineralogical Approx
Composition Abbreviation Function
composition Percentage
Rapid
Tricalcium silicate 3CaO.SiO2 C3S 45-65% Contribution to
strength
Slow
Dicalcium silicate 2CaO. SiO2 C2S 12-30% Contribution to
strength
Rapid
Tricalcium aluminate 3CaO.Al2O3 C3A 6-12% Contribution to
strength
Very Slow
Tetracalcium
4CaO. Al2O3.Fe2O3 C4AF 6-15% Contribution to
aluminoferrite
strength

C - CaO , S - SiO2 , A - Al2O3 , F - Fe2O3

 HYDRATION OF PORTLAND CEMENT
C3S and C2S are the two major component that contribute to the ultimate
strength as they hydrate. The majority of the hydration of C3S reaction
has taken place within 28 days and is to a large degree effectively
complete after one year. But in case of C2S hydration reaction occurs
after 28 days and significant hydration ensues beyond one year.
2Ca3SiO5 + 6 H2O Ca3Si2O7. 3H2O + 3Ca(OH)2 + 125 cal/gC3S
2Ca2SiO4 + 4 H2O Ca3Si2O7. 3H2O + Ca(OH)2 + 62 cal/gC2S
In cement nomenclature
C3S + Water C-S-H + 3CH + Heat
C2S + Water C-S-H + CH + Heat
 C3S is responsible for early strength of concrete
• C2S is responsible for later strength of concrete
• C-S-H gel makes up 50-60% of volume of solids in a completely hydrated cement
paste. It determines the good properties of concrete
• Ca(OH)2 is soluble in water and gets leached out making concrete porous,
particularly in hydraulic structures
A TYPICAL CLINKER COMPOSITION
Composition Percentage
Calcium oxide (CaO) 63-66%
Silicon di oxide (SiO2) 19-22%
Aluminum oxide (Al2O3) 4-6%
Ferric oxide (Fe2O3) 2-4%
Magnesium oxide (MgO) 5% Max
Sulphuric Anhydride (SO3) 1% Max
Sodium oxide (Na2O) 0.5% Max
Potassium oxide (K2O) 0.5% Max
Free lime (Free CaO) 1% Max
Loss on ignition 0.5% Max
Insoluble residue 0.5% Max
Chloride 0.1% Max
Tricalcium silicate (C3S) 45- 65%
Dicalcium silicate (C2S) 12-25%
Tricalcium aluminate (C3A) 6-12%
Tetra calcium aluminoferrite (C4AF) 6-15%
 CEMENT STANDARD

ASTM (American Society for Testing and Materials)

EN (Europeen de Normalisation)
European standard EN 197-1: 2000 is adopted as a BDS Standard
Bangladesh Standard
BDS:EN 197-1: 2003
 CEMENT CLASSIFICATION
As per Bangladesh Standard (BSTI)/European Standard (EN Standard)
EN 197-1 defines and gives the specification of 27 distinct common cement products
and their constituents

CEM I Portland cement

Portland Composite cements
Portland slag cement
Portland silica fume cement
CEM II
Portland fly ash cement
Portland limestone cement
Portland composite cement
CEM III Blast furnace cement

CEM IV Pozzolanic cement

CEM V Composite cement

 NOMENCLATURE

Others main components of composite cements

S – Blast furnace slag

D - Silica fume
P – Natural pozzolana
Q - Natural Calcined pozzalona
V – Siliceous fly ash
W –Calcarious fly ash
L - Limestone
T – Burnt shale
M - Composite (two or more of the above)
 MECHANICAL and PHYSICAL REQUIREMENTS
As per BDS EN Standard

Compressive Strength Initial

MPa Soundness
setting
Strength (expansion)
Standard time
class Early Strength
strength
mm
2 days 7 days 28 days minute
32.5 N -- ≥ 16.0
≥ 32.5 ≤ 52.5 ≤ 75
32.5 R ≥ 10.0 --
42.5 N ≥ 10.0 -- ≥ 42.5
≤ 62.5 ≤ 60 ≤ 10
42.5 R ≥ 20.0 --
52.5 N ≥ 20.0 -- ≥ 52.5
-- ≤ 45
52.5 R ≥ 30.0 --
MPa = Mega Pascal
N/mm2 = Newton/millimeter 2 1 MPa = 1 N/mm2 = 145 PSI
PSI = Pound per square inch
 CHEMICAL REQUIREMENTS
As per BDS EN Standard

Property Cement type Strength class Requirements

CEM I All
Loss on ignition ≤ 5.0%
CEM III
CEM I All
Insoluble residue ≤ 5.0%
CEMIII
32.5 N
CEM I 32.5 R ≤ 3.5%
Sulfate content CEM II 52.5 N
(as SO3) CEM IV 42.5 R
CEM V 52.5 N
52.5 R ≤ 4.0%
CEM III All
Chloride content All All ≤ 0.10%
Pozzolanicity CEM IV All Satisfies the test
 ELEPHANT BRAND CEMENT
PORTLAND COMPOSITE CEMENT
BDS:EN 197.2000:CEM II/B-M (SVL) 42.5 N

ELEPHANT BRAND PORTLAND COMPOSITE CEMENT SPECIFICATION

SL. ELEPHANT
PARAMETERS BDS:EN REQUIREMENT
NO BRAND
Strength
01 2 DAYS 10 MPa (1450 PSI) Minimum 15 MPa Min
28 DAYS 42.5 MPa (6162 PSI) Minimum 45 MPa Min
Setting time 140 -160
02 ≥ 60 Minute
Initial Minute
Soundness
03 ≤ 10 mm 2 mm
(Expansion)
Fineness
04 Specific Surface --------- 4000 cm2/gm
(Blaine)
 ELEPHANT BRAND CEMENT
PORTLAND COMPOSITE CEMENT
BDS:EN 197.2000:CEM I, 52.5 N

SL. ELEPHANT BRAND PORTLAND CEMENT SPECIFICATIONELEPHANT

PARAMETERS BDS:EN REQUIREMENT
NO BRAND
STRENGTH
01 2 DAYS 20 MPa (2900 PSI) Minimum 25 MPa Min
28 DAYS 52.5 MPa (7612 PSI) Minimum 55 MPa Min
Setting time 140 -160
02 ≥ 45 Minute
Initial Minute
Soundness
03 ≤ 10 mm 2 mm
(Expansion)
Fineness
04 Specific Surface --------- 3500 cm2/gm
(Blaine)
 HARMFUL AGENTS IN PORTLAND CEMENT

Harmful Ingredients Permissible limit Harmful effects Affected Structure

Corrosion of
Chloride ≤ 0.1%
reinforcement

Exceeds 1 per cent,

it leads to the
Alkali (Na2O+ K2O) ≤ 0.6%
failure of concrete
(ASR)

Cracks mortar or
MgO ≤ 5% concrete
(Expansion)