INITIAL & FINAL SETTING TIME (IS:4031-PART 5-1988)

Initial setting time is that time period between the time water is added to cement and time at
which 1 mm square section needle fails to penetrate the cement paste, placed in the Vicat’s
mould 5 mm to 7 mm from the bottom of the mould.

Final setting time is that time period between the time water is added to cement and the time
at which 1 mm needle makes an impression on the paste in the mould but 5 mm attachment
does not make any impression.

PROCEDURE

(A)TEST BLOCK PREPARATION

Before commencing setting time test, do the consistency test to obtain the water required to
give the paste normal consistency (P).

Take 400 g of cement and prepare a neat cement paste with 0.85P of water by weight of
cement.

Gauge time is kept between 3 to 5 minutes. Start the stop watch at the instant when the water
is added to the cement. Record this time (t1).

Fill the Vicat mould, resting on a glass plate, with the cement paste gauged as above. Fill the
mould completely and smooth off the surface of the paste making it level with the top of the
mould. The cement block thus prepared is called test block.

INITIAL SETTING TIME

Place the test block confined in the mould and resting on the non-porous plate, under the rod
bearing the needle.

Lower the needle gently until it comes in contact with the surface of test block and quick
release, allowing it to penetrate into the test block.

In the beginning the needle completely pierces the test block. Repeat this procedure i.e. quickly
releasing the needle after every 2 minutes till the needle fails to pierce the block for about 5
mm measured from the bottom of the mould. Note this time (t2).

FINAL SETTING TIME

For determining the final setting time, replace the needle of the Vicat’s apparatus by the needle
with an annular attachment.
The cement is considered finally set when upon applying the final setting needle gently to the
surface of the test block; the needle makes an impression thereon, while the attachment fails
to do so. Record this time (t3).

CALCULATION

Initial setting time=t2-t1

Final setting time=t3-t1,

Where,

t1=Time at which water is first added to cement

t2=Time when needle fails to penetrate 5 mm to 7 mm from bottom of the mould

t3=Time when the needle makes an impression but the attachment fails to do so.

PRECAUTIONS

Release the initial and final setting time needles gently.

The experiment should be performed away from vibration and other disturbances.

Needle should be cleaned every time it is used.

Position of the mould should be shifted slightly after each penetration to avoid penetration at
the same place.

Test should be performed at the specified environmental conditions.

False Set: This refers to the rapid setting that occurs without the liberation of much heat.
Plasticity can be regained by further mixing without the need to add more water, and thus is
not a problem where concrete is mixed for long periods (ready-mixed concrete). Increasing
mixing time when possible will help to reduce a false set problem.

Flash Set (or quick set): This behavior is accompanied by the liberation of considerable heat.
The plasticity of the mixture cannot be regained with additional mixing or water.
SOUNDNESS OF CEMENT BY LE-CHATELIERS METHOD (IS:4031-PART 3-1988)

In the soundness test a specimen of hardened cement paste is boiled for a fixed time so that
any tendency to expand is speeded up and can be detected. Soundness means the ability to
resist volume expansion.

APPARATUS

MEASURING INSTRUMENTS

NAME CAPACITY / RANGE / SIZE ACCURACY / LEAST COUNT

Le-chatelier apparatus Should be made as per

IS:5514

Water bath 1000C (min) 10C

Caliper 30 cm 0.5 mm

Measuring cylinder 100 ml 1 ml

Balance 100 g 1g

OTHER APPARATUS

Glass sheets (2 nos), Enamel tray, trowel

 ENVIRONMENTAL CONDITIONS

Temperature 27 ± 20 C

Humidity 65 ± 5 %

PROCEDURE

Before commencing setting time test, do the consistency test to obtain the water required to
give the paste normal consistency (P).

1. Prepare a paste by adding 0.78 times the water required to give a paste of standard
consistency (i.e. 0.78P).
2. Lightly oil the Le-chatelier mould and place it on a lightly oiled glass sheet.
3. Fill the mould with the prepared cement paste. In the process of filling the mould keep the
edge of the mould gently together.
4. Cover the mould with another piece of lightly oiled glass sheet, place a small weight on this
covering glass sheet.
5. Submerge the whole assembly in water at a temperature of 27 ± 20 C and keep there for
24 hours.
6. Remove the whole assembly from water bath and measure the distance separating the
indicator points to the nearest 0.5 mm (L1).
7. Again submerge the whole assembly in water bath and bring the temperature of water
bath to boiling temperature in 25 to 30 minutes. Keep it at boiling temperature for a
period of 3 hours.
8. After completion of 3 hours, allow the temperature of the water bath to cool down to
room temperature and remove the whole assembly from the water bath.
9. Measure the distance between the two indicator points to the nearest 0.5 mm (L2).

CALCULATIONS

Soundness/expansion of cement = L1-L2

L1=Measurement taken after 24 hours of immersion in water at a temp. of 27 ± 20 C

L2=Measurement taken after 3 hours of immersion in water at boiling temperature.

Calculate the mean of two values to the nearest 0.5 mm.

 Note::In the event of cement failing to comply with the specified requirements, a further
test should be made from another portion of the same sample in manner described above,
 but after aeration (done by spreading out to a depth of 75 mm at a relative humidity of 50
to 80% for a total period of 7 days).

PRECAUTIONS

 All the measurements should be done accurately.

 Do not apply extra pressure while filling the moulds.
 During boiling water level should not fall below the height of the mould.

STANDARD SPECIFICATIONS

Type/Name of cement Reference Indian standard Expansion (max.)

OPC (33) IS:269-1989 10 mm

OPC (43) IS:8112-1989 10 mm
OPC (53) IS:12269-1987 10 mm
Rapid hardening IS:8041-1990 10 mm
Low heat cement IS:12600-1989 10 mm
Super sulphated IS:6909-1990 5 mm
Portland pozzolana IS:1489-1991(part 1) 10 mm
PSC IS:455-1976 10 mm
High alumina cement IS:6452-1989 5 mm
SRC IS:12330-1988 10 mm
Masonry cement IS:3466-1988 10 mm
IRS-T-40 Railway standards 5 mm

TECHNICAL DISCUSSION

Volume expansion in cement mortar or in cement concrete is caused by the presence of

unburnt lime (CaO), dead burnt MgO and also CaSO4.

By Le-chatelier method we can only find out presence of unburnt lime (CaO).

Presence of unburnt lime may develop cracks in the cement because of increase in volume.

Free lime (CaO) and magnesia (MgO) are known to react with water very slowly and increase in
volume considerably, which result in cracking, distortion and disintegration.

TEST STANDARD REFERENCE

IS:4031(Part 3):1988-Methods of physical tests for hydraulic cement (Determination of

soundness)
FINENESS

So we need to determine the fineness of cement by dry sieving as per IS: 4031 (Part 1) –
1996.The principle of this is that we determine the proportion of cement whose grain size is
larger then specified mesh size.

The apparatus used are 90µm IS Sieve, Balance capable of weighing 10g to the nearest 10mg, A
nylon or pure bristle brush, preferably with 25 to 40mm, bristle, for cleaning the sieve.

Sieve shown in pic below is not the actual 90µm seive.Its just for reference.

Procedure to determine fineness of cement

i) Weigh approximately 10g of cement to the nearest 0.01g and place it on the sieve.

ii) Agitate the sieve by swirling, planetary and linear movements, until no more fine material
passes through it.

iii) Weigh the residue and express its mass as a percentage R1,of the quantity first placed on the
sieve to the nearest 0.1 percent.

iv) Gently brush all the fine material off the base of the sieve.

v) Repeat the whole procedure using a fresh 10g sample to obtain R2. Then calculate R as the
mean of R1 and R2 as a percentage, expressed to the nearest 0.1 percent. When the results
differ by more than 1 percent absolute, carry out a third sieving and calculate the mean of the
three values.

Reporting of Results

Report the value of R, to the nearest 0.1 percent, as the residue on the 90µm sieve.
CONSISTENCY OF CEMENT

The basic aim is to find out the water content required to produce a cement paste of standard
consistency as specified by the IS: 4031 (Part 4) – 1988. The principle is that standard
consistency of cement is that consistency at which the Vicat plunger penetrates to a point 5-
7mm from the bottom of Vicat mould.

Apparatus – Vicat apparatus conforming to IS: 5513 – 1976, Balance, whose permissible
variation at a load of 1000g should be +1.0g, Gauging trowel conforming to IS: 10086 – 1982.

Procedure to determine consistency of cement

i) Weigh approximately 400g of cement and mix it with a weighed quantity of water. The time
of gauging should be between 3 to 5 minutes.

ii) Fill the Vicat mould with paste and level it with a trowel.

iii) Lower the plunger gently till it touches the cement surface.

iv) Release the plunger allowing it to sink into the paste.

v) Note the reading on the gauge.

vi) Repeat the above procedure taking fresh samples of cement and different quantities of
water until the reading on the gauge is 5 to 7mm.

Reporting of Results

Express the amount of water as a percentage of the weight of dry cement to the first place of
decimal.
The standard consistency is that consistency, which will permit the vicat plunger to penetrate to
a point 5 to 7mm from the bottom of the vicat mould when tested as described below.

APPARATUS

1. VICAT APPARATUS

The vicat apparatus consists of a frame having a movable rod with a cap at one end and at the
other end any one of the following attachment, which are interchangeable.

i) Needle for determining the initial setting time

ii) Needle for determining the final setting time

iii) Plunger for determining the standard consistency

2.NEEDLES

NEEDLE FOR INITIAL SETTING TIME

The needle is having a cross sectional area of 1mm2. The end of the needle is flat.

NEEDLE FOR FINAL SETTING TIME

The needle is circular having a cross sectional area of 1mm2. The needle is fitted with a metal
attachment. The end of the needle projects beyond the cutting edge of the hollowed out metal
attachment.

PLUNGER FOR STANDARD CONSISTANCY

It is of polished brass 10 ± 0.05mm in diameter with a projection at the upper end for insertion
into the movable rod. The lower end is flat.

3.MOVABLE ROD

Movable rod carries an indicator which moves over a graduated scale attached to the frame
(certain models have an additional attachment of dash pot, which facilitates lowering of
movable rod slowly).

4. GRUADUATED SCALE

Graduated scale is 40mm in length and the smallest division of scale is 1mm.
5. VICAT MOULD

Single mould: – The vicat mould is in the foam of a frustum of a cone having an internal
diameter of 60+/-0.5mm at the top, 70 +/- 0.5mm at the bottom and height 40 +/_ 0.5mm.

1.1.2.2.2 Split type vicat mould:- The split type vicat mould is used as an alternative to single
mould. This mould consist of a split ring having an internal diameter 80+/- 0.1mm and a height
40+/_0.5mm. A non-porous base plate is provided. The split mould is provided with a suitable
clamping ring.

PROCEDURE

 Keep the vicat apparatus on a level base (when using vicat apparatus with dash pot,
keep the bearing movable rod to its highest position and pin it.) Unscrew the top of the
dash pot. Half fill the dash pot with any suitable oil of viscosity and screw the top. Work
the plunger a number of times.
 Attach the plunger for determining standard consistency to the movable rod. Work the
plunger a number of times.
 Take 400 gm of cement in a pan and a weighed quantity of water in a beaker.
 Prepare a paste with the water added to cement. Start a stop watch at the time of
adding water to cement.
 Keep the vicat mould on a non porous plate and fill the cement paste in it.
 After completely filling the mould, shake it slightly to expel the air. Smooth off the
surface of the paste making it level with the top of the moulder. The cement paste thus
prepared is the test block.
 Place the test block resting on the non porous plate under the movable rod, bearing the
needle.
 Lower the plunger gently to touch the surface of the cement paste and quickly release;
(when vicat apparatus with dash pot is used, place the mould filled with cement paste
and the non absorbent plate on the base plate of the vicat apparatus. Raise the plunger
of the dash pot, bring it in contact with the top cap of the movable bearing rod. Remove
the pin holding the movable bearing rod to the surface of the cement paste and quickly
release by pushing down the plunger to sink in to the paste). This operation shall be
done immediately after filling the mould.
 Prepare trial test specimens with varying percentages of water until plunger penetrates
to a point 5 to 7mm from the bottom of the vicat mould, which is read on the scale.
Express the water required as percentage by weight of the dry cement.
OBSERVATIONS AND CALCULATIONS

Weight of cement taken (g) = _________

Initial percentage of water added to cement = __________

Quantity of water added to cement =_______

TABLE

SL. NO. QUANTITY OF WATER ADDED (ml) DEPTH OF PENETRATION(mm)

Standard Consistency

= (Quantity of water for 5-7 mm penetration/Weight of cement) X 100

POINTS TO BE NOTED

1. The time of gauging should not be less than 3 minutes and not more than 5 minutes. Gauging
time is the time elapsing from the time of adding water to the dry cement until commencing to
fill the mould.

2. The test should be conducted at room temperature 27oC +/- 2oC

3. There should be no vibration on the working table.

4. The plunger should be cleaned during every repetition.

RESULT

Percentage of water content for standard consistency = %

Types of Cement
Types of Cement Composition
Rapid Hardening Cement Increased Lime content
Quick setting cement Small percentage of
aluminium sulphate as an
accelerator and reducing
percentage of Gypsum with
fine grinding
Low Heat Cement Manufactured by reducing tri- It is used in massive concrete construction like
calcium aluminate gravity dams
Sulphates resisting Cement It is prepared by maintaining
the percentage of tricalcium
aluminate below 6% which
increases power against
sulphates
Blast Furnace Slag Cement It is obtained by grinding the
clinkers with about 60% slag
and resembles more or less in
properties of Portland cement
High Alumina Cement It is obtained by melting
mixture of bauxite and lime
and grinding with the clinker
it 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 It is produced by mixing
mineral pigments with
ordinary cement.
Pozzolanic Cement It is prepared by grindin
pozzolanic clinker with
Portland cement
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.
Hydrographic cement It is prepared by mixing water
repelling chemicals
Purpose
Attains high strength in early days it is used in
concrete where form work are removed at an
early stage.
Used in works is to be completed in very short
period and concreting in static and running
water
It is used in construction exposed to severe
sulphate action by water and soil in places like
canals linings, culverts, retaining walls,
siphons etc.,
It can used for works economic considerations
is predominant.
It is used in works where concrete is subjected
to high temperatures, frost, and acidic action.
It is more costly and is used for architectural
purposes such as pre-cast curtain wall and
facing panels, terrazzo surface etc.,
They are widely used for decorative works in
floors
It is used in marine structures, sewage works,
sewage works and for laying concrete under
water such as bridges, piers, dams etc.,
This type of cement is specially suited to
improve the workability with smaller water
cement ratio and to improve frost resistance of
concrete.
This cement has high workability and strength
Ordinary Portland Cement (OPC): This is by far the most common cement used in general
concrete construction when there is no exposure to sulphates in the soil or in ground water. In
consequence, modern cements have higher 28 days strength than the past, but the later gain in
strength is smaller. A practical consequence of this is that we can no longer expect
‘improvement with age’. Ordinary Portland cement is the cement most widely used. Moreover,
using highly early strength cement for a given specified 28 days strength of concrete, it is
possible to use a leaner mix, with higher water/ cement ratio. Some of these mixes have an
inadequate durability.

Portland Pozzolana Cement (PPC) contains up to 35% fly ash. The fly ash is pozzolanic, so that
ultimate strength is maintained. Because fly ash addition allows a lower concrete water
content, early strength can also be maintained. Where good quality cheap fly ash is available,
this can be an economic alternative to ordinary Portland cement As a rule, Portland Pozolana
Cements gain strength slowly and therefore require curing over a comparatively long period,
but the long term strength is high shows that similar behavior occurs where the pozzolana
replaces part of cement, but the long-term strength depends on the level of replacement.

Portland Slag Cement (PSC) contains up to 70% ground granulated blast furnace slag, with the
rest Portland clinker and a little gypsum. All compositions produce high ultimate strength, but
as slag content is increased, early strength is reduced, while sulfate resistance increases and
heat evolution diminishes. Used as an economic alternative to Portland sulfate-resisting and
low-heat cements. The hydration of slag is initiated when lime liberated in the hydration of
Portland Cement provides the correct alkalinity; subsequent hydration does not depend on
lime. Typical use are in mass concrete because of lower heat of hydration and in sea-water
construction because of a better sulphate resistance (due to a lower C3A content)than with
ordinary Portland cement. Slag with a low alkali content can also be used with an aggregate
suspected of alkali reactivity.

SRC- Sulphate Resisting Cement: (C3A < 5%)

Sulphate Resisting Portland Cement is a type of Portland Cement in which the amount of
tricalcium aluminate (C3A) is restricted to lower than 5% and 2C3A + C4AF lower than 25%. The
SRC can be used for structural concrete wherever OPC or PPC or Slag Cement are usable under
normal conditions. The use of SRC is particularly beneficial in such conditions where the
concrete is exposed to the risk of deterioration due to sulphate attack, for example, in contact
with soils and ground waters containing excessive amounts of sulphates as well as for concrete
in sea water or exposed directly to sea coast . The IS 456 (revised draft code) has made
elaborate provisions for use of particular type of cement against different percentages of
soluble sulphate salts.
Low heat portland cement : Low Heat Portland Cement is particularly suited for making
concrete for dams and many other types of water retaining structures, bridge abutments,
massive retaining walls, piers and slabs etc. In mass concreting, there is often considerable rise
in temperature because of the heat produced as the cement sets and hardens. The shrinkage
which occurs on subsequent cooling sets up tensile stresses in the concrete, may result in
cracking. The use of low heat cement is advantageous since it evolves less heat than OPC. This
cement is not available in the market on regular basis and has to be obtained on specific orders.

Rapid hardening cement : The Rapid Hardening Cement is used for repair and rehabilitation
works and where speed of construction and early completion is required due to limitations of
time, space or other reasons. The cement is to be used in cold weather concreting i.e. temp < 5
0C. Rapid hardening cement is basically OPC but its fineness is 3250 cm2/gm against
2250cm2/gm in case of OPC. The compressive strength after 1 day is 16 N/mm2 and that of 3
days 27N/mm2. These days higher grade OPC are available in the country to meet these
requirements and therefore, this cement is not being manufactured and marketed on regular
basis. The characteristics of this cement can be effectively met by only good quality 53 grade
OPC.