7/25/2010

CONTENT SCHEDULE 1st Meeting

Civil Engineering Materials

SAB 2112

Introduction to Cement
Dr Mohamad Syazli Fathi
Department of Civil Engineering RAZAK School of Engineering & Advanced Technology UTM International Campus

1. Introduction, cement manufacturing process, types of cement, chemical composition of OPC 2. Hydration of cement, testing of cement, types of aggregates, physical and mechanical characteristics gg g p y of aggregates 3. Size distribution and testing of aggregates, water in concrete, types of chemical admixtures

July 25, 2010

Objectives of the lecture

The main objective of this lecture is to explain to students that: How cement is manufactured, its principal constituents, the types of cement, cement standards and the application of different types of cement Cement is a mixture of limestone, clay, silica and gypsum. It is a fine powder which when mixed with water sets to a hard mass as a result of hydration of the constituent compounds. It is the most commonly used construction material 4

Leonard P. Zakim Bunker Hill Bridge in Boston. (Image courtesy of the Federal Highway Administration.)

Definition
In BS EN 197-1, cement is defined as: A hydraulic binder, i.e. a finely ground inorganic material which, when mixed with water, forms a paste which sets and hardens by means of hydraulic reactions and processes and which, after hardening, retains its strength and stability even under water. Factory produced EN 197 cements are given the designation CEM In British Standards, mixer combinations are given the designation C not CEM

History of Cement
In 1824, Joseph Aspdin, a British (Leeds) stone mason, obtained a patent for a cement he produced in his kitchen. hi kit h The inventor heated a mixture of finely ground limestone and clay in his kitchen stove and ground the mixture into a powder create a hydraulic cement-one that hardens with the addition of water.

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History of Cement
Aspdin named the product Portland cement because it resembled a stone quarried on the Isle of Portland off the British Coast. th B iti h C t With this invention, Aspdin laid the foundation for today's Portland cement industry.
Cement is so fine that one kg of cement contains more than 300 billion grains

Basic Composition
The raw materials required to produce Portland cement are found and exploited in nearly all parts of the world, which is a significant reason for its universal importance as a building material. material. Table 1 indicates the standard mineralogical composition of Portland cement and Table 2 indicates its standard chemical composition. composition.

Basic Composition
Table 1 Mineralogical Composition of Portland Cements (Brandt, 1995)
Chemical Name tricalcium silicate dicalcium silicate tricalcium aluminate tetracalcium aluminoferite pentacalcium trialuminate calcium sulphate dihydrate Common Name alite belite belite celite celite gypsum Chemical Notation 3CaO.SiO2 2CaO.SiO2 3CaO.Al2O3 4CaO.Al2O3.Fe2O3 5CaO.3Al2O3 CaSO4.2H2O C 3S C 2S C3A C4AF C4AF CSH2
Gypsum (3.5%)

Basic Composition
Other (1.5%)

Abbreviated Mass Contents Notation (%) 38-60 3815-38 157-15 10-18 101 -2 2 -5

Tetracalcium Aluminoferrite (8%)

Tricalcium Aluminate (12%)

Tricalcium Silicate (50%)

Dicalcium Silicate (25%)

Basic Composition
Table 2 Chemical Composition of Portland Cements (Brandt, 1995)
Chemical Name calcium oxide silicon dioxide ili di id aluminium oxide ferric oxides magnesium oxide sulphur trioxide alkaline oxides Common Name lime silica ili alumina iron magnesia sulphuric anhydrite alkalis Chemical Notation CaO SiO2 Al2O3 Fe2O3 + FeO MgO SO3 K2O and NaO2 Abbreviated Notation C S A F M S K+N Mass Contents(%) 58-66 581818-26 4-12 1 -6 1 -3 0.5-2.5 0.5<1

Manufacturing of Cement
Producing a cement that meets specific chemical and physical specifications requires careful control of the manufacturing process. The first step in the Portland cement manufacturing process is obtaining raw materials. G Generally, raw materials consisting of combinations of ll t i l i ti f bi ti f limestone, shells or chalk, and shale, clay, sand, or iron ore are mined from a quarry near the plant. At the quarry, the raw materials are reduced by primary and secondary crushers. Stone is first reduced to 5-inch size (125-mm), then to 3/4-inch(19 mm). Once the raw materials arrive at the cement plant, the materials are proportioned to create a cement with a specific chemical composition.

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Manufacturing of Cement
Type of Manufacturing Wet Process Dry Process - 74% of cement produced Preheater/Precalciner Process

Manufacturing of Cement Dry Process

Dry Process In the dry process, dry raw materials are proportioned, ground to a powder, blended together and fed to the kiln in a dry state. In the wet process, a slurry is formed by adding water to the properly l proportioned ti d raw materials. The grinding and blending operations are then completed with the materials in slurry form. After blending, the mixture of raw materials is fed into the upper end of a tilted rotating, cylindrical kiln.

Manufacturing of Cement

In cement plant, to produce cement need seven steps

1.Crushing and Preblending In cement production process, most of the material need to be broken, such as limestone, clay, iron ore and coal, etc. Limestone is the largest amount of raw material in cement production, after mining the size of limestone is large, with high hardness, so the limestone crushing plays a more important role in cement plant. 2. raw material preparation In cement production process, producing each 1 ton of Portland cement need grinding at least 3 tons of materials (including raw materials, fuel, clinker, mixed materials, gypsum). Grinding operation consumes power about 60% of total power in cement plants, raw material grinding takes more than 30%, while coal mill used in cement palnt consumes 3%, cement grinding about 40%. So choosing the right grinding mills in cement plant is very important. 3. raw materials homogenization Adopting the technology of homogenization could rationally get the best homo-effect and afford an eligible production to the demand 4. preheating and precalcing Preheater and calciner is key equipment for precalcing production technique.
Image from : http://www.adelaidebrighton.com.au/Images/cement%20manufacturing%20process%20low-res.jpg

Source: http://www.crushersmill.com/production-line/cement-plant.html

Manufacturing of Cement Dry Process

5.burning cement clinker in a rotary kiln. The calcination of Rotary Kiln is a key step of cement production , it makes directly influence on the quality of cement clinker. 6. cement grinding Cement grinding is used for grinding cement clinker (and gelling agent, performance tuning materials, etc.) to the appropriate size (in fineness, specific surface area, said), optimizing cement grain grading, increasing the hydration area, accelerating the hydration rate to meet the requirements of cement paste setting, hardening. 7. cement packing
Source: http://www.tradekorea.com/products/heater.html?nationCd=CN&linkFlag=

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Manufacturing of Cement Dry Process

In the dry process, dry raw materials are proportioned, ground to a powder, blended together and fed to the kiln in a dry state. In the wet process, a slurry is formed by adding water to the properly proportioned raw materials. Th grinding and bl di operations are then The i di d blending i h completed with the materials in slurry form. After blending, the mixture of raw materials is fed into the upper end of a tilted rotating, cylindrical kiln. The mixture passes through the kiln at a rate controlled by the slope and rotational speed of the kiln.

Manufacturing of Cement Dry Process

Burning fuel consisting of powdered coal or natural gas is forced into the lower end of the kiln. Inside the kiln, raw materials reach temperatures of 1430oC to 1650oC. At 1480oC, a series of chemical reactions cause the materials to fuse and create cement clinker-grayish-black pellets, often the size of marbles. Clinker is discharged red-hot from the lower end of the kiln and transferred to various types of coolers to lower the clinker to handling temperatures.

Summary of Kin Reactions

Clinker

Source: http://www.aboutcivil.com/engineering-materials/cement-composition-types-and-manufacture.pdf

Manufacturing of Cement Dry Process

Cooled clinker is combined with gypsum and ground into a fine g y p gray powder. The clinker is ground so fine that nearly all of it passes through a No. 200 mesh (75 micron) sieve. This fine gray powder is Portland cement.

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Manufacturing of Cement Wet Process

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Cement Standards
BS EN 197-1:2000 (Inc. Amendment No.1:2004)
Composition, specifications and conformity criteria for common cements

BS EN 197-4:2004
Composition, specifications and conformity criteria for low early strength blast furnace cements

BS EN 196-series
Methods of testing cement

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Cement Standards
Cements are factory produced materials primarily conforming to BS EN 197-1 or BS EN 197-4 Some cements, such as Sulphate-resisting Portland cement (SRPC) are however, still covered by residual British Standards g g g p There is a wide range of cements ranging from simple Portland cement to Composite cements containing up to three major constituents Cements may be produced by inter-grinding or blending the constituents at the cement works Cements can be CE marked against BS EN 197 standards using BS EN 197-2 Conformity evaluation

Types of Portland Cement

Different types of Portland cement are manufactured to meet various physical and chemical requirements. The American Society for Testing and Materials (ASTM) Specification C-150 provides for eight types of Portland cement C 150 cement. BS EN 197-1 specified Five main classes of Portland cement However, Both BS EN and ASTM specified some other types of cements for special functions.

Types of BS EN 1971Portland Cement

How are Cements Designated

Portland Cement
Portland cement is CEM I NOT Ordinary Portland cement OPC or PC cement, BUT CEM I

Cement strength Classes (I)

Note: Use of comma rather than decimal point i t

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Cement strength Classes (II)

Cement strength Classes (II)

These classes apply to all CEM cements

Low Heat Cement

Minor Additional Constituents (I)

BS EN 197-1 allows for the inclusion of up to 5% by mass of a minor additional constituent (or mac) in all types of cement A mac is defined as: specially selected inorganic natural mineral materials, inorganic mineral materials derived from the clinker production process or [specified cement] constituents unless they are [already] included as main constituents in the cement Materials typically used as a mac include:
Finely ground limestone Fly Ash Cement kiln dust (CKD)

Example: CEM III/B 32,5N - LH

Minor Additional Constituents (II)

Other Cements

A CEM I Portland cement with 5% mac is still a Portland cement and will perform in the same way as a similar cement without a mac !

These standards will eventually be replaced by new European Standards, but progress on a standard for sulfate-resisting cement is slow

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CHEMICAL COMPOSITION OF PORTLAND CEMENT

HYDRATION PROCESS OF CEMENT

Compound

Chemical Formula

Common Formula*

Usual Range, weight (%) 45 60 15 30 6 12 68

Tricalcium silicate Dicalcium silicate Tricalcium aluminate Tetracalcium aluminoferrite

3CaO SiO2 2CaO SiO2 3CaO Al2O3 4CaO Al2O3 Fe2O3

C3S C2S C 3A C4AF

Cement + H2O C-S-H gel + Ca(OH)2 Chemical reaction between cement particles & water. It is an exothermic process where heat is liberated. The silicates, C3S and C2S, are the most important compounds, which are responsible for the strength of hydrated cement paste. C3S provides the early strength and liberated higher heat of hydration.
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*The cement industry commonly uses shorthand notation for chemical formulas: C = calcium oxide. S = silicon dioxide, A = aluminium oxide and F = iron oxide. (Michael S. Mamlouk & John P. Zaniewski, 1999)

Hydration Reaction 1 & 2

Tricalcium Silicate 2C3S + 6H C3S2H3 + 3CH
water C-S-H calcium hydroxide cement gel
C3A + 6H

Hydration Reaction 3 & 4

Tricalcium Aluminate (C3A)
C3AH6 calcium aluminate hydrate C6ASH32 ettringite 3C4ASH12 monosulphaluminate + new sulphate ions = ettringite

C3A + 3CASH2 +26H 2C3A + C6ASH2 + 4H

Dicalcium Silicate 2C2S + 4H

C3S2H3 + CH
1/3 to 1/2 1/4 vol
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Tetracalcium Aluminoferrite (C4AF)

Similar to C3A
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Development of structure in the cement paste

Development of structure in the cement paste

The C-S-H phase is initially formed. C3 A forms a gel fastest.

++

Water + + + + C3 S ++ C2 S ++ C3 A + + C4 AF

++

The volume of cement grain decreases as a gel forms at the surface. Cement grains are still able to move independently, but as hydration grows weak interlocking begins grows, begins. Part fo the cement is in a thixotropic state; vibration can break the weak bonds. + (b)

(a)

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Development of structure in the cement paste

Development of structure in the cement paste

The initial set occurs with the development of a weak skeleton in which cement grains are held in place.

Final set occurs as the skeleton becomes rigid, cement particles are locked in place, and spacing between cement grains increases due to the volume reduction of the grains. (c) (d)

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Development of structure in the cement paste

Clinker Microstructure

Speaces between the cement grains are filled with hydration products as cement paste develops strength and durability.

(e)

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Source: http://www.aboutcivil.com/engineering-materials/cement-composition-types-and-manufacture.pdf

Grinding Mill

Cement hydration
Cement hydration is affected by:1. 2. 3. 4. time, temperature, water:cement ratio, and cement fineness and composition.

Source: http://www.aboutcivil.com/engineering-materials/cement-composition-types-and-manufacture.pdf

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Typical results for heat evolution at 20C of different Portland cements: (A) low heat, (B) ordinary & (C) rapid hardening
600

Rates of Hydration of Cement Compounds in OPC Paste

100

500

C Heat of hydratio (J/g) on

400

80 60

C3 A C3 S C4AF C2 S

300

40
200 100

20
3 days 7 days 28 days 90 days 1 yr 5 yrs

0 1 day

0 20
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Age (log scale)

40 60 Time (days)

80

100
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Compressive Strength Development in OPC Paste

70 60 % 50 40 30 20 10 0 20 40 60 Time (days) C3 A C4AF 80 100
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Significant of Fineness

C3 S

C2 S

HYDRATION PROCESS OF CEMENT

C2S reacts slowly, provide later strength, highly chemical resistance (sulphate & chloride). C3A is undesirable, it contributes little or nothing to the strength of cement except at early ages and ages, when hardened, cement paste is attacked by sulphates, the formation of sulphoaluminate (ettringite) may cause disruption. However, C3A is beneficial in the manufacture of cement in that it facilitates the combination of lime & silica.
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HYDRATION PROCESS OF CEMENT

C4AF does not affect the behaviour of cement hydration significantly. However, it reacts with gypsum to form calcium sulphoferrite and its presence may accelerate the hydration of silicates.

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Hydration of Cement
When Portland cement is mixed with water its chemical compound constituents undergo a series of chemical reactions that cause it to harden (or set). These chemical reactions all involve the addition of water to the basic chemical compounds This chemical reaction with water is compounds. called "hydration". Each one of these reactions occurs at a different time and rate. Together, the results of these reactions determine how Portland cement hardens and gains strength. Tricalcium silicate (C3S). Hydrates and hardens rapidly and is largely responsible for initial set and early strength. Portland cements with higher percentages of C3S will exhibit higher early strength.

Hydration of Cement
Dicalcium silicate (C2S). Hydrates and hardens slowly and is largely responsible for strength increases beyond one week. Hydrates and hardens Tricalcium aluminate (C3A). quickest. Liberates a large amount of heat almost immediately and contributes somewhat to early strength Gypsum is added to strength. Portland cement to retard C3A hydration. Without gypsum, C3A hydration would cause Portland cement to set almost immediately after adding water. Tetracalcium aluminoferrite (C4AF). Hydrates rapidly but contributes very little to strength. Its use allows lower kiln temperatures in Portland cement manufacturing. Most Portland cement colour effects are due to C4AF.

Hydration of Cement
The result of the two silicate hydrations is the formation of a calcium silicate hydrate (often written C-S-H because of is variable stoichiometry). C S H makes up about 1/2 - 2/3 the volume of the C-S-H hydrated paste (water + cement) and therefore dominates its behavior (Mindess and Young, 1981).

TESTING OF CEMENT

Why do we have to conduct the tests? To ensure the quality of cement. To determine the properties of cement. What are the properties of cement? Chemical properties Physical properties

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TESTING OF CEMENT
Tests should be conducted according to the relevant standard:
1. 2. 3. MS 522 Part 1, 2, 3 OPC BS 12: 1978 OPC and RHPC BS 4550: Part 1: 1978 Methods of testing cement.

TESTING OF CEMENT

New Standards
1. 2. BS EN 197-1:2000 (Inc. Amendment No.1:2004) Composition, specifications and conformity criteria for common cements BS EN 197-4:2004 Composition, specifications and conformity criteria for low early strength blast furnace cements BS EN 196-series Methods of testing cement
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Testing of cement includes: Chemical composition Fineness of cement S i time Setting i Soundness Strength

3.

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Chemical Composition

Physical Properties of Cement

Portland cements are commonly characterized by their physical properties for quality control purposes. Their physical properties can be used to classify and compare Portland cements. The challenge in physical property characterization is to develop physical tests that can satisfactorily characterize key parameters.

To determine the amount of C3S, C2S, C3A and C4AF. T being conducted at the cement factory. Test b i d d h f For research, test has to be conducted in the lab.

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Physical Properties of Cement

Keep in mind that these tests are, in general, performed on "neat" cement pastes - that is, they only include Portland cement and water. Neat cement pastes are typically difficult to handle and test and thus they introduce more variability into the results results. Cements may also perform differently when used in a "mortar" (cement + water + sand). Over time, mortar tests have been found to provide a better indication of cement quality and thus, tests on neat cement pastes are typically used only for research purposes (Mindess and Young, 1981). However, if the sand is not carefully specified in a mortar test, the results may not be transferable.

Physical Properties of Cement

Fineness Fineness, or particle size of Portland cement affects hydration rate and thus the rate of strength gain. The smaller the particle size, the greater the surface area-tovolume ratio, and thus, the more area available for water-cement interaction per unit volume. The effects of greater fineness on strength are generally seen during the first seven days (PCA, 1988). Fineness can be measured by several methods: AASHTO T 98 and ASTM C 115: Fineness of Portland Cement by the Turbidimeter. AASHTO T 128 and ASTM C 184: Fineness of Hydraulic Cement by the 150mm (No. 100) and 75-mm (No. 200) Sieves AASHTO T 153 and ASTM C 204: Fineness of Hydraulic Cement by Air Permeability Apparatus AASHTO T 192 and ASTM C 430: Fineness of Hydraulic Cement by the 45-mm (No. 325) Sieve

Fineness Test

Air Permeability Lea & Nurse

Rate of hydration depends on the fineness of cement. Fineness is a vital property of cement; both BS and ASTM require the determination of the specific surface (m2/kg). f ( g) The specific surface can be determined by the following apparatus: Air Permeability Lea & Nurse: Blaine test:
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By the Air Permeability Lea & Nurse: Measure the pressure drop when dry air flows at a constant velocity through a bed of cement of known p porosity and thickness. y From this the surface area per unit mass of the bed can be related to the permeability of the bed. BS 4550: Part 3: Section 3.3: 1978.

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Blaine test

Fineness Test

Blaine test: A modification of the above method. ASTM C240-84. The air does not pass through the bed at a constant p g rate, but a known volume of air passes at a prescribed average pressure. The rate of flowing diminishing steadily. The time of flow to take place is measured For a given apparatus and standard porosity, the specific surface can be calculated.
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Fineness Fineness Fineness Fineness Fineness

Strength ??? Workability ??? Bleeding ??? Heat of hydration ??? Cost of production ???

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Physical Properties of Cement - Soundness

Soundness When referring to Portland cement, "soundness" refers to the ability of a hardened cement paste to retain its volume after setting without delayed destructive expansion (PCA, 1988). This destructive expansion is caused by excessive amounts of free lime (CaO) or magnesia (MgO). Most Portland cement specifications limit magnesia content and expansion. The typical expansion test places a small sample of cement paste i t an autoclave ( hi h pressure steam vessel). t t into t l (a high t l) The autoclave is slowly brought to 2.03 MPa (295 psi) then kept at that pressure for 3 hours. The autoclave is then slowly brought back to room temperature and atmospheric pressure. The change in specimen length due to its time in the autoclave is measured and reported as a percentage. ASTM C 150, Standard Specification for Portland Cement specifies a maximum autoclave expansion of 0.80 percent for all Portland cement types.
The standard autoclave expansion test is: AASHTO T 107 and ASTM C 151: Autoclave Expansion of Portland Cement

Soundness

It is essential that the cement paste after setting does not undergo a large change in volume i.e. expansion. Expansion may occur due to reactions of free lime, magnesia and calcium sulphate. Free lime hydrates very slowly occupying a large volume than the original free lime oxide.
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Soundness

Soundness

Magnesia reacts with water in a manner similar to CaO, but only the crystalline form is deleteriously reactive so that unsoundness occurs. Calcium sulphate cause expansion through the formation of calcium sulphoaluminate (ettringgite) from excess gypsum (not used up by C3A during setting).

Cements exhibiting this type of expansions are classified as unsound. Le Chatteliers accelerated test is prescribed by BS 4550: g Part 3: Section 3.7: 1978 for detecting unsoundness due to free lime only. For OPC, expansion not more than 10 mm. In practice, unsoundness due to free lime is very rare. Autoclave test ASTM C 151-84 for testing unsoundness due to magnesia. Calcium sulphate no specific test is available.

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Physical Properties of Cement Setting time

Setting Time

Setting Time Cement paste setting time is affected by a number of items including: cement fineness, water-cement ratio, chemical content (especially gypsum content) and admixtures. Setting tests are used to characterize how a particular cement g p paste sets. For construction purposes, the initial set must not be too soon and the final set must not be too late. Additionally, setting times can give some indication of whether or not a cement is undergoing normal hydration (PCA, 1988). Normally, two setting times are defined (Mindess and Young, 1981):
Initial set. Occurs when the paste begins to stiffen considerably. Final set. Occurs when the cement has hardened to the point at which it can sustain some load.

Term to described the stiffening of cement paste or the change from fluid to a rigid state. Cement paste = Cement + Water Setting mainly caused by a selective hydration of C3A & C3S and is accompanied by the temperature rises in the cement paste.

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Setting Time

Setting Time

Initial set corresponds to a rapid rise of temperature. Final set corresponds to the peak temperature temperature. False set different from initial and final set. Sometimes occurs within a few minutes of mixing with water. No heat is evolved in a false set and the concrete can be remixed without adding water.
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Flash set caused by the rapid reaction between C3A with water and liberate heat. Prevented by the addition of gypsum Test can be conducted using Vicat apparatus. For O C and RHPC: OPC d C Initial set time not less than 45 minutes. Final setting time not more than 600 minutes. Final time = 90 + (1.2 Initial time) Final time is affected by: Temperature 20 2C Relative humidity 65% 90%.
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Physical Properties of Cement Vicat & Gillmore

Physical Properties of Cement Vicat & Gillmore

Test Method Set Type Initial Final Initial Final Time Specification 45 minutes 375 minutes 60 minutes 600 minutes

These particular times are just arbitrary points used to characterize cement, they do not have any fundamental chemical significance. Both common setting time tests the Vicat needle and the tests, Gillmore needle, define initial set and final set based on the time at which a needle of particular size and weight either penetrates a cement paste sample to a given depth or fails to penetrate a cement paste sample. The Vicat needle test is more common and tends to give shorter times than the Gillmore needle test. Table 3.14 shows ASTM C 150 specified set times.

Vicat

Gillmore

The standard setting time tests are: AASHTO T 131 and ASTM C 191: Time of Setting of Hydraulic Cement by Vicat Needle AASHTO T 154: Time of Setting of Hydraulic Cement by Gillmore Needles ASTM C 266: Time of Setting of Hydraulic-Cement Paste by Gillmore Needles

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Physical Properties of Cement

Strength Cement paste strength is typically defined in three ways: compressive, tensile and flexural. These strengths can be affected by a number of items including: water-cement ratio, cement-fine aggregate ratio, type and grading , gg g , yp g g of fine aggregate, manner of mixing and molding specimens, curing conditions, size and shape of specimen, moisture content at time of test, loading conditions and age (Mindess and Young, 1981). Since cement gains strength over time, the time at which a strength test is to be conducted must be specified. Typically times are 1 day (for high early strength cement), 3 days, 7 days, 28 days and 90 days (for low heat of hydration cement).

Strength

Strength tests are not made on neat cement paste difficult to obtain good specimen. Two T methods: h d Mortar test Concrete test BS 4550: Part 3

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Mortar Test

Mortar Test
After 24 hours, demould the mortar cubes and cure in water until they are tested in a wet-surface condition. Get the average strength for three cubes. According to MS 522: Part 1: 1. OPC 23 MPa at 3 days 41 MPa at 28 days 2. RHPC 29 MPa at 3 days 46 MPa at 28 days
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Mortar = Cement + Sand + Water Cement : Sand = 1 : 3 Mass of water = 10% of the mass of dry materials Sand standard sand, one size and spherical shape Cube size of 71 mm Materials being mixed and compacted using vibrating table.

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Concrete Cube Test

Cement : Aggregate = 1 : 6 Water cement ratio: 0.6, 0.55, 0.45 Materials must be mixed uniformly in the mixer Cube size of 100 mm Preparation procedures are the same as mortar test P ti d th t t t
1. OPC 11.5 MPa at 3 days 26 MPa at 28 days 2. RHPC 18 MPa at 3 days 33 MPa at 28 days
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Physical Properties of Cement

When considering cement paste strength tests, there are two items to consider: 1. Cement mortar strength is not directly related to concrete strength. Cement paste strength is typically used as a quality control measure measure. 2. Strength tests are done on cement mortars (cement + water + sand) and not on cement pastes.

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Physical Properties of Cement

Compressive Strength The most common strength test, compressive strength, is carried out on a 50 mm (2-inch) cement mortar test specimen. The test specimen is subjected to a compressive load (usually from a hydraulic machine) until failure. This loading sequence must t k no l t take less th than 20 seconds and no more th d d than 80 seconds. Following Table shows ASTM C 150 compressive strength specifications. The standard cement mortar compressive strength test is: AASHTO T 106 and ASTM C 109: Compressive Strength of Hydraulic Cement Mortars (Using 50-mm or 2-in. Cube Specimens) ASTM C 349: Compressive Strength of Hydraulic Cement Mortars (Using Portions of Prisms Broken in Flexure)
Curing Time 1 day

Physical Properties of Cement

Portland Cement Type IIA III IIIA 10.0 12.4 ( (1800) (1450) ) ( ) 10.3 8.3 24.1 19.3 (1500) (1200) (3500) (2800) 17.2 13.8 -(2500) (2000) II

I 12.4 (1800) 19.3 (2800)

IA 10.0 (1450) 15.5 (2250)

IV -

V -

8.3 3 days (1200) 15.2 6.9 7 days (1000) (2200) 20.7 17.2 28 days (2500) (3000) Note: Type II and IIA requirements can be lowered if either an optional heat of hydration or chemical limit on the sum of C3S and C3A is specified

Physical Properties of Cement

Tensile Strength Although still specified by ASTM, the direct tension test does not provide any useful insight into the concrete-making properties of cements. cements It persists as a specified test because in the early years of cement manufacture, it used to be the most common test since it was difficult to find machines that could compress a cement sample to failure.

Physical Properties of Cement

Flexural Strength Flexural strength (actually a measure of tensile strength in bending) is carried out on a 40 x 40 x 160 mm (1.57-inch x 1.57-inch x 6.30-inch) cement mortar beam. The beam is then loaded at its center point until failure. The standard cement mortar flexural strength test is: ASTM C 348: Flexural Strength of Hydraulic Cement Mortars Specific Gravity Test Specific gravity is normally used in mixture proportioning calculations. The specific gravity of Portland cement is generally around 3.15 while the specific gravity of Portland-blast-furnace-slag and Portland-pozzolan cements may have specific gravities near 2.90 (PCA, 1988). The standard specific gravity test is: AASHTO T 133 and ASTM C 188: Density of Hydraulic Cement

Physical Properties of Cement

Heat of Hydration The heat of hydration is the heat generated when water and Portland cement react. Heat of hydration is most influenced by the proportion of C3S and C3A in the cement, but is also influenced by water-cement ratio, fineness and curing temperature. As each one of these factors is increased, heat of hydration increases. In large mass concrete structures such as gravity dams, hydration heat is produced significantly faster than it can be dissipated (especially in the center of large concrete masses), which can create high temperatures in the center of these large concrete masses that, in turn, may cause undesirable stresses as the concrete cools to ambient temperature. Conversely, the heat of hydration can help maintain favorable curing temperatures during winter (PCA, 1988). The standard heat of hydration test is: ASTM C 186: Heat of Hydration of Hydraulic Cement

Physical Properties of Cement

Loss on Ignition Loss on ignition is calculated by heating up a cement sample to 900 - 1000C (1650 - 1830F) until a constant weight is obtained. The weight loss of the sample due to heating is then determined. A high loss on ignition can indicate pre-hydration and carbonation, which may be caused by improper and prolonged storage or adulteration during transport or transfer (PCA, 1988). The standard loss on ignition test is contained in:
AASHTO T 105 and ASTM C 114: Chemical Analysis of Hydraulic Cement

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Application of Different Types of Cement

Portland Cement CEM I CEM I is the cement that has been commonly used throughout the world in engineering and building works. Concretes and mortars made using CEM versatile, durable and forgiving of construction practice.

Applications of Type - CEM I

most civil I are poor

Application of Different Types of Cement

Sulphate-Resisting Cements SRPC is normally a low alkali cement which benefits concrete in resisting the alkali silica reaction (ASR). However, it is not the only sulphate-resisting cement available. Various factorymade composite cements are also sulphate-resisting including the generally available CEM II/B-V type of Portland-fly ash cement containing at least 25% of fly ash. Such CEM II/B-V cements are permitted for use in the same wide-range of sulphate exposure conditions as is SRPC and are also low in reactive alkalis. Moreover, SRPC is a type of CEM I cement with a high clinker content, it is no longer manufactured in the UK and is becoming more difficult to source. Consequently, greener sulphate-resisting composite cements will continue to grow in importance.

Applications of Type - CEM II

Application of Different Types of Cement

SRPC is used where precaution against moderate sulphate attack is important, as in drainage structures where sulphate concentrations in groundwater are higher than normal but not y ( ) unusually severe (Table).

Sulphate Resistant Porland Cement (SPRC)

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Application of Different Types of Cement

Rapid Hardening Portland Cements Rapid hardening versions of CEM I cements are available. The average particle size is smaller in these cements and they gain strength more quickly than do ordinary CEM I types. They generate more heat in the early stages and can be useful in cold weather concreting. However, their principal use is in manufacturing precast concrete units where the high early strength of the concrete permits quick re-use of moulds and formwork.

Rapid Hardening Portland Cements

Application of Different Types of Cement

White Cement

White Cement

White cement is a Portland cement CEM I made from specially selected raw materials, usually pure chalk and white clay (k li ) ll h lk d hi l (kaolin) containing very small quantities of iron oxides and manganese oxides. White cement is frequently chosen by architects for use in white, off-white or coloured concretes that will be exposed, inside or outside buildings, to the public's gaze.

Admixtures
Material which is added to concrete during mixing in order to modify particular properties of concrete
1. 2. 3. 4. 5. Accelerators (CaCl) NaCl, formate triethenolamine CaCl) NaCl, Retarders Gypsum, sugars, lignosulphates Air entrainers Wood resins/soaps, fats and oils Water reducers (plasticisers) Others eg Corrosion Inhibiting Admixtures

Summary
Portland cement, the major ingredient in concrete, is the most widely used building material in the world. In the presence of water, the chemical compounds within Portland cement hydrate causing hardening and strength gain. Portland cement can be specified based on its chemical composition and other various physical characteristics that affect its behavior. Tests to characterize Portland cement, such as fineness, soundness, setting time and strength are useful in quality control and specifications but should not be substituted for tests on PCC.

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