CIV2101/DCE2101 –
CONCRETE
TECHNOLOGY
CEMENT
Arc. B. Abdullahi
INTRODUCTION
A cement is a binder, a
substance used for construction Cement mixed with fine
that sets, hardens, and adheres aggregate produces mortar for
to other materials to bind them masonry, or with fine aggregate
together. and coarse aggregate, produces
concrete.
Cement is not often used on its Concrete is the most widely
own, but rather to bind fine used material in existence and is
behind only water as the planet's
aggregate (sand) and coarse most-consumed resource.
aggregate (gravel) together.
Cements used in construction are usually inorganic, often
lime or calcium silicate based, which can be characterized as
non-hydraulic or hydraulic respectively, depending on the
ability of the cement to set in the presence of water.
• Hydraulic cements
(e.g., Portland cement) set and
• Non-hydraulic cement
become adhesive due to a chemical
This does not set in
reaction between the dry ingredients
wet conditions or under
and water.
water. Rather, it sets as it The chemical reaction results in
dries and reacts with mineral hydrates that are not very water-
carbon dioxide in the soluble and so are quite durable in
air. It is resistant to attack water and safe from chemical attack.
This allows setting in wet
by chemicals after setting.
conditions or under water and further
protects the hardened material from
PORTLAND
CEMENT:
• This cement is made
calcination liberates a
by heating limestone
molecule of carbon dioxide
(calcium carbonate) from the calcium
with other materials carbonate to form calcium
(such as clay) to 1,450 oxide, or quicklime, which
°C (2,640 °F) in a then chemically combines
with the other materials in
KILN, in a process
the mix to form calcium
known as calcination.
• Portland cement is a basic ingredient of
concrete, mortar, and most non- specialty
grout.
• The most common use for Portland
cement is to make concrete. Concrete is a
composite material made of cement,
aggregate (gravel and sand), and water.
• Asa construction material, concrete can
be cast in almost any shape, and once it
hardens, can be a structural (load
bearing) element.
• Portland cement may be grey or white.
PORTLAND CEMENT BLEND:
Portland cement blends are often available as inter-
ground mixtures from cement producers, but similar
formulations are often also mixed from the ground
components at the concrete mixing plant.
• Portland blast-furnace slag
cement, or blast furnace cement:
• Portland-fly ash
cement:
Portland blast-furnace slag cement is
a type of cement that mostly contains
ground granulated blast furnace
• contains up to 40% fly
slag (up to 95%). The rest is
ash under ASTM
Portland clinker (the main standards (ASTM C595),
ingredient in regular cement) and a or 35% under EN
small amount of gypsum, which
helps control how fast the cement standards (EN 197–1).
hardens. The fly ash is pozzolanic.
Portland pozzolan cement
Includes fly ash cement, since fly ash is
a pozzolan, but also includes cements
made from other natural or artificial
pozzolans.
In countries where volcanic ashes are
available (e.g., Italy, Chile, Mexico, the
Philippines), these cements are often the
most common form in use.
The maximum replacement ratios are
generally defined as for Portland-fly ash
cement.
Portland silica fume cement.
Addition of silica fume can yield
exceptionally high strengths, and
cements containing 5–20% silica
fume are occasionally produced,
with 10% being the maximum
allowed addition under EN 197–1.
However, silica fume is more
usually added to Portland cement
at the concrete mixer.
Masonry cements
• are used for preparing brick laying mortars
and stuccos and MUST NOT be used in
concrete
• They are usually complex proprietary
formulations containing Portland clinker
and a number of other ingredients that
may include limestone, hydrated lime, air
entrainers, retarders, water proofers, and
colouring agents.
Expansive cements
• contain, in addition to Portland
clinker, expansive clinkers (usually
sulfo-aluminate clinkers), and are
designed to offset the effects of
drying shrinkage normally
encountered in hydraulic cements.
• Thiscement can make concrete for
floor slabs (up to 60 m square)
without contraction joints.
Coloured cements
White blended • serve decorative
purposes. Some
cements
standards allow the
• may be made using addition of pigments to
white clinker produce coloured
(containing little or Portland cement.
no iron) and white • Otherstandards (e.g.,
supplementary ASTM) do not allow
materials such as pigments in Portland
high-purity cement, and coloured
cements are sold as
metakaolin.
blended hydraulic
cements.
TYPES OF CEMENT (Other cements)
1. Ordinary Portland 7. Blast Furnace Slag
Cement (OPC) Cement
2. Portland Pozzolana 8. High Alumina Cement
Cement (PPC) 9. White Cement
3. Rapid Hardening Cement 10. Coloured cement
4. Quick setting cement 11. Air Entraining Cement
5. Low Heat Cement 12. Expansive cement
6. Sulphates resisting 13. Hydrographic cement
cement
1. Ordinary Portland Cement (OPC)
The principal raw materials used in the
manufacture of Ordinary Portland Cement are:
1. Argillaceous or silicates of alumina in the
form of clays and shales.
2. Calcareous or calcium carbonate, in the form
of limestone, chalk and marl which is a
mixture of clay and calcium carbonate.
The ingredients are mixed in the proportion of
about two parts of calcareous materials to one
part of argillaceous materials and then crushed
and ground in ball mills in a dry state or mixed in
wet state.
Ordinary Portland Cement (OPC)
The dry powder or the wet slurry is then
burnt in a rotary kiln at a temperature
between 1400 degree C to 1500-degree C.
The clinker obtained from the kiln is first
cooled and then passed on to ball mills
where gypsum is added and it is ground to
the requisite fineness according to the class
of product.
2. Portland Pozzolana Cement
(PPC):
• Portland Pozzolana cement is integrated cement
which is formed by synthesising (combining) OPC
cement with pozzolanic materials in a certain
proportion.
• It is commonly known as PPC cement.
3. Rapid Hardening Cement:
• Rapidhardening cement is a particular type of
cement that is used in exceptional cases of
concrete pouring.
• As the name implies, rapid hardening cement needs
the shortest time to set up and consolidate.
• It achieves higher strength on lesser days. With such,
it can attain seven days strength in only three days.
4. Quick setting cement:
• Quick Setting Cement (QSC) is a special cement
formulation that develops a rapid compressive
strength and significantly reduces the waiting on
cement (WOC) time compared to traditional
cement systems.
• This cement loses its plasticity quicker than
ordinary Portland cement, but does not achieve a
higher rate of strength.
5. Low Heat Cement:
• Lowheat cement is a special tailored
cement which generates low heat of
hydration during setting.
• Itis manufactured by modifying the
chemical composition of normal Portland
cement.
6. Sulphate resisting cement:
• The sulphate resisting cement is the
cement which has the capability to
resist against sulphate attack by
introducing low C3A and relatively low
C4AF content in the cement.
• Thespecification for sulphate cement
content should not allow C3A content
more than 5 percent.
7. Blast Furnace Slag Cement:
• Blast furnace slag cement is the mixture of
ordinary Portland cement and fine
granulated blast furnace slag obtained
as a by-product in the manufacture of steel
with percent under 70% to that of cement.
• Ground granulated blast furnace slag
cement (GGBFS) is a fine glassy granule
which contain cementitious properties.
8. High Alumina Cement:
• High alumina cement refers to a fast-
hardening, high-strength, heat-
resistant and corrosion-resistant
cementitious material.
• All clinker based on calcium aluminate
and alumina content of about 50% and
ground hydraulic cementitious material
are called high alumina cement.
9. White Cement:
• The manufacturing process of white
cement is same as that of grey cement,
but the selection of raw material is an
important part in the manufacturing
process.
• The oxides of chromium, manganese,
iron, copper, vanadium, nickel and
titanium imparts the grey colour to the
cement.
10. Coloured cement:
• Coloured Cement may be obtained by
intimately mixing mineral pigments
with ordinary cement.
• Theamount of colouring material may
vary from 5 to 10 per cent.
• If this percentage exceeds 10 per cent,
the strength of cement is affected.
10. Coloured cement:
1. The chromium oxide gives green
colour.
2. The cobalt imparts blue colour.
3. The ton oxide in different proportions
gives brown, red or yellow colour
4. The manganese oxide is used to
produce black brown coloured cement
11. Air Entraining Cement:
• Air-entrained Portland cement is a
special cement which has air bubbles
introduced in the cement or concrete
that provides the space for expansion
of minute droplets of waters in the
concrete due to freezing and thawing
and protects from cracks and damage
of concrete.
Advantages of Air-Entrained
Cement
i. Workability of concrete increases.
ii. Use of air entraining agent reduces the
effect of freezing and thawing.
iii.Bleeding, segregation and laitance in
concrete reduces.
iv.Entrained air improves the sulphate
resisting capacity of concrete.
v. Reduces the possibility of shrinkage and
crack formation in the concrete surface.
12. Expansive cement:
• Expansive cement is special type of cement
when mixed with water, which forms a
paste that tends to increase in volume to a
significantly greater degree than Portland
cement paste after setting.
• The expansion of the cement mortar or
concrete is compensated for the shrinkage
losses.
CHEMICAL PROPERTIES OF PORTLAND
CEMENT
PHYSICAL PROPERTIES OF ORDINARY
PORTLAND CEMENT
BOGUES COMPOUNDS:
When water is added to cement, it react with the ingredients
of the cement chemically and results in the formation of
complex chemical compounds terms as BOGUES
compounds
• TriCalcium Aluminate (3CaO.Al2O3 or C3A) ------- 8-
12%
• Tetra Calcium Alumino Ferrate (4CaO.Al 2O3.Fe2O3 or
C4AF)- 6-10%
• Tri-Calcium Silicate (3CaO.SiO2 or C3S)---------------------
30-50%
• Di-Calcium Silicate (2CaO.SiO2 or C2S)----------------------
20-45%
HYDRATION
• When cement, OF CEMENT
water, aggregate, and additives
are mixed together, a significant heat increase
occurs.
• This is due to the exothermic process in the
reaction between cement and water (called
hydration).
• Measuring the concrete temperature over time
enables you to know how far the concrete is in
the hydration process (Concrete Maturity) and
thereby also an estimated concrete strength.
• The hydration process is divided into five
phases:
Phase 1: Initial Mixing Reaction
Initial after mixing the cement and
water comes into contact with each
other, a peak in temperature
happens.
The aluminate (C3A) reacts with H2O
(Calcium and sulfate ions) to form
ettringite (aluminate hydrate).
The release of the energy from
these reactions causes the initial
Phase 2: Dormancy
A result of the reaction described in
phase 1 is a surface coating of the
cement particles.
This coating keeps increasing, but
also slows down the reaction
(hydration) as the access to H2O
isn’t as good as when the concrete
was mixed.
The amount of hydrated concrete
keeps increasing on a steady level
Phase 3: Strength Acceleration
A heat increase happens due to the
reaction between calcium silicate
(C3S and C2S) which creates the
silicate hydrate CSH (heat increase
also caused by other minor
reactions).
The creation of CSH also has a major
impact on the concrete strength
Phase 4: Speed reduction
A maximum temperature has now been
reached and the availability of free
particles is now reduced and therefore
slows down the temperature increase.
This phase often ends with the desired
strength and the formwork around the
concrete can now be removed.
Monitoring of concrete maturity and
temperature and therefore enable the user
Phase 5: Steady Development / Post
Formwork
The hydration process is now slowed down
and will continue slowly to finish the
remaining available cement and water
particles.
The formwork is now often removed and
the concrete will now over time (can take a
long time) finish the hydration process and
Testing of cements:
1. Laboratory Tests of Cement
Fineness Test Soundness Test
Consistency Test Heat of Hydration Test
Setting Time Test Tensile Strength Test
Strength Test Chemical Composition
Test
Testing of cements:
1. Laboratory Tests of Cement
Fineness Test Soundness Test
Consistency Test Heat of Hydration Test
Setting Time Test Tensile Strength Test
Strength Test Chemical Composition
Test
2. Physical Tests of Cement
Colour Test
Presence of Lumps Date of Manufacturing
Cement AdulterationFloat Test
Test
