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Cement is a hydraulic binder, i.e., an inorganic, non-metallic, finely ground substance which, after
mixing with water, sets and hardens independently as a result of chemical reactions with the mixing
water and, after hardening, it remains its strength and stability even under water. The most
important area of application is therefore the production of mortar and concrete, i.e., the bonding
of natural or artificial aggregates to form a strong building material which is durable in the face of
normal environmental effects.
Portland cement is the name given to a cement 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. Nevertheless, cement can be considered
as being in frozen equilibrium, i.e., the cooled products are assumed to reproduce the equilibrium
existing at the clinkering temperature.
Major Compounds in Cement: In all the Portland Cements, there are four major compounds. The
variation in percentage composition of compounds influences the properties of cement. These
compounds are given in table 1.1 below:
Table 1.1
Composition of cement
SN
1
2
Name of
compound
Tricalcium
Silicate
Dicalcium
Silicate
Oxide
composition
Abbreviati
on
Approx
Percentage
3CaO.SiO2
C3 S
45-55%
2CaO.SiO2
C2 S
20-30%
Tricalcium
Aluminate
3CaO.AI2O3
C3 A
6-10%
Tetracalcium
Aluminoferrite
4CaO.AI2O3
Fe2O3
C4AF
15-20%
Function
Mainly responsible for
early & later strength
Mainly responsible for later
strength (7 days and beyond)
C3A increases rate of
hydration of C3S. C3A gives
flash set in absence of
gypsum
It hydrates rapidly but its
contribution to strength is
uncertain and generally very
low.
These main phases are present in the clinker and in the non-hydrated Portland cement.
They are formed at high temperature (1450 C) in the cement kiln. Compounds referred as C3S, C2S,
C3A and C4AF are known as the main crystalline phases of Portland cement. The phase composition
of a particular cement can be quantified through a complex set of calculation known as the Bogue
Formula.
CCN
CH
C-S-H
C-A-H
AFt
AFm
C3AH6
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 uses
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.
It is necessary to use cement of appropriate grade and type for specific applications
and environment conditions. Various type of cement produced in India are shown in
table 1.1.
Table 1.1
Various type of cement under IS codes.
Sl.No.
1
2
3
Cement Variety
As per code
Gd-33 IS : 269-1989
Gd-43 IS : 8112-1989
Gd-53 IS : 12269-1987
PPC(Portland Pozzolana
Cement)
PBFSC (Portland Blast Furnace
Slag Cement)
Others Rapid Hardening Cement
Low Heat Cement
Sulphate Resisting Cement
Super sulphated Cement
IS : 1489-1991
IS : 455-1989
IS : 8041-1990
IS :12600-1989
IS :12330-1988
IS : 6909-1990
1.2 The physical and chemical characteristics of various cements are given in Table 1.3 & 1.4
Table 1.3
Physical characteristics of various types of cement
Sr.
No.
1
2
3
9
10
11
12
Type of
Cement
33 grade OPC
(IS 2691989)
43 grade OPC
(IS 8112
1989)
53 grade OPC
(IS 12269
1987)
Sulphate
Resisting
Cement. SRC
(IS 12330
1988)
Portland
Pozzolana
Cement. PPC
(IS 1489
1991) Part-I
Rapid
Hardening
Cement. PPC
(IS 8041
1990)
Portland Slag
Cement. PSC
(IS 4551989)
Super
Sulphated
Cement. (IS
69091990)
Low Heat
Cement. (IS
126001989)
Masonry
Cement. (IS
34661988)
43-S grade
OPC (IS 8112
1989)
53-S grade
OPC (IS
122691987)
Finene
ss
(m2 /
Kg)
Min
Soundness
Setting Time
(minutes)
Initial
Final
(min)
(max)
Le- Chat
(max)
(mm)
Autoclave
(max) (%)
225
10
0.8
30
225
10
0.8
225
10
225
3D
(min)
7D
(min)
28 D
(min)
600
NS
16
22
33
30
600
NS
23
33
Min-43
Max-58
0.8
30
600
NS
27
37
53
10
0.8
30
600
NS
10
16
33
300
10
0.8
30
600
NS
16
22
33
325
10
0.8
30
600
16
27
NS
NS
225
10
0.8
30
600
NS
16
22
33
400
NS
30
600
NS
15
22
30
320
10
0.8
60
600
NS
10
16
35
10
1.0
90
1440
NS
NS
2.5
5.0
370
10
0.8
60
600
NS
NS
37.5
NS
370
10
0.8
60
600
NS
NS
37.5
NS
NS-Not specified.
*residue on 45 Micron IS sieve, Max, Percent (by wet sieving) is 15.
4
Table 1.4
Chemical characteristics of various types of cement
Sr.
No.
1
2
3
10
11
Type of
Cement
33 grade OPC
(IS 2691989)
43 grade OPC
(IS 8112
1989)
53 grade OPC
(IS 12269
1987)
Sulphate
Resisting
Cement. SRC
(IS 12330
1988)
Portland
Pozzolana
Cement. PPC
(IS 1489
1991) Part-I
Rapid
Hardening
Cement. PPC
(IS 8041
1990)
Portland Slag
Cement. PSC
(IS 4551989)
Super
Sulphated
Cement. (IS
69091990)
Low Heat
Cement. (IS
126001989)
43-S grade
OPC (IS 8112
1989)
53-S grade
OPC (IS
122691987)
Lime
Saturation
Factor (%)
0.66 Min.
1.02 Max.
Alumina Iron
Ratio (%)
Min.
Insoluble
Residue
(%) Max.
Magnesia
(%) Max.
Sulphuric
Anhydride
(%) Max.
Loss on Ignition
(%) Max.
0.66
4.0
6.0
3.5
5.0
0.66 Min.
1.02 Max.
0.66
4.0
6.0
3.5
5.0
0.80 Min.
1.02 Max.
0.66
4.0
6.0
3.5
4.0
0.66 Min.
1.02 Max.
NS
4.0
6.0
2.5
5.0
NS
NS
X+4 (100X)/100
6.0
3.0
5.0
5.0
0.66 Min.
1.02 Max.
0.66
4.0
6.0
2.5 % Max.
When C3A is
5.0 or less.
3.0% Max.
When C3A is
greater than
5.0
NS
NS
4.0
8.0
3.0% Max.
5.0
NS
NS
4.0
10.0
6.0% Min.
NS
NS
NS
0.66
4.0
6.0
2.5 % Max.
When C3A is
5.0 or less.
3.0% Max.
When C3A is
greater than
5.0
0.66 Min.
1.02 Max.
0.66
4.0
5.0
3.5
0.80 Min.
1.02 Max.
0.66
4.0
5.0
3.5
NS - Not specified.
5
1.5 Factors affecting choice of cement: Following factors govern choice of cement.
Durability Characteristics
Functional requirement - Deflection, crack width etc.
Design parameters- Strength, fineness, setting time requirement etc.
Speed of construction- Time for construction etc.
Environmental Conditions- Ground conditions, soluble salts, sulphates, Chemical plants etc.
Class
> 0.2
0.2 0.5
1.0-1.9
0.3-1.2
0.5 1.0
1.9-3.1
1.2 2.5
1.0 2.0
3.1-5.0
2.5 5.0
>2.0
>5.0
>5.0
Type of cement
OPC, PSC or PPC
OPC, PSC or PPC
SSC or SRC
SSC or SRC
PSC or PPC
SSC or SRC
SRC or SSC with protective
coating
Foundations, piles
Basement and underground structures
Sewage and water treatment plants
Chemical factories
Suitable for underground works where Sulphate is present in the Soil and water.
Attention:
i)
ii)
Sulphate resisting cement is not suitable where there is danger of chloride attack.
This will cause corrosion of rebar.
If both Chlorides and Sulphates are present, Ordinary Portland Cement with C3A
between 5& 8 should be used.
Pozzolana
Slag
Moderate
C3A <8%
No special
prescription
Slag > 36%
C3A < 2%
G. 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.
H. 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.
8
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.
I. Special grade cement (43-S and 53-S): Special Grade Cement is manufactured as per
specification laid down by BIS IS 8112 & 12269. It is a very finely ground cement with high
C3S content designed to develop high early strength required for manufacture of concrete
sleeper for Indian Railways. This cement can also be used with advantage for other
applications where high strength concrete is required. This cement can be used for
prestressed concrete elements, high rise buildings, high strength concrete etc.
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