1.

INTRODUCTION

The history of Cementing material is as old as the history of engineering

construction, some kind of Cementing materials were used by Egyptians, Romans and
Indians in their ancient construction. It is believed that the early Egyptians mostly used
Cementing materials, obtained by burning gypsum. In the general sense, Cement can be
described as materials with adhesive and cohesive properties, which makes it capable of
binding mineral fragments into a compact mass.

It’s remarkable property of strength development, ease of handing, bond with

reinforcement, mouldability and relative impervious ness has made it as favorite
construction material .The general materials in Cement are Calcareous materials, such
as, Limestone or chalk and Agrillaceous material such as shale or clay an hydrous
Cement compounds when mixed water, reacts with each other to from hydrated
compounds of very low solubility .The reaction of Cement with water is exothermic. The
hydration of Cement can be visualized in two ways. The first is “ Through solution” and
second is “solid state “ and both of this may occur during the course of reactions between
Cement and water.

The Cement also having some other properties, which govern the process of gaining
strength. According to the properties Cement can be classified as –

1. Ordinary Portland Cement.

2. Other special purpose Cement.

But today after using OPC, it has shown some dissatisfactory results. It gets
attacked by weathering agencies. It is also having property of Leaching which is quiet
disappointing. This has lead to discover advance and good quality Cement material,
which is having higher resistance to weathering agencies, low leaching, sulphate
resistance, Low heat of hydration etc. which is came to known as composite Cement.
As the name suggests, it has been added some special kind of additives which leas
to better performance of Cement.
The Associated Cement Companies has been introduced the most successful
composite Cement in the market knowing by “ACC Suraksha a Cement “
The ACC Suraksha Cement is having greater resistance to weathering, leaching,
chemical attacks, and Low heat of hydration with higher work ability at Low w/c ratio,
and has shown excellent strength results. All of these qualities are very difficult to be
found in one Cement without any kind admixture to it. That’s why the “ACC Suraksha
Cement” is welcomed in the market greatly.

1
 2. CEMENT

1) History of Cement Material: -

The use of Cement material dates back to several thousand years .The Egyptian
pyramids were built using calcined impure Gypsum as a bonding material between huge
blocks of stone. The Greeks and the Romans extensively used calcined Limestone.
Historical structure like the Roman Pantheon, the Coliseum were built using these
Cementing material .The Romans used volcanic [Pozzolanic] deposits which were finely
ground and blended with Lime and sand to yield Cementing material. This mortar not
able to resist the action of water and weathering effects to a remarkable degree.

2) Development of Portland Cement:-

It was in the 18th century that the most important advances in the development of
Cement were made which finally led to the invention of Portland Cement .In 1756 John
Smeaton showed that Hydraulic Lime (which can resist the action of water) can be
obtained not only from pure hard Limestone but also from a Lime stone which contained
substantial proportion of clay .In 1796,Joseph Parker found that modulus of Argillaceous
Lime stone made an excellent hydraulic Cement when burned and reduced to a powder in
the usual manner. It appears that Joseph Aspdin an English Bricklayer in 1824 took out a
patent which he called ‘Portland Cement’ as he fancied that it had resemblance in its
colour, after setting to Portland stone. Though his patent made no mention .

3) What is Cement?
The general defination of Cement is that it is finely ground material which on addition of
requisite quantity of water is capable of hardening both under water and in air by the
chemical interaction of its constituents with water and is also capable of bonding together
appropriate materials.
Portland Cement is the Cement obtained by grinding Portland clinker with the possible
addition and a small quantity of gypsum, water or both, and not more than 1%of air
entraining agents or other agents which have proved not to be harmful.
Additives:- In the manufacture of Port land Cement any material ,other than water or
gypsum, or both ,which is inter ground than with the clinker, in an amount not to exceed
1% .

CHEMICAL COMPOSITION

The raw materials used for the manufacture of Cement consist mainly of Lime,
Silica, Alumina And Iron oxide. These oxides interact with one another in the kiln to form
more complex compounds. The relative proportions of influencing the various properties
of Cement; in addition to rate of cooling and fineness of grinding. Table 1 shows the
approximate oxide composition limits of ordinary Portland Cement.

2
 Table - 1
Approximate Oxide Composition Limits of Ordinary Portland Cement
______________________________________________________________________
Oxide Percent, Content
CaO 60-67
SIO2 17-25
AI2O3 3.0-6.0
Fe2O2 0.5-6.0
MgO 0.1-4.0
Aikalies (K2O9 Na2O) 0.4-1.3
SO3 1.0-3.0

Indian standard specification 269:1976 specifies the following chemical requirements:

(a) Ratio of percentage of Lime to percentage of Silica, Alumina And Iron oxide; When
calculated by the formula-
CaO-0.7 SO3 _ Not greater than
1.02 and not less
2.8 SIO2+1.2AL2O3+0.65Fe2O3 than 0.66

(b) Ratio of percentage of

Alumina to that of iron oxide
(c) Weight of insoluble residue
(d) Weight of magnesia
(e) Total sulphur content, calculated
as sulphuric anhydride (SO3)
(f) Total loss on ignition
– Not less than 0.66
– Not more than 2 percent
– Not more than 6 percent
– Not more than 2.75 percent
– Not more than 5 percent

The identification of the major compounds is largely based on R.H. Bogue’s

work and hence it is called “Bogue’s Compounds”. The four compounds usually
regarded as major compounds are listed in table 2
Table 2
Bogue’s Compounds

Name of compound Formula Abbreviated Formula

Tricalcium Silicate 3CaO.SiO2 C3S

Dicalcium Silicate 2CaO.SiO2 C2S
Tricalcium Aluminate 3CaO. Al2O3 C3A
Tetracalcium Aluminoferrite 4CaO.Al2O3.Fe2O3 C4AF

In addition to the four major compounds, there are many minor compounds formed in the
kiln. Two of the minor compounds namely K2O and Na2O referred to as alkalis in Cement
are of some importance.70-80% of Tricalcium silicate and dicalcium silicate in Cement
are the most important compounds responsible for strength. The average C3S content in
modern Cement is about 45 percent and that of C2S is about 25 percent. The sum of the

3
 contents of C3A and C4AF has decreased slightly in modern Cements. An increase in
Lime content beyond a certain value makes it difficult to combine with other
compounds and free Lime will exist in the clinker which causes unsoundness in Cement.
An increase in silica content at the expense of the content of alumina and ferric oxide will
make the Cement difficult to fuse and form clinker.

1) CALCIUM SILICATE HYDRATES - During the course of reaction of C3S or C2S

with water, calcium silicate hydrate and calcium hydroxide are formed. C3S and C2S
results in the formation of the same hydrated compound. It can be seen that C3S produces
a comparatively lesser quantity of calcium silicate hydrates and more quantity of Ca
(OH)2 than that formed in the hydration of C2S Ca(OH)2 is not a desirable product in the
concrete mass, it is soluble in water and gets leached out making the concrete porous,
particularly in hydraulic structures. Under such conditions it is useful to use Cement with
higher percentage of C2S content. C3S readily reacts with water and produces more heat
of hydration. It is responsible for early strength of concrete.
C2S hydrates rather slowly. It is responsible for the later strength of concrete. It
produces less heat of hydration. The calcium silicate hydrate formed is rather dense and
its specific surface is higher.

2) CALCIUM ALUMINATE HYDRATES - The hydration of Aluminates does not

contribute anything to the strength of paste. On the other hand, their presence is harmful
to the durability of concrete particularly where the concrete is likely to be attacked by
sulphates. As it hydrates very fast it may contribute a little to the early strength.

WATER REQUIREMENTS FOR CEMENT

It has been brought out earlier that of C3S requires 24% of water by weight of
Cement and C3S requires 21%. Therefore a total 38 percent of water by weight of
Cement is required for the complete chemical reactions and to occupy the space within
gel-pores.
As per the IS

PHYSICAL REQUIREMENTS OF CEMENT

1) Fineness :- By Blains air permeability method as describes in .IS 4031 –1968,the Cement
shall comply with the following requirements.
Cement type Sp. surface cm2/g
Ordinary Not less than 2250
Low Heat Not less than 3200
2) Soundness:- When tested by the ‘Le Chatelier method described in IS 4031 –1968
,unaerated Ordinary and low heat port land Cements shall not have an expansion of
more than 10 mm.

3) Setting Time:- The setting time of the Cement ,when tested by the Vicat apparatus
method described in the Is 4031 –1968 shall confirm to the follow requirement

4
 a) Initial setting time Ordinary Low Heat
(Minutes) not less than 30 60
b) Final setting time
(Minutes) not more than 600 600
4) Compressive Strength:-
The average compressive strength of at least 3 mortar cubes (face area 50 cm2)having the
proportion 1:3 [confirming to 650-1966]by mass and p/4 +3.0% (of Cement and sand
mix) water and prepared ,stored. and tested in the manner described in Is 4031 –1968
shall be as:
Ordinary Low Heat
2
(Kgf/cm ) (Kgf/cm2)
a) 72+ 1h not less than 160 100
b) 168 h not less than 220 160
c) 672 I 4h not less than - 350

5) Heat of Hydration:-
This requirement shall apply only to low heat Cement .When tested by the method
described in Is 4031-1968,the heat of hydration of low heat port land Cement shall be as
follow.
a) 7 Days not more than 65 cal/g.
b) 28 days not more than 75 cal/g.
It is seen from testing and practical used ordinary Cement this chemical and physical
properties of Cement can not resist the weathering action, sulphate attack, ,corrosion of
reinforcement ,leaching of mortar or concrete, Alkali –Aggregate reaction , Sulphate
reaction ,sulphate resistance etc .so the remedy for this in cure is necessary ,and that the
way the concept of fly Ash as a construction material is outputted.

6) Slump Test :-
Is the most commonly used method of measuring consistency of concrete. It is not
suitable method for very wet or very dry concrete.

Degree of Slump mm Use for

workability

Very low 0-25 Roads power vibrator.

Low 25-50 Roads Hand operated vibrator

Medium 50 –100 Slab, beam, column i.e. heavily reinforce s/c.

High 100 – 175 For s/c with congested reinforce

5
 3. FLY ASH AS A PART OF CEMENT

After Aluminum and steel, the manufacture of Portland Cement is the most energy
intensive process. Now the Cement industry has made major strides introducing the
energy consumption, by replacing wet production facilities with new modern dry
processing plants. The loss in capacity due to this change can be met by the use of “Fly
Ash”. At present Enormous energy is required to burn such huge amount of material at a
high temperature of 1450 *c to form the Cement clinker ,which releases @ 1 tone of
carbon dioxide (CO2) in the atmosphere.
Fly ash is a finely divided residue resulting from combustion of pulverized
bituminous coal or sub-bituminous in thermal power plant. It generally consists of
inorganic mineral constituents of coal. It is generally Gray in colour, refractory in nature,
has a fineness of 2500 to 6000 Sq.cm/g and possesses Pozzolanic characteristics, particle
range in size from as much as 150 to less than 1 micron in equivalent diameter.
It has been proven that when fly ash is added to Cement, it improves its strength and
durability. For efficient utilization of fly ash; mix designs for concrete must be developed.

A. The Advantages of using fly Ash in Cement

1) Conversion of 75% production of OPC to PPC can
 Use25 MT fly Ash/year.
 Make available additional 25 MT Cement/year with the marginal lead time and
investment.
 Reduction in Cement cost by 10-15%
 Annual saving @ Rs 2000 Crores
 Conservation of mineral resources as Lime is finite.

2) Technical
 High long term strength
 Better workability
 Higher impermeability
 Less heat of hydration
 Corrosion resistance
 High resistance to aggressive environment.
 More durability

3)Environmental and Economic

 110 MT Cement production/year.
 consumes 180 MT of Lime
 consumes 65 MT of coal
 produces 110 MT of CO2

B) Quality Considerations
Quality requirements of fly ash in India, for use in Cement and concrete, are
governed by the provision of IS 3812 (I). As per is 3812(I0 fly ash shall be supplied in
the following grades corresponding to the chemical and physical properties

6
 Grade designation General use
Grade I For incorporation in Cement mortar and concrete
and in Lime Pozzolana mixture and for manufacture
of Portland Pozzolana Cement(PPC)
Grade II For incorporation in Cement mortar and concrete
and in Lime Pozzolana mixture.

Note: Fly Ash of Grade II also may be used for manufacture IS 1489 (I) 1991 (PPC
specification fly ash based)
Fly ash, when tested in accordance with the methods of test specified in IS 1727- 1967
shall confirm to the chemical / physical requirements given in table 3.
Table 3
Specifications for Fly Ash in Cement and concrete

Item ASTM IS 3812 Part 1

C-618 1981 2003
Chemical properties
SiO2, mininum - 35 35
Reactive SiO2 minimum - - 20
SiO2 + Al2O3+Fi2O3min 70 70 70
MgO, max. - 5 5
LOI max.. 6 12 5
Total alkalis, max. 1.5 1.5 1.5
SO3 max. 5 2.75 3.0
Free CaO3 max. - - -
Reactive CaO3 max. - - -

Physical Properties
(1) (2)
Fineness 45 micron max 34 - - 34
Blaine’s fineness, m2/kg mini - 320 250 320
Cement activity 28 day 75 80 - 80
Lime reactivity N/mm2 - 4 3.0 4.5
Soundness - - - 10

As per the IS 3812, the fly ash may be extracted from flue gases of ground or pulverized
coal or lignite fired boilers. In order to have reactive fly ash, it should be collected in dry
form, as pond ash disposed in wet slurry form, loses the reactive fine particles. Dry fly
ash is collected in hoppers of ESP or bag house (BH) filters.

C) Processing of fly ash during Cement manufacture

As per IS 1489 (I) Portland Pozzolana Cement shall be manufactured either by
intimately the intergrinding Portland Cement clinker and Fly Ash or by intimately and
uniformly blending Portland Cement and fine fly ash

7
 Gypsum (natural or chemical) may be added if PPC made by intergrinding Portland
Cement clinker with fly ash makes the PPC. The fly ash constituent shall not be less than
10-15%and not more than 25-35% by mass of PPC. The homogeneity of the mixture
shall be guaranteed within +_ 3% in the same consignment. Intergrinding during
manufacture of PPC, the particles a of fly ash become finer. Use of fly Ash in the Cement
plant through the blended Cement route has the following advantages.

1) It ensures through and uniform bending with the Cement.

2) When the does of Fly Ash addition has been fixed from durability considerations like

resistance to alkali-silica reaction (ASR) , sulphate resistance or resistance to corrosion

of reinforcement etc, blended PPC with the desired proportion of fly Ash is helpful for
quality control in construction.

3) It reduces the need to procure and store another extra ingredient of concrete at the
construction site.
4) By finer grinding of the blend, early strength can be achieved, almost at par with OPC
systems.
5) In inter-grinding process of manufacture of PPC, fly ash gets processed. Its fineness
and particle sizes are controlled within narrow tolerances, along with that of the blended
Cement.

On the other hand, direct addition of fly ash in the concrete mixer offers the following
advantages.

1) It gives the flexibility to alter the relative proportions of Cement and fly ash. It is
therefore, preferable in large projects and in RMC (Ready Mixed Concrete) plants.
2) If affords a chance to check the quality of fly ash at any stage. The proportion of fly
ash added can also be known accurately.
3) During inter-grinding process, the particles of fly ash get fragmented. In case of site
mixing, the particles remain, more or less, intact and contribute to improve the
workability of concrete.
4) Heat of hydration of concrete is reduced by the addition of fly ash.

D) Proportion of Fly Ash used

As per IS 456- 2000 does not restrict the proportion of fly ash in concrete to any
present level. The proportion of fly Ash, currently being used in structural concrete in
India varies from 15 to 50%. It depends upon the type of construction and characteristics
of concrete.
1) Fly Ash used in 15 to 25% - 1) Factory produced PPC (Portland Pozzolana Cement).
2) When concrete is to be pumped.
3) With higher grades of concrete in RMC.
2) Fly Ash used in 25 to 40% - A)for durability consideration.
1) To reduce heat of hydration
2) Alkali-silica reactivity.
3)For underground construction.

8
 4)Concrete for lining.
B) For self compacting concrete to road.
C) For pavement quality concrete.
3) Fly Ash used in 50 to more % 1) High volume fly Ash concrete for road.
2) Roller compacted concrete for dam.

E) Engineering Properties of concrete with Fly Ash.

Table 4 relates to M20 concrete designed with 30 percent fly ash and reducing Cement
content from 336 kg to 267 kg/m3. The data show that concrete with fly ash as a part
replacement of OPC had physical properties superior to those with OPC, with
comparison being made on concrete of comparable strength grade.

Physical properties of concrete with and without fly ash:

Table 4

Sr.No. Properties After water curing, days

7 28 365
1. Compressive strength, N/mm2
control 21.8 27.5 40.0
with fly ash 21.2 28.0 53.5
2. Flexural strength, N/mm2
control 2.5 3.9 4.9
with fly ash 3.1 4.4 7.4
3. water permeability, 10-12 m/s
control – 8.9 -
with fly ash – 3.8 -

Table 5

Comparison of physical properties of OPC and PPC in concrete :

Sr. No. Properties of concrete OPC mix {OPC + Fly Ash mix}

1. Workability, slump, mm 60 70
2. Compressive strength, Mpa
7 – days 20 23.6
28 – days 30.1 35.1
56 – days 34.6 42.2
3. Water permeability at 28
days, m/s x 10-12 8.7 6.6

Table 5 highlights details of concrete used in a multistoried residential complex, in which

OPC concrete (345 kg/m3 of Cement) and fly ash concrete (275 kg OPC +160 kg fly ash
per m3) are compared.
The data in Tables 4 and 5 show that concrete with fly ash as part replacement of OPC
had physical properties superior to those with OPC, where the concrete is of comparable

9
strength grade. In particular, the increase in flexural strength, as a proportion of
compressive strength due to addition of sly ash is noteworthy.

F) Durability
Durability advantage due to use of fly Ash are given in below. Doubts about
effects of Pozzolana like fly ash on durability of concrete had initially inhibited their full
use in structural concrete.
Corrosion of reinforcement, sulphate attack and alkali silica reaction (ASR) in concrete
are the major issues of durability. Use of fly ash is known to be beneficial in all such
cases.

1) Corrosion of reinforcement

Beneficial effects of supplementary Cementing materials like Fly Ash, Slag and Silica
Fume on reducing the incidence of corrosion of reinforcement in concrete are due to the
following factors. –
a) Denser microstructure.
b) Modification of the pore structure of the Cement paste.
c) Increased impermeability of concrete.
d) Lower electrical conductivity of concrete.
e) Increase chloride binding.
f) pH value of the pore solution is maintained.

2) Alkali-Silica reaction (ASR)

CSH formed due to reaction of fly ash has a lower C / S ratio than the hydration
of OPC and can accommodate more alkalis in solid solution. The amount of fly ash added
has to be high – generally greater than 20 – 25 percent. At lower dosages, the alkalis in
fly ash, which are generally greater in percentage than in OPC, can augment the pore
solution alkali and no benefit results.

3) Sulphate resistance

Concrete structures exposed to seawater or sulphate – bearing soils, sub-soils and

ground waters may suffer deterioration during their service –life due to ‘sulphate attack’.
The sulphate ions can react with calcium hydroxide and alumina-bearing phases of
hydrated Cement. This leads to formation of expansive salts like calcium-sulpho-
aluminate hydrate and calcium sulphate (Gypsum). These result in expansion, sapling,
cracking and loss of strength of concrete.

C3A content in sulphate – resistant Portland Cement (SRPC) is required to be less than 5
percent and (2C3A + C4Af) less than 25 percent. The resistance to sulphate attack is
enhanced by the presence of fly ash or slag. In particular, low-Lime fly ash – as are
majority of fly ashes in India – are known to be compositionally better suited to enhance
sulphate resistance. The following mechanisms are involved.

10
a) Reduced C3A content
b) Reduction is calcium hydroxide in the system
c) Pore structure modification

Slagcem ent 10%

Others 1%
OPC 45%
PPC 44%

Production of different varieties of Cement in India, 2003 - 04.

11
 4. A.C.C. SURAKSHA CEMENT

1) What is A.C.C Suraksha?

ACC suraksha is the brand name for a new specially blended Cement, produced by
intergrinding higher strength ordinary Portland Cement clinker with high quality
processed reactive silica – based on norms set by ACC’s own R and D division. This
makes ACC Suraksha a ‘value-added product’ with long-standing hydraulic binding
properties – not found in ordinary Cements. Which means constructions that will last for
generations and generations when you build with ACC Suraksha.

 What is the difference between ACC Suraksha and OPC?

While OPC is manufactured simply by intergrading Portland Cement clinker with a
certain percentage of gypsum, ACC suraksha is made by intergrading higher strength
clinker with specially processed reactive silica. This reactive silica has very good
characteristics. Which gives a greater degree of fineness to ACC suraksha Cement,
improved workability properties while mixing, and making concrete more corrosion
resistant and impermeable.
Because the reactive silica is extremely fine, the intergrading is crucial and is done in a
sophisticated mill system which incorporates a high efficiency separator. Each particle of
reactive silica becomes reactive during grinding, and the ultimate Cement has a better
particle size distribution. All of this makes for better long term strength and improved
corrosion resistance and therefore, greater life for your constructions.

2) Compared with OPC does ACC suraksha offer any advantages?

In concrete made from ordinary Cements, moisture reacts with calcium hydroxide in
concrete to from calcium bicarbonate, which leaches out of the concrete leaving behind
voids (pores) which reduce the strength of concrete.

ACC suraksha has ingredients, which react with calcium hydroxide to form CSH gel to
give additional strength making the concrete grow in strength over the years.

12
The Indian Standard IS 1489 (part I) 1991 issued by BIS in its foreword states, “PPC
produces less heat of hydration and offers greater resistance to the attack of aggressive
waters than normal Portland Cement. Moreover, it reduces the leaching of calcium
hydroxide liberated during the setting and hydration of Cement.”

3) Can ACC Suraksha be used for all jobs in construction wherever OPC is
normally used?
Yes. No matter the type of construction activity – commercial/residential;
bungalows/complexes; foundation/columns/beams/slabs/RCC jobs – ACC Suraksha
easily replaces OPC and gives additional advantages and safeguards as noted earlier. This
is especially true in mass concreting work and where soil conditions and prevailing
environment take heavy toll of construction made with ordinary Cements.

Is ACC Suraksha stand up to corrosive environments?

ACC Suraksha’s extremely good characteristics produce corrosion resistant concrete.
This means it is far more impermeable than concrete made with OPC. All of this means
greater protection to steel.

4) Applications of ACC Suraksha.

 All constructions including plain and reinforced work.
 All marine concrete structures such as docks, harbors, jetties.
 Bridge piers.
 Industrial plants.
 Large foundation work.
 Mass constructions.

5) Is ACC Suraksha compatible with admixtures?

Yes, ACC Suraksha is compatible with chemical admixtures. For the same dosage,
workability and slump retention is better with ACC Suraksha.

6) Can ACC Suraksha be used in concrete pavements?

The static modulus of elasticity and modulus of rupture of pavement grade concrete made
with ACC Suraksha are similar to OPC concrete. In addition ACC Suraksha concrete is
more durable. ACC Suraksha concrete can be used in pavements with the same designs as
for OPC concrete.

7) Characteristics of ACC Suraksha Cement :

1. Reduction in heat during hydration and hence reduction in thermal expansion and
cracking.
2. Increased long term strength.
3. Improved resistance to sulphate attack.
4. Retention of water, freedom from segregation and less bleeding.
5. Reduction in permeability due to pore refinement and better interface
with.aggregates

13
 6. Improved resistance to corrosion of re-bars.
7. Improvement in workability.
8. Improved resistance to chloride attack
9. Alkali – aggregate reaction is inhibited.

8) Physical and Chemical properties of ACC Suraksha Cement

Test Parameters OPC ACC-Suraksha

Specific Surface ( m2/Kg) 233 396

Standard consistency (%) 25.3 26.5
Setting time (min)
Initial 140 165
Final 240 230
Soundness
Autoclave Expansion (%) 0.04 0.004
Le Chatelier Expansion (cm) 1.0 0.005
Compressive Strength (Mpa)
1 day 26.5 23.5
3 day 38.5 29.5
7 day 47.5 39.5
28 day 54.5 58.5
Chemical Constituents (%)
Lime (CaO) 63.4 53.0
Silica (SiO2) 22.2 32.2
Alumina (Al2O3) 4.7 4.9
Iron oxide(Fe2O3) 3.9 3.3
Magnesia (MgO) 1.1 1.7
Loss on Ignition(LOI) 1.7 1.9
Sulphur (SO3) 2.0 2.2
Insoluble Residue”fly ash”(IR) 0.5 17.5
Alkali equivalent (Na2O) 0.65 0.68
Cl 0.04 0.05

9) Fly Ash
Fly ash used in making ACC Suraksha was collected in dry form from selective
hoppers of electrostatic precipitators from Raichur thermal power plant. The collected fly
ash is tested for selective parameters as received and complied with physical and
chemical requirements for fly ash use of Pozzolana and admixture as per IS 3812 as
prescribed in previous chapter.

10) The Secret Of Suraksha

Ordinary Portland Cements (OPC)
Ordinary Portland Cement has the following compounds :
a) C3S (Fast reaction, early strength, high lime release)
b) C2S (Slow reaction, late strength, moderate lime release)
c) C3A (Fastest reaction, low strength)

14
 d) C4AF (Very low strength, low heat of hydration)

Primary Hydration of Cement:

2C3S + 6H C3S2D3 + 3Ca (OH)2

(100g + 24g 75g + 49g)
2C2S + 4H C3S2H3 + Ca (OH)2
(100g + 21g 99g + 22g)
Weight for weight, C2S produces more of binding material (C3S2H3) and 50% less lime
(Ca(OH)2). Lime (Ca(OH)2) is the weakest link since it is prone to chemical attack
ultimately leading to distress, leaching, seepage, corrosion, cracks and expansion leading
to finally disintegration of concrete.

Secondary Hydration – The Secret Of ACC Suraksha :

Certain types of siliceous materials, which are made reactive and in a finely divided form,
will be able to combine with lime, at ordinary temperatures to produce a binder, similar in
composition to that resulting from hydration of Portland cement.
Ca(OH)2 + SiO2 C3S3H3
The secondary hydration reactions continue over years, and make concrete and cement
plaster dense, impervious to water seepage, carbonation, Sulphate attack, Chloride attack,
protects pH value of cover and protects reinforcement against corrosion. Concrete and
cement plaster grows in strength over years.
Lime in highly corrosive environments leaches out of the concrete and plaster, making
the structure porous.
Secondary hydration of reactive silica in ACC Suraksha converts lime to strength forming
stable CSH gel.

11) Water Demand for concrete:

Concrete mixes were tested for workability by slump test as specified in IS 1199-
1959. The density of fresh concrete and yield were also measured. A number of testes
were conducted to study the water demand of concrete for different workability levels
for different Cement contents. It was observed that water demand for ACC Suraksha
concrete is about 10-15%lower than that of OPC concrete. Therefore min. water required
for 1 bag of Suraksha Cement is 22 lit and max. water use is 25 lit.

12) Durability of concrete structures :

Durability of concrete is its ability to perform satisfactorily in the working
environment during its anticipated exposure conditions during service. One of the main
characteristics influencing the durability of concrete is its impermeability to ingress of
moisture, oxygen, carbon dioxide, chloride, sulphates and other potentially deleterious
substances.
Impermeability of concrete is governed by its constituents and workmanship. Adequate
Cement content and low free water-Cement ratio as per IS 456 – 2000 are needed for

15
ensuring low permeability subject to good compaction and curing. Crushing strength
alone is not a reliable guide.
 Compressive strength of concrete
Concrete specimens were tested to see the development of the strength of concrete up to
six months. The test results noted are given in table.

Development of strength

Concrete Initial Compressive strength (Mpa)

Particulars Slump
(mm) 1D 3D 7D 28D 90D 180D
M-20 G Concrete
OPC 60 8.3 14.3 21.0 28.9 32.5 36.6
ACC Suraksha 90 7.6 13.8 20.6 30.2 36.8 42.2
M-35 G Concrete
OPC 65 15.8 21.2 30.5 43.5 46.8 48.5
ACC Suraksha 85 14.8 20.5 31.2 44.8 50.2 54.2

It can be seen that initial strength of ACC Suraksha concrete is lower than that of
OPC concrete up to 3 days. However strength is almost at par at 7 days and slightly
higher at 28 days. Strength of ACC Suraksha concrete at 90 and 180 days is
significantly higher than that of OPC concrete showing the effect of secondary hydration.

Chloride and Sulphate Resistance of concrete:

Concrete were tested for resistance to chloride and sulphate penetration by Rapid
Chloride penetration test as per ASTM C 1202. This measures ability of concrete to resist
chloride ions penetrations by electrical indication.

Chloride resistance of concrete

Type of Concrete Charge passed, Coulombs

28 days 90 days
M20 OPC 4500 4220
M20 ACC Suraksha 3100 1750

The test result indicates that chloride penetration values for ACC Suraksha concrete
are much lower as compared to that of OPC concrete, thus proving the impermeability of
concrete made with ACC Suraksha.

 Corrosion Resistance:
Accelerated Corrosion resistance studies of re-bars in concrete were made with OPC
and ACC Suraksha by half-cell potential method as per ASTM C 876.

Chloride resistance

16
Type of Concrete Half cell Potential , mV
50 days 90 days 180 days
M20 OPC -219 -396 -649
M20 ACC Suraksha -172 -311 -561
M35 OPC -268 -476 -690
M35 ACC Suraksha -177 -192 -575

It is evident from the data a that under the accelerated environment, ACC Suraksha
concrete provides better protection to rebars against corrosion.

13) How much time is needed for curing and removal of formwork?
Curing, formwork, and setting timings are similar to OPC, and as recommended by BIS
specifications.
Curing is the process of preventing loss of moisture from the concrete
whilst maintaining a satisfactory temperature regime. Prevention of loss of moisture is
important if the water Cement. Ratio is low. Curing regime should prevent development
of high temperature gradients within the concrete. Under normal weather conditions a
minimum of 10 days curing and in dry and hot weather conditions a minimum of 14 days
curing is recommended. The investment on curing is worth the value from the point of
performance.

14) ACC Suraksha is an Eco-Friendly :

By using reactive silica – a byproduct from thermal power stations – which,
if released into the atmosphere, would despoil the environment, ACC Suraksha helps
safeguard the environment. It also helps conserve natural resources and energy. Besides
the reactive silica, (specially processed according to ACC norms) gives the Cement
additional properties referred to earlier. All this ‘adds value’ to constructions – making
them more stable and durable.

15) ACC Reliability:

ACC has effectively pledged its reputation as the market leader in the
quality of Cement. Maintaining this lead calls for harnessing the resources and expertise
of the company –from basic research and production to marketing. ACC’s tradition of
reliable and consistent quality along with the application of modern technology, creates
the basis for widespread confidence expressed by customers – a confidence which has
made ACC Cement “the customer’s first choice.”

16) Structures with ACC Suraksha :

1. Cement House, Mumbai.

2. Chinmay A International School, Coimbatore.
3. Ambadeep, New Delhi.
4. Science City, Kolkata.
5. Grape City , Nasik.

17
 6. Ramakrishna Mission, Lucknow.
7. Price Water House Coopers, Kolkata.
8. Statue Of Buddha, Patna.
9. Amrita Institute Of Tech. And Science, Coimbatore.
10. Statue Of Lord Shiva , Murudeshwar.
11. ACC Regional Training Center, Jamul.
12. Bhakra Nangal Dam.
13. Vaitarna Dam, Near Mumbai.
14. Sacred Heart Cathedral, Shimoga.
15. Link Manor, Kochi.
16. Ganga Bridge, Patna.
17. SRC In Use At Dabhol.
18. Apar Corporation, Mumbai.
19. J.J. Flyover In Mumbai.
20. Hotel Hilton, New Delhi.
21. Soubhagya Apartments, Calicut.
22. Vijay Rattan Marriage Palace, Muktasar, Punjab.

17) Production Factories

1. ACC Wadi plant, Karnataka. --- 12.00 MT/Day production.
2. ACC Tikaria plant, Uttar Pradesh.

18) Economy of ACC Suraksha :

Economy is the last but not least factor while choosing Cement for construction
work. As the fly Ash/Reactive silica contain in ACC Suraksha Cement is near @ 25 to
35% by wt. The % age of Lime contain is reduced which is beneficial for strength
development, low heat hydration, resistance against the sulphate and chloride attack,
reduction in Alkali – silica reaction, gives higher workability. Due to denser
microstructure of Cement and silica the corrosion of reinforcement also reduced. In
Suraksha Cement, as it contain reactive silica it is better resistance to leaching. As the
Suraksha Cement is advantageous and excellent in above mentioned properties, it is
economical for general use in construction work.

18
 5. ASSOCIATED CEMENT COMPANY.

The Associated Cement Companies Limited or ACC as it is popularly known, is

India’s Largest Cement manufacture, with an installed capacity of 18.28 MT/Annum and
sales turnover of @ Rs. 4000 crores.

ACC was established in 1936 when 10 existing Cement plants belonging to four
groups came together under one umbrella of “The Associated Cement Company Ltd.”
with a unique merger.

Indian Cement industry is the second largest in the world with installed capacity
of nearly @ 125 MT and a production of 101 M.T. the ACC is the India’s largest Cement
manufacturing company with the production of @ 18.28 MT. The company’s various
businesses are supported by a powerful, in-house research and technology. This ensures
not just consistency in product quality but also continuous improvements in products,
processes and application areas. Hence ACC Ltd acknowledged as one among the most
trusted names in corporate India, ACC is listed as one of the super brands of India. Due to
leadest position. ACC purchased by a Switzerland’s company, named as ‘HoleCem’.

In India, ACC’s brand name is synonymous with the Cement. The company
manufactures ACC Super which is Portland slag Cement having grade 43 using the slag
as per IS 455: 1989. The ACC Suraksha Cement as we already seen, is a Portland
Pozzolana Cement made with fly ash as per IS 1489 ( I) 1991. The ACC’s third Cement
product is ACC Samrat which is OPC made for sulphate resisting action having grade 53
as per the IS 12269 – 1987. ACC Super Finish is basically Decorative Cement which is
best suitable for flooring and Grit wash.
ACC pioneered the distribution of Cement in Bulk Transporter. ACC Ready
Mix Concrete is also the largest manufacture of RMC. ACC is also manufactures the
refractory castables (Monolithics) for steel, Cement, fertilizers, power, petrochemicals
and non-ferrous industries. Through subsidiary companies, ACC manufactures machinery
and Equipments such as Bulk transporters, vertical regrinding roller mills, blowers, Tyre
and Rubber making machinery and special alloy steel castings.
That’s the reason ACC going to rich the no.1 position in the market.

19
 6. CONCLUSION

With a appropriate connection in water content to obtain same level of

workability, compressive strengths and other structural properties can be achieved with
ACC Suraksha Cement are comparable with OPC Cement.

Use of ACC Suraksha is the answer to most of the durability problems for their ability
to provide the concrete with the following properties.

 Lower Permeability.

 Higher Resistance To Leaching.

 Higher Resistance To Alkali – Aggregates Reaction.

 Higher Resistance To Sulphate And Chloride Attack.

 Higher Workability.

 Better Resistance To Corrosion Of Reinforcement .

 Low Heat Of Hydration.

20
 7. REFERENCES

1. www.acclimited.com.

2. Indian Concrete Journal March 2005.

3. Indian Concrete Journal June 2005.

4. IS 3812 – 1981 Sp. For Fly Ash for use as Pozzolana and Admixture.

5. IS 4845 – 1968 Definition and terminology relating to Hydraulic Cement.

6. IS 269 – 1976 Sp. For Ordinary and Low heat Portland Cement.

7. IS 1489 (I) – 1991 Portland Pozzolana Cement (Fly Ash based)

8. Guidance By – Manish Wani. (Officer - Quality Control ACC RMC.)

21