Composite Cement - An Option For Sustainable Construction

COMPOSITE CEMENT –
AN OPTION FOR SUSTAINABLE CONSTRUCTION
M.V.Karandikar & S.A.Khadilkar
ACC Ltd.,
Quality & Product Development Division,
ACC Thane Complex, L.B.S. Marg,
Thane 400 604, India
Background
Over the last two decades, the Indian construction

industry has gradually moved from an OPC dominated
usage to blended Cement / Blended Concrete
Concrete structures made with blended cement have

demonstrated durability and resisted environmental
factors causing deterioration of concrete structure
PPC and PSC have been able to establish their superiority

over OPC in terms of Durability of resultant Structures
With the new BIS composite cement, IS 16415:2015 in
place it opens a new avenue for sustainable construction
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30.09.16
ACC Ltd., Q&PD Division Composite Cement-An Option for Sustainable Construction
Background..
Fly ash and Slag Compliment each other in properties

determining the Concrete Durability 3
30.09.16
Background..
Indian standards on composite cement ( IS 16415:2015)

permits
Portland cement clinker /Ordinary Portland Cement (35–65%)

Fly Ash (15 – 35%) &
Granulated slag (25 – 50%)
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Characterization of Materials
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Preparation of Composite Cements,
OPC,PPC and PSC
PPC was prepared by inter grinding clinker, fly ash(30%) and gypsum
PSC was prepared by inter grinding Clinker, slag (50%) and gypsum
OPC was prepared by inter grinding clinker and gypsum
Targeted %R45 residue :8-10% & % SO3 : ~2.5%
OPC,PPC and PSC were prepared for comparison with composite cement
Composite cements were also prepared with different combinations of fly ash
& slag targeting specific surface area of 400 m2/kg & SO3 content of 2.5% in
intergrinding mode
C1 C2 C3 C4 C5
Clinker (%) 60.0 50.0 49.0 40.0 35.0
Fly ash (%) 15.0 20.0 18.0 20.0 15.0
Slag (%) 20.0 25.0 28.0 35.0 45.0
Gypsum (%) 5.0 5.0 5.0 5.0 5.0

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Testing of Composite cements
Physical properties as per BIS standards against OPC/PPC/PSC
Hydration Studies
Neat cement pastes were cast and de-moulded after 1 day and cured
for different ages of hydration i.e. 1, 3, 7 & 28 days
Concrete Strength
Concrete Durability Studies
Water Permeability (DIN – 1048 Part-5)

Rapid Chloride penetration Test (ASTM C 1202 – 07)
Sulphate resistance (ponding method )
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30.09.16
Quality of OPC, PPC, PSC & Composite Cements -
Mortar
BIS
OPC PPC PSC C1 C2 C3 C4 C5 requirement
Clinker (%) 95.0 65.0 45.0
60.0 50.0 49.0 40.0 35.0 35 to 65
Fly ash (%) - 30.0 - 15.0 20.0 18.0 20.0 15.0 15 to 35
Slag (%) - - 50.0
20.0 25.0 28.0 35.0 45.0 20 to 50
Gypsum(%) 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0
Surface Area (m2/kg)
324 374 365 398 398 415 401 401
%NC 29.0 30.8 29.0 31.5 31.5 32.0 31.8 31.5
Setting Time in minutes
Initial 120 150 155 150 150 145 170 185
Final 190 210 195 200 210 205 230 260
Compressive Strength (MPa)
1 Day 25.4 15.6 11.4 14.8 14.2 13.5 10.2 9.7
3 Days 37.8 26.1 22.1 26.0 23.6 22.4 17.6 16.1 16
7 Days 49.9 36.9 31.7 36.1 35.5 32.0 28.2 23.9 22
28 Days 69.2 58.1 52.8 58.1 57.0 52.2 44.1 35.1 33
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Comparative Hydration Characteristics of Cements
Combined water lost at different temperature is indicative of

type of hydrates formed ( Inhouse method developed at Author’s
Lab)
Low polymeric hydrates ( of Lower Molecular weight) (80-3800C)
Chemical bound water as calcium and Magnesium hydroxides (380-5000C)
Higher Polymeric hydrates (of high Molecular weight) (500-9000C)
At each age of hydration the neat cements were assessed for

Nature of the hydrates formed by TG/DSC
Free hydrated lime [Ca(OH)2] content by XRD & confirmed by glycol extraction
Hydrated phases formed by XRD
Morphology & microstructure of 28 day hydrated cement by SEM
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Comparative Hydration Characteristics of Cements-
Relative % Ettringite by XRD
Ettringite
Formation in
composite
cements is
comparatively
more than
OPC,PPC and
PSC
Similar trend
was observed
for Ettringite for
3 days
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Low polymeric hydrates by TG/DSC
OPC shows lower

Low polymeric
hydrates
Composite
cements and PPC
shows
comparatively
higher Low
polymeric
hydrates than
OPC and PSC
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Chemically bound water as calcium & magnesium
hydroxides by TG/DSC
OPC shows a
gradual increase
in Calcium &
Magnesium
Hydroxides .
PSC and
Composite
cements show a
gradual decrease
The decrease for

PPC although is
not so rapid
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Free Ca(OH)2content in hydrated cements by TG/DSC
OPC : free %
Calcium hydroxide
of cement gradually
increases with the
age of hydration
PPC : A gradual
decrease in calcium
hydroxide content
from 1-day to 28-
days
Composite cement :
lower calcium
hydroxide content
as compared to PPC
and OPC
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High polymeric hydrates content by TG/DSC
As compared
to OPC, PSC &
composite
cement,
PPC exhibits a
higher content
of these
hydrates .
PPC at all
ages indicates
these
hydrates
significantly
higher than
rest of the
cements 14
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Comparative decrease of C3S+C2S phases in hydrated
cement pastes with age of hydration
Comparative degree
of hydration of the
OPC /clinker
component with age
as assessed through
the decrease in the
area of the C3S+C2S
peak indicates that
rate of hydration of
OPC and PPC is very
slow when compared
with PSC and
Composite cements
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Microstructure of the 28 Days hydrated Cement
Pastes of OPC,PPC and PSC
OPC PPC PSC

OPC : Growth of CH crystals (portlandite) progresses
PPC : Microstructure becomes relatively more compact and denser
PSC : Highly dense and compact paste,due to the high degree of
inetworking of fibrous and thin plate like CSH
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Microstructure of the 28 Days hydrated Cement
Pastes of Composite cement
C-2 C-4 C-5

Composite cements
Composite cements shows a more denser microstructure with higher
formation of CSH
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Concrete Studies with OPC,PPC,PSC and
Composite Cements
Concrete studies were undertaken to assess the performance of
the some of the selected Composite cements (C1, C2, C3,C4 &
C5) and results were compared with concrete made with OPC,
PPC & PSC
M20 mix design (kg/m3)
W/C Cement Water 20 mm 10 mm Sand
0.56 350 196 635 618 673
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Concrete Strength
Concrete Strength development of composite cements are

comparable or even better than PPC & PSC 19
30.09.16
Durability Studies - Water Permeability
PSC shows lowest permeability, followed by Composite cements

when compared to OPC & PPC 20
30.09.16
Durability Studies - Rapid Chloride penetration Test
(ASTM C 1202 – 07)
Composite cements show lower Chloride permeability compared to

all other cements 21
30.09.16
Durability Studies - Sulphate Resistance :
(Ponding Test )
Composite
Cement & PSC
were highly
resistant against
sulphatic
environment in
terms of depth of
penetration of
sulphate ions
when compared
with OPC ,
indicating more
resistance to
sulphatic
environment
Suphate medium : 5% Sodium sulphate (Na2SO4)
Evaluation : depth of penetration of sulphate ions was measured chemically
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Some avenues for Improvements in Strength
Development of Composite cements
Through Use of Cement additives (Grinding aids, accelerators etc.) &
Partial use of Ultrafine / fly ash / slag on Strength Development of
Composite cements
advantage in terms
of higher fly ash
and slag
absorption with use
of cement additives
and partial use of
ultrafine fly ash /
ultrafine slag in
composite cements
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30.09.16
Estimation of Fly ash and Slag in Composite cement
by Method developed at Author’s Lab
Composite % Blending components % Blending components

cement added ( Theoretical) as per New Method
Mixes developed at Author’s Lab
% Fly ash % Slag % Fly ash % Slag
CC 1 15.0 20.0 13.7 19.7
CC 2 15.0 40.0 13.8 40.5
CC 3 20.0 35.0 18.9 34.6
CC 4 15.0 45.0 14.2 45.7
CC 5 18.0 28.0 17.5 28.3
CC6 20.0 25.0 14.6 24.4
Validation of the New Method
New method could be useful for determination of fly ash & slag in composite cements
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Conclusions
In composite cements, properties of fly ash and slag would
compliment each other , thus making the cement a performing
cement in concrete and would enhance the durability of the
concrete structures
Composite cements out perform OPC and have an edge over PPC
& PSC in terms fresh and hardened concrete properties
Composite cements needs to be tested for carbonation
test and would look at testing the comparison of
Carbonation Characteristics would be carried out at NCBM
labs
In a tropical country like India having abundant availability of
Fly ash and slag, a Composite Cement would gradually establish
itself as a preferred durable Cement.
Country would also achieve an increased production capacity by
at least 15 to 20% without Capital investments, with substantial
reduction in CO2/T of cement produced 25
30.09.16
Conclusions…
Composite Cements are expected to perform much better in

aggressive environments (having higher sulphate and Chloride
concentrations).
Long term durability studies are continued at the author’s lab

and the results would be very useful to understand the
composite cements and it would help the country to take a
giant leap towards the objective of sustainable development.
Composite cements made with separate grinding and

interblending or through use of an ultrafine ground fly ash or
slag partially could result in further improved performance of
composite cements
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Thank You
27
30.09.16
ACC Ltd., Q&PD Division

Composite Cement - An Option For Sustainable Construction

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COMPOSITE CEMENT –

AN OPTION FOR SUSTAINABLE CONSTRUCTION

M.V.Karandikar & S.A.Khadilkar

Over the last two decades, the Indian construction

Concrete structures made with blended cement have

PPC and PSC have been able to establish their superiority

Fly ash and Slag Compliment each other in properties

Indian standards on composite cement ( IS 16415:2015)

Portland cement clinker /Ordinary Portland Cement (35–65%)

Clinker (%) 60.0 50.0 49.0 40.0 35.0

Fly ash (%) 15.0 20.0 18.0 20.0 15.0

Slag (%) 20.0 25.0 28.0 35.0 45.0

Gypsum (%) 5.0 5.0 5.0 5.0 5.0

Physical properties as per BIS standards against OPC/PPC/PSC

Concrete Durability Studies

Water Permeability (DIN – 1048 Part-5)

Combined water lost at different temperature is indicative of

At each age of hydration the neat cements were assessed for

OPC shows lower

The decrease for

OPC PPC PSC

C-2 C-4 C-5

M20 mix design (kg/m3)

W/C Cement Water 20 mm 10 mm Sand

0.56 350 196 635 618 673

Concrete Strength development of composite cements are

PSC shows lowest permeability, followed by Composite cements

Composite cements show lower Chloride permeability compared to

Composite % Blending components % Blending components

Validation of the New Method

Composite Cements are expected to perform much better in

Long term durability studies are continued at the author’s lab

Composite cements made with separate grinding and

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