Beruflich Dokumente
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03
CEMENT
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Cement
Cement is a binder, a substance that sets and hardens
independently, and can bind other materials together.
Cement is a crystalline compound of calcium silicates
and other calcium compounds having hydraulic
properties (Macfadyen, 2006).
Cements in general are adhesive and cohesive
materials which are capable of bonding together
particles of solid matter into compact durable mass.
For civil engineering, they are restricted to calcareous
cements containing compounds of lime as chief
constituent to bind the fine and coarse aggregate
particles together.
Cement History
History
England
Cheops, Giza
Stones were brought from Aswan and
Tura using the Nile river
Built around 2566 B.C.
It would have taken over 2,300,000
blocks of stone with an average weight
of 2.5 tons each
Total weight of 6 million tons
30 years and 100,000 slaves to build it
Has a height of 482 feet (140m)
It is the largest and the oldest of the
Pyramids of Giza
Mortars made by calcining impure
gypsum
Cement
Portland cement is so named because a
paste of cement with water, after it sets
hard, resembles in color and hardness a
Portland stone, a limestone quarried in
Dorset (a county in South West England).
Uses of cement
Masonry work, plastering, pointing, joints for
pipes & drains.
Used in concrete for laying floors, roofs,
constructing lintels, beams, stairs,
pillars/columns etc.
Used in manufacturing of precast pipes, piles,
fencing posts etc.
Important engineering structures e.g. bridges,
culverts, dams, tunnels, etc.
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Chemical Composition of
Oxide
Cement %age Function
Lime (CaO)
Silica (SiO2)
Alumina (Al2O3)
4-8
Iron oxide
(Fe2O3)
2-4
Magnesium
oxide (MgO)
1-3
Na2O+K2O,
TiO2, P2O5
0.10.5
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Functions of ingredients of
cement
Lime (CaO)
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Functions of ingredients of
cement
Silica (SiO )
2
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Functions of ingredients of
cement Alumina (Al O )
2
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Functions of ingredients of
cement
Iron oxide (Fe2O3)
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Harmful ingredient of
cement
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Types of Cement
Cements are considered hydraulic because of their ability to set
and harden under or with excess water through the hydration of the
cements chemical compounds or minerals.
There are two types:
Those that activate with the addition of water
And pozzolanic that develop hydraulic properties when the
interact with hydrated lime Ca(OH)2
Pozzolanic: any siliceous material that develops hydraulic
cementitious properties when interacted with hydrated lime.
HYDRAULIC CEMENTS:
Hydraulic lime: Only used in specialized mortars. Made from
calcination of clay-rich limestones.
Natural cements: Misleadingly called Roman. It is made from
argillaceous limestones or interbedded limestone and clay or shale,
with few raw materials. Because they were found to be inferior to
Portland, most plants switched.
Cement Types
Portland Cement
Ordinary Portland Cement (Type I)
Moderate Sulphate Resistance Cement (Type II)
Rapid Hardening or High Early Strength Portland Cement (Type
III)
Low Heat Portland Cement (Type IV)
Sulphate Resistant Portland Cement (Type V)
Water Repellent Portland Cement
Water Proof Portland Cement
Air Entraining Portland Cement (Type I-A, II-A, III-A)
Pozzolana Portland Cement
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White Cement
OPC with pure white color produced with white chalk
or clay free from iron oxide
Instead of coal, oil fuel is used for burning
Much more costlier than OPC
Colored Cement
Suitable pigments used to impart desired color
Pigments used should be chemically inert and
durable under light, sun or weather
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Cement Manufacturing
Steps
Processes
Dry process. Dry mixing and grinding of
constituents. Difficult for composition control, slow,
costly.
Wet process. Wet mixing and grinding into slurry
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which turns into clinker on burning in kiln.
Wet processCalcareous
Raw slurry
Argillaceous
materials
( clay)
materials
( limestone)
elevators
Preliminary
crushing
Wash mills
Correction
silos
Elevators (storage
bins)
Elevators (storage
bins)
Lime slurry
Clay slurry
Hoppers
Water
Wet
grinding
(Ball mills)
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Gypsum
Gypsum
hopper
Correction silos
Fuel-coal
Rotary kilns
Crushing &
grinding
(Ball mill)
Clinker
Pulverized
coal
Elevators
(Clinker storage)
Clinker grinding
(Cement grinding
mills)
Elevator (Cement
silos)
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Wet process
Collection of raw materials:
Calcareous materials (limestone, marl, chalk, etc.) are
quarried by blasting. Argillaceous materials (clay, slate,
etc.) are transported to the site.
Wet
process
(contd.)
Burning
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Wet
process
(contd.)
Burning
When slurry moves down the kiln, it encounters
progressively high temperatures.
At first water is driven off, and CO2 is liberated. The
material becomes dry.
The dry material undergoes a series of chemical
reactions until finally, in the hottest part of kiln, 2030 % of the material becomes liquid, and lime, silica
and alumina recombine.
The mass fuses into balls, 0.3-2.5 cm dia, known as
clinker.
The clinker drops into coolers.
A large kiln can produce 700 tonnes of cement a 42
day
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Clinker
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Clinke
r
Gypsum
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Wet
process
(contd.)
Grinding
The cool clinker is crushed with 3-4% of gypsum
(CaSO4) in order to prevent flash setting of cement.
Once the cement has been satisfactorily ground it
is ready for packing in bags.
Each bag contains 50 kg of cement.
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Cement Clinker
Tri-calcium
silicate 3CaO SiO
Composition
or C3S (Alite)
Properties of cement
components
Component
Rate of
reaction
Heat
Ultimate
liberated cementing
value
Tri-calcium silicate,
C3S
Medium
Medium
Good
Di-calcium silicate,
C2S
Slow
Small
Good
Fast
Large
Poor
Slow
Small
Poor
Tri-calcium
aluminate, C3A
Tetra-calcium
alumino ferrite, C4AF
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Cement Properties
Fineness: Finer cements react quicker with water
and increase shrinkage and cracking of concrete.
Soundness: Change in volume of concrete after
setting. It may cause cracks, distortion and
disintegration of concrete.
Setting time: Initial setting time is that stage
after which any cracks that may appear do not
reunite. Final setting is that stage when it has
attained sufficient strength and hardness.
Compressive strength of cement and sand mortar
should not be less than
115 kg/cm2 after 3 days
175 kg/cm2 after 7 days
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Portland cements.
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C4AF (Felite)
It is
comparatively
inactive and
contributes
little to the
strength of
concrete and
the heat of
hydration.
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Sequence of Hydration
Ettringite (needle shape prismatic crystals or rod
like shape) make appearance with few minutes of
hydration
A few hours later large crystals of CH form
Simultaneously very small fibrous of C-S-H start
to fill the gaps
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Etteringite
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C-S-H fibres
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Testing of Portland
cement
Fineness test
Consistency test
Setting time test
Soundness test
Tensile strength test
Compressive strength test
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Fineness of cement
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Fineness test
Excessive fineness is not desirable because
Cost of grinding to achieve fineness increases
Excessively fine cement deteriorates more quickly
Greater fineness requires more gypsum for proper
retardation
Water required for standard consistency increases
for finer cements.
Fineness test
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Consistency test
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Vicats apparatus
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Consistency test
Method: Consistency is measured by Vicat
apparatus by using a 10 mm dia plunger
fitted to needle holder
A trial past of cement (600 g) and water (e.g. 30%
by weight or 180 g) is mixed and placed in the
mould.
The plunger is brought into contact with top
surface of paste and released.
If plunger penetrates paste to a point 30+-(1) mm
from top of the mold, it is termed as standard
consistency.
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Usual range is between 26 and 33%.
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Soundness test
objective: this
test is performed
to detect the
presence of
uncombined lime
and magnesia in
cement.
Le Chatelier
apparatus:
consists of brass
cylinder split along
its generatix.
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Soundness
test
Method :
Method
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Compressive strength
test
Method
1:3 mortar cubes (50x50x50 mm) or cylinders
(150x300 mm) are prepared.
Mortar composition: Cement = 185 g,
sand
= 555 g,
water = 74 g.
The cubes/cylinders are tested in compression.
Average compressive strength should not be
less than 11.5 N/mm2 (after 2 days) and 17.5
N/mm2 (after 7 days).
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Questions ?
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