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BAHAN KEJURUTERAAN AWAM

CIVIL ENGINEERING MATERIALS
BFC 10502
DR. NOR HAZURINA BINTI OTHMAN
DEPARTMENT OF STRUCTURAL AND MATERIAL ENGINEERING,
FACULTY OF CIVIL & ENVIRONMENTAL ENGINEERING,
UNIVERSITI TUN HUSSEIN ONN MALAYSIA.

SYLLABUS
1. CEMENT
1.1 Types of Cement
1.2 Chemical Composition
1.3 Testing of Cement
1.4 Manufacturing of Cement
1.5 Method of Cement Storing

2. AGGREGATES
2.1 Types of Aggregates
2.2 Classification of Aggregates
2.3 Properties of Aggregates
2.4 Grading of Aggregates
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SYLLABUS
3. CONCRETE
3.1 Introduction to Fresh and Hardened concrete
3.2 Concrete Preparation
3.3 Workability of Fresh Concrete
3.4 Strength and Grade of Concrete
3.5 Properties of Hardened Concrete
3.6 Standard testing of Hardened Concrete
3.7 Concrete Mixture and Design
3.7.1 DOE Method for Normal Concrete
3.7.2 ACI Method for Normal Concrete

4. BRICKS AND MASONRY

4.1 Bricks Classification
4.2 Types of Bricks
4.3 Manufacturing of Bricks
4.4 Bricks Bonding and Arrangement
4.5 Mortar and Plastering
4.6 Standard Testing for Bricks

SYLLABUS
5. TIMBER
5.1 Timber Classification.
5.2 Timber Structure.
5.3 Moisture, Shrinkage and Strength.
5.4 Timber Defects
5.5 Treatment and Curing
5.6 Timber Products
5.7 Wood in Construction
5.8 Timber Standard Testing

6. STEEL
6.1 Steel Classification
6.2 Manufacturing of Steel
6.3 Properties of Steel
6.4 Common Types of Steel and Usage in
Construction
6.5 Mechanical Testing of Steel
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SYLLABUS
7. OTHER CONSTRUCTION MATERIALS
7.1 Bitumen
7.2 Rubber
7.3 Plastics
7.4 Polymer
7.5 Gypsum Board
7.6 Glass
7.7 Alloy

ASSESSMENT
QUIZ – 5%
ASSIGNMENT – 5%
PROJECT – 20%
TEST : TEST 1– 10% ( CHAPTER 1 & 2)
TEST 2 – 10% ( CHAPTER 2&3)
FINAL – 50% (ALL CHAPTER)

TOTAL = 100%
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CHAPTER 1 : CEMENT

1.1. Types of Cement

1.2. Chemical Composition
1.3. Testing of Cement
1.4. Manufacturing of Cement
1.5. Method of Cement Storing

INTRODUCTION OF CEMENT
Cement is a manufactured construction material and widely used forstructural
constructions such as buildings, bridges, tunnels, dams, factories, pavementand etc. It
is an instant glue and capable to bond mineral fragments intocompact whole. There
are variety type of cements can be found in the market. Eachtype is manufactured
under certain condition depending on its special properties. However today, Portland
cement is the most commonly used asmortar and
concrete in structural construction.
• Mortar: A mixture of cement, fine aggregates or sand and waterto form a paste.
• Concrete: A mixture of cement, sand, coarse aggregates andwater under certain
ratio.
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1.1 TYPES OF CEMENT

• Cement is manufactured with two basic raw ingredients calledcalcareous and an
argillaceous material. The cement in making of concrete has the propertyof
setting and hardening under water by virtue of chemical reaction with it andthis
type of cement is called hydraulic cement.

• Calcareous: The calcareous material is a calcium oxide, such as limestone, chalk, or

oyster shells.

• Argillaceous: Argillaceous is a combination of silica and alumina that can be found

from clay, shale and blast furnace slag.

1.1 TYPES OF CEMENT

• Setting Time
Setting refers to the stiffening of the cement paste or thechange from a
plastic state to a solid state. The setting time refersto changes of the cement
paste from fluid to rigid. Setting isusually described in two levels namely,
initial setting and final setting.
• Initial Setting:Initial setting is defined as the beginning of thenoticeable
stiffening in the cement paste and it’s corresponding to therapid rise
temperature. This normally takes about 45 – 175 minutes.
• Final Setting Time: This refers to completion of setting which correspond
to the peak temperature in the cement paste. The stiffening of cement
paste increase as the volume of the gel increases and the stageat which
this is completed, the final hardening process begins.It normally takes
between 3 to 10 hours for this to happen.

• Hardening
This is referred to the gained of the strength of the cementpaste. Actually
during the setting time, the cement gained verylittle strength.
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1.1 TYPES OF CEMENT

• Different concrete applications require cements with different properties.Some

applications require rapid strength gain to expeditethe construction and other
applications require low heat hydration to control volume change andassociated
shrinkage cracking. Hence, each type of cement is manufactured by alteringthe
ratios of four basic compounds namelyTricalcium Silicate, Dicalcium
Silicate,Tricalcium Aluminate and Tetracalcium Aluminoferitte to fit the applications.

Name of Compound Usual Abbreviation Reaction

Tricalcium Aluminate C3A Very quick
Tricalcium Silicate C3S Quick
Dicalcium Silicate C2S Slow
Tetracalcium C4AF Not very important
Aluminoferitte

1.1 TYPES OF CEMENT

TWO CATEGORIES OF CEMENT:

1. HYDRAULIC CEMENT
2. HIGH ALUMINA CEMENT

1. HYDRAULIC CEMENT:
Hydraulic cement is consists of silicates and aluminates of lime. This type of
cement can be classified as;
a. Natural Cement
Natural cements are powders obtained from certain natural rocks (clayey
limestone type) which are quarried, crushed and processes. Enough heat is
required to dry off carbonic acid gasses. Besides, it is brown incolour and
sets slowly or quickly when mixed with water, depending on the amount of
clay in the limestone. The strength is low and not used for concrete work.

b. Aluminous Cement
The chief ingredients of aluminous cement are calcareous andaluminious
materials (limestone or chalk and bauxite). These are heated to a
temperature of 1400oC and the whole mass is grinded to powder form.
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1.1 TYPES OF CEMENT

c. Portland Cement
The hardening of Portland cement is a chemical process during which heatis evolved.
Modified forms of Portland based on different ratio of fourmain compositions are made, to
suit the varying demands of different kindsof structural application.
CLASSIFICATION OF PORTLAND CEMENTS
Name Application
Normal General concrete work when the special properties of
other types are not needed. Suitable for floors,reinforced concrete
structures, pavements, etc.
Moderate Protection against moderate sulfate exposure, 0.1-0.2% weight water
Sulfate soluble sulfate in soil or 150-1500ppm sulfate in water (sea water). Can
Resistance be specified with moderate heat of hydration, making it suitable for
large piers, heavy abutments, and retaining walls. The moderate heat of
hydration is also beneficial when placing concrete in warm weather.
High Early of Used for fast-tract construction when forms need to be removed as soon
Hydration as possible or structure need to be put in service as soon of possible. In
cold weather, reduces time required for controlled curing.
Low Heat of Used when mass of structure, such as large dams, requires careful
Hydration control of heat of hydration.
High Sulfate Protection from severe sulfate exposure, 0.2-2.0% weight water soluble
Resistance sulfate in soils or 1500-10,800 ppm sulfate in water.

1.1 TYPES OF CEMENT

What is cement
hydration?

• Hydration is chemical reaction between cement particles and water. The

features of this reaction are the change in matter, the change in energy
level, and the rate of reaction.
• Example:
Tricalcium silicate + Water Calcium silicate hydrates (C-S-H) + Calcium
hydroxide
C-S-H makes the hydrated cement paste strong and calcium hydroxideis
susceptible to attack by sulfate and acidicwater.
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1.1 TYPES OF CEMENT

Ordinary Portland Cement – OPC ( BS 12 : 1971)
OPC has a medium rate of hardening and is suitable for mosttype of work. It is the one
most commonly used for structuralpurposes when the special properties specified for
other four types of cement are not required.

ii) Rapid Hardening Portland Cement – RHPC (BS 12 : 1971)

RHPC hardens rather more rapidly than OPC. It is similarin chemical composition to
OPC but the proportions of thevarious compounds may be slightly different, and it is
finely ground. Due to its finer grinding, it will increase the rate of hydration at early
ages, and this leads to the increased rate of early hardening as impliedby the name.
This early strength is achieved by increasing C2S and C3A content of the cement and
finer grinding. Since it has high heatevaluation, RHPC should not be used in large
masses. With 15% of C3A, it has lower sulfate resistance. The may be limited to obtain
moderate sulfate resistance or to 5% when high sulfate resistance is required.
Rapid-hardening Portland cement should not be regarded asquick setting cement. The
setting time specified in BS 12:1971 for RHPC is similar as specified for OPC.

1.1 TYPES OF CEMENT

iii) White and Coloured Portland Cement (BS 12 : 1971)
Generally used for decorative work. It is made by using Chinaclay in place of
ordinary clay to exclude impurities, especially ironoxide and limestone. Coloured
cements are made by mixing pigments withPortland Cement.

iv) Low Heat Portland Cement – LHPC (BS 1370: 1974)

LHPC hardens and evolves heat more slowly than OPC. Ithas slightly different
chemical composition. It is obtained byincreasing the proportion of C2S and
reducing C3S and C3A. It thus hydrates more slowly and evolves heat less rapidly
than OPC. The strength of LHPC is slow developed but the ultimate strength is
same. However, the initial setting time is greater than OPC.
Setting Time
Cement Initial Setting Final Setting
Type Time, minutes Time, minutes
(min) (max)
OPC 30 600
RHPC 30 600
LHPC 60 600
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1.1 TYPES OF CEMENT

v) Portland Blust furnace Cement - PBC (BS 146: 1973)
PBC is made by grinding a mixture of OPC clinker withselected granulated blast
furnace slag. The proportion of slag is limitedby the British Standard to not more
than 65% of the finished cement. The properties of blast furnace cement are very
similar to those of OPC but it hydrates slower than those of Portland cement so this
cement evolves less heat and hardens more slowly than OPC.The resistance to
sulfate is often considered to be intermediatebetween that of sulfate-resisting
Portland cement.

vi) Sulfate-Resisting Portland Cement – SRPC (BS 4027: 1972)

SRPC is specified where there is extensive exposure tosulfate. Typical applications
include hydraulic structure exposed towater with high alkali content and structures
subjected to seawater exposure. The surface resistance to SRPC is achieved by
reducing the C3A content to a minimum since that compound ismost susceptible to
sulfate attack. It usually has a higher content ofC4AF.Concrete made with this
cement is more resistant to attackby sulfate compounds which may be found
dissolved in ground water and which are present in sea water. SRPC tends to be
darker in colour than OPC.

1.1 TYPES OF CEMENT

vii) High Strength Portland Cement – HSPC

HSPC is produced from the same material as the case of OPC.The higher strength
achieved by increasing C3S content and also by finer grinding of clinker. The initial
and final setting times are the same as that of OPC. At higher water cement ratios,
the HSPC has about 80% higher strength and at lower cement ratio 40% higher
strength than OPC.

viii) Masonry Cement (BS 5224: 1976)

For hand work such as rendering and bricklaying, mortarcomposed only of
Portland cement and sand are not ideal. Suchmortars harden too quickly, are too
strong, and lack the plasticity andwater retention desirable in a masonry mortar. It
has been customary to overcome this difficulty by mixing lime with the cement
mixtures. Masonry cement, under various brand names consists ofPortland
cement with a fine inert admixture and plasticizing agent.
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1.1 TYPES OF CEMENT

Minimum Compressive Strength of Concrete Cube specified by

BS 4550 for Portland Cement
Type of Compressive Strength (N/mm2)
Portland 3 days 7 days 28 days
Cement
OPC 13 - 29
RHPC 18 - 33
PBC 8 14 22
LHPC 5 - 19
SRPC 10 - 27

1.1 TYPES OF CEMENT

2. HIGH ALUMINA CEMENT

High alumina cement is quite different both in composition and properties

from Portland cement. It is comparatively slow-setting but rapid hardening,
thus, produces very high early strength. As a considerable amount of heat is
generated during the setting and hardening process, it should not be used in
rich mixes or large masses. It is essential that the concrete be kept continuously
wet for at least 24 hours from the time it begins to harden. About 80% of the
ultimate strength is developed at the age of 24 hours. High alumina cement has
an initial setting time about 4 hours and final setting time about 5 hours. The
heat that generated during the hardening period has one advantage, as it
enables the concrete to be placed at lower temperatures than OPC.

For the same water cement ratio, the alumina cement ismore workable than
Portland cement. If high alumina cement concrete is used in placewhere
moisture and a high temperature present simultaneously, there will be aloss
strength whether these conditions occur early of late in the life of the concrete.
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1.1 TYPES OF CEMENT

High alumina cement concrete is more resistant than OPC to the action of sulfates,
therefore suitable under sea water applications.

The raw materials are limestone or chalk and bauxite which are crushed into lumps
not exceeding 100mm. The materials are heated to the fusion point at about 1600 oC.

The solidified material is fragmented and then ground to a fineness of 2500-3200

cm2/g. The product of very dark grey powder is passed through magnetic separators to
remove metallic iron. The alumina cement is considerably more expensive.
Chemical Oxide Composition for High Alumina Cement
Alumina (Al2O3) 39%
Ferric Oxide (Fe2O3) 10%
Lime (CaO) 38%
Ferrous Oxide (FeO) 4%
Silica (SiO2) 6%

1.2 CHEMICAL COMPOSITION

Chemical Composition Limit of Portland Cement

Name of Raw Material Chemical Composition Percentage Limit

Lime CaO 60 - 67
Silica SiO2 17 - 25
Alumina Al2O3 3-8
Iron oxide Fe2O3 0.5 - 6
Magnesium MgO 0.1 - 4
Alkalis (Soda and or/ Na2O,K2O 0.2 – 1.3
potash)
Sulphur Trioxide SO3 1- 3
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1.2 CHEMICAL COMPOSITION

The interaction of Portland cement raw materials are interacted in kiln by forming
complex chemical compounds.Calcination in the kiln restructures the molecular
composition by producing four main chemical compounds.

Main Compounds of Portland Cement

Name of Compound Chemical Formula Usual Range by Weight (%)
Tricalcium Silicate 3CaO.SiO2 45 - 60
Dicalcium Silicate 2CaO.SiO2 15 - 30
Tricalcium Aluminate 3CaO.Al2O3 6 - 12
Tetracalcium 4CaO.Al2O3.Fe2O3 6-8
Aluminoferitte
The minor compounds such as magnesium oxide, titanium oxide, manganese
oxide, sodium oxide, and potassium oxide are represented a few percentages by
weight of cement.

1.3 TESTING OF CEMENT

1.3.1 SETTING
A. Vicat Set Time Apparatus
Setting time can be determined with theVicat apparatus. The Vicat test requires sample
of cement using the amount of water required for normalconsistency according to a
specified procedure.
Procedure:
The 1 mm (0.04in) diameter needle is allowed to penetrate the paste for30 seconds and
the amount of penetration is measured. The penetration processis repeated every 15
minutes until a penetration of 25 mm (1in) or less isobtained. By interpolation, the time
when a penetration of 25 mm occurs is determinedand recorded as the initial set time.
The final set time is when the needle doesnot penetrate visibly into the paste.
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1.3 TESTING OF CEMENT

B. Gilmore Set Time Apparatus
The Gilmore requires a normal consistency cement paste sample. A pat witha flat
top is molded and the initial Gilmore needle is applied lightly to itssurface. The
application surface is repeated until the pat bears the force of theneedle without
appreciable indentation, and the elapsed time is recorded as theinitial time. This
process is then repeated with the final Gilmore needle and the finalset time is
recorded.

1.3 TESTING OF CEMENT

1.3.2 SOUNDNESS (LE CHATELIER TEST)
Soundness of the cement paste refers to its ability to retain its volume after
setting. Expansion after setting, caused by delayed or slow hydration or reactions,
could result if the cement is unsound. The autoclave expansion test is used to
check the soundness of the cement paste. In this test, cement paste bars are
subjected to heat and high pressure, and theamount of expansion is measure.
ASTM C150 limits autoclave expansion to 0.8%.

Le Chatelier Water Bath

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1.3 TESTING OF CEMENT

1.3.3 COMPRESSIVE STRENGTH
Compressive strength of mortar is measured by preparing 50mm (2in.) cubes and
subjecting them to compression according to ASTM C109. The mortar is
prepared with cement, water and standard sand (ASTM C778). Minimum
compressive strength values are specified by ASTM C150 for different cement
types at different ages. The compressive strength of mortar cubes is proportional
to compressive strength of cylinders. However, the compressive strength of the
concrete cannot be predicted accurately from mortar cube strength, since the
concrete strength is affected by aggregate characteristics, the concrete mixing
and the construction procedures.

1.4 MANUFACTURING OF CEMENT

Production of Portland cement deals with two basic raw ingredients namely
calcareous and argillaceous. These materials are crushed and stored in thesilos. The
raw materials, in the desired proportions, are passed through grindingmill, using
either wet or dry process. The ground material is stored until it can besent to the kiln.

Modern dry process cement plants use aheat recovery cycle to preheat the ground
material, or feed stock, with the exhaust gas from the kiln. Someplants use a flash
furnace to further heat and feed stock. Both the preheater andflash furnace improves
the energy efficiency of cement productions. In the kiln, theraw materials are melted
at temperatures 1400oC to 1650oC, changing the materials into cement clinker. The
clinker is cooled and stored. The small amountof gypsum is added to regulate the
setting time of the cement in the concrete.

The finished product may be stored and transported in eitherbulk or sacks. The
cement can be stored for long periods of time, provided it iskept dry.
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1.4 MANUFACTURING OF CEMENT

1.5 METHOD OF CEMENT STORING

1. MOISTURE
If moisture is kept away from cement, it is found that cement will
maintain its quality for an indefinite period. Absorption of 1 to 2% of
moisture has no appreciable effect on quality of cement. But if
moisture absorption exceeds 5%, the cement becomes totally
useless. Hence, when cement is to be stored for a long period, it
should be stored in air-tight containers.

2. PERIOD OF STORAGE
The lose cement may be stored indefinitely in air-tight
containers. But it is advisable to avoid storing of cement in jute
bags for a period longer than 3 months. If it is unavoidable, the
cement should be tested to ascertain its properties.

3. PILES
The cement bags are stacked in piles. It is advisable to form a pile of maximum 10
bags. There should be a clear distance of about 300 mm between the piles of cement
bag and exterior walls of building. In between individual pile a passage of 900 mm
should be provided for easy access. Use tarpaulins or water proof paper at the top
and bottom of piles, while storing cement for long period.
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1.5 METHOD OF CEMENT STORING

4. REMOVAL OF CEMENT
While removing cement bags from pile of sufficient height, then steps
should be formed by taking out two or three bags from front piles. Cement
should be removed in order of its storage period, i.e. the rule offirst in,
first out should be followed.

5. STORAGE SHEDS
The walls, roof and floor of storage sheds should be of water
proof construction. A minimum number of windows should be
provided and they should be kept tightly shut. The floor
should be above ground. For determining the size of storage
shed, it is found that 20 bags or 10kN of cement will require
about 1m3 of space.
SHARE THIS:
CONCLUSION
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TUTORIAL 1
1. What is the best storing system for
cement?. Explain

2. How to speed up the strength

development of concrete?. Explain.

3. What are the effects of non-potable

water on concrete quality? Explain.