CEMENT

A soft gray powder that is mixed with water and other substances to make concrete. : the hard substance that is made
when cement is mixed with water and allowed to dry. : a substance that is used to make things stick together. Cement mixed with
fine aggregate produces mortar for masonry, or with sand and gravel produces concrete. It is derived from the Latin word
“CAEMENTUM” and is from Latin verb “to cut”.

Types of Cement
Cement is mainly classified into two categories depending on the hardening and setting mechanism. These are-

1. Hydraulic Cement
2. Non-hydraulic Cement

Hydraulic Cement

As the name indicates, hydraulic cement is those which harden by hydration in the presence of water. Limestone, clay, and
gypsum are the main raw material to produce non-hydraulic cement. This raw material is burned at a very high temperature to
manufacture Hydraulic Cement.

Hydraulic cement (cement that not only hardens by reacting with water but also forms a water-resistant product) produced by
pulverizing clinkers which consist essentially of hydraulic calcium silicates, usually containing one or more of the forms of calcium
sulfate as an inter ground addition.

Non-hydraulic Cement

The non-hydraulic cement doesn't require water to get harden. It gets with the help of carbon dioxide (CO2) from the air. This
type of cement needs dry conditions to harden. Lime, gypsum plasters, and oxychloride are the required raw material to
produce non-hydraulic cement. Example: slaked lime is a non-hydraulic cement.

Along with these main types, depending on the composition and characteristics there are many types of cement. Followings
are the other cement types:

1. Ordinary Portland Cement (OPC)

2. Portland Pozzolana Cement (PPC)
3. Rapid Hardening Cement
4. Quick Setting Cement
5. Low Heat Cement
6. Sulphate Resisting Cement
7. Blast Furnace Cement
8. High Alumina Cement
9. White Cement
10. Colored Cement
11. Air Entraining Cement
12. Expansive Cement
13. Hydrophobic Cement

Ordinary Portland Cement (OPC)

In usual construction work, Ordinary Portland Cement is widely used. Portland cement clinker is a hydraulic material which
shall consist of at least two-thirds by mass of calcium silicates, (3 CaO·SiO2, and 2 CaO·SiO2), the remainder consisting of
aluminum - and iron-containing clinker phases and other compounds. The ratio of CaO to SiO2 shall not be less than 2.0. The
magnesium oxide content (MgO) shall not exceed 5.0% by mass.

Uses of Ordinary Portland Cement

 It is used for general construction purposes.

 It is also used in most of the masonry works.
Portland Pozzolana Cement
Pozzolans are natural or synthetic materials that contain silica in reactive forms. It reacts with calcium hydroxide generated by
hydrating cement to form additional cementations materials when it is finely divided. The composition of Portland Pozzolana Cement:

 OPC clinker
 Gypsum
 Pozzolanic Materials (Fly ash, volcanic ash, and Calcined clay or silica fumes.)

Uses of Portland Pozzolana Cement

 PPC is usually used in hydraulic structures, marine structures, construction near the seashore, dam construction, etc.
 It is also used in pre-stressed and post-tensioned concrete members.
 As it gives a better surface finish, it is used in decorative and art structures.
 It is also used in the manufacture of precast sewage pipes.

Rapid Hardening Cement

When finely grounded Tri-calcium silicate (C3S) is present in OPC with higher content, it gains strength more quickly than OPC.
This type of OPC is called Rapid Hardening Cement. It’s initial Setting Time 30 minutes and Final Setting Time 600 minutes.

Uses of Rapid Hardening Cement

 Rapid hardening cement is mostly used where rapid construction is needed like the construction of pavement.
 It also gives high strength.

Quick Setting Cement

Quick setting cement is the cement which sets in a very short time. The initial setting time is 5 minutes and the final setting
time is 30 minutes. The composition of Quick Setting Cement:

 Clinker
 Aluminum sulfate (1% to 3% by weight of clinker)
 The aluminum sulfate increases the hydration rate of silicate.

Uses of Quick Setting Cement

 It is used in underwater construction.

 It is also used in rainy & cold weather conditions.
 It is used a higher temperature where water evaporates easily.
 Used for anchoring or rock bolt mining and tunneling

Low Heat Cement

It is a spatial type of cement which produces low heat of hydration during the setting. Some chemical composition of Ordinary
Portland Cement is modified to reduce the heat of hydration.

Uses of Low Heat Cement

 It is used for the construction of dam’s large footing, large raft slabs, and wind turbine plinths.
 It is also used for the construction of chemical plants.
Sulphate Resisting Cement

Sulfate resisting cement is used to resist sulfate attacks in concrete. Due to the lower percentage of Tricalcium aluminate, the
production of calcium sulpho-aluminates gets reduced.

Uses of Sulphate resisting Cement

 Construction in contact with soils or groundwater having more than 0.2% or 0.3 % g/l sulfate salts respectively.
 Concrete surfaces subjected to alternate wetting and drying such as bridge piers, concrete surface in the tidal zone,
apron, Building near the seacoast.
 Effluent treatment plans, Chimney, Chemical industries, water storage, sumps, drainage works, Cooling towers, Coastal
protective works such as sea walls, breakwaters, tetrapods, etc.

Blast Furnace Cement

Portland cement clinker and granulated blast furnace slag are intergraded to make blast furnace cement. A maximum of 65
percent of the mixture could be comprised of blast furnace slag.

Uses of Blast Furnace Cement

 It is highly sulfate resistant

 Frequently used in seawater construction.

High Alumina Cement

High Alumina cement is obtained by mixing calcining bauxite (it’s an aluminum ore) and ordinary lime with clinker during the
manufacture of OPC. In which the total amount of alumina content should not be lesser than 32% and it should maintain the ratio by
weight of alumina to the lime between 0.85 to 1.30.

Uses of High Alumina Cement

 It is used where concrete structures are subjected to high temperatures like workshops, refractory, foundries, etc.
 It also used where the concrete is subjected to frost and acidic action.

White Cement

White cement is quite similar to Ordinary Portland Cement except for color. Amounts of iron oxide and manganese oxide are
low in White Cement. It is expensive then OPC so not economical for ordinary work.

Uses of White Cement

 It is usually used in decorative work.

 It can also use for traffic barriers, tile grouts, swimming pools, roof tiles patching materials, and terrazzo surfaces.

Colored Cement

To make 5 to 10 percent of suitable pigments are ground with OPC. Types of pigments are selected according to the desired
color.

Uses of Colored Cement

 Colored cement is used for different decorative work.

Air Entraining Cement

It is seen that entrainment of air or formation of gas bubbles while applying cement increases resistance to frost action, fire,
scaling, and other similar defects. Air-entraining cement is a special type of cement which entrains tinny air bubbles in concrete. It is
produced by grinding minute air entertaining materials with clinker by adding some resinous materials e.g. vinsol resin to ordinary
portland cement. When the water in concrete gets frizzed due to low temperature, it expands. When air-entraining cement, the air
voids in concrete provides space for water to expand without cracking concrete. But this type of cement does not provide high strength
in concrete.

Uses of Air-Entraining Cement

 Especially it is used in areas where the temperature is very low.

 It also resists the Sulphet attack.
 It is used where the de-icing chemical is used.

Expansive Cement

In the hydration process, the expansive cement expands its volume. It can be possible to overcome shrinkage loss by using
expansive cement.

There are three types of expansive cement:

1. K Type expansive cement

2. M Type expansive cement
3. S Type expansive cement K Type expansive cement

K Type expansive cement

Raw materials of these types of cement

 Portland cement
 Anhydrous tetracalcium trialuminate sulfate (C4A3S)
 Calcium sulfate (CaSO4)

 Lime (CaO).

M Type Expansive Cement

Raw materials of these types of cement

1. Portland cement clinkers

2. Calcium sulfate.

S Type Expansive Cement

Raw materials of these types of cement

1. Portland cement clinkers

2. Calcium sulfate (High amount)

 Tricalcium aluminate (C3A) (High amount)

Uses of Expansive cement

 It is used in the construction of the pre-stressed concrete component.

 It is also used for sealing joints and grouting anchor bolt.
 In the construction of different hydraulic structures, this type of cement is used.
Hydrophopic Cement

To resist the hydration process in the transportation or storage stage, clinkers are ground with water repellent film substance such as
Oleic Acid or Stearic Acid. These chemicals form a layer on the cement particle and do not allow water to mix and start the hydration
process. When cement and aggregate are thoroughly mixed in the mixer, protective layers break and start normal hydration with some
air-entrainment which increases workability.

Uses of Hydrophobic Cement

 Usually, it is used in the construction of water structures such as dams, spillways, or other submerged structures.
 It is also used in the construction of underground structures like tunnel etc .

Types of Portland Cement

A. Type 1: Normal

- is a generally purpose portland cement used whenever the special properties of the other types are not
necessary such as sulfate attack from soil or water or objectionable temperature rise in the concrete due to hydration.

- used for purposes such as pavements, sidewalks, reinforced concrete, structural members, bridges, tanks and
masonry.

B. Type 2: Moderate

- is used when protection against moderate sulfate attact found in some soils and ground water is necessary.

C. Type 3: High Early Strength

- provides high strength faster than type 1 or type 2.

- used when forms are to be removed as soon as possible or to get strength faster in cold weather, thus reducing
the curing period when special protection is necessary.

- high early strength normally reduces the curing time required to one week or less.

D. Type 4: Low Heat of Hydration

- used when it is necessary to reduce the rate and amount of heat generated by hydration.

- it develop strength lower than type 1.

- it’s major used is for structures having large concrete masses suh as dams and nuclear plants.

E. Type 5: Sulfate Resisting

- used only in concrete that is exposed to severe sulfate condition. This most frequently occur in soils and ground
water in areas where sulfate concentration are high.
 Properties of Portland Cement

 Fineness of cement
 Soundness – ability of the hardened paste to retain it’s volume after setting
 Consistency – ability to fresh mixture to flow
 Strength
 Setting time
 Heat of hydration – the heat generated when the cement and water chemically react.
 Loss of ignition – a test to find out how much weight a sample of Portland cement will lose when heated.
 Specific Gravity – SG of Portland cement is about 3.15
 Compressive strength
 False Set – characteristics can be altered with adhesives

How Cement is made?

Cement is manufactured through a closely controlled chemical combination of calcium, silicon, aluminum, iron and other
ingredients. Common materials used to manufacture cement include limestone, shells, and chalk or marl combined with shale, clay,
slate, blast furnace slag, silica sand, and iron ore. These ingredients, when heated at high temperatures form a rock-like substance
that is ground into the fine powder that we commonly think of as cement

Manufacturing Process of Cement

1. Mining

2. Crushing, stacking, nd reclaiming of raw materials

3. Raw meal drying, grinding, and homogenization

4. Clinkerization

5. Cement grinding and storage

6. Packing