CONCRETE TECHNOLOGY: CODE CE 516

Arup Deka
Associate Professor
CED, Jorhat Engg. College
arup.deka8@gmail.com

DEPARTMENT OF CIVIL ENGINEERING

ASSAM ENGINEERING COLLEGE, GUWAHATI- 781 013, ASSAM 1
Introduction-History
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 constructions.

It is believed that the early Egyptians mostly used cementing

materials, obtained by burning gypsum.

An analysis of mortar from the Great Pyramid showed that it

contained 81.5 per cent calcium sulphate and only 9.5 per cent
carbonate.

The early Greeks and Romans used cementing materials obtained

by burning limestones.
2
Early History of Modern Cement

The story of the invention of Portland cement is, however,

attributed to Joseph Aspdin, a Leeds builder and bricklayer; even
though similar procedures had been adopted by other inventors.

Joseph Aspdin took the patent of Portland cement on 21st October

1824.

The fancy name of Portland was given owing to the resemblance

of this hardened cement to the natural stone occurring at
Portland in England

3
Early History of Modern Cement
(Early construction of concrete structure in India)

In India, Portland cement was first manufactured in 1904 near

Madras, by the South India Industrial Ltd. But this venture failed.

A three storeyed structure built at Byculla, Bombay is one of the

oldest RCC structures using Portland cement in India.

Some of the oldest concrete structures in India.

(1) A concrete masonry building on Mount Road at Madras (1903),

(2) The Har-ki-pauari bridge at Haridwar (1908) and

(3) The Cotton Depot Bombay then one of the largest of its kind in
the world (1922)
4
Portland Cement : Why it is called Portland cement?

Joseph Aspdin, an English mason who patented the product in

1824, named it Portland cement because it produced a concrete
that resembled the color of the natural limestone quarried on the
Isle of Portland, a peninsula in the English Channel.

Most cement used today is Portland cement.

This is a carefully proportioned and specially processed

combination of lime, silica, iron oxide, and alumina.

5
General Production Process of Cement

There are three fundamental stages in the production of Portland

cement:

1. Preparation of the raw mixture

2. Production of the clinker

3. Preparation of the cement

6
7
8
Manufacture of Portland cement
The raw materials required for manufacture of Portland cement are
calcareous materials, such as limestone or chalk, and argillaceous
material such as shale or clay.

The process of manufacture of cement consists of grinding the raw

materials, mixing them intimately in certain proportions depending
upon their purity and composition and burning them in a kiln at a
temperature of about 1300 °C to 1500°C (at which temperature, the
material sinters and partially fuses to form nodular shaped clinker).

The clinker is cooled and ground to fine powder with addition of

about 3 to 5% of gypsum. The product formed by using this
procedure is Portland cement.
9
10
11
12
 Preheating

Packaging

13
Manufacture of Portland cement

There are two processes known as "wet" and "dry" processes

depending upon whether the mixing and grinding of raw materials is
done in wet or dry conditions.

The dry process requires much less fuel as the materials are already
in a dry state, whereas in the wet process the slurry contains about
35 to 50 per cent water.

Hope Within next few years most of the cement factories will adopt
dry process system.

14
Types of Cement

ORDINARY PORTLAND CEMENT (OPC) [IS 269-1989; IS 8112-1989; IS

12269-1987]
RAPID HARDENING CEMENT (IS 8041-1990)
EXTRA RAPID HARDENING CEMENT
SULPHATE RESISTING CEMENT (IS 12330-1988)
PORTLAND SLAG CEMENT (IS 455-1989)
QUICK SETTING CEMENT
SUPER SULPHATE CEMENT (IS 6909-1990)
LOW HEAT CEMENT (IS 12600-1989)
PORTLAND POZZOLANA CEMENT
---------IS 1489 (PART I) 1991-FLY ASH
---------IS 1489 (PART II) 1991- CALCINED CLAY BASED
AIR ENTRAINING CEMENT
COLOURED CEMENT:WHITE CEMENT(IS 8042-1989)
---------AND MANY MORE. . . . . . . . . .. . . . . 15
Ordinary Portland Cement (OPC)

Three Grades
(1) OPC 33 Grade (IS 269-1989)
(2) OPC 43 Grade (IS 8112-1989)
(3) OPC 53 Grade (IS 12269-1987)
Prior to 1987, there was only one grade of OPC which was governed
by IS 269-1976.

After 1987 higher grade cements were introduced in India.

The OPC was classified into three grades, namely 33 grade, 43

grade and 53 grade depending upon the strength of the cement at
28 days when tested as per IS 4031-1988.

If the 28 days strength is not less than 33N/mm2 it is called 33

grade cement, if the strength is not less than 43N/mm2, it is called
43 grade cement, and if the strength is not less than 53 N/mm2, it is
called 53 grade cement. 16
 Ordinary Portland Cement (OPC)

But the actual strength obtained by these cements at the factory

are much higher than the BIS specifications.

It has been possible to upgrade the qualities of cement by using

high quality limestone, modern equipment, closer on line control of
constituents, maintaining better particle size distribution, finer
grinding and better packing.

Generally use of high grade cements offer many advantages for

making stronger concrete.

Although they are little costlier than low grade cement, they offer
10-20% savings in cement consumption and also they offer many
other hidden benefits.

One of the most important benefits is the faster rate of

development of strength.

17
 Ordinary Portland Cement (OPC)

In the modern construction activities, higher grade cements have

become so popular that 33 grade cement is almost out of the
market.

The manufacture of OPC is decreasing all over the world in view of

the popularity of blended cement on account of lower energy
consumption, environmental pollution, economic and other
technical reasons.

18
 Ordinary Portland Cement (OPC)

In advanced western countries the use of OPC has come down to

about 40 per cent of the total cement production.

In India for the year 1998-99, out of the total cement production
i.e., 79 million tons, the production of OPC in 57 million tons i.e.,
70%.

The production of PPC is 16 million tone i.e., 19% and slag cement
is 8 million tons i.e., 10%.

In the years to come the use of OPC may still come down, but all
the same the OPC will remain as an important type for general
construction.

19
Quick Setting Cement
------Name indicates sets very early (The early setting
property is brought out by reducing GYPSUM content at the time
of clinker grinding)

20
Portland Pozzolana Cement (IS 1489-1991)
PPC is manufactured by intergrinding of OPC Clinker with 15 to 35
% of Pozzolanic material.
A pozzolanic material is essentially a silicious or aluminous
material
---which while in itself possessing no cementitious
properties,
--- which will , in finely divided form and in the
presence of water, react with calcium hydroxide,
--liberated in the hydration process at
ordinary temperature to form compounds
possessing cementitious properties.

21
Portland Pozzolana Cement (IS 1489-1991)
The pozzolanic material generally used for manufacture of PPC are
-----Calcined Clay (IS 1489 part 2 of 1991)
----- Fly ash (IS 1489 part I of 1991)

{ Fly ash is a waste material generated in the thermal power station

when powdered coal is used as a fuel.}

The Pozzolanic action is shown below

Calcium Hydroxide+ Pozzolana + Water  C-S-H (gel)

22
Air-Entraining Cement

It has been developed to produce concrete that is resistant to

freeze-thaw action, and to scaling caused by chemicals applied for
severe frost and ice removal.

Air-entrained concrete has been used in pavements in the

northern states for about 25 years with excellent results.

Air-entrained concrete also reduces both the amount of water loss

and the capillary/water-channel structure.

26
Rapid Hardening Cement (IS 8041:1990)

The use of rapid hardening cement is recommended in the following

situations:

(1) In pre-fabricated concrete construction,

(2) Where formwork is required to be removed to be removed

early for re-use elsewhere,

(3) Road repair works,

(4) In cold weather concrete where the rapid rate of

development of strength reduces the vulnerability of
concrete to the frost damage.

27
Extra Rapid Hardening Cement

The acceleration of setting, hardening and evaluation of large

quantity of heat in early period of hydration makes the cement very
suitable for concreting in cold weather.

28
Sulphate Resisting Cement (IS 12330:1988)

The use of sulphate resisting cement is recommended for concrete to

be used

in marine condition,

in basement,

in construction of sewage treatment works for fabrication of

pipes which are likely to be buried in marshy region or
sulphate bearing soils.

Super Sulphated Cement – IS 6909:1990

This cement has high sulphate resistance.

Because of this property this cement is particularly recommended for

use in foundation, where chemically aggressive conditions exist.
29
Portland Slag Cement – IS 455:1989

It has low heat of hydration and is relatively better resistant to

chlorides soils and water containing excessive amount of sulphates
or alkali metals, alumina and iron, as well as to acidic waters and
therefore this can be used for marine works with advantage.

Using slag cement to replace a portion of Portland cement in a

concrete mixture is an efficient way to make concrete more
consistent.
Among the measurable improvements are (1) Higher Workability, (2)
Higher Finish-ability, (3) Lower Permeability, (4) Improved
Resistance to Aggressive Chemicals, (5) More Consistent Plastic
and Hardened Properties, (6) Higher Compressive and Flexural
Strengths.
30
Low Heat Cement – IS 12600:1989

Cement having low heat property is developed for use in mass

concrete construction, such as dams, where temperature rise by the
heat of hydration can become excessively large.

31
Portland Pozzolana Cement – IS 1489:1991

Portland pozzolana cement can be used in all situations where OPC

is used except where high early strength is of special requirement.

As PPC needs enough moisture for sustained pozzolanic activity, a

little curing is desirable.

Use of PPC would be particularly suitable for the following situations:

For hydraulic structures,

For mass concrete structures like dam, bridge piers and thick
foundation,

For marine structures,

For sewers and sewage disposal works etc.

32
Coloured Cement (White Cement) – IS 8042:1989

For manufacturing various coloured cements white cement is used

as a base.

The miscellaneous applications of coloured cement are in swimming

pools, for moulding sculptures and statues, for painting garden
furniture etc.

White cement is also used for fixing marble and glazed tiles.

33
ASTM CLASSIFICATION

The type of construction, chemical composition of the soil,

economy, and requirements for use of the finished concrete are
factors that influence the selection of the kind of cement to be
used.

Type I:
Type I cement is general-purpose cement for concrete that does
not require any of the special properties of the other types.

Generally, it is more available than the other types.

Type I cement reaches its design strength in about 28 days.

36
 Type II
Type II cement is modified to resist moderate sulfate attack. It also
usually generates less heat of hydration and at a slower rate than
type I.

However, the temperature rise in type II cement can be a problem

when concrete is placed during warm weather.

Type II cement reaches its design strength in about 45 days.

37
 Type III
Type III cement is a high-early strength cement that produces
design strengths at an early age, usually 7 days or less.

It has a higher heat of hydration and is more finely ground than

type I.

Richer mixtures of type I can obtain high early strength, but type III
produces it more satisfactorily and economically.

The high heat of hydration can cause shrinkage and cracking.

38
 Type IV
Type IV cement is a special cement. It has a low heat of hydration
and is intended for applications requiring a minimal rate and
amount of heat of hydration.

Its strength also develops at a slower rate than the other types.

Type IV cements reaches its design strength in about 90 days.

39
 Type V

Type V cement is sulfate-resistant and should be used where

concrete is subjected to severe sulfate action.

Type V cements reaches its design strength in 60 about days.

40
Summary of Type of Cement (ASTM Classification)

Type Use

I For use in General Construction where the special properties

specified for Types II, III, IV and V are not required

II For use in General Construction exposed to moderate

sulphate action or where heat of hydration is required.

III For use when high early strength is required (Rapid hardening
cement)

IV For use when low heat of hydration is required (Low heat

cement)

V For use when high sulphate resistance is required (Sulphate

resistance cement)

41
 Raw materials : 1 Lime
2 Silica
3 Alumina
4 Iron Oxide
 These oxides interact with one another in the kiln
at high temperature to for more complex
compounds.

 The relative proportions of these oxide compounds

are responsible for various physical properties of
cement.

 Rate of cooling and fineness of grinding also effect

the properties of cement.

42
 Oxide Content (%)
Lime CaO 60-70
Silica SiO2 17-25
Alumina Al2O3 3-8
Iron Oxide Fe2O3 0.5-6
Magnesia MgO 0.5-4
Alkalies K2O, 0.3-1.2
Na2O
Sulphates SO3 1-3 43
  The identification of the major compounds is largely
based on R.H. Bogue’s work & Hence it is called “Bogue’s
compounds”
 Bogue’s Compound
Name Formula Abbreviation % by mass

Tricalcium
Silicate
3CaOSiO2 C3S Alite 30-50
Dicalcium
Silicate
2CaOSiO2 C2S Belite 20-45

Tricalcium
Aluminate
3CaOAl2O3 C3A Celite 8-12

Tetracalcium
Aluminoferrite
4CaOAl2O3Fe2O3 C4AF Felite 6-10
44
Cement hydration

Clinker is anhydrous (without water) having come from a hot kiln.

Cement powder is also anhydrous if we ignore the small amount of

water in any gypsum added at the clinker grinding stage.

The reaction with water is termed "hydration".

When the cement comes in contact with water, the hydration of

cement proceeds both inward and outward in the sense that the
hydration products get deposited on the outer periphery and the
nucleus of the unhydrated cement inside gets gradually diminished
in volume.

45
The crystals of various resulting compounds from an interlocking
random three-dimensional network gradually filling the space
originally occupied by the water, resulting in stiffening and
subsequent development of strength.

The reactions of compounds of cement and their products may be

represented as

2  3 C aO . SiO 2   6 H 2 O  3 C aO .2 SiO 2 .3 H 2 O  3 C a  O H 2
The hydration process: reactions

In the anhydrous state, four main types of minerals are normally

present:
alite
belite
aluminate (C3A)
a ferrite phase (C4AF)

Also present are small amounts of clinker sulfate (sulfates of sodium,

potassium and calcium) and also gypsum, which was added when
the clinker was ground up to produce the familiar grey powder.

47
The hydration process: reactions

When water is added, the reactions which occur are mostly

exothermic, that is, the reactions generate heat.

We can get an indication of the rate at which the minerals are reacting
by monitoring the rate at which heat is evolved using a technique
called conduction calorimetry.

48
Three principal reactions occur:

Almost immediately on adding water some of the clinker sulphates

and gypsum dissolve producing an alkaline, sulfate-rich, solution.

Soon after mixing, the (C3A) phase (the most reactive of the four main
clinker minerals) reacts with the water to form an aluminate-rich gel.

Stage I on the heat evolution curve above

49
Stage II is a period of a few hours of relatively low heat evolution is
known as dormant or induction period.

The first part of the dormant period up to perhaps half-way through,

corresponds to when concrete can be placed.

As the dormant period progresses the paste becomes too stiff to be

workable.

50
At the end of the dormant period the alite and belite in the cement
start to react with the formation of calcium silicate hydrate and
calcium hydroxide.

This corresponds to the main period of hydration (Stage III), during

which time concrete strengths increase.

51
The individual grains react from the surface inwards, and the
anhydrous particles become smaller.

(C3A) hydration also continues, as fresh crystals become accessible

to water.

The period of maximum heat evolution occurs typically between

about 10 and 20 hours after mixing and then gradually tails off.

52
Cement Storage

Portland cement is packed in cloth or paper sacks, each weighing

50 kg.

Cement will retain its quality indefinitely if it does not come in

contact with moisture.

55
Thanks-----------

60