Chapter 5: Cement

5.1 Introduction
5.2 Type, Properties and Uses of Cement
5.3 Ingredients of Cement
5.4 Manufacture of Cement (Flow Diagram)
5.5 Composition and Function of Cement clinker
5.6 Standard Test of Cement
5.7 Cement Water Proofers
5.8 Admixtures
Cement:
• Joseph Aspidin in 1824 invented a cementing material by
burning together fixed proportion of Limestone and Clay
at very high temperature and reducing burnt product to a
very fine powder.
• On setting and hardening a mortar of this cement with
sand resembled in looks with the famous Limestone rock
of Portland in England and name given as Portland
Cement.
• Cement can be defined as a material with adhesive and
cohesive properties which make it capable of bonding
mineral fragments into a compact whole.
• It is a good binding material and is used for Manufacture
of Mortars and Concrete of different grades and
properties.
Type, Properties and Uses of Cement:
Cement can be broadly classified as:
1. Natural Cement:
• It is manufactured from stones containing 20 to 40%
of clay. The remainder being carbonate of lime
mixed with carbonate of magnesia.
• Stones are first burned and then crushed
• It posses a brown color and sets rapidly when mixed
with water.
2. Artificial Cement:
• It maybe Portland cement or special cement.
• It is prepared in various proportions.
There are different types of cement depending upon their
chemical composition and practical applications:

• Ordinary Portland Cement (OPC)

• Rapid hardening or High Early Strength Cement
• Portland Slag Cement
• Low Heat Cement
• High Alumina Cement
• Portland Pozzolona Cement (PPC)
• White Cement
• Quick Setting Cement
• Color Cement
Properties of Cement:
• Provides strength to Structure
• Hardens or stiffens easily
• Possess good plasticity
• Excellent Building material
• Easily workable
• Good moisture resistant
Uses of Cement:
• Used in cement mortar for masonry, plastering and pointing
work.
• Used in Construction of Engineering structures like Building,
Bridges, Culverts, Tunnels, Dams, Reservoir, Roads
• Used in the preparation of Foundations, water tight floors,
footpaths, platforms etc.
• Used in construction of light structures like badminton court,
electrical posts.
• Used in construction of Precast pipes, Piles, slabs etc.
• Used for making joints for pipes, drains etc.
• Used in manufacture of Asbestos cement products and light
weight boards.
Ingredients of Cement:
Lime (CaO): 60-65%
• Major constituent of cement
• Proportion need to be maintained carefully.
• Excess makes cement unsound and causes the cement to expand
and disintegrate.
• Deficiency decreases the strength of cement and cement sets
quickly.(i.e. reduces setting time)
Silica (SiO2): 17-25%
• Imparts strength due to formation of C2S and C3S.
• Excess provides greater strength but prolongs setting time.
• Silica in the cement is found by clay.
Alumina (Al2O3) 3-8%
• Imparts quick setting to cement.
• Excess reduces the strength of cement.
Calcium Sulphate (CaSO4) 3-5% ……….(Gypsum)
• Increases setting time of cement.
• Acts as a retarder.
Iron Oxide (Fe2O3) 0.5-6%
• Provides color, hardness and strength to the cement.
Magnesium Oxide (MgO) : 0.5-4 %
• If present in small amount, imparts color and hardness to the
cement.
• Excess makes the cement unsound.
Sulphur Trioxide (SO3) 1-2%
• Smaller quantity makes cement unsound.
Alkalis:
Should be present in small quantities.
• Excess causes efflorescence.
Cement Clinker
Manufacture of Cement:
2 Processes: 1. Wet Process
2. Dry Process
Both the Processes involves
the following Fundamental
Steps:
a. Raw material collection
b. Crushing, Grinding and
mixing of raw materials
c. Burning - Formation of
clinker
d. Cooling and Grinding of
clinker
e. Storing of Product and
Packaging
Idle Conditions of Site for Cement Factory:
• Favorable climatic conditions
• Easily and continuously availability of raw materials in large quantity
• Labor should be easily available
• Site should be connected by roads
• Electric Power and Fuel should be available at Economic rates
• Site should be nearby market area
• General facilities should be available in the vicinity
• Bearing capacity of the site should be adequate
• Sufficient quantity of water should be available.
Field Test for Cement:
• Color-Uniformly Greenish Grey
• Should feel smooth when rubbed in between fingers
• When hand is thrusted into a bag of cement, it should feel cool and not warm.
• A handful of cement thrown into a bucket of water, should float in case of good
cement.
• Any lump found in cement bag should be powdered by pressing the thumb and
fore finger.(kada dallo hunuhudaina).
• Take 100g of cement and make a stiff paste. Pepare a cake with sharp edges and
put on the glass plate. Immerse this plate in water. Observe that the sharps
should not get disturbed while setting. It should be able to set and attain
strength.

Cement is capable of setting under water and that is why it is also called as
‘Hydraulic cement’.
Precautions to be taken while storing Cement:
• Cement should be kept in special water tight shed with dry damp proof
floor, water proof walls and leak proof roof on the top.
• Cement bags should not be placed directly on floors; planks or iron sheets
may be placed underneath to guard against dampness.
• The cement bags should be placed at a distance of 30 cm from the walls.
• Stack of bags should be of such a height as can be easily handled.
• Cement bags should be so arranged that they can be used on the principle
of first come first served.
• Cement bags that were stored first should be used first.
• Cement bags should be stacked close together to avoid free circulation of
air.
• Storing of cement during rainy season should be avoided.
• Cement should not be stored for long period as far as possible.
• When cement is to be stored in bulk form, it should be stored in air tight
cylindrical containers, known as silos or bins.
• Cement bags must not be piled up in the field at work site, instead they
should be piled up on a raised platform and covered with a sheet.
Effect of storage on strength of Cement:

Effect of Storage Relative Strength (%) at 28 days

Fresh 100
3 Months 80
6 months 70
1 year 60
5 year 50
Composition and Function of Cement Clinker:
What is Clinker?? (Find Yourself)

The following Bogue compounds are formed

during Clinkering Process:
(Principal Mineral compounds in Portland Cement)
1. Tricalcium Silicate : Alite
2. Dicalcium Silicate : Belite
3. Tricalcium Aluminate : Celite
4. Tetracalcium Alumino Ferrite : Felite
Hydration of Cement:
The chemical reaction between cement and water is known as
hydration of cement. The reaction takes place between the
active components of cement (C4AF, C3A, C3S and C2S) and
water.
Setting of Cement:
The phenomenon by virtue of which the plastic cement
changes into a solid mass.
Hardening of Cement:
The phenomenon by virtue of which the cement paste, which is
finally set, develops strength is known as hardening of cement.
On setting, the cement binds the aggregate into a solid mass
which gains strength as the time lapses, till the hydration of
cement is complete.
Details of Different Grades of OPC:
33 Grade OPC:
• Compressive Strength after 28 days is 33N/mm2.
• General Construction works in normal environmental condition.
• Cannot be used where higher grade of concrete above M-20 is
required.
• Use of this cement has progressively decreased and virtually
passed out.
Similarly, Read Yourself for;
43 Grade OPC:
53 Grade OPC:
Notes:
Portland Slag Cement (PSC) – OPC + Slag
Portland Pozzolana Cement (PPC) – OPC + Fly Ash
LAB PORTION

Following Slides:
5.6 Standard Test of Cement:

Consistency Test:
The test is conducted to determine the percentage of water required for preparing the
cement paste of standard consistency for other test (Setting time, Compressive Strength,
…………….)

Done by Vicat’s Apparatus (We will deal in Lab)

Vicat apparatus is a penetration device used in testing of hydraulic cements and similar
materials to determine their normal or standard consistency. It is also used to determine
the initial setting time and final setting time of hydraulic cements and similar materials.

Note:

• The water content of standard paste is expressed as percentage by weight of dry

cement and the usual range is about 26 to 33%.
• It is said to be standard when plunger penetrates the paste 5 to 7 mm from the bottom
of mould.
• Movable rod weighing 300g having diameter 10 mm and length 50 mm .(Std. Plunger)
Check Different Plunger for Initial Setting time.
What is Consistency of Cement?
A Minimum quantity of water required to initiate the chemical reaction between
water and cement to form a paste is known as consistency of cement.

• Standard Consistency – It is that cement consistency which will allow the Vicat
plunger to penetrate to 5-7 mm point from the bottom of Vicat mould is
known as standard consistency.
Importance of Cement Consistency
• As we all know the strength of concrete depends on the quality material used
in it. Cement is one of them. In order to attain the required cement strength,
we need to add the right amount of water.
• Water less than the standard consistency would not initiate the chemical
reaction between water and cement resulting in the strength of cement.
• Water more than the consistency result in excess water and strength
reduction. That’s why it is important to know the standard consistency of
cement material.
Cement Consistency Test with Vicat Apparatus
• The whole test is conducted in trial and error method.
• First, we assume some percentage as the standard consistency. We
test it out against our Vicat apparatus.
Objective
• The Aim of this test is to find the basic required
quantity of water to form a cement paste which
the Vicat plunger will penetrate to 5-7mm point
from the bottom of Vicat mould.
Test Procedure

• Take 400 grams of Cement.

• Assuming that consistency would be 29.5% since we are taking OPC. This is trial
and error method.
• Take 29.5% of water that means (400×29.5%) = 118 Grams of water.
• Mix the water with cement within 3-5 Minutes.
• Now fill the Vicat mould with the cement paste.
• Ensure to compact the paste well after filling the mould.
• Fill the cement paste to the top of the mould. Remove the excess paste by the
trowel.
• Now place the mould at the Vicat apparatus.
• Now remove the plunger and allow it to penetrate through the paste.
• After Removing wait for 3 seconds.
• Note down the reading on the Vicat measuring scale.

Test Result
• The test result should be – 5-7 mm measurement in Vicat apparatus.(From
Bottom)
Standard Test of Cement:
1. Fineness Test
2. Setting time Test
3. Soundness or Constant of volume Test
4. Compressive Strength Test
5. Tensile Strength Test

We will deal in Lab.

 2. Setting Time Test
Initial setting time.
Final setting time.
Initial Setting Time: The time elapsed between the moment that the
water is added to the cement, to the time that the paste starts losing
its plasticity.
• Normally a minimum of 30min has maintained for mixing
transportation, placing and compaction.
• It should not be less than 30min.
Final Setting Time: The time elapsed between the moment the water is
added to the cement, and the time when the paste has completely lost
its plasticity and has attained sufficient firmness to resist certain definite
pressure and can be used as early as possible.
• It should not exceed 10 hours.
• So that it is avoided from least vulnerable to damages from external
activities.
 Procedure for Setting Time Test
The cement paste is prepared as mentioned in
the consistency test and is filled in the Vicat
mould.
Initial Setting Time:-
• Round or Square Needle of 1 mm2 CSA is attached
and penetrated at regular intervals until it penetrates
about(35mm from top) 5mm from bottom, which is
taken as initial setting time.
• Note that we take 0.85 P of water. P is normal
consistency.
• E.g. If P is 26% and Cement 400 (0.85*26%*400)
(Check in Lab)

Final Setting Time:

• It is the time at which the needle fails to penetrate
the specimen but only makes a slight impression .
• And the circular needle of 5mm dia makes no
impression at all.
1. Fineness Test:
To check the proper grinding of cement as finer
cements have quicker action with water and gain
early strength.
Excessive Fineness is not desired because of:
• Cost of Grinding
• Deteriorate more quickly when exposed to air
• More Shrinkage
• Greater amount of gypsum requirements
The Fineness of cement is tested by:
a. Sieve test:
b. Surface area test:
a. Sieve test:
The maximum residue after sieving
through a 90 micron IS Sieve
should be limited to 10% by
weight for OPC and 5% for Rapid
Hardening Portland Cement.

b. Surface Area Test (Specific

Surface Test):
It is better than Sieve test. Specific
Surface is the total surface of all
the particles of cement per unit
weight. It can be determined by
Air Permeability method or
Wagner’s turbidimeter.
Unit: cm2/g
3. Soundness or Constant of volume Test
This test is performed to detect the presence of
uncombined lime and magnesia in cement.
Soundness of cement is tested with ‘Le Chatelier Apparatus’.
• It is very important that the cement after setting shall
not undergo any appreciable change of volume.
• This test is to ensure that the cement does not show any
subsequent expansions.
• The unsoundness in cement is due to the presence of
excess of lime combined with acidic oxide at the kiln.
• This is due to high proportion of magnesia & calcium
sulphate.
• Therefore magnesia content in cement is limited to 6%
and Gypsum 3-5%.
 APPARATUS FOR SOUDNESS TEST
The cement paste is prepared; the percentage
of water is taken as determined in the
consistency test.
• The cylinder is placed on a glass plate and it is filled
with the cement paste. It is covered at the top with
another glass plate. A small weight is placed on the
top.
• The whole assembly is immersed in water at 24 to 35
deg for 24 hrs. At the end of that period the distance
between the indicators is measured.
• The mould is immersed in water again and brought to
boil in 30 mins. After boiling for 1 hr, the mould is
removed. And after cooling it , the distance between
the indicators is again measured.
• The increase in this distance represents the expansion
of the cement and it should not exceed 10 mm.
4. Compressive Strength Test:
To determine the suitability of cement for developing required
compressive strength of concrete and mortar.
Strength tests are not carried out on neat cement pastes, because it
is very difficult to form these pastes due to cohesive property of
cement.
The test is performed on 1:3 Cement Mortar cubes made by gauging
185 gm Cement, 555 gm of Standard Sand and 74 gm of water.
Average compressive strength for three cubes should not be less
than 11.5 N/mm2 and 17.5 N/mm2 after 2 and 7 days respectively.

Note : For Lab

The quantity of water shall be (P/4+3)% of combined weight of
cement and sand where, p is the % of water required to produce a
paste of standard consistency determined earlier.
Procedure:
• Take 185gms of cement & 555gms
of standard sand. (i.e., 1:3 ratio of
cement and sand)
• Mix them for 1min, then add water.
• Mix three ingredients thoroughly
until the mixture is of uniform
colour.
• Then the mortar is filled into a
cube mould of 7.06cm.
• Compact the mortar.
• Keep the compacted cube in the
mould at a temperature of 27°C ±
2°C for 24 hours.
• After 24hours the cubes are
removed & immersed in water.
• Measured by UTM
5. Tensile Strength test:
Method:
• The tensile strength test is carried out by fracturing six
briquettes made of cement mortar in the ratio of 1:3 using
standard sand and test cement.
• The percentage of water by weight of cement required to
make the cement mortar is given by the relation (P/5+2.5),
where P is a percentage of water required to make cement
paste of normal consistency.
• The briquettes are moulded in a standard manner, cured at
a temperature of 27+- 2 deg. for 24 hours and tested in
direct tension, the pull being applied.
• Average strength for 6 Briquettes tested after 3 and 7 days
should not be less than 2 N/mm2 and 2.5 N/mm2 resp and
28 days should not be below 45 kg/cm² or 4.50 N/mm².
5.7 Cement Water Proofers:
• Cement mortar or concrete, rich in cement becomes fairly water
tight when set.
• However, addition of certain water proofers to cement mortar or
concrete, during mixing, makes them absolutely water tight on
setting.
• The water proofers maybe in powder, paste or liquid forms.
Uses:
• Swimming pool
• Basements
• Reservoirs
• Cold storages
• Refrigeration rooms
• Water supply and sewage works
• Bath rooms and Kitchens
Etc.
5.8 Admixtures
These are the materials which are added in cement mortar or concrete to improve
upon their quality.
Admixtures are materials other than water, aggregate and hydraulic cement, added
to the concrete mix, just before or during the mixing process to modify one or more
properties of concrete in plastic or hardened stage. Admixtures are used to modify
the properties of ordinary concrete so as to make it more suitable for any situation
Note: Additive is the material which is added at the time of grinding cement
clinker at the cement factory

Purposes:
• Improves the strength, durability and workability of concrete
• Increases the resistance to chemical attack, freezing and thawing
• Reduces bleeding , segregation effect and permeability of concrete
• controls alkali aggregate reaction
• improves wear resistance to concrete
• accelerate or retard the rate of hydration of cement
• Increases bond strength between reinforcement and concrete
• Reduces shrinkage during setting of mortar or concrete
 Some Old Questions
5. Draw a Flowchart for wet process of cement
manufacture. Explain different constituents of
cement clinker with their function. [2+3]
(2076)
5. Explain about manufacture of flow diagram of
cement. Briefly illustrate the procedure to
determine the compressive strength of cement in
laboratory. [1+3]
(2074)
5. Sketch out the graph related to the
contribution of clinker compound to strength with
respect to time of cement compound. Define
Admixtures and cement water proofers.
• 1. What is the initial setting time of cement?
• The time period where you can mold the cement
mixture at any desired shape without losing its final
design strength is called the initial setting time of
cement.
• or in other words,
• When cement is mixed with water, from that moment
cement starts to set slowly. So, this time period where
the cement starts to lose its plasticity and making it
hard to pour in the mold or in the formwork is taken as
the initial setting time of cement.
• For ordinary portland cement, this time period is
about 30 min.
• What is the final setting time of cement?
• The time period where the cement, after mixing
with water, completely loses its plasticity and has
the ability to withstand its shape in the molds or
in the formwork with certain rigidity is called the
final setting time of cement.
• For ordinary portland cement, this time period is
about 600 min.
• What is the importance of the initial setting time of
cement?
• When the cement is mixed with the water, the
hydration process starts and the cement began to
harden slowly losing its plasticity. But after mixing
concrete, we need some time to carry the concrete
and place them in the formwork or any other molds.
For most of the works, we can complete this job
conveniently within 30 minutes of the time period.
While manufacturing the cement, by taking this time
period into consideration, certain ingredients were
added to provide plasticity to the cement mixtures
without losing their design strength.
• What is the importance of the final setting time of
cement?
• After pouring the concrete in the formwork or in the
molds, the next day, we need the working area to be
set, to walk over it, and to keep up the progress in
the construction work. The formwork or molds needs
to be removed and reused to reduce the working
cost and also it becomes necessary to provide
regular daily work for the laborers. Keeping it in
mind, the convenient time period of 600minutes ( 10
hrs.) is maintained in the regular cement as the final
setting time.
• Can we change the initial setting time of
cement?
• Yes. By adding the admixtures we can change
the setting time of cement. We add chemical
retarders to slow the setting rate and an
accelerator to speed up the process.