CEMENT

Lecture 2
Concrete Ingredients
 At the end of class students should understand…
1) Raw materials in cement
manufacturing process
2) Chemical compositions of
Portland cement and their
functions
3) Hydration process of cement
4) Types of Portland cement and
their applications
 Motivational Quote of the Day

"Failure cannot cope with persistence."

Napoleon Hill
Concrete Problem
Read Pages:
1 – 21
(Cement)
 CEMENT

Is the product obtained by grinding clinker formed

by burning raw-materials (argillaceous and
calcareous) primarily consisting of lime (CaO),
silicate (SiO2), alumina (Al2O3), and iron oxide (Fe2O3)
 History of Portland Cement

• 1824 – patented by Joseph Aspdin

• Materials to produce cement were found and after
manufactured resemble the stone found on the
English Isle of Portland
• Thus, called PORTLAND CEMENT
 Characteristics of cement

• Set and harden when mix to a

paste with water
• Cohesive and Adhesive
• A material that binds concrete
ingredients – essentially like
GLUE

14
 Cement
• When it is mixed with water it forms a paste,
which hardens and binds aggregates (sand/gravel
and/or crushed rock) together to form a hard
durable mass called concrete
 Cement Manufacturing

• Argillaceous (20%) + Calcareous (60%)

Silica (SiO2 -60%) Lime (CaO -20%)
Alumina (Al2O3 -10%)
Ferum oxide (Fe2O3)
Ferum oxide + Alumina = 10%
Others = 10%

Argillaceous – clay, sandstone, shale

Calcareous – limestone, chalk, oyster shells
Common Raw Materials

Raw Materials Compound

Cement rock Lime, Silica, Alumina
Limestone Lime
Chalk Lime
Slag Lime, Silica, Alumina
Oyster shell Lime
Marble Lime
Clay Silica, Alumina, Iron Oxide
Shale Alumina
Fly Ash Silica, Alumina, Lime
Kaolin Alumina
Bauxite Alumina
Sand Silica
 Categories of Cement

1) Hydraulic cement – turns into solid or able to set

and harden in the presence of water e.g. OPC

2) Non-Hydraulic cement – requires no water to

transform into solid or harden, only require air to
harden e.g. lime
 Manufacturing Process

Two types of process:

• Wet Process – softer materials (clay + chalk)

• Dry Process – harder materials (shale + limestone)

• More efficient and require higher fuel
 Steps in manufacturing process

1) Grinding and mixing of raw materials

2) Burning in a rotary kiln

3) Cooling, grinding and sieving

4) Storing, packing and distributing

 Wet Process

1) Materials being ground (80% passing 75µm) and

mixed with the correct proportions

2) The mixture in a slurry form (30-40% water) is fed

into a rotary kiln where it is heated/burnt to a
temperature of 1500 °C to form clinker
1. Grinding Raw Materials
 2. Mixing

Proportions of ingredients
3. Burning
 Calcination process

• 100 °C – water is driven off

• 850 °C – limestone changes to calcium oxide and
CO2 is liberated
• 1500 °C – CaO reacts with SiO2 to form Calcium
Silicate (CS)
• CaO reacts with other compounds to form Calcium
Aluminate (CA) and Calcium Aluminoferite (CAF)
4. Grinding

Why clinker need to be

ground?
Gypsum added (2-3%)
 Wet Process

3) Cooling and grinding – Gypsum [Ca(SO)4] is

added (2-3%) during the grinding process to
prevent flash setting

4) Storing – stored in silo/air tight container

Final Products - cement
 Dry Process

• The process is relatively the same as wet process

except in dry process the raw materials (harder
materials) are mixed in dry condition.
• Small amount of water is added to form 12mm in
diameter ‘balls’
• The ‘balls’ are burnt in a rotary kiln and the
chemical reactions are the same as wet process
CHEMICAL COMPOSITION OF PORTLAND CEMENT

Will affects:
• Strength of cement/mortar/concrete
• Rate of hydration
• Amount of heat of hydration
• Durability of cement/mortar/concrete
Chemical Composition of Portland Cement

Abb. Compound Oxide Percent Reaction

(%) with water
C 3S Tricalcium silicate 3CaO.SiO2 45-60 Medium

C 2S Dicalcium silicate 2Cao.SiO2 15-30 Slow

C 3A Tricalcium 3CaO.Al2O3 6-12 Fast

Aluminate
C4AF Tetracalcium 4CaO.Al2O3.Fe2O3 6-8 Medium
Aluminoferrite
Others 8

31
 Others of Minor Compounds

• Magnesium oxide
• Titanium oxide
• Manganese oxide
• Sodium oxide
• Potassium oxide

• Minor – refers to quantity not important

 Alkalis in Cement

• Sodium oxide (Na2O) and

Potassium oxide (K2O)

• May cause problem – Alkali

Silica Reaction

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HYDRATION PROCESS OF PORTLAND CEMENT

• Is the chemical reaction between the compounds

of cement and water that yields products that
achieve the binding property after hardening
• Two stages:
setting and hardening
Setting - cement starts to stiffen
 Setting

• Initial setting – when the paste beginning to stiffen

• Final setting - when the paste beginning to harden and
able to carry some loads

• Flash set – rapid development of permanent rigidity of the

cement paste – along with high heat

• False set – rapid development of rigidity without the evolution of

heat, premature stiffening, can be reworked
Set – reaches a state in which its form cannot be changed without rupture
 Hydration Process of Cement

Cement + H2O → C-S-H gel + Ca(OH)2

• C3S (50-60% Vol of solid)
• C2S
• C3A
• C4AF

• For complete hydration, it is estimated that 1 g of cement requires 0.32 g of water

(w/c=0.32)
 Factors Affecting Rate of Hydration

• Chemical • Amount C3S, C2S, C3A,

compositions C4AF

Finer
• Fineness – measuring
the surface area per
Coarser
unit mass (m2/kg)

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 Hydration of Cement

• It is an exothermic process where heat is liberated

(heat of hydration)

Mass concrete
Cracks
100 ºC 30 ºC

Difference 70 ºC
 Hydration of Cement

• The silicates, C3S and C2S (75%), are the most

important compounds, which are responsible for
the strength of the hydrated cement paste

• C3S provides the early strength and liberated

higher heat of hydration (twice compared to C2S)
Hydration of cement
 C-S-H gel and Ca(OH)2

C-S-H
gel

Ca(OH)2
 Cont.

• C2S reacts slowly, provide later strength, highly

chemical resistance (sulphate, chloride)

• C3A is undesirable, contribute little or nothing to

the strength of cement except at early ages, and
when hardened cement paste is prone to be
attacked by sulphates, forming sulphoaluminate
that may cause disruption in concrete
Hydration of C3A
 Cont.

• C4AF does not affect significantly the behaviour of

cement hydration.

• However, it reacts with gypsum to form calcium

sulphoferrite and its presence may accelerate the
hydration of silicates
Hydration Process
Rate of Hydration
Effect on porosity
W/C effect on porosity
Strength vs porosity
 Types of Portland Cement

1) Ordinary Portland Cement (OPC) – Type I

2) Rapid Hardening Portland Cememt (RHPC)
3) Sulphate Resisting Portland Cement (SRPC) – Type V
4) Modified Portland Cement (MPC) – Type II
5) Low Heat Portland Cement (LHPC) – Type IV
6) Portland-Blastfurnace Cement (PBC) – Type IS
7) Portland-Pozzolan Cement (PPC) – Type IP
8) Coloured cement
9) Others
 Effect of chemical composition

• Cement differing in chemical compositions may

exhibit different properties when hydrated i.e.
Strength, durability, rate of strength gain, heat of
hydration
 Ordinary Portland Cement (Type I)

• By far the most common (60%) cement used in

general concrete construction when there is no
exposure to sulphates in the soil or groundwater
• Minimum fineness of 225 m2/kg
• Rate of hardening is moderate
• Standards: BS 12:1991, MS 522,ENV 197-1:1992
• Cement loses
its binding
properties

54
 Rapid Hardening Portland Cement (RHPC – Type III)

• Rapid strength gain due to higher C3S content (70%)

• Minimum fineness of 325 m2/kg
• Used when:
formwork is to be removed early for reuse or where sufficient
strength for further construction is required quickly
• Should not be used in mass concrete construction or in
large structural sections because of its higher rate of heat
development that can cause cracking
 RHPC (cont.)

• For construction at low temperatures, the use of

RHPC may provide a satisfactory safeguard against
early frost damage

• The setting time and chemical compositions of

RHPC and OPC is relatively the same
Sulphate Resisting Portland Cement (SRPC – Type V)

• This cement has low C3A (3.5%) content so as to avoid sulphate

attack from outside the concrete
• Minimum fineness of 250 m2/kg
• Active salts are magnesium and sodium sulphates – increase in
volume, cause concrete to disintegrate and crack
• Sulphate attack is greatly accelerated if accompanied by wetting
and drying (splash zone)
• The heat develop by SRPC is not much higher than the low-heat
cement, which is an advantage
Sulphate attack

58
Dry

Wet and Dry

Severe damage

Cont. Wet
Less O2
 Blended Cement

• Is a combination between Ordinary Portland

Cement (60%) and Pozzolanic materials (40%)
(contains reactive SiO2)

• Blended Cement = OPC + Slag

= OPC + Fly Ash
= OPC + Silica Fume
= OPC + RHA
 Portland-Blastfurnace Cement

• Made by inter-grinding or blending Portland cement

clinker with granulated blast-furnace slag
• Known as slag cement
• Slag contains lime, silica and alumina, but not in the same
proportions as in Portland cement
• Minimum fineness of 275 m2/kg
• Early strength are generally lower than OPC but later
strength are similar or even higher
 Portland-Blastfurnace Cement

• Typical uses are in mass concrete because of low

heat of hydration and in seawater construction
due to better sulphate resistance ( lower C3A
content) than with the OPC
• The amount of slag replacement between 25 to
70% of the mass of the mixture
 Portland-Pozzolan Cement

• Made by inter-grinding or blending pozzolans with

Portland cement
• A pozzolan is a siliceous or siliceous and aluminous
material which itself possesses little or no cementitious
value BUT in finely divided form and in the presence of
moisture, chemically react with Ca(OH)2 liberated during
the hydration of Portland cement to form compounds
possessing cementitious properties
 Cont..

• Portland-Pozzolan cement gain strength slowly and

therefore require curing over a comparatively a long
period of time, but the long-term strength is higher
than OPC

• Amount replacement between 25 to 40%

• More durable than OPC

 Hydration Process of Blended Cement

• Cement + H2O C-S-H (gel) + Ca(OH)2

• SiO2 + Ca(OH)2 C-S-H (gel)

 Normal plain
Concrete with silica concrete
fume

DENSE
CONCRETE
 What to consider?

Materials?
Cement?
Type of
construction?
 Discussion

• What are the main materials used for the manufacture of

cement?
• What is the purpose of adding gypsum to cement?
• Why cement clinker needs to be ground?
• What are the chemical composition of Portland cement?
• Different types of OPC and applications.
 ReCap

• Cement ingredients
• Manufacturing process
• Chemical compositions
• Hydration process
• Types of cement and application
 Thank You

help you parents…