Do It Yourself……..

CEMENT
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
CEMENT
 Hydration
process
 Ingredients
 Testing of
 Manufacturing
cement
process
 Chemical
compositions
 Type of
cements
 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)
Characteristics of
cement
 Setting and
hardening
when mix to a
paste with
water

 Cohesive and
Adhesive
History of Portland
Cement

 1824 – patented by Joseph

Aspdin
 Materials to produce cement
were found on the English Isle of
Portland
 Thus, called PORTLAND CEMENT
Brands of Cement
Cement
 Argillaceous + Calcareous
Silica (SiO2 -60%) Lime (CaO -20%)
Alumina (Al2O3 -10%)
Ferum oxide (Fe2O3)

Argillaceous – clay, sandstone, shale

Calcareous – limestone, chalk, oyster shells
Cement
 Hydraulic cement – able to set
and harden in the presence of
water e.g. OPC
 Non-Hydraulic cement –
requires no water to 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)
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 and

mixed with the correct
proportions

2) The mixture in a slurry form 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
3. Burning
Burning
 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?
Wet Process

3) Cooling and grinding –

Gypsum [Ca(SO)4] is added
during the grinding process
to prevent flash setting
4) Storing – stored in silo
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 affect:
 Strength of cement

 Rate of hydration

 Amount of heat of hydration

 Durability of cement
Chemical Composition of Portland
Cement
Abb. Compound Oxide Percent
C3 S Tricalcium 3CaO.SiO2 45-60%
silicate
C2 S Dicalcium 2Cao.SiO2 15-30%
silicate
C3 A Tricalcium 3CaO.Al2O3 6-12%
Aluminate
C4AF Tetracalcium 4CaO.Al2O3.Fe2O3 6-8%
Aluminoferrite
Others 8%
Others of Minor Compounds

 Magnesium oxide
 Titanium oxide
 Manganese oxide
 Sodium oxide
 Potassium oxide
 Minor – refers to quantity not
importance
Alkalis in Cement
 Sodium oxide
(Na2O) and
Potassium
oxide (K2O)
 May cause
problem –
Alkali Silica
Reaction
 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
 Hydration Process of
Cement
 Cement + H2O → C-S-H gel + Ca(OH)2

 It is an exothermic process where heat is

liberated (heat of hydration)
 The silicates, C3S and C2S, are the most
important compounds, which are responsible
for the strength of hydrated cement paste
 C3S provides the early strength and liberated
higher heat of hydration
Set – reaches a state in which its form cannot
be changed without rupture
Setting

 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
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
attacked by sulphates, the
formation of sulphoaluminate may
cause disruption
Hydration of C3A
Cont.

 C4AF does not affect the

behaviour of cement hydration
significantly.
 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
 Types of Portland Cement
1) Ordinary Portland Cement (OPC) – Type I
2) Rapid Hardening Portland Cement (RHPC) –
Type III
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) Others
Effect of chemical
composition
 Cement differing in chemical
composition may exhibit
different properties when
hydrated
 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
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
 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
composition 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 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
Severe damage
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
Cont.
 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, but
the long-term strength is high
 Amount replacement between 25
to 40%
 More durable than OPC
Concrete with silica fume Normal plain concrete

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 clinker (cement) needs to be
ground?
 What are the chemical composition of
Portland cement?
 Different types of OPC and applications.
Summary
 Cement ingredients
 Manufacturing process
 Chemical compositions
 Hydration process
 Types of cement and
application
Thank You