Cement Tests

To ensure that the cement is of the desired quality; and It conforms to the requirements of the relevant national standards. Cement tests: Particle Size and Fineness; Consistence of Standard Paste; Setting Time; Soundness; Strength Tests; and Specific Gravity.

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Particle Size Distribution

Cement particles larger than 45 m hydrates at slow rate and cement particles larger than 75 m may never completely hydrate. Average particle size of cement is around 15 m. 95 % of cement particles are smaller than 45 m. Direct method: measuring particle size distribution by sedimentation or elutriation either cumbersome or require expensive equipment.
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Cement Fineness
The rate of hydration at early stages depends on the fineness of cement particles; higher fineness is necessary for rapid development of strength; The cost of grinding and heat evolved during hydration set limits on the fineness; For quality control purposes in the cement industry, the fineness is easily determined as the residue on standard sieves such as No. 200 mesh (75 m) and No. 325 mesh (45 m)

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Specific Surface (or Surface Area)

Both ASTM and BS require the determination of the specific surface (or surface area), in m2/Kg; Surface area is determined by using Blaine test apparatus.

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Consistency of Standard Paste

Normal consistency: A standard measure of plasticity of a cement paste. Determined by Vicat apparatus A paste has normal consistency when a Vicat plunger (10 mm in diameter) penetrates 10 1 mm in 30 sec under its own weight. The required water/cement ratio is determined by trial and error. Cement of normal consistency is required to measure setting time. Water content is 26-33% by the mass of dry cement.
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Setting
Setting: Solidification of the plastic cement paste or change from fluid to a rigid state. Hardening: Strength gain with time. Four forms of setting: Initial: Start stage of setting = Rapid temperature rise; Final: Final stage of setting = Peak Temperature; Flash: Very fast setting, liberation of Heat; False: No Heat is evolved = (happens in few minutes: concrete can be remixed).

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Initial Setting Time

The time at which the concrete can no longer be properly mixed, finished or compacted; Represented by a Vicat needle (1 mm in diameter) penetration of 25 mm or less. ASTM C150 prescribes a minimum initial setting time of 60 minute for Portland cement; BS12 prescribes 45 minutes.
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Final Setting Time

Final setting time: The time required for the cement to harden to a point where it can sustain some load; Represented by no penetration of Vicat needle, the needle makes an impression and the cutting edge fails. ASTM C150 prescribes a maximum final setting time of 10-12 hours for Portland cement.
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Soundness
After it has set, cement may undergo appreciable expansion, which could disrupt a mortar or concrete. Soundness is the ability of hardened cement paste to retain its volume after setting; It is tested by subjecting the set cement to boiling in water or to high-pressure steam. Unsoundness can arise from the presence in the cement of too much free magnesia or hard-burned free lime, or calcium sulfate Tests used to check the expansion of cement: 1) Le-Chatelier test
method (BS 4550); and 2) Autoclave method (ASTM C151)
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Le-Chatelier Test Method

Described by BS 4550; Measure the expansion of cement due to free lime only

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Autoclave Method
Cement paste bars are exposed to high temperature and pressure in the autoclave; The volume stability of the cement paste is determined; Measure the expansion due to presence of free lime and free magnesia; Measure the change in the length of the test specimen, If L< 0.8% of L0 then magnesia and free lime is below limits Cement is sound

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Strength Tests
Several forms of strength tests: Compressive strength; (Most important) Flexural strength; and Direct tensile strength. Standards (such as ASTM and BS) require a minimum strength for different cement types and classes at certain ages (at 1, 2, 3, 7 and 28 days)

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Compressive Test
Usually mortar specimen made of standard sand having fixed water content ( or fixed consistency), are molded and cured in standard way until age of testing. Apply the load to specimen faces that were in contact with the true plane surfaces of the mold Compressive strength (c) = P/A (where A = 50*50 mm2)

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Flexural Test
Using Prisms (40*40*160) mm The flexural test uses simplysupported mortar prisms loaded at mid span. MC Flexural strength (f) = I

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Direct Tensile Test

Using briquette Specimen Fill the mold in two layers, press each layer 12 times by thumb. Tensile strength (t) = P/A; where A = 25*25 mm2)

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Specific Gravity (SG)

The specific gravity test for cement is described by ASTM C 188; Le Chatelier flask and kerosine are used in this test; SG of cement is calculated by dividing the density of cement by the water density; SG of cement are between 3.1-3.15.

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