Basic

Composition of Portland cement

The basic components of cement are:

SiO2 Al2 O3 Fe2 O3 CaO MgO SO3 Na2 + K2O Cl IR

17-25 % 4-8% 0.5-0.6 % 61-63 % 0.1-4.0 % 1.3-3.0 % 0.4-1.3 % 0.01-0.1% 0.6-1.75 %

There are four major compounds in cement and these are known as C2S, C3S, C3A & C4AF, and their composition varies from cement to cement and plant to plant. In addition to the above, there are other minor compounds such as MgO, TiO2, Mn2O3, K20 and N2O. They are in small quantity. Of these K2O and Na2O are found to react with some aggregates and the reaction is known as Alkali Silica Reaction (ASR) and causes disintegration in concrete at a later date. The silicates C3S and C2S are the most important compounds and are mainly responsible for the strength of the cement paste. They constitute the bulk of the composition. C3A and C4AF do not contribute much to the strength., but in the manufacturing process they facilitate combination of lime and silica, and act as a flux. In a typical Portland cement, the composition of mineralogical compounds could be

Table 1 : The extent of chemical compounds in cement

S no 1 2 3 4

Compound C3S C2S C3A C4AF

Composition as % 48-52 % 22-26 % 6-10 % 13-16 %

Freelime

1-2 %

Role of compounds on properties of cement

Characteristic Setting Hydration Heat Liberation (Cal/gm) 7 days

C3S Quick Rapid

C2S Slow Slow

C3A Rapid Rapid

C4AF -

Higher High up to 14 days Moderate at later stage

Lower

Higher Not muc h beyond 1 day

Higher

Early Strength

Low up to 14 days

Insignificant

Later Strength

High at later stage after 14 days

Heat of Hydration

Most of the reactions occurring during the hydration of cement are exothermic in nature (heat is generated). This heat is called heat of hydration. It is desirable to know the heat producing capacity of cement in order to choose the most suitable cement for a given purpose. For Ordinary Portland Cement, half of the total heat is liberated between 1-3 days, about th in 7 days and nearly 90% in 28 days. The rate at which the heat is produced is important for practical purposes. It may lead to cracks if not properly dissipated. The sum total heat produced, if spread over a longer period can be dissipated to a greater degree with fewer problems. The hydration of C3S produces higher heat as compared to the hydration of C2S. Fineness of cement also affects the rate of heat development. The heat of hydration generated is generally as follows at 28 days.

Comparative table of heat of hydration produced at the end of 90 days

S no Compound 1 2 3 4 C3S C2S C3A C4AF

Heat of hydration (calories per gram) 100-110 50-60 300-315 95-105

It may be seen that the heat produced by C3S is twice that of C2S and that by C3A is still higher. It follows that,

S no 1

Type of cement

End Use

OPC 33

Used for general civil construction works under normal/mild environmental conditions. OPC 33 grade is normally not used where high grade concrete is required due to limitations of its strength. Nowadays t his variety is not generally produced Nowadays 43 grade is being used widely for general construction work. However, 43 grade OPC is gradually being replaced by blended cements. Used in RCC and pre-stressed concrete of higher grades, cement grouts, instant plugging mortars etc. where initial higher strengt h is the criteria PSC provides better protection against chloride and sulphate attack. PSC is preferred over OPC for usage in constructions where t he structures are susceptible to sulphate and c hloride attack. eg Marine structure, structures near the sea, sewage disposal treatment works, water treatment plants, etc PPC makes concrete more impermeable, denser as compared to OPC. The long-term strength of PPC is higher compared to OPC. PPC produces less heat of hydration and offers greater resistance to the attack of aggressive waters than normal OPC. PPC can be used for all types of construction.

OPC 43

OPC 53

Portland Slag Cement (PSC)

Portland Pozzolana Cement (PPC)

Sulphate IIn SRC, amount of C3A is restricted to lower than 5% and 2C3 A + C4AF lower than 25%. SRC can Resisting be used for Foundation, Piles, Basements, Underground structures, sewage and water treatment Portland Cement plants and coastal works, where Sulphate attack due to water or soil is anticipated (SRC) Low Heat Low heat Portland cement is particularly suitable for making mass concrete for dams and many Portland Cement other types of water retaining structures, bridge abutments, massive retaining walls, piers and slabs, etc Rapid Hardening The Rapid hardening cement is used for repair and rehabilitation works and where speed of Cement (RHC) construction and early completion is required due to limitations of time, space or other reasons Hydrophobic It is manufactured under special requirement for high rainfall areas to improve t he s helf life of Portland Cement cement. The cement particles are given a c hemical coating during manufacturing, which provides water-repelling property, and the cement is not affected due to high humidity and can be stored for longer period. Due to abundant availability of cement in all parts of the country, this cement is very rarely produced these days. W hite Portland Cement is made from raw materials containing very little iron oxide and manganese oxide. Burning in the kiln is done wit h furnace oil or gas instead of coal. Limited quantities of certain chemicals, whic h improve whiteness of cement, are added during manufacturing. This type of cement is generally meant for non-structural works. It is used for arc hitectural purposes such as mosaic tiles, wall paintings, GRC and special effects.

10 W hite Cement

reducing the proportions of C3S and C3A, the heat of hydration and its rate can be reduced.

What is hydration of cement?

When water is added to cement, the paste is formed due to chemical reaction, which hardens into rock like mass over a period of time. Compounds like C3S and C2S react in the presence of moisture and fully hydrated reaction can be expressed as 2C3S +6H -> C3S2H3 +3Ca(OH)2 2C2S +4H -> C3S2H3 +Ca(OH)2 C3S2H3 (Calcium Silicate Hydrate) becomes a hard mass over a period of time and normally called as C-S-H gel. While C3S contributes to most of the strength development during the first two weeks, C2S influences gain of strength after two weeks. However, in the long term (over a year) the contribution to strength is same for equal individual weight. Types of cement

There are many types of cement in the market to suit every need. Some of them which are included in the revised IS : 456-2000 are as follows: Ordinary Portland Cement 33, 43, 53 grade (OPC), 53-S (Sleeper Cement) Portland Pozzolana Cement (PPC), both Fly Ash and Calcined Clay based Rapid Hardening Portland Cement Portland Slag Cement (PSC) Sulphate Resisting Portland Cement (SRC) Low Heat Portland Cement Hydrophobic Cement Selection of cement

The type of cement selected should be appropriate for the intended use. Functional requirement of the structure, design parameters, speed of construction, durability characteristics, environmental condition are some of the major factors which affect selection of cement for appropriate application. The suggested uses of various cements are given in the following table.

Classification

Grade M10

Applications PCC (Plain Cement Concrete) e.g. Levelling course, bedding for footing, concrete roads, etc. PCC e.g. Levelling course, bedding for footing, concrete roads, etc. RCC (Reinforced Cement Concrete) e.g. Slabs, beams, columns, footings, etc. (for mild exposure) RCC (Reinforced Cement Concrete) e.g. Slabs, beams, columns, footings, etc. RCC e.g. Slabs, beams, columns, footings, etc. RCC e.g. Slabs, beams, columns, footings, etc. RCC e.g. Pre-stressed concrete, slabs, beams, columns, footings, etc. RCC e.g. Runways,Concrete Roads (PQC), Prestressed Concrete Girders, RCC Columns, Prestressed beams RCC e.g. Runways,Concrete Roads (PQC), Prestressed Concrete Girders, RCC Columns, Prestressed beams RCC e.g..Prestressed Concrete Girders and Piers

Ordinary

M15 M20 M25 M30 M35 M40

Standard

M45 M50 M55

High Strengt h

M60 M80

RCC work W here high compressive strengt h is required such as high rise buildings, long span bridges, ultra-t hin white topping etc and constructions in aggressive environment e.g. Spillways of dams, coastal construction

In addition to producing normal grade concrete ranging from M10 to M80, we produce customized special types of concrete for different applications.
Types of Special Concrete High Volume Fly As h Concrete Silica fume concrete Application Mass concrete, raft foundations, roads, pavements etc. All high strengt h concrete applications in extreme environmental exposure condition like marine structure etc. GGBS, Slag based concrete All underground RCC application requiring high chemical resistance and enhanced durability Ternary blend concrete All RCC application directly in contact with aggressive soil / chemicals in marine environment and in sewage / effluent treatment plants Light weight concrete Repair and rehabilitation work, for thermal insulation, light weight structural fill, and light weight pre - cast panel etc Corrosion resistant concrete All types of RCC applications in high water table area including work near coastal areas, water tanks, etc Polymer concrete Repair and rehabilitation work for floorings and buildings where high early strengt h is required Self Compacting Concrete Thin sections and elements wit h congested reinforcements. Recently IS 456 has also included SCC with specifications in its codal provision. Coloured Concrete For arc hitectural and aesthetic use Fibre-reinforced Concrete For concrete wit h higher ductility and abrasion/erosion resistance Pervious Concrete Concrete for parking areas, pavements, drive-ways to ensure drainage or rain-water harvesting Water-proof Concrete Terraces, basements, water contact structures Temperature Controlled Concrete Mass concrete, hot-weather concrete etc.

Types of modern cement

[edit] Portland cement
Main article: Portland cement Cement is made by heating limestone (calcium carbonate), with small quantities of other materials (such as clay) to 1450 C in a kiln, in a process known as calcination, whereby a molecule of carbon dioxide is liberated from the calcium carbonate to form calcium oxide, or quicklime, which is then blended with the other materials that have been included in the mix. The resulting hard substance, called 'clinker', is then ground with a small amount of gypsum into a powder to make 'Ordinary Portland Cement', the most commonly used type of cement (often referred to as OPC). Portland cement is a basic ingredient of concrete, mortar and most non-speciality grout. The most common use for Portland cement is in the production of concrete. Concrete is a composite material consisting of aggregate (gravel and sand), cement, and water. As a construction material, concrete can be cast in almost any shape desired, and once hardened, can become a structural (load bearing) element. Portland cement may be grey or white.

[edit] Portland cement blends

Portland cement blends are often available as inter-ground mixtures from cement manufacturers, but similar formulations are often also mixed from the ground components at the concrete mixing plant.[10] Portland blastfurnace cement contains up to 70 % ground granulated blast furnace slag, with the rest Portland clinker and a little gypsum. All compositions produce high ultimate strength, but as slag content is increased, early strength is reduced, while sulfate resistance increases and heat evolution diminishes. Used as an economic alternative to Portland sulfate-resisting and lowheat cements.[11] Portland flyash cement contains up to 30 % fly ash. The fly ash is pozzolanic, so that ultimate strength is maintained. Because fly ash addition allows a lower concrete water content, early strength can also be maintained. Where good quality cheap fly ash is available, this can be an economic alternative to ordinary Portland cement.[12] Portland pozzolan cement includes fly ash cement, since fly ash is a pozzolan, but also includes cements made from other natural or artificial pozzolans. In countries where volcanic ashes are available (e.g. Italy, Chile, Mexico, the Philippines) these cements are often the most common form in use. Portland silica fume cement. Addition of silica fume can yield exceptionally high strengths, and cements containing 520 % silica fume are occasionally produced. However, silica fume is more usually added to Portland cement at the concrete mixer.[13] Masonry cements are used for preparing bricklaying mortars and stuccos, and must not be used in concrete. They are usually complex proprietary formulations containing Portland clinker and a number of other ingredients that may include limestone, hydrated lime, air entrainers, retarders, waterproofers and coloring agents. They are formulated to yield workable mortars that allow rapid and consistent masonry work. Subtle variations of Masonry cement in the US are Plastic Cements and Stucco Cements. These are designed to produce controlled bond with masonry blocks. Expansive cements contain, in addition to Portland clinker, expansive clinkers (usually sulfoaluminate clinkers), and are designed to offset the effects of drying shrinkage that is normally encountered with hydraulic cements. This allows large floor slabs (up to 60 m square) to be prepared without contraction joints. White blended cements may be made using white clinker and white supplementary materials such as high-purity metakaolin. Colored cements are used for decorative purposes. In some standards, the addition of pigments to produce "colored Portland cement" is allowed. In other standards (e.g. ASTM), pigments are not allowed constituents of Portland cement, and colored cements are sold as "blended hydraulic cements".

Very finely ground cements are made from mixtures of cement with sand or with slag or other pozzolan type minerals that are extremely finely ground together. Such cements can have the same physical characteristics as normal cement but with 50% less cement particularly due to their increased surface area for the chemical reaction. Even with intensive grinding they can use up to 50% less energy to fabricate than ordinary Portland cements.[14]