SESSION 2

CEMENT
CEMENT
• Cements in a general sense are adhesive
and cohesive materials which are capable
of bonding together particles of solid
matter into a compact durable mass
• Its primary function being to bind the fine
(sand) and coarse (grits) aggregate particles
together.
• Joseph Aspedin of was the first to introduce
Portland cement in 1824 formed by heating a
mixture of limestone and finely divided clay in
a furnace to a temperature
Cement
Cement

Argillaceous Calcareous
(clay) (lime)
Constituents of Cement
Lime (CaO) • 62-65%

Silica (SiO2) • 17-25% 𝑀𝐴𝐽𝑂𝑅

Alumina (Al2O3) • 3-8%

Gypsum (CaSO4) • 3-4 %

Iron Oxide (Fe2O3) • 3-4%

Magnesia (MgO) • 1-3%

Sulphur (S) • 1-3%

Alkalies (K2O, N2O) • 0.2-1

Functions of Different Constituents of Cement
1. Lime (62-65%)
▪ Imparts strength and Soundness (volume)
▪ Excess- it becomes difficult to combine with other
compounds, free lime will be present in clinkers which
makes cement unsound, causes it to expand &
disintegrate
▪ Deficiency- reduces strength of cement, causes it to set
quickly

2. Silica(17-25%)
▪ Imparts Strength to Cement
▪ Excess- increases strength of cement BUT increases setting
time of cement
Functions of Different Constituents of Cement
1. Lime (62-65%)
▪ Imparts strength and Soundness (volume)
▪ Excess- it becomes difficult to combine with other compounds,
free lime will be present in clinkers which makes cement
unsound, causes it to expand & disintegrate
▪ Deficiency- reduces strength of cement, causes it to set quickly
2. Silica(17-25%)
▪ Imparts Strength to Cement
▪ Excess- increases strength of cement BUT increases setting time
of cement
3. Alumina (3-8%)
▪ Imparts quick setting property
▪ Reduces clinkering temperature, if it is in excess weakens the
cement
Functions of Different Constituents of Cement
4. Gypsum (3-4%)
▪ Present in form of calcium sulphate
▪ Used to increase initial setting time of cement
5. Iron Oxide (3-4%)
▪ Imparts Colour, Strength and hardness to cement
▪ It induces reddish brown tint to the cement
6. Magnesia (1-3%)
▪ Imparts Strength and colour to cement (yellowish
tint)
▪ Excess- makes cement unsound
Functions of Different Constituents of Cement
4. Gypsum (3-4%)
▪ Present in form of calcium sulphate
▪ Used to increase initial setting time of cement
5. Iron Oxide (3-4%)
▪ Imparts Colour, Strength and hardness to cement
▪ It induces reddish brown tint to the cement
▪ It helps highly silicious raw materials to burn
6. Magnesia (1-3%)
▪ Imparts Strength and colour to cement (yellowish tint)
▪ Excess- makes cement unsound
Functions of Different Constituents of Cement
7. Sulphur (1-3%)
▪ It is also responsible for imparting soundness
Note: Soundness due to lime and Magnesia can be
measured directly but no test is available to measure
soundness due to sulphur
8. Alkalies (0.2-1%)
▪ Presence of alkalies causes efflorescence and
staining of structure
▪ Alkalies react with water and white grey spots are
formed
▪ Alkalies accelerate setting of cement paste
Bougues Compounds/Composition of Cement Clinker
• Various constituents combine in burning and form
cement clinker. The compounds formed in the
burning process have properties of setting and
hardening in presence of water
1. TriCalcium Aluminate (Celite)
They are known as Bogue
2. TetraCalcium Alumino Ferrite (Felite) compounds after the name of
Bogue who identified them.
Le-Chatelier and Tornebohm have
referred these compounds as Alite
3. TriCalcium Silicate (Alite) (C3S), Belite (C2S), Celite (C3A) and
Felite (C4AF).

4. DiCalcium Silicate (Belite)

Bougues Compounds
1. TriCalcium Aluminate (C3A or
3CaO.Al2O3)
• 4-14% by weight
• Formed within 24 hours of addition of water
in cement
• Responsible for maximum amount of heat of
hydration
• It is responsible for initial set, higher heat of
hydration and greater tendency to volume
changes
Civil Engineering by Sandeep Jyani Sir
Bougues Compounds
2. TetraCalcium Alumino Ferrate (C4AF or
4CaO.Al2O3.Fe2O3)
• 10-18% by weight
• It is also formed within 24 hours of addition of water to
cement
• Amount of heat of hydration evolved during formation of
this compound initially is comparatively more which goes
on decreasing with time
• It is also responsible for flash set but generates less heat

Civil Engineering by Sandeep Jyani Sir

Bougues Compounds
3. TriCalcium Silicate(C3S or 3CaO.SiO2)
• 45-85% by weight
• It is supposed to be the best cementing material and is well burnt
cement
• Formed within a week of addition of water in cement
• Responsible for development of early strength of cement in initial
stages (7 days strength)
4. DiCalcium Silicate(C2S or 2CaO. SiO2)
• 15-35% by weight
• It is formed very slowly after addition of water in cement and may
require a year of so for its formation
• It imparts resistance to chemical attack
• It is responsible for progressive strength of cement in later stages

Civil Engineering by Sandeep Jyani Sir

Bougues Compounds
Note:
✓If early strength is required-
increase C3S (emergency road
work, prefabricated construction
work, etc.)
✓Strength in required to be
increased in later stages- increase
C2S

Civil Engineering by Sandeep Jyani Sir

 Hydration of Cement
• The chemical reaction between cement and water is known as
Hydration of Cement
• Heat of hydration of Ordinary Portland Cement during 7 days is
about 89-90cal/gm and during 28 days is about 90-100 cal/gm
• Water- About 23% of by weight of cement is required to carry out
the complete hydration
• About 15% of water is used up in filling voids of the cement
particles, hence effectively 38% of water (by wt of cement) is
required to carry out complete hydration

𝑯𝒆𝒂𝒕 𝒐𝒇 𝑯𝒚𝒅𝒓𝒂𝒕𝒊𝒐𝒏 𝑪𝟑 𝑨 > 𝑪𝟑 𝑺 > 𝑪𝟒 𝑨𝑭 > 𝑪𝟐 𝑺

𝑹𝒂𝒕𝒆 𝒐𝒇 𝑯𝒚𝒅𝒓𝒂𝒕𝒊𝒐𝒏 𝑪𝟒 𝑨𝑭 > 𝑪𝟑 𝑨 > 𝑪𝟑 𝑺 > 𝑪𝟐 𝑺

Civil Engineering by Sandeep Jyani Sir
Manufacturing of Cement
Manufacturing of cement includes
three basic operations:

1. Mixing 2. Burning Grinding

Methods of Manufacturing of Cement

Methods

1. Dry Method 2. Wet Process

(New) (Old)
1. Dry Method (New Method)
𝑨𝒓𝒈𝒊𝒍𝒍𝒂𝒄𝒆𝒐𝒖𝒔 𝑪𝒂𝒍𝒄𝒂𝒓𝒆𝒐𝒖𝒔
(𝑺𝒍𝒂𝒕𝒆 / 𝑳𝒂𝒕𝒆𝒓𝒊𝒕𝒆) (𝑳𝒊𝒎𝒆 / 𝑴𝒂𝒓𝒃𝒍𝒆)

𝑪𝒓𝒖𝒔𝒉𝒊𝒏𝒈 𝒕𝒐 𝟐𝟓 𝒎𝒎 𝑪𝒓𝒖𝒔𝒉𝒊𝒏𝒈 𝒕𝒐 𝟐𝟓 𝒎𝒎

𝑭𝒊𝒏𝒆 𝑮𝒓𝒊𝒏𝒅𝒊𝒏𝒈 𝒊𝒏 𝑻𝒖𝒃𝒆 / 𝑩𝒂𝒍𝒍 𝑴𝒊𝒍𝒍 𝑭𝒊𝒏𝒆 𝑮𝒓𝒊𝒏𝒅𝒊𝒏𝒈 𝒊𝒏 𝑻𝒖𝒃𝒆 / 𝑩𝒂𝒍𝒍 𝑴𝒊𝒍𝒍

𝑺𝒕𝒐𝒓𝒂𝒈𝒆 𝑺𝒕𝒐𝒓𝒂𝒈𝒆

𝑴𝒊𝒙𝒊𝒏𝒈 𝒐𝒇 𝑹𝒂𝒘 𝑰𝒏𝒈𝒓𝒆𝒅𝒊𝒆𝒏𝒕𝒔

𝒊𝒏 𝑪𝒐𝒓𝒓𝒆𝒄𝒕 𝑷𝒓𝒐𝒑𝒐𝒓𝒕𝒊𝒐𝒏
1. Dry Method (New Method)

𝑴𝒊𝒙𝒊𝒏𝒈 𝒐𝒇 𝑹𝒂𝒘 𝑰𝒏𝒈𝒓𝒆𝒅𝒊𝒆𝒏𝒕𝒔

𝒊𝒏 𝑪𝒐𝒓𝒓𝒆𝒄𝒕 𝑷𝒓𝒐𝒑𝒐𝒓𝒕𝒊𝒐𝒏

𝑷𝒓𝒆 𝒉𝒆𝒂𝒕𝒊𝒏𝒈 𝒂𝒕 𝟖𝟎𝟎 𝒅𝒆𝒈𝒓𝒆𝒆 𝒄𝒆𝒍𝒔𝒊𝒖𝒔 𝒃𝒚 𝒆𝒙𝒉𝒂𝒖𝒔𝒕 𝒈𝒂𝒔𝒆𝒔

𝑭𝒆𝒅 𝒕𝒐 𝒓𝒐𝒕𝒂𝒓𝒕𝒚 𝑲𝒊𝒍𝒏𝒔 𝒇𝒐𝒓 𝒃𝒖𝒓𝒏𝒊𝒏𝒈 𝒂𝒕 𝟏𝟒𝟎𝟎℃ − 𝟏𝟓𝟎𝟎℃

𝑪𝒍𝒊𝒏𝒌𝒆𝒓𝒔 𝒂𝒓𝒆 𝒇𝒐𝒓𝒎𝒆𝒅

𝑭𝒊𝒏𝒆 𝑮𝒓𝒊𝒏𝒅𝒊𝒏𝒈 𝒊𝒏 𝑻𝒖𝒃𝒆 𝑴𝒊𝒍𝒍𝒔 𝑪𝒆𝒎𝒆𝒏𝒕 𝑺𝒊𝒍𝒐𝒔 𝑪𝒐𝒐𝒍𝒆𝒅 𝒅𝒐𝒘𝒏 𝒂𝒏𝒅 𝑷𝒂𝒄𝒌𝒆𝒅
2. Wet Process (Old Method)
𝑨𝒓𝒈𝒊𝒍𝒍𝒂𝒄𝒆𝒐𝒖𝒔 𝑪𝒂𝒍𝒄𝒂𝒓𝒆𝒐𝒖𝒔
(𝑺𝒍𝒂𝒕𝒆 / 𝑳𝒂𝒕𝒆𝒓𝒊𝒕𝒆) (𝑳𝒊𝒎𝒆 / 𝑴𝒂𝒓𝒃𝒍𝒆)

𝑪𝒓𝒖𝒔𝒉𝒊𝒏𝒈 𝒕𝒐 𝟐𝟓 𝒎𝒎 𝑪𝒓𝒖𝒔𝒉𝒊𝒏𝒈 𝒕𝒐 𝟐𝟓 𝒎𝒎

𝑺𝒕𝒐𝒓𝒂𝒈𝒆 𝑺𝒕𝒐𝒓𝒂𝒈𝒆
𝑾𝒆𝒕 𝑮𝒓𝒊𝒏𝒈𝒊𝒏𝒈 𝒊𝒏 𝑩𝒂𝒍𝒍
𝑴𝒊𝒍𝒍 𝒕𝒐 𝒇𝒐𝒓𝒎 𝑺𝒍𝒖𝒓𝒓𝒚

𝑩𝒍𝒆𝒏𝒅𝒊𝒏𝒈 𝒐𝒇 𝑺𝒍𝒖𝒓𝒓𝒚 𝒕𝒐 𝒄𝒐𝒓𝒓𝒆𝒄𝒕𝒆𝒅 𝑷𝒓𝒐𝒑𝒐𝒓𝒕𝒊𝒐𝒏𝒔

𝑭𝒆𝒅 𝒕𝒐 𝑹𝒐𝒕𝒂𝒓𝒚 𝑲𝒊𝒍𝒏𝒔 𝒇𝒐𝒓 𝒃𝒖𝒓𝒏𝒊𝒏𝒈

2. Wet Process (Old Method)

𝑭𝒆𝒅 𝒕𝒐 𝑹𝒐𝒕𝒂𝒓𝒚 𝑲𝒊𝒍𝒏𝒔 𝒇𝒐𝒓 𝒃𝒖𝒓𝒏𝒊𝒏𝒈 𝟏𝟓𝟎𝟎℃ − 𝟏𝟔𝟎𝟎℃

𝑪𝒍𝒊𝒏𝒌𝒆𝒓𝒔 𝒂𝒓𝒆 𝒇𝒐𝒓𝒎𝒆𝒅

𝑭𝒊𝒏𝒆 𝑮𝒓𝒊𝒏𝒅𝒊𝒏𝒈 𝒊𝒏 𝑻𝒖𝒃𝒆 𝑴𝒊𝒍𝒍𝒔

𝑪𝒆𝒎𝒆𝒏𝒕 𝑺𝒊𝒍𝒐𝒔

𝑪𝒐𝒐𝒍𝒆𝒅 𝒅𝒐𝒘𝒏 𝒂𝒏𝒅 𝑷𝒂𝒄𝒌𝒆𝒅

Testing of Cement 1. Color Test

2. Physical
Field Test
Property Test

Testing of cement
3. Strength Test

Testing of cement is 1. Fineness Test

carried out to analyze the
2. Standard
presence of desirable Consistency Test
properties in it. 3. Setting time
Test
Laboratory Tests
4. Soundness Test

5. Strength Test

6. Chemical
Composition Test
Civil Engineering by Sandeep Jyani Sir
Testing of Cement
I. Field Test
1. Colour test: Cement should possess
uniform grey colour
2. Physical Property Test:
• Should feel smooth when rubbed in
between fingers
• Cement should float for little time and
then sink in water and should not float
over the surface
• Sample should be free from presence
of any lumps which are formed due to
absorption of moisture
Testing of Cement
3. Strength Test
• Prepare a block of cement to be
tested of size 25x25x200 cubic mm
• Immerse in water for 7 days
• Now remove the mould and subject
it to point load of 340N by placing it
over supports 150mm apart
• Sample should show no sign of
failure under the application of this
load
Testing of Cement
II. Lab Test
1. Fineness Test: used to check proper grinding which has direct impact on
rate of hydration, rate of gain of strength and evolution of heat
A. Sieve Test:
• Take 100gm of cement and place it on IS Sieve no. 9 (90 micron)
• Perform sieving for 15mins
• Weight of residue should not exceed 10% of original weight for OPC
B. Air Permeability Test: represented in terms of specific surface area (cm2/gm)
• Blaines air permeability apparatus is used
• Based on relationship between flow of air through cement bed and surface area of cement
particles forming the bed
• For OPC, SSA should not be less than 2250cm2/gm
• For rapid hardening cement, SSA should not be less than 3250cm2/gm
Testing of Cement
2. Standard Consistency Test:
• Standard Consistency should be known before we
know about soundness
• Standard Consistency-permits penetration of vicat
plunger of size 10mm dia and 50 mm height upto a
depth of 33-35mm from top into the mould
• We find the water content at which the cement
consistency is produced
• Take 500gm of cement and add 23% of water by
weight of cement in first trial
• Lower the plunger gently up to surface of mould and
release quickly
• The moisture content at which this cement paste of
standard Consistency is produced is termed as “P”.
Testing of Cement
3. Setting time Test: carried out to know whether cement
is deteriorated due to storage. Two times are associated
with setting of cement:
A. Initial Setting Time
B. Final Setting time

A. Initial Setting time: time which is being measured from

the instant water is added to cement up to the time cement starts
loosing its plasticity.
• Take 500gm cement and gauge it with 0.85P
• Lower the square needle gently and release it quickly
• Note time required by needle to penetrate 33-35mm from top
• This time is called Initial Setting time
✓ For OPC, initial setting time is 30 mins
Testing of Cement
B. Final Setting time: time which is
being measured from the instant water is
added to cement up to the time cement
completely looses its plasticity and attains
sufficient firmness.
• Take 500gm cement and gauge it with
0.85P
• Lower the annular collar with needle
gently and release it quickly
• Final setting time is the time when annular
collar fails to make an impression over the
mould but needle does show
✓For OPC, final setting time is 10 hours
Testing of Cement
4. Soundness Test:
It is important that cement after setting does not show any appreciable change
in volume as it seriously affects the durability of the structure
LE CHATLIER APPARATUS
• Soundness of Cement is due to LIME, MAGNESIA and SULPHUR
A. Soundness due to Lime
• Gauge 100 gm cement with 0.78P and fill the
paste in mould
• Cover top and bottom with glass plates and
immerse entire assembly in water having
temperature 27-32°c for 24hours
• Remove mould and note the displacement of split
with help of indicator arms
• Then again we immerse entire assembly, increase
temperature in 25-30 mins upto boiling point, and
maintain it for next three hours
• Note the displacement of split with the help of
indicator arms
✓The difference in reading in both the parts of test
should not exceed 10mm for OPC
Testing of Cement
4. Soundness Test:
B. Soundness due to Lime and
Magnesia
• This test is sensitive to both Lime and
Magnesia
• Prepare a mould of lean cement of size
25 ×× 25 × 250 𝑚𝑚
• Place in autoclave in which steam
pressure is increased upto 21kg/cm2
and is maintained for next three hours
• The mould is removed, percentage
expansion of the mould is noted in
each direction which should not
exceed 0.8% for OPC