CEMENT

DEFINITION: Cement is defined as a material which possess very good adhesive and
cohesive properties, which make it possible to make bond with other materials (sand and
aggregate) to form compact mass.

MANUFACTURING OF CEMENT: The most common way to manufacture cement is

through a dry method. The first step is to quarry the principal raw materials, mainly limestone,
clay, and other materials. After quarrying the rock is crushed and combined with other
ingredients such as iron ore or fly ash and fed to a cement kiln. The cement kiln heats all the
ingredients to about 2,700 degrees Fahrenheit in huge cylindrical steel rotary kilns lined with
special fire brick. The finely ground raw material or the slurry is fed into the higher end, at the
lower end is a roaring blast of flame, produced by precisely controlled burning of powdered
coal, oil, or gas . As the material moves through the kiln, certain elements are driven off in the
form of gases. The remaining elements unite to form a new substance called clinker. Clinker
comes out of the kiln as grey balls. Clinker is discharged red-hot from the lower end of the kiln
and generally is brought down to handling temperature in various types of coolers. After the
clinker is cooled, cement plants grind it and mix it with small amounts of gypsum and
limestone.

Ingredients of Cement: The three main ingredients of cement are Calcite (CaCO3) Silica
(SiO2) and Alumina (Al2O3), plus minor amounts of iron, limestone and shale. These are
ingredients which are the main part of the cement.
Ingredients percentage %
Cao 60-67
SiO2 17 – 25
Al2O3 3-8
Fe2O3 0.5 – 6.0

TYPES OF CEMENT
Ordinary Portland Cement
It is a basic Portland cement and is used in all general masonry and concrete works.
Rapid Hardning Cement
It develops strength rapidly, setting time is same as OPC. It is accompanied by a high rate of
heat development therefore not used in mass concreting.
Extra Rapid Hardning Cement: It is Obtained by inter grinding calcium chloride with rapid
hardening cement. Quantity of calcium chloride should not exceed 2%.

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Quick Setting Cement: This cement sets very early. This property of cement is brought out by
reducing the gypsum content at the time of clinker grinding. This type of cement is mostly
used in under water construction.
Low Heat Cement: The rise in temp in the interior of a large concrete mass due to the heat of
hydration can lead to serious cracking. Hence it is necessary to limit the rate of heat evolution
in this type of structure. Heat of hydration should not exceed 65 cal / gram and 75 cal / gm at
the end of 7 and 28 days respectively. This cement can be obtained by increasing the
proportion of C2S, reducing C3S and restricting C3A.

Blast Furnace Cement: This type of cement is made by inter grinding Portland cement clinker
and granulated blast furnace slag.( a waste product in the manufacturing of pig iron and which
is a mixture of lime ,silica and alumina).The proportion of slag is limited to 65% of the weight
of mixture. It is used in sea water construction. Unsuitable for cold weather.
High Alumina Cement: It is also known as aluminous cement or aluminate cement. This
cement is used to resist the attack gypsum bearing water and chemical attack.

Expanding Cement: This type of cement is used to form a concrete which neither shrinks nor
expands. The Useful application of this cement is in repair work.

Sulphate Resisting Cement: This type of cement is similar to Ordinary Portland cement
except that the quantity of tri calcium aluminate (C3A) which is the least stable compound in
strictly limited to 5 %.The reaction between gypsum and C3A is to form sulpho-aluminates
which have expansive properties and cause disintegration in concrete this cement is used in
marine conditions and fabrication of pipe/foundation soils containing sulphates.

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 NORMAL CONSISTENCY OF CEMENT
(ASTM - C 187)

INTRODUCTION: This method covers determination of the normal consistency of cement

by means of the Vicat apparatus.

DEFINITION: The percent amount by weight of cement of water required to prepare cement
paste of specified consistency under specific test conditions and specially designed eqpt is
called normal consistency of cement.
APPARATUS
 Scale
 Vicat Apparatus
 Conical Mold
 Graduated cylinder – 200 to 250 ml capacity
 Spatula
 Balance
 Gloves
 Straight edge

PROCEDURE
 The temperature of the air in the vicinity of testing place shall be maintained between
20˚C to 27.5˚C.
 The temperature of the mixing water and moist room shall not vary from 23˚C+1.7˚C.
 The relative humidity of laboratory is not less than 50 percent where the test performed.
 Mix 650gm of cement with measured quantity of clean water manually.
 Quickly form the cement paste.
 Prepared it in shape of ball with gloved hands.
 Toss six times from one hand to the other maintaining the hands about 6 inch apart.
 Press the ball, resting in the palm of the hand, into the larger end of the conical ring,
held in the other hand, completely filling the ring with paste.
 Remove the excess at the larger end by single movement of the palm of the hand.
 Place the ring on its larger end on a base plate and slice off the excess paste at the
smaller end at the top of the ring by single stroke of sharp edge by taking care to not
compress the paste.
 Center the paste confined in the ring, resting on the plate, under rod, the plunger end of
rod shall be brought in contact with the surface of the paste and tighten the setscrew.
 Set the movable indicator to the upper zero mark of the scale or note its initial reading.
 Release the rod quickly by releasing the set screw and allow the plunger to settle for 30
second and then take reading to determine penetration.
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  The time must not exceed than 30sec after completion of mixing.
 The apparatus shall be free of all vibrations during the test.
 The paste shall be of normal consistency when the rod settles to a point 10 + 1mm
below the original surface in 30sec after being released.
 Make trial pastes with varying percentages of water until the normal consistency is
obtained.
 Make each trail with fresh cement.
OBSERVATION & CALCULATION
S/No Water Percentage Penetration (mm) Remark
With in 30 sec
1
2
3
4
5
6
7
8
9
10

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 INITIAL AND FINAL SETTING TIME OF CEMENT
(ASTM : C 191)

INTRODUCTION: A charge is happened in cement consistency after making paste with

addition of definite amount of water. This change in cement consistency is called setting of
cement. The time elapsed to initialize the loss of plastic consistency is called initial setting
time. Similarly minimum time elapsed in which cement paste totally loss its plastic consistency
is called final setting time. Initial and final setting time is measured by specially designed
apparatus called vicat apparatus.
APPARATUS
 Scale
 Vicat Apparatus
 Conical Mold
 Graduated cylinder – 200 to 250 ml capacity
 Spatula
 Balance
 Gloves
 Straight edge

PROCEDURE
 The temperature of the air in the vicinity of the mixing
slab, the dry cement, molds and base plates shall be
maintained between 20˚C to 27.5˚C.
 The temperature of the mixing water and moist room shall
not vary from 23˚C + 1.7˚C.
 The relative humidity of laboratory is not less than 50
percent where the test performed.
 Take 650gm of cement and add clean water with respect
of consistency of that cement.
 Quickly form the cement paste.
 Prepare it in shape of ball with gloved hands.
 Toss six times from one hand to the other
maintaining the hands about 6inch apart.
 Press the ball, resting in the palm of the hand,
into the larger end of the conical ring, held in
the other hand, completely filling the ring with
paste.
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 Remove the excess at the larger end by single movement of the palm of the hand.
 Place the ring on its larger end on a base plate and slice off the excess paste at the
smaller end at the top of the ring by single stroke of sharp edge by taking care to not
compress the paste.
 Center the paste confined in the ring, resting on the plate, under rod, the needle end
of rod shall be brought in contact with the surface of the paste and tighten the setscrew.
 Set the movable indicator to the upper zero mark of the scale or note its initial reading.
 Release the rod quickly after passing 15 min from water added time by releasing the set
screw and allow the needle to settle for 30 second and note it penetration.
 Determine the penetration after every 15min until a 25 mm penetration achieved.
 Determine the time frame from water add to 25 mm penetration and note as Initial
setting time.
 Continue penetrations till paste become hard enough and no more penetration make.
 Note the time frame from water added to zero mm penetration as Final setting.
 Each penetration should be made ¼ inch apart and not closer than 3/8 inch from
previous penetration.
OBSERVATION & CALCULATION
Time Penetration (mm)
S/No. Remarks
(Min) Within 30 Sec
1
2
3
4
5
6
7
8
9
10

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 TENSILE STRENGTH OF CEMENT MORTARS
(ASTM: C 190)

INTRODUCTION: This method covers determination of the tensile strength of cement

mortar employing the briquette specimen.
DEFINITION: The maximum force per unit area required to break the sand cement moisture
solid eight shape mold by pulling it in opposite direction is known as tensile strength of
cement.

APPARATUS
 Weighing Device
 Sieves (#20 and #30)
 Graduated glass cylinder – 100 ml capacity
 Molds
 Trowel
 Testing Machine (Load application rate 2.67 + 0.11 KN/min)

STANDARD SAND
 The sand used for making test specimens shall be natural silica sand. It should be
passing of sieve no.20 and retained of sieve no. 30.
TEMPERATURE & HUMIDITY
 The temperature of air in the vicinity of the mixing slab,
the dry materials, molds and base plates shall be
maintained between 20 and 27.5 ⁰C.
 The temperature of mixing water should 23 + 1.7 ⁰C.
 The relative humidity of the laboratory shall be less
than 50 %.
SAMPLE
 The proportions of the standard mortar shall be 1 part cement to 3 parts of dry standard
sand by mass.
 The quantities of dry materials to be mixed at one time in the batch of mortar not less
than 1000 gm and not more than 1200 gm for making 6 briquettes, whereas 1800 gm
required for nine briquettes.
 The percentage of water used in the standard mortar shall depend upon the percentage
of water required to produce a neat cement paste of normal consistency from the same
sample of cement.
 Weigh the dry materials, place them upon a smooth non-absorbent surface.
 Thoroughly mix dry, sand and form a crater in center.
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  Pour the proper percentage of clean water into the crater and mix it thoroughly, with
hand for 1 ½ minutes.
 Before filling mold, thinly cover the molds with a film of mineral oil.
 Place the molds on glass or metal plates, fill the molds heaping full without
compacting.
 Then press the mortar in firmly with the thumbs.
 Applying the force 12 times to each briquette at point to include the entire surface. The
force shall be simultaneous application of both
thumbs.
 Draw the trowel over the mold.
 Cover the mold with a plane glass or metal plate,
 Rotate the mold about its longitudinal axis.
 Remove the top plate and repeat the operation of
heaping, thumbing and smoothing off.

PROCEDURE
 Keep all specimen, immediately after molding, leave it for 20 to 24 hr in moist room on
base plate.
 After 24 hours remove the specimen from mold and base plate.
 Shift it in to the water for specified period.
 Change the water from water tank on daily basis.
 Test on briquette is performed on 24hr, 3 days, 7 days and 28 days after casting.
 Three samples should cast for mention day testing.
 Remove the sample from water bath after completion of time.
 Wipe each briquette to a surface dry condition.
 Place the briquette in center of machine clip for griping.
 Apply the load continuously at rate of 2.67 KN/min of 0.0445 KN / sec.
 Determine the displacement and maximum load at which briquette break.
 Calculate the tensile strength against respective load (cross area is 1 in2).

FORMULA
Max.Load
Tensilstrength (KN / mm 2 ) =
Cross section Area

Cross section Area of briquette = 1 in2 or 645.16 mm2

Total amount of water required for use to prepare sand cement mortar is as under:-
Water required = (2 x water as consistency of cement) + Sand Constant
(3x (no's of parts of sand w.r.t cement +1)

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 Y = [(2 x P) / (3 x n + 1)] x K
Where:
y = Water required for mortar.
P = Water required for consistency of cement
n = Number of part of sand with respect to cement mass.
K = Constant for sand which is equal to 6.5

OBSERVATION & CALCULATION

Water Casting Testing Tensile Avg Tensile

Sr Consistency Mixing Mass Max Load
Content Date Date Days Strength Strength
no (%) Ratio (%) (KN) (KN/mm2) (KN/mm2)
(gm)

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 COMPRESSIVE STRENGTH OF CEMENT MORTAR
(ASTM : C 109)

INTRODUCTION: This method covers determination of the compressive strength of cement

mortar of 2 in2 cube.
DEFINITION: The maximum force applied per unit area required to break the sand cement
mortar cube by compressing it, known as compressive strength of cement.

APPARATUS
 Weighing Device
 Sieves (#20 and #30)
 Graduated glass cylinder – 100 ml capacity
 Specimen Molds – 2 in cube
 Mixer Bowl and Paddle
 Tamper
 Trowel
 Moisture Cabinet or Water bath
 Compressive Strength Machine (Load application
rate 2.67 + 0.11 KN/min)
STANDARD SAND
 The sand used for making test specimens
shall be natural silica sand. It should be
passing of sieve no.20 and retained of sieve
no. 30.
TEMPERATURE & HUMIDITY
 The temperature of air in the vicinity of the
mixing slab, the dry materials, molds and
base plates shall be maintained between 20 and 27.5 ⁰C.
 The temperature of mixing water should 23 + 1.7 ⁰C.
 The relative humidity of the laboratory shall be less than 50 %.
PROCEDURE
 Make two or three specimens from a batch of mortar for each period for test or test age.
 Apply a thin coating of release agent to the interior faces of the mold and non-
absorptive base plates.
 Prepare mortar with one part of cement with 2.75 part of standard sand by weight.
 Use 0.485 water – cement ratio for all Portland cement and 0.46 for all air entraining
Portland cement.

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  Mix the Materials thoroughly in mixer.
 Fill the mold in two layers.
 Apply 32 stroke per layer with tamp in about 10 second in 4 rounds.
 Remove the additional material and level the top surface with trowel.
 Immediate upon completion of molding place the test specimen in the moist air.
 After 24 hours, remove the mold and base plate, and then place the sample in water
bath as per desired period for curing the specimen at 25 ⁰C.
 Testing age mortar cube are 24 hours, 3 days, 7 days and 28 days.
 After completion of coring period the specimen from water bath, dry its outer surface.
 Weigh the sample and place it compressive strength machine for testing.
 Apply the load with rate of 900 to 1800 N/sec and determine the max load against
failure of cube.
 Divide the Max load with area of contact of cube and calculate compressive strength of
mortar cube.
FORMULA
Max.Load
Compressivestrength (KN / mm 2 ) =
Area of contact

OBSERVATION & CALCULATION

Avg
Water Casting Testing Max Compressi
Sr Mixing Mass Compressive
Content Date Date Days Load ve Strength
No Ratio Strength
(%) (gm) (KN) (KN/mm2) (KN/ mm2)

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 SOUNDNESS TEST OF CEMENT BY AUTO CLAVE EXPENSION
(ASTM: C 151)

INTRODUCTION: This method covers determination of Auto Clave Expansion of Portland

cement by mean of a test on a neat cement specimen.
APPARATUS

 Weighing Device
 Flat Trowel 4 to 6 in(100mm to 150mm)
 Graduated glass cylinder – 250 ml capacity
 Molds 1by 1 inch (25mm by 25mm)
 Rupture Disk temperature 68 to 450 o F(20 to 216 O C)
 Autoclave
 Length Comparator
TEMPERATURE & HUMIDITY
 Molding room (maintain the temperature of the molding room, dry material and mixing
water and the relative humidity of the molding room).
 Moist storage facilities (temperature and the humidity control facility).

PREPRATION OF TEST SPECIMEN

 Mixing cement paste
 Molding specimen
 Storage of test specimen
PROCEDURE
 At 24hours ± 30min after molding, remove the specimens from the moist atmosphere,
immediately obtain a length comparator reading from each specimen, and place in the
autoclave at the room temperature in a rake so that all side of the specimen will be
exposed saturated steam.
 The autoclave shall contain enough water, at an initial temperature of (20 to 28 O C) to
maintain at atmosphere of the saturated steam vapour during the entire test.
 Generally 7 to 10 % of the volume of the autoclave should be occupied by water.
 To permit air to escape from the autoclave during the early portion of the heating
period, leave the vent valve open until steam begins to escape.
 Close the valve and raise the temperature of autoclave at the rate that will bring the
gauge pressure of the steam 295 psi (2 Mpa) in 45 to 75 min from the heat to turn on.
 Maintain the 295 ± 10 psi (2 0.07 Mpa) pressure for 3 hours.
 At the end of 3 h period , shut off the heat supply and cool the autoclave at the such rate
the pressure will be less than 10 psi at the end of 1 ½ h .

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  At the end of 1 ½ h period, slowly release any remaining pressure by partially opening
the vent valve until atmospheric pressure is attained.
 And then open the autoclave and place the test specimen in water at the temperature
above (90 O C).
 Cool the water surrounding the bars at a uniform rate by adding cold water so that the
temperature of water will be lowered to (23 O C) in 15 min.
 Maintain the water surrounding the specimen at 74 O F for an additional 15 min then
remove one the range of 0.11% to 0.94% expansions, bolt the pain , but not the
specimen and obtained the length comparator reading.

CALCULATION
 Calculate the change in length of the test specimen by subtracting the length
comparator reading before autoclaving from that autoclaving and report as present of
effective gauge length to the nearest 0.01%.
 Report the percentage of increase in length as the autoclave expansion.
 Indicate a decrease in length by minus sign prefixed to percent valve.

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 FINENESS OF CEMENT
(ASTM: C 184)

INTRODUCTION: This method covers the determination of the 100% of non-pulverized

material or fineness of hydraulic cement by means of No. 100 and No. 200 sieves.

DEFINITION: The test in which the retained percentage of cement on sieve no.100 or
no.200 is measured. This test is known as fineness of cement by sieves.

APPARATUS
 Sieves no.100 & no. 200
 Balance
 Brush
 Scope

PROCEDURE

 Place a 50gm sample of the cement on the clean, dry No.100 or No.200 sieve with

the pan attached.

 While holding the sieve and pan in hands, sieve with a gentle wrist motion until most of

the fine material has passed through and the residue look fairly clean.

 When the residue appears clean place the cover on the sieve and removes the pan.

 Then, with the sieve and cover held firmly in one hand, gently tap the side of the sieve

with the handle of brush used for cleaning the sieve.

 Dust adhering to the sieve will thus be dislodged and the underside of the sieve may be

swept clean.

 Empty the pan and thoroughly wipe it out with a cloth.

 Replace the sieve in the pan, and carefully remove the cover.

 Return any coarser material that has been caught in the cover during the taping to the

sieve.

 Continue the sieving without the cover for 5 to 10 min. depending on the condition of

cement.

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  If the cement in proper condition, there should now be no appreciable dust neither

remaining in the residue nor adhering to the sieve or pan.

ONE MINUTE TEST

 Hold the sieve, with pan and cover attached, in one hand in a slightly inclined position

and move it forward and backward in the plane of inclination; at same time gently

strike the side about 150 times/min against the palm of the other hand on the upstroke.

 Perform the sieving over a white paper.

 Return any material escaping from the sieve or pan and collecting on the paper to the

sieve.

 After every 25 strokes, turn the sieve about one sixth of revolution, in the same

direction.

 Continue the sieving operation until not more than 0.05 g of the material passes through

in 1 min of continuous sieving.

 Then transfer the residue on the sieve to the balance pan.

 Taking care to brush the sieve cloth thoroughly from both sides to ensure the removal

of all residues from the sieve.

FORMULA
W 
Fineness of cement %  100   R  100
 WT 
Here
WR  Re sidue from sample retained on sieve ( gm)
WT  Mass of sample ( gm)

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OBSERVATION & CALCULATION
Sample Sample mass WT Residue mass WR Fineness of cement
No (gm) (gm) (%)

Result:
Fineness of Cement % = __________

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