Introduction
Cement is an extremely fine material having adhesive and cohesive properties
which provides a binding medium for the discrete ingredients.
Cement is a product obtained by pulverizing clinker formed by calcinating raw-
materials primarily consisting of lime (CaO), silicate (SiO2) Alumina (Al2O3)
and iron oxide (Fe2O3)
When cement is mixed with water it forms a paste which hardens and bind
aggregates (fine coarse) together to form a hard durable mass called concrete.
Cements used in construction industry can be classified as hydraulic and non-
hydraulic.
Hydraulic cement set and harden extremely fast in presence of water (Due to
the chemical action between cement and water known as hydration) and
results in water resistance product which is stable. This allows setting in wet
condition or underwater and further protects the hardened material from
chemical attack, e.g.: (Portland cement).
Non-hydraulic cements are derived from calcination of gypsum or limestone
because their products of hydration are not resistant to water. However, the
addition of pozzolanic materials can render the gypsum and make cement
hydraulic. Thus, it will not set in wet condition or underwater, rather it sets as
it dries and reacts with carbon-dioxide in the air. It can be attacked by some
aggressive chemicals after setting. E.g.: Plaster of Paris.
The cement experiences the exothermic chemical reactions when comes in
contact with water.
The cement is assumed to have a specific gravity of 3.15.
Standard density of cement is 1440kg/m3 and 1 bag of cement is of 50 kg,
thus volume would be 50/1440 = 0.0347m3 Hence, volume of 1 bag of cement
can be approximated as 0.035 m3 or 35 litres.
Cement can be manufactured either from natural cement stones or artificially
by using calcareous and argillaceous materials.
Types of cement
1. Ordinary Portland Cement (OPC)
It is obtained by Pulverizing argillaceous and calcareous material in correct
proportion.
Portland cement is most common variety of artificial cement and most
commonly known as O.P.C.(Ordinary Portland Cement).
It is available in 3 grades:
a) OPC-33 grade (IS: 269-989)
b) OPC-43 grade (IS: 8112-1989)
c) OPC-53 grade (IS: 12269-1987
The number 33, 43. 53 corresponds to 28 days characteristic compressive
strength of cement as obtained from standard test on cement sand mortar
(1:3) specimens.
The OPC 33 is recommended for concrete mix having strength upto 20
N/mm² i.e. M20.
These are most commonly used in general concrete construction, where
there is no exposure to sulphates.
Due to high fineness, the workability of concrete increases for a given
water-cement ratio. IS10262 has classified the OPC gradewise from “A to F”
based on 28 days compressive strength as follows:
It is presently available in three different grades viz. OPC 33, OPC 43 and
OPC 53. The numbers 33, 43 and 53 correspond to the 28 days
(characteristic) compressive strength of cement as obtained from standard
tests on cement-sand mortar specimens.
It is used in general concrete construction where there is no exposure to
sulphates in the soil or in ground water.
2. Rapid Hardening Cement (RHC)
It is finer than ordinary Portland cement.
It contains more CS and less CS than the OPC.
The 1 day strength of this cement is equal to the 3 days strength of OPC
with the same water cement ratio.
The main advantage of rapid hardening cement is that shuttering may be
removed much earlier, thus saving considerable time and expenses.
Rapid hardening cement is also used for road work where it is imperative to
open the road traffic with the minimum delay.
Cost of Rapid hardening cement is nearly 10-15% more than OPC.
It can be safely exposed to frost as it matures more quickly.
3. Extra Rapid Hardening Cement (ERHC)
It is obtained by mixing calcium chloride (not exceeding 2% by weight of the
rapid hardening cement) with rapid hardening cement.
Addition of CaCl, imparts quick setting properties in extra rapid hardening
cement.
The acceleration of setting, hardening and evolution of heat in the early
period of hydration makes this cement very suitable for concreting in cold
weathers.
The 1 or 2 day strength of extra rapid hardening cement is 25% more than
that of rapid hardening cement.
The gain of strength disappears with age and 90 days strength of extra rapid
hardening cement and rapid hardening cement are nearly the same.
Use of extra rapid hardening cement is prohibited in prestressed concrete
construction. Maximum time of using this cement is 20 minute for mixing,
transporting, placing and compaction
4. Low Heat Cement (LHC)
It is a Portland cement which is obtained by reducing the more rapidly
hydrating compounds, CS and CA and increasing CS.
As per the Indian Standard specifications, the heat of hydration of low-heat
cement shall be as follows:
7 days not more than 65 calories per gm
28 days-not more than 75 calories per gm
Since the rate of gain of strength of this cement is slow, hence adequate
precaution should be taken in its use such as with regard to removal of
formwork, etc.
LHC is used in massive construction works like abutments, retaining walls,
dams, etc. where the
Rate at which the heat can be lost at the surface is lower than at which the
heat is initially generated.
It has low rate of gain of strength, but the ultimate strength is practically
the same as that of OPC.
5. Portland Blast Furnace Slag Cement
This cement is made by intergrinding Portland cement clinker arid
granulated blast furnace slag.
The proportion of the slag being not less than 25% or more than 65% by
weight of cement.
The slag should be granulated blast furnace slag of high lime content, which
is produced by rapid quenching of molten slag obtained during the
manufacture of pig iron in a blast furnace.
In general blast furnace slag cement is found to gain strength more slowly
than the ordinary portland cement.
The heat of hydration of Portland blast furnace slag cement is lower than
that of OPC. So this cement can be used for mass concreting but is
unsuitable for cold weather. It has fairly high sulphate resistance, rendering
it suitable for use in environments exposed to sulphates (in the soil or in
ground water).
It is used for all purpose for which ordinary Portland cement is used.
Because of its low heat evolution, it can be used in mass concrete structure
such as dams, foundations and bridge abutments.
6. Portland Pozzolana Cement (PPC)
It can be produced either by grinding together Portland cement clinker and
pozzolana with the addition of gypsum or by blending uniformly Portland
cement and fine pozzolana.
As per the latest amendment, the proportion of pozzolana may vary from
15 to 35% by weight of cement clinker, Earlier, it was 10 to 25%
A pozzolanic material is essentially a siliccious or aluminous material which
in itself possess no cementitious properties, which in finely divided form
and in the presence of water reacts with calcium hydroxide, liberated in the
hydration process at ordinary temperature to produce compounds
possessing cementitious properties. This is known as pozzolanic action.
The pozzolanic materials generally used for manufacture of Portland
pozzolana cement are calcined clay (IS: 1489 part 2 of 1991) or fly ash (IS:
1489 part 1 of 1991).
PPC produces less heat of hydration and offers great resistance to the attack
of impurities in water than OPC.
PPC is particularly useful in marine and hydraulic constructions, and other
mass concrete structures.
The disadvantage of using PPC is that the reduction in alkalinity reduces the
resistance to corrosion of steel reinforcement. But considering the fact that
PPC significantly improves the permeability of concrete, thereby increases
the resistance to corrosion of reinforcement.
This cement has higher resistance to chernical agencies and to sea water
because of absence of lime.
It evolves less heat and its initial strength is less but final strength (28 days
onward) is equal to OPC
It has lower rate of development of strength than OPC
The average compressive strength of cement mortar (1:3) at
a) At 1 day ± 1 hr 16 MPa (Minimum)
b) At 7 day ± 2 hr 22 MPa (Minimum)
c) At 28 day ± 4 hr 33 MPa (Minimum)
7. Acid Resistant Cement (ARC)
An acid resistant cement is composed of the following:
(i) Acid resistant aggregates such as quartz. Quartzites, etc.
(ii) Additive such as Na SiF (This accelerates hardening).
(iii) Solution of sodium silicate or soluble glass (sodium silicate is a
binding material).
The addition 0.5% of linseed oil or 2% of cerussite increases resistance to
water also.
8. Sulphate Resisting Cement (SRC)
The Portland cement with low C3A and C4AF and ground finer than OPC is
known as sulphate resisting cement and generally C3S and C2S kept about
45% each.
This cement is sulphate-resistant because the disintegration of harden
concrete caused by the chemical reaction of C.A with soluble sulphate lime
MgSO, CaSO and Na,SO, is inhibited.
The setting time are same as that of OPC.
The compressive strength of the cubes should be as follows:
3 Day ± 1 hr 10 N/mm²
7 Day ± 2 hr = 16 N/mm²
28 Day ± 4 hr = 33 N/mm²
This cement is “sulphate resistant” because the disintegration of concrete
caused by the reaction of C3A in hardened cement with a sulphate salt from
outside is inhibited.
It is used in marine structures, sewage treatment works, and in foundations
and basements where soil is infested with sulphates.
However, recent research indicates that the use of sulphate resisting
cement is not beneficial in environments where chlorides are present.
9. Coloured Cement (White Cement)
The process of manufacturing white cement is the same but the amount of
iron oxide which is responsible for greyish colour is limited to less than 1
per cent.
Sodium Alumino Ferrite (Cryolite) Na3, AlF6, is added to act as flux in the
absence of iron [Link] properties of white cement is nearly same as
OPC.
Whiteness of white cement is measured by ISI scale or Hunter’s scale.
The whiteness should not be less than 70% on ISI scale and on Hunter’s
scale it is generally 90%.
The strength of white cement is much higher than what is stated in IS:
8042-1989, the code for white cement.
Grey colour of OPC is due to the presence of iron oxide. Hence in white
cement, Fe₂O, is limited to 1%. Sodium Alumino Ferrite (Cryolite) Na3, AlF6,
is added to act as flux in the absence of iron oxide.
[Link] Alumina Cement (HAC)
It is very different in composition from Portland cement.
In this cement the C.A content is very low due to which it is resistant to
sulphur attacks and chemical attacks.
Its sets quickly and attains higher ultimate strength in a short period. Its
strength after 1 day is about 40 N/mm² and that after 3 days is about 50
N/mm².
It is characterized by its dark colour, high early strength, high heat of
hydration.
The raw materials used for its manufacture consists of limestone (or chalk)
and bauxite which is a special clay with high alumina content.
The bauxite is an aluminium ore. It is specified that total alumina content
should not be less than 32 per cent and the ratio by weight of alumina to
the lime should be between 0.85 and 1.30.
It is resistant to freezing and thawing.
It has an initial setting time of 3.5 hours and final setting time of about 5
hours.
High alumina cement is very expensive to manufacture.
It is used where early removal of the formwork is required
Its rapid hardening properties arise from the presence of calcium
aluminate, chiefly monocalcium. Aluminate (Al2O3, CaO), as the
predominant compound in place of calcium silicates of Portland cement and
for setting and hardening there is no free hydrated lime as in the case of
Portland cement
It must not be mixed with any other type of cement.
[Link] Setting Portland Cement
In the manufacture of this cement, gypsum content is reduced to get the
quick setting property. Also small amount of aluminium sulphate is added.
It is ground much finer than OPC
It sets quickly but does not harden quickly.
Initial setting time = 5 minutes, Final setting time = 30 minutes
It is used when concrete is to be laid under water.
[Link] Cement (IS: 3466)
Masonry cement consists of a mixture of Portland cement or blended
hydraulic cement and plasticizing materials (such as limestone or hydrated
or hydraulic lime) together with other materials introduces to enhance one
or more properties such as setting time, workability, water retention, and
durability.
Addition of these materials gives good workability, reduces shrinkage and
water retentively. This cement is used for masonry works, plaster work etc.
This cement must not be used for concrete work but used far Masonry
construction.
Masonry cement when used for making mortar, incorporates all the good
properties to lime mortar and discards all the non ideal properties of
cement mortar.
[Link] Entraining Cement (AEC)
This cement is made by mixing a small amount of an air entraining agent
with OPC clinker at the time of grinding
It is manufactured by mixing a small amount of air entraining agent Le, 0.1%
to 0.3% with OPC clinker at time of grinding.
It offers good workability due to which it is having higher initial setting time
than OPC.
It is having lesser final setting time as compared to OPC, due to which it
offers resistance to freezing and thawing.
Air entrainment improves workability and w/c ratio can be reduced which in
turn reduces shrinkage etc.
It is yet not been covered by Indian Standard so far.
Some of the air entraining agents are:
(i) Alkali salts of wood resins.
(ii) Synthetic detergents of the alkyl-aryi sulphonate type.
(iii) Calcium ligiosulphate.
It produces tough, tiny, discrete, non-coalescing air bubbles at the time of
mixing in the body of concrete which will modify the properties of plastic
concrete with respect to workability, segregation and bleeding.
[Link] Cement
It is obtained by intergrinding OPC with 0.1-0.4 per cent of water repellant
film-forming substance such as oleic acid or stearic acid.
The water repellant film formed around each grain of cement reduces the
rate of deterioration of the cement during long storage, transportation, or
under unfavourable conditions.
The properties of hydrophobic cement are nearly the same as that of OPC.
The cost of this cement is nominally higher than OPC.
Hydrophobic cement also features greater water resistance and water
impermeability.
