DURABILITY OF CONCRETE STRUCTURES

CHAPTER - 6

Selection Of Cement
6.1
It is necessary to use cement of appropriate grade and type for specific
applications and environment conditions. Various type of cement produced in
India are shown in table 6.1.
Table 6.1
Various type of cement produced in India
S
N
1

2
3
4

Cement Variety

As per code

OPC (Ordinary Portland

Cement)

Gd-33 IS:269-1989
Gd-43 IS:8112-1989
Gd-53 IS: 12269-1987
IS :1489-1991

Quantity in million tonnes.

(Yr : 1996-97)

48.4
70%

13.6
19%

IS: 455-1989

7.33

10%

0.60

1%

PPC(Portland Pozzolana
Cement)
PBFSC (Portland Blast
Furnace Slag Cement)
Others
Rapid Hardening Cement
Low Heat Cement
Sulphate Resisting Cement
Super sulphated Cement

IS:8041-1990
IS :12600-1989
IS :12330-1988
1S:6909-1990
TOTAL

70.00

6.2 Major Compounds in Cement: In all the Portland Cements, there are
four major compounds. The variation in percentage composition of
compounds influences the properties of cement. These compounds are given
in table 6.2 below:
Table 6.2
Composition of cement
SN

Name of
compound

Oxide
composition

Abbreviation

Approx.
Percentage

Function

Tricalcium
Silicate

3CaO.SiO2

C3S

45-55%

Dicalcium
Silicate

2CaO.SiO2

C2S

20-30%

Tricalcium
Aluminate

3CaO.AI2O3

C3A

6-10%

Tetracalcium
Aluminoferrite

4CaO.AI2O3Fe
2O3

C4AF

15-20%

Mainly responsible for

early strength (1 to 7
days)
Mainly responsible for
later strength (7 days
and beyond)
C3A increases rate of
hydration of C3S. C3A
gives flash set in
absence of gypsum
It hydrates rapidly but
its
contribution
to
strength is uncertain
and generally very
low.

DURABILITY OF CONCRETE STRUCTURES

6.3 The physical and chemical characteristics of various cements are given in
Table 6.3 & 6.4
Table 6.3
Physical characteristics of various types of cement
Sr.
No.

10

11

Type of
Cement

33 grade
OPC (IS:
269-1989)
43 grade
OPC (IS:
8112-1989)
53 grade
OPC (IS:
122691987)
Sulphate
Resisting
Cement
(IS : 123301988 )
Portland
Pozzolana
Cement (IS:
1489-1991)
Part I
Rapid
Hardening
Cement (IS:
8041-1990)
Slag
Cement (IS:
455-1989)
Super
Sulphated
Cement (IS:
6909-1990)
Low Head
Cement
(IS:126001989)
Masonry
Cement
(IS:34661988)
IRS-T40

(m2 /
Kg) Min
225

Soundness by
Le Cha- Auto
telier
Clave
(max.) max
mm
%
10
0.8

Setting time
(minutes)
Initial
Final
Min
Max
30

600

Compressive strength
1
3
7
28
day
days days days
Min. Min Min
Min
Mpa Mpa Mpa
Mpa
NS
16
22
33

225

10

0.8

30

600

NS

23

33

43

225

10

0.8

30

600

NS

27

37

53

225

10

0.8

30

600

NS

10

16

33

300

10

0.8

30

600

NS

16

22

33

325

10

0.8

30

600

16

27

NS

NS

225

10

0.8

30

600

NS

16

22

33

400

NS

30

600

NS

15

22

30

320

10

0.8

60

600

NS

10

16

35

10

90

1440

NS

NS

2.5

370

0.8

60

600

NS

NS

37.5

NS

Fineness

NS-Not specified.
* residue on 45 Micron IS sieve, Max, Percent (by wet sieving) is 15.

DURABILITY OF CONCRETE STRUCTURES

Table 6.4
Chemical characteristics of various types of cement
Sr.
No.

Type of
cement

Lime
saturation
factor
(%)
0.66Min
1.02Max
.

Alumina
Iron ratio
(%)Min

Insoluble
residue
(%) Max

0.66

Magnesi
a
(%)
Max
6

Sulphuric
anhydride

Loss
on
igniton
(%)
Max
5

33 grade
OPC
(IS:269-1989)

43 grade
OPC
(IS: 81121989)

0.66 Min
1.02Max

0.66

53 grade
OPC
(IS:122691987)

0.8 Min
1.02Max

0.66

Sulphate
Resisting
Cement
(IS:123301988)
Portland
Pozzolana
Cement (IS:
14891991)PartI
Rapid
Hardening
Cement (IS:
8041-1990)

0.66Min
1.02Max

NS

2.5%Max. When
C3A is 5 or less.
3% Max. when
C3A is greater
than 5
2.5%Max. When
C3A is 5 or less.
3% Max. when
C3A is greater
than 5
2.5%Max. When
C3A is 5 or less.
3% Max. when
C3A is greater
than 5
2.5%Max

NS

NS

X+4(
100 - X ) /
100

3% Max

0.66Min
1.02Max

0.66

NS

NS

2.5%Max. When
C3A is 5 or less.
3% Max. when
C3A is greater
than 5
3% Max

NS

NS

10

6%Min

NS

0.66

0.8 Min.
1.02Max

0.66

2.5% Max. When

C3A is 5 or less.
3% Max. when
C3A is greater
than 5
3.5% Max.

7
8

10

Slag Cement
(IS:455-1989)
Super
Sulphated
Cement
(IS:69091990)
Low Heat
Cement (IS:
12600-1989)

IRS-T40

X - Declared percentage of fly ash.

NS - Not specified.

5
NS

DURABILITY OF CONCRETE STRUCTURES

6.4 Important properties and draw backs in Indian specifications:
i)
Initial setting time: As per Indian standard, the minimum initial setting
time is 30 minutes. Considering the hot weather conditions prevailing in India,
it is all the more necessary to insist on a higher initial setting time for cement
e.g. at least 60 minutes.
ii)
Chemical properties: The chloride content is a very important
requirement affecting the durability of concrete and is missing in IS
specification.
iii)
Fineness of cement: IS code provides for a minimum specific surface
of 225M2/Kg except for Portland Pozzolana Cement. Most of the Indian
cement manufacturers resort to producing cement with increased fineness
even higher than 300 presumably to improve the compressive strength of
cement. This is not desirable in hot weather concreting. It is, therefore,
necessary to lay down upper limit of fineness while ordering cement or
framing contract conditions for concrete works. The upper limit should be
around 280.
iv)
When should a cement be rejected: The table 6.5 gives list of major
defects in cement in respect of various properties . IS does not specify.
Table 6.5
SN
1

2
3
4
5
6

Property
Strength lower limit
28 days
7 days
Strength- Upper limit 28 days
Setting time
Soundness
Sulphate Content
Chloride Content

Deviation from the requirements

- 2.5 N/sq.mm
- 2.0N/sq.mm
Not specified
-15 minutes
+1mm
+0.5%
+0.01%

v)
Heat of hydration: Heat of hydration should be specified for the
cements for hot weather concreting it should be (i) 7 days <270 Kj/Kg and for
28 days < 320Kj/Kg. For cold weather it should be more .
6.5 Factors affecting choice of cement: Following factors govern choice
of cement.

Durability Characteristics
Functional requirement - Deflection, crack width etc.
Design parameters- Strength, fineness, setting time requirement
etc.
Speed of construction- Time for construction etc.
Environmental Conditions- Ground conditions, soluble salts,
sulphates, Chemical plants etc.

DURABILITY OF CONCRETE STRUCTURES

6.6 Suitability of various types of cement:
i)
33 grade OPC: It is used for normal grade of concrete upto M-20,
plastering, flooring, grouting of cable ducts in PSC works etc. The fineness
should be between 225 and 280.
ii)

43 grade OPC:
It is the most widely used general purpose cement.
For concrete grades upto M-30, precast elements.
For marine structures but C 3A should be between 5 - 8%.

iii) 53 grade OPC:

For concrete grade higher than M-30, PSC works, bridge, roads,
multistoried buildings etc.
For use in cold weather concreting.
For marine structures but C 3A should be between 5 - 8%.
iv) Portland Slag Cement (PSC) i.e. OPC + granulated slag: It gives low
heat of hydration. The slag should be more than 50% and upto 70%. It is used
for ;
Marine and off shore structures- very high chloride and sulphate
resistant.
Sewage disposal treatments works
Water treatment plants
Constructions which are expected to be attacked by dissolved
chlorides and sulphate ions.
Should be mainly used for all future structures.
v)

Portland Pozzolana Cement: IS: 1489(part-I) - 1991 (using flyash):

It gives low heat of hydration and reduces the leaching of calcium
hydroxide. This cement
should be used only after proper
evaluation. This should be tested as per IS: 1489 (Pt I) 1991. It
is used for :
hydraulic structures- dams, retaining walls
Marine structures
Mass concrete works- like bridge footings
under aggressive conditions
Masonry mortar and plastering.

vi)
SRC- Sulphate Resisting Cement: (C3A < 3%) Sulphate Resisting
Portland Cement is a type of Portland Cement in which the amount of
tricalcium aluminate (C3A) is restricted to lower than 5% and 2C 3A + C4AF
lower than 25%. The SRC can be used for structural concrete wherever OPC
or PPC or Slag Cement are usable under normal conditions.
The use of SRC is particularly beneficial in such conditions where the
concrete is exposed to the risk of deterioration due to sulphate attack, for
example, in contact with soils and ground waters containing excessive
amounts of sulphates as well as for concrete in sea water or exposed directly

DURABILITY OF CONCRETE STRUCTURES

to sea coast . The IS 456 (revised draft code) has made elaborate provisions
for use of particular type of cement against different percentages of soluble
sulphate salts. These provisions are given in table 6.6 below:
Table 6.6
Class

In soil

1
2

<0.2
0.2-0.5

Concentration of Sulphates
expressed as SO3
In ground water
SO3 In 2:1
(g/L)
water : soil
extract (g/L)
<1.0
<0.3
1.0-1.9
0.3-1.2

0.5-1.0

1.9-3.1

1.2-2.5

4
5

1.0-2.0
>2

3.1-5.0
>5.0

2.5-5.0
>5.0

Total SO3
%

Type of cement

OPC,PSC or PPC
OPC,PSC or PPC
SSC or SRC
SSC or SRC
PSC or PPC
SSC or SRC
SRC or SSC with
protective coating.

The use of SRC is recommended for following applications:

Foundations, piles
Basement and underground structures
Sewage and water treatment plants
Chemical factories
Suitable for underground works where Sulphate is present in the
Soil and water.
Attention:
i)
Sulphate resisting cement is not suitable where there is danger of
chloride attack. This will cause corrosion of rebar.
ii) If both Chlorides and Sulphates are present, Ordinary Portland
Cement with C3A between 5& 8 should be used.
Sulphate resistance of cements : Chemical resistance of various types of
cement in different environmental conditions is given in table 6.7 .
Table 6.7
Type of
Cement
Ordinary Portland

Pozzolana
Slag

Chemicals resistance to sulphates

Moderate
High
Very High
C3A <8%
C3A <5%
C3A =0%
2C3A+C4AF<25% C4AF< 20%
or
or
C4AF +C2F<25% C4AF +C2F<20%
No special
C3A <6%
C3A < 3.5%
prescription
Slag > 36%
Slag > 70%
C 3A < 2%

DURABILITY OF CONCRETE STRUCTURES

vii)
Low heat portland cement :
Low Heat Portland Cement is
particularly suited for making concrete for dams and many other types of
water retaining structures, bridge abutments, massive retaining walls, piers
and slabs etc. In mass concreting, there is often considerable rise in
temperature because of the heat produced as the cement sets and hardens.
The shrinkage which occurs on subsequent cooling sets up tensile stresses in
the concrete, may result in cracking. The use of low heat cement is
advantageous since it evolves less heat than OPC. This cement is not
available in the market on regular basis and has to be obtained on specific
orders.
viii) Rapid hardening cement : The Rapid Hardening Cement is used for
repair and rehabilitation works and where speed of construction and early
completion is required due to limitations of time, space or other reasons. The
cement is to be used in cold weather concreting i.e. temp < 5 0C. Rapid
hardening cement is basically OPC but its fineness is 3250 cm 2/gm against
2250cm2/gm in case of OPC. The compressive strength after 1 day is 16
N/mm2 and that of 3 days 27N/mm 2. These days higher grade OPC are
available in the country to meet these requirements and therefore, this cement
is not being manufactured and marketed on regular basis. The characteristics
of this cement can be effectively met by only good quality 53 grade OPC.
ix) Hydrophobic portland cement : Hydrophobic Portland Cement is
manufactured on special requirement for high rainfall areas to improve the
shelf life of the cement. The cement particles are given a chemical coating
during manufacturing which provides water repelling property and the cement
is not affected due to high humidity and can be stored for a longer period .
This has to be obtained on special order from the cement manufactures.
x)
IRS-T 40 special grade cement : IRS-T 40 Special Grade Cement is
manufactured as per specification laid down by Ministry of Railways under
IRS-T 40:1985. It is a very finely ground cement with high C 3S content
designed to develop high early strength required for manufacture of concrete
sleeper for Indian Railways. This cement can also be used with advantage for
other applications where high strength concrete is required. This cement can
be used for prestressed concrete elements, high rise buildings, high strength
concrete etc.
7.

Summary
i
ii

iii

If both Cl - and SO3 are present ; use blended cement (OPC +

GGBFS)
If only Cl- like Sea water - never use Sulphate Resistant Cement .
Cl- diffusion is maximum in sulphate Resistant Cement. Use
blended Cement. The C 3A content should be between 5-8%. Use
low heat OPC. (OPC 30% +GGBFS 70%) is the best combination.
If SO3 present: C3A < 5. Use sulphate resistant cement (which is
equal to grade 33 OPC in strength). High strength and sulphate
resistance do not go together, or use blended cement with GGBFS
or fly ash.

DURABILITY OF CONCRETE STRUCTURES

iv

For high grade concrete > 100 Mpa, use OPC53 (30-40%)
+GGBFS (>50% ) + Silica fumes (10%), with w/c around 0.30.
Curing is very important. It must start within half an hour.
v For better plaster use OPC 33 : GGBFS as 1: 2. Plastering by
Grade 53 or OPC will cause shrinkage cracks.
vi The cement should not have very high fineness.
vii For grouting of cables use only Gd 33 cement with fineness less
than 260.
viii Ground soil and quality of water (especially in case of sea and
marine structures), should be examined and specifications for the
cement to be used for the structure should be decided at the
planning stage itself.
ix The percentage of mineral admixtures in blended cement should
be as under:
GGBFS
> 50% (upto 70%)
Fly Ash
> 10 % (upto 25%)
Silica Fumes = 8 to 10%.
Attention: The rate of development of strength is slow in case of
blended cement i.e. Portland pozzolana cement and Portland slag
cement etc., as compared to ordinary Portland cement. This aspect
should be taken care while planning to use blended cement.
Accordingly, stage of prestressing period of removal of form work and
period of curing etc. should be suitably increased.