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 Cement Variety As per code Quantity in million tonnes.

N (Yr : 1996-97)
1 OPC (Ordinary Portland Gd-33 IS:269-1989 
Cement) Gd-43 IS:8112-1989  48.4 70%
Gd-53 IS: 12269-1987 
2 PPC(Portland Pozzolana IS :1489-1991 13.6 19%
Cement)
3 PBFSC (Portland Blast IS: 455-1989 7.33 10%
Furnace Slag Cement)
4 Others 0.60 1%
Rapid Hardening Cement IS:8041-1990
Low Heat Cement IS :12600-1989
Sulphate Resisting Cement IS :12330-1988
Super sulphated Cement 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 Oxide Abbreviation Approx. Function

compound composition Percentage

1 Tricalcium 3CaO.SiO2 C3S 45-55% Mainly responsible for

Silicate early strength (1 to 7
days)
2 Dicalcium 2CaO.SiO2 C2S 20-30% Mainly responsible for
Silicate later strength (7 days
and beyond)
3 Tricalcium 3CaO.AI2O3 C3A 6-10% C3A increases rate of
Aluminate hydration of C3S. C3A
gives flash set in
absence of gypsum
4 Tetracalcium 4CaO.AI2O3Fe C4AF 15-20% It hydrates rapidly but
Aluminoferrite 2O3 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. Type of Fine- Soundness by Setting time Compressive strength

No. Cement ness Le Cha- Auto (minutes) 1 3 7 28
telier Clave Initial Final day days days days
(m2 / (max.) max Min Max Min. Min Min Min
Kg) Min mm % Mpa Mpa Mpa Mpa
1 33 grade 225 10 0.8 30 600 NS 16 22 33
OPC (IS:
269-1989)
2 43 grade 225 10 0.8 30 600 NS 23 33 43
OPC (IS:
8112-1989)
3 53 grade 225 10 0.8 30 600 NS 27 37 53
OPC (IS:
12269-
1987)
4 Sulphate 225 10 0.8 30 600 NS 10 16 33
Resisting
Cement
(IS : 12330-
1988 )
5 Portland 300 10 0.8 30 600 NS 16 22 33
Pozzolana
Cement (IS:
1489-1991)
Part I
6 Rapid 325 10 0.8 30 600 16 27 NS NS
Hardening
Cement (IS:
8041-1990)
7 Slag 225 10 0.8 30 600 NS 16 22 33
Cement (IS:
455-1989)
8 Super 400 5 NS 30 600 NS 15 22 30
Sulphated
Cement (IS:
6909-1990)
9 Low Head 320 10 0.8 60 600 NS 10 16 35
Cement
(IS:12600-
1989)
10 Masonry * 10 1 90 1440 NS NS 2.5 5
Cement
(IS:3466-
1988)
11 IRS-T40 370 5 0.8 60 600 NS NS 37.5 NS

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. Type of Lime Alumina Insoluble Mag- Sulphuric Loss

No. cement saturat- Iron ratio residue nesi anhydride on
ion (%)Min (%) Max a igniton
factor (%) (%)
(%) Max Max
1 33 grade 0.66Min 0.66 4 6 2.5%Max. When 5
OPC 1.02Max C3A is 5 or less.
(IS:269-1989) . 3% Max. when
C3A is greater
than 5
2 43 grade 0.66 Min 0.66 2 6 2.5%Max. When 5
OPC 1.02Max C3A is 5 or less.
(IS: 8112- 3% Max. when
1989) C3A is greater
than 5
3 53 grade 0.8 Min 0.66 2 6 2.5%Max. When 4
OPC 1.02Max C3A is 5 or less.
(IS:12269- 3% Max. when
1987) C3A is greater
than 5
4 Sulphate 0.66Min NS 4 6 2.5%Max 5
Resisting 1.02Max
Cement
(IS:12330-
1988)
5 Portland NS NS X+4( 6 3% Max 5
Pozzolana 100 - X ) /
Cement (IS: 100
1489-
1991)PartI
6 Rapid 0.66Min 0.66 4 6 2.5%Max. When 5
Hardening 1.02Max C3A is 5 or less.
Cement (IS: 3% Max. when
8041-1990) C3A is greater
than 5
7 Slag Cement NS NS 4 8 3% Max 5
(IS:455-1989)
8 Super NS NS 4 10 6%Min NS
Sulphated
Cement
(IS:6909-
1990)
9 Low Heat NS 0.66 4 6 2.5% Max. When 5
Cement (IS: C3A is 5 or less.
12600-1989) 3% Max. when
C3A is greater
than 5
10 IRS-T40 0.8 Min. 0.66 2 5 3.5% Max. 4
1.02Max

X - Declared percentage of fly ash. NS - Not specified.

 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 Property Deviation from the requirements

1 Strength lower limit
28 days - 2.5 N/sq.mm
7 days - 2.0N/sq.mm
2 Strength- Upper limit 28 days Not specified
3 Setting time -15 minutes
4 Soundness +1mm
5 Sulphate Content +0.5%
6 Chloride Content +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 Concentration of Sulphates Type of cement

expressed as SO3
Total SO3 SO3 In 2:1 In ground water
% water : soil (g/L)
extract (g/L)
1 <0.2 <1.0 <0.3 OPC,PSC or PPC
2 0.2-0.5 1.0-1.9 0.3-1.2 OPC,PSC or PPC
SSC or SRC
3 0.5-1.0 1.9-3.1 1.2-2.5 SSC or SRC
PSC or PPC
4 1.0-2.0 3.1-5.0 2.5-5.0 SSC or SRC
5 >2 >5.0 >5.0 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 Chemicals resistance to sulphates

Cement Moderate High Very High
Ordinary Portland C3A <8% C3A <5% C3A =0%
2C3A+C4AF<25% C4AF< 20%
or or
C4AF +C2F<25% C4AF +C2F<20%
Pozzolana No special C3A <6% C3A < 3.5%
prescription
Slag 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 If both Cl - and SO3 are present ; use blended cement (OPC +

GGBFS)
ii 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.
iii 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.