DTEL (Department for Technology Enhanced Learning)

The Centre for Technology enabled Teaching & Learning , N Y S S, India

Teaching Innovation - Entrepreneurial - Global 1

DEPARTMENT OF CHEMISTRY
I B-SEMESTER

UNIT NO.VI
CEMENT

2
 CEMENT:- SYLLABUS

1 Portland cement: Manufacture,

.
Role of microscopic constituents, Heat of hydration, soundness
2

3 Setting and hardening, Types of cement

4 Ready-mix concrete, Grading of cement, Ferro-cement.

DTEL
3
 CEMENT : SPECIFIC OBJECTIVE / COURSE OUTCOME

Students will be able to:

get the knowledge of an important building material and

understand the role of chemistry involved in manufacturing,
setting- hardening and designing of different types of cement for
1 various applications .

Understand the importance of lubrication& its mechanism and

select suitable lubricants for different jobs by correlating the
requirements and properties of lubricants
2

DTEL 4
LECTURE 1:-INTRODUCTION

Cement is a material possessing adhesive and cohesive property

and capable of bonding materials like stones, bricks building
blocks etc.

DTEL 5
LECTURE 1:-CEMENT History

• Romans were the first to use cement.

TOP TEN CEMENT
• Joseph Aspedin in1824 invented cement. FACTORIES IN INDIA
created the first true artificial cement by
burning ground limestone and clay • ACC Limited
together. • Gujarat Ambuja Cements
Limited
• Romans prepared cement from volcano • Ultratech
ash and lime. • Grasim
• India Cements
• The first cement factory in India was • JK Cement Ltd
started in 1904 in Chennai. • Jaypee Group
• Century Cement
• In 1756, British engineer, John Smeaton • Madras Cements
made the first modern concrete (hydraulic • Birla Corp.
cement)

DTEL 6
 LECTURE 1:- MANUFACTURE Raw materials

• Calcareous materials :
Supply CaO eg. lime stone,chalk
• Argillaceousmaterials:
Supply Al 2O3,SiO2,Fe2O3 eg . Clay,sand
• Fuel oil or coal
• Gypsum

Composition & effect of raw materials

Lime 60-69% Strength
Silica 17-25% Strength , Slow setting
Alumina 3-8 % Strength, Quick setting, Flux
Iron oxide 2-4 % Colour, Flux
Sulpher trioxide 1-5 % Soundness
Alkali oxide 1-3 % Efforescence

DTEL 7
LECTURE 1:- MANUFACTURE Flow chart

Mixing Burning Cooling Grinding Packing

Mixing

DRY WET

DTEL 8
LECTURE 1:- MANUFACTURE Rotary kiln

DTEL 9
LECTURE 1:- MANUFACTURE Temperature Zones & Reactions

• Drying Zone - 400 0C

Removal of water
• Calcination Zone - 10000C
CaCO3 → CaO + CO 2

• Clinkering Zone - 15000C

• 4CaO+Al2O3+Fe2O3 → 4CaO.Al 2O3.Fe2O3(C4AF)

• 3CaO+Al2O3 → 3CaO.Al 2O3(C3 A)

• 3CaO+SiO2 → 3CaO.SiO 2(C3S)

• 2CaO+SiO2 → 2CaO.SiO 2(C2S)

Clinkers

DTEL 10
LECTURE 1:- MANUFACTURE Storage , grinding & packing

Tube mill Siloes

Grinding Packing

DTEL 11
 LECTURE
LECTURE 1:- MANUFACTURE
2:-MICROSCOPIC CONSTITUENTS Properties

• Name % Setting Heat of Rate of

time Hydration hydration
Days Cal/ g
3CaO.Al2O3 45 7 120 73.5%

2CaO.SiO2 25 28 60 37.5%

3CaO.Al2O3 10 1 210 82.5%

4CaO.Al2O3.Fe2O3 9 1 100 57%

CaSO4 5 --

CaO 2 --

MgO 4 --

12

DTEL 12
LECTURE 2:-MICROSCOPIC CONSTITUENTS Strength

DTEL 13
LECTURE 2:- HEAT OF HYDRATION

When Portland cement is mixed with water, heat is

liberated as a result of the exothermic chemical reaction
between cement and water. This heat is called as heat of
hydration. The heat generated by the cement’s hydration
raises the temperature of concrete.
The average heat of hydration of Ordinary portland
cement is of the order of 120 Cal/g
C3A > C3S > C 4AF > C 2S
210 Cal/g 120Cal/g 100 Cal/g 60Cal/g
Significance:
• Avoid Shrinkage cracks
• Formulation of different types of cements
• Maintain proper temperature during setting & hardening
reactions

DTEL 14
LECTURE 2:- SHRINKAGE CRACKS

DTEL 15
LECTURE 2:- SOUNDNESS

“Soundness" refers to the ability of a hardened cement paste to

retain its volume after setting without delayed destructive expansion
This destructive expansion is caused by excessive amounts of free
lime (CaO) or magnesia (MgO). Most Portland cement specifications
limit magnesia content and expansion.

Soundness of cement is tested by Le-Chatelier's test.

Significance:
Avoid expansion cracks,
Structure failure
Structural deformation

DTEL 16
LECTURE 2:- EXPANTION CRACKS

DTEL 17
LECTURE 3:- SETTING AND HARDENING

Cement + water→ Plastic paste →non plastic paste → Hard mass

with high
Setting hardening comp.
strength
• Takes place because of Hydration and hydrolysis reactions of
microscopic constituents resulting in the formation of insoluble
crystalline products.
• Steps:
• Initial setting:
Paste acquires certain stiffening
Standard needle penetrates only up to certain depth
Takes place after 1/2hrs.of mixing
• Final setting:
Takes place after 10 hrs. of mixing
Standard needle dose not penetrate at all.

DTEL 18
LECTURE 3:- SETTING AND HARDENING Reactions

3CaO.Al 2O3 + 6 H 2O → 3CaO.Al 2O3.6 H2O (crystals)

3CaO.Al 2O3 + x.H2O + y.CaSO4 → 3CaO.Al 2O3.y.CaSO 4 . z.H2O

Where, y= (1-3), z=(10-33)

4CaO.Al 2O3.Fe 2O3+ z.H2O → 3CaO.Al 2O3. 6.H 2O + CaO.Fe2O3.H2O

(crystals) (gel)

3CaO.SiO 2 + (x+1) H 2O → 2CaO.SiO 2 . x.H2O + Ca (OH)2

(gel) (crystals)

2CaO.SiO 2 → 2CaO.SiO 2 . x.H2O

(gel)

DTEL 19
LECTURE LECTURE
3:- SETTING
3:- AND HARDENING

DTEL 20
LECTURE 3:- TYPES OF CEMENT

• Portland cements
Rapid Hardening cement

• Blended cement
Portland pozzolana cement

• Non Portland cement

High Alumina cement

DTEL 21
 LECTURE3:-
LECTURE 4:-TYPES OF CEMENT
NUMBER SYSTEM Rapid Hardening Cement

This is manufactured in the same way as that of OPC except keeping

high lime saturation factor and grinding the product to more fineness.

Composition:
C 3S-54% C2S-18% C3A -12% C4AF-08%

Properties:
C3S hydrolysis causes the development of early strength.
Uses:
Rapid hardening cement is used for the constructions where high
early strength is required to develop and for used in concrete
constructions.
It is mostly used for emergency constructions. For eg. Border roads .

DTEL 22
LECTURE 3:- TYPES OF CEMENT High alumina cement

It is manufactured by heating until molten, a mix of limestone and

bauxite and quickly cooling the product.
Composition: 35 to 55% Al 20 3 -35 to 40 %, CaO- 5-10 % silica and
5-15 % Fe 20 3

Properties:
Rapid hardening, very high strength develops within 24 hrs.
Very high heat of hydration.
Refractory, can withstand temperature up to 10000C
Good sulphate resistance, acid resistance

Uses:
For ‘in situ’ constructions.
Constructions under low temperature conditions.
Constructions on seashore, near water bodies.

DTEL 23
LECTURE
LECTURE4:-
4:-TYPES OF CEMENT
NUMBER SYSTEM Portland pozzolana cement

Pozzolana are the materials which they themselves do not have any
hydraulic property but when mixed with lime without heating, produce
hydraulic cementing material.eg. Volcano ash, burnt clay etc.
It is obtained by grinding together Portland cement clinkers, Pozzolana in
3:1 proportion and 6% gypsum.

Properties:
Low heat of hydration
Low porosity
Resistance to sulphate attack.

Uses:
Mass concrete work
Lining of canals
Sea-shore constructions

DTEL 24
LECTURE 4:- GRADING OF CEMENT

Grade refers to the strength of cement in 28 days, (IS: 4031-1988).

33 Grade Cement :28 days strength is less than 33 N/mm2.This cement

is used for general civil construction work under normal environmental
conditions. Due to low compressive strength, this cement is normally not
used where high grade of concrete is required.

43 Grade Cement : :28 days strength lies between 33 to 43 N/mm2,This

the most popular general-purpose cement in the country today. The
production of 43 grade OPC is nearly 50% of the total production of
cement in the country.

53 Grade Cement: :28 days strength lies between 43 to 53 N/mm2 This is

a higher strength cement to meet the needs for higher strength concrete.
For certain specialized works, such as pre-stressed concrete ,precast
concrete requiring consistently high strength concrete, 53 grade OPC is
found very useful at very economical cement content.

DTEL 25
LECTURE
LECTURE4:-
4:-FERROCEMENT
NUMBER SYSTEM

Ferrocement is a form of reinforced concrete(cement, sand,

water) using closely spaced multiple layers of mesh and/or small diameter
rods completely infiltrated with, or encapsulated in, mortar. The most
common type of reinforcement is steel mesh. Other materials such as
selected organic, natural or synthetic fibres may be combined with metallic
mesh. Thus it is a composite material which is used in building or sculpture
with and wire or mesh material.

Properties and uses:

Ferrocement has great strength and economy.
It is fireproof, earthquake safe and does not rust, rot or blow down in
storms.
It has a broad range of applications which include home building,
creating sculptures, repair of existing artifacts and building boats and ships.

DTEL 26
LECTURE
LECTURE4:4:-
FERROCEMENT
NUMBER SYSTEM Advantages & Disadvantages

Advantages:
• Low maintenance costs and long life.
• When overloaded, it will tend to fold instead of crack or rupture.
• low weight .
• Ferrocement has great strength,durability and economy, can also be built
quickly, which can have economic advantages.
• It is fireproof, earthquake safe and does not rust, rot or blow down in storms.

Disadvantages:
The disadvantage of ferrocement constructions is the labor intensive nature of it,
which makes it expensive for industrial application in the western world

DTEL 27
LECTURE 4:REDYMIX CONCRETE Ready Mixed Concrete

Ready Mixed Concrete, or RMC refers to concrete that is specifically

manufactured for delivery to the customer's construction site in a freshly
mixed and plastic or unhardened state. Ready Mixed Concrete is bought
and sold by volume.RMC can be custom-made to suit different
applications. It is manufactured under computer-controlled operations
and transported and placed at site using sophisticated equipment and
methods. At RMC plants, ready mix concrete is mixed using precise
formulas and then transported to construction sites ready to pour. It is
carried to the construction sites in a ‘ transit mixer’.

DTEL 28
LECTURE
LECTURE4:4:-REDYMIX
NUMBERCONCRETE
SYSTEM Advantages & Disadvantages

Advantages :

• Better quality concrete is produced.

• Elimination of storage space for basic materials at site.
• Elimination of Procurement / Hiring of plant and machinery
• Wastage of basic materials is avoided.
• Labour associated with production of concrete is eliminated.
• Time required is greatly reduced.
• Noise and dust pollution at site is reduced.

Disadvantages:

• Traveling time from the plant to the site is critical over longer distances
• Ready mix concrete is marginally expensive compared to site mix.

DTEL 29
 THANK YOU

DTEL 30
 References:
BOOKS:
• A Text book of Engineering Chemistry by S S. Dara; S.Chand &
Co New Delhi. Eleventh Edition.
• Engineering Chemistry by Jain & Jain; Dhanpat Rai & sons New
Delhi. Sixteenth Edition.

WEB:
• www.cement.org/cement-concrete-basics/how-
cement-is-made
• http://www.tutorvista.com/content/chemistry/chemistry -ii/
chemical-compounds/cement.php#concrete
31

DTEL 31