1 Portlandcement

CHAPTER CONSTRUCTION
MATERIALS
1 Lecture Notes:
Dr Mohamad El Dandachy
Beirut Arab University
Portland Cement
Reference:
Portland Cement Association
Design and Control of
Concrete Mixtures
CONSTRUCTION MATERIALS Portland Cement Association
What is Portland Cement
• Portland cement is a hydraulic cement composed primarily of hydraulic

calcium silicates.
• Its name is Portland as it resembles in its final state to the color of premier
building stone of England (Portland limestone).
• It is a fine powder that when mixed with water becomes the ‘glue’ that holds
aggregates together in concrete.
Dr Mohamad El Dandachy Beirut Arab University Fall 2018-2019 1-2

Sources of Raw Materials
• Based on raw materials proportions, many types of cement exist.

THE CEMENT MANUFACTURING PROCESS

1- quarry
. BLASTING . dumper
loader
TRANSPORT
Quarry
face
. CRUSHING &
TRANSPORTATION storage
at the
crushing plant
conveyor
• BLASTING : The raw materials that are used to manufacture cement (mainly limestone
and clay) are blasted from the quarry.
• TRANSPORT : The raw materials are loaded into a dumper.
• CRUSHING AND TRANSPORTATION : The raw materials, after crushing, are
transported to the plant by conveyor belts. The plant stores the materials before they are
homogenized.


2- Raw grinding and burning
. RAW
GRINDING
preheating .
BURNING
kiln
cooling
clinker
• RAW GRINDING : The raw materials are very finely ground to produce the raw mix.
• BURNING : The raw mix is preheated before it goes into the kiln, which is heated by
a flame that can be as hot as 2000 °C. The raw mix burns at 1500 °C producing
clinker which, when it leaves the kiln, is rapidly cooled with air fans. So, the raw
mix is burnt to produce clinker : the basic material needed to make cement.


3- Grinding, storage, packing,
dispatch Gypsum and the secondary additives are
added to the clinker.
. GRINDING
clinker Finish
storage grinding
. STORAGE, PACKING,
DISPATCH
silos
dispatch
bags
.GRINDING : The clinker and the gypsum are very finely ground giving a “pure
cement”. Other secondary additives and cementitious materials can also be added to
make a blended cement.
.Gypsum: is a soft sulfate mineral composed of calcium sulfate dihydrate, with the
chemical formula CaSO. 4· 2H2O.
.STORAGE, PACKING, DISPATCH :The cement is stored in silos before being
dispatched either in bulk or in bags to its final destination.
Clinker Gypsum

Background: Portland Cement Clinker Components,Oxides

& Compounds.
Oxides Compounds
• Rust Fe2O3 C4AF C = CaO
S = SiO2
• Alumina AL2O3 C3A A = Al2O3
F = Fe2O3
• Silica S̅ = SO3
SiO2 C2S H = H 2O
K = K2 O
• Lime CaO C3S N = Na2O
Chemical Composition & Industrial Process
Preparing row materials
Lime stone Sand

Sand silt Iron Ore
Iron Ore
Ca CO3.2H2O SiO2
SiO2 Fe2O3+ Al2O3+Sio3+SiO2 Fe2O3
Fe2O3
Crushing & Pre-Heating
Calcium Oxide Silicon Oxide Aluminum & Ferric Oxides Ferric oxide
Ca O SiO2 Fe2O3+ Al2O3+SiO3 Fe2O3
Weighing , kiln feeding & burning

Tri-calcium Silicate Di-calciumSilicate Tri-calcium Aluminates Tetra calcium Aluminates Ferrite
C3S C2S C3A C4AF
3 CaO · SiO2 2 CaO · SiO2 3 CaO · Al2O3 4 CaO · Al2O3 · Fe2O3
Phases of clinker for different types of Portland cements
Adding proper ratio of gypsum & grinding
Type I Type IIII TypeIIIIII

Type TypeIVIV
Type TypeVV
Type
OPC PC
Modified PC Highearly
High earlyPC
PC Lowheat
Low heatPC
PC SRC
SRC

Formation of Chemical Reactions.
Fe2O3 AL2O3 CaO
C4AF
AL2O3 CaO
C3 A SiO2 CaO
C2 S CaO
C3 S
Dr Mohamad El Dandachy Beirut Arab University Fall 2018-2019 1 - 10

Effect of changes in Fe2O3

on the C4AF and C3A
C4AF
Fe2O3
C 3A

Effect of changes in SiO2

on the C2S and C3S
C2S
SiO2
C3S

Cement Compounds & Hydration

CSH: Calcium Silicate Hydrate
Tr-calcium Gaining
Aluminates Form compressive
Gel CSH
C3A the strength
P paste
Tetra calcium
ort
Portland Cement.
Aluminates structur
la Ferrite e
(CH) Fill the Provide alkaline
nd C4AF Ca (OH)2 or
pores protective
C
e Tri-calcium
Hydration paste + medium for
m Silicate process. structure steel bars
e
nt C3S Mixed with Water
Voids
. Reduce
Heat
Heatofof
Di-calcium
Silicate Hydration
Hydration + Durability
Crack
Cracks
C2S s

Cement Phases & rate of releasing heat of hydration.
800
Tr-calcium
Aluminates 750
710
C3A Hydration
P process
ort
Portland Cement.
Tri-calcium
la Silicate
nd
C C3S 420
e 380
m Tetra calcium
e Aluminates
330
nt Ferrite
. C4A 170
130
F Di-calcium 80 130
80
Silicate 40
C2S da y 3 da y 7 da y 28

Effect of Heat of hydration on durability
Fat
Calories Per
9
Gram
Starch 4
Sugars
Sugar 4
s
Proteins
Protein 4
s
Type II 63 (7d.)
Type I 80 (7d.)
• Cement heat of hydration is one of the most important factors affecting

durability as it increases generation of cracks in concrete and causes
concrete deterioration specially in the aggressive media.

Hydration of cement phases.
3days 7days 28days

Tri-calcium Ettringite
Aluminates Setting of Hydration
C3A cement paste process.
paste
Po Mono
Tetra calcium
Portland Cement.
r Aluminates ( sulfate)
tl Setting of
a
n Ferrite
d cement paste
C4AF
C paste
e
m
e Early
n compressive
t. Tri-calcium Silicate
strength CSH
C3S
3days
&7days
Di-calcium
ultimate
compressive
+
Silicate strength
starting from
CH
C2S
28days

Heat of Hydration of Pure Compounds
Heat of Hydration
(cal/gr) • The amount of heat liberated is
affected by the fractions of the
C3S 120
compounds of the cement.
C2S 62
• Heat of Hydration(cal/gr)=
C3A 207
• 120*(%C3S)+62*(%C2S)+
C4AF 100 207*(%C3A)+100*(C4AF)

The requirement of ASTM C 150 varies in the

three types of cement as follows :
C3A
1. The content Of C3A Type V SRC Type II Type I OPC
5% 8%
2. The Content of SO3. Type V SRC Type II Type I OPC
2.5% 3% 3.5
%
SO3
For type II chemical analysis is more restrict consenting defining the content of
each of:
• Silicone oxide 20% minimum,
• Aluminum oxide & ferric Oxide that are 6% maximum
• Summation of contents of the component C3S & Component C3A is
58 % maximum
Type II production needs more accuracy in Quality

control a16s it is more restricted in its components

Effects of cement chemical components & physical

properties on concrete properties
Cement Effects
Place ability Cement amount, fineness, setting characteristics
Strength Cement composition (C3S, C2S and C3A), loss on ignition,

fineness
Drying Shrinkage SO3 content, cement composition
Permeability Cement composition, fineness
Resistance to sulfate C3A content
Resistance to C3A content
Chlorides
Alkali Silica Alkali content
Reactivity
Cracking Cement content, Heat of hydration, C3A, C3S, air
entrained
Corrosion of Cement Composition (esp. C3A content)
embedded
steel
C3A content is the most important component affecting properties of concrete,

specially vis-à-vis durability .
Cement Hydration

Types of Portland Cement (ASTM C 150)

Portland cement types and their uses:
Cement Use
type
I1 General purpose cement, when there are no extenuating conditions
II2 Aids in providing moderate resistance to sulfate attack
III When high-early strength is required
IV3 when low heat of hydration is required`
V4 When high sulfate resistance is required

IA4 A type I cement containing an integral air-entraining agent
IIA4 A type II cement containing an integral air-entraining agent
IIIA4 A type III cement containing an integral air-entraining agent
1Cements that simultaneously meet requirements of Type I and Type II are also widely available.
2Type II low alkali (total alkali as Na2O < 0.6%) is often specified in regions where aggregates susceptible to alkali-silica reactivity are employed. 3
3Type IV cements are only available on special request.
4These cements are in limited production and not widely available.

Standard Cements (ASTM)

• Type I: Ordinary Portland Cement
• Suitable to be used in general concrete construction when special
properties are not required.
• Type II: Modified Portland Cement

• Suitable to be used in general concrete construction. Main difference
between Type I&II is the moderate sulfate resistance of Type II cement
due to relatively low C3A content (≤%8). Since C3A is limited rate of
reactions is slower and as a result heat of hydration at early ages is less.
• It is suitable to be used in small scale mass concrete like retaining
walls.

Type III:
• High Early Strength P.C. Strength development is rapid.

3 days f’c = 7 days f’c of Type I
• It is useful for repair works, cold weather & for early demolding.
• Its early strength is due to higher C3S & C3A content.
Type IV: Low Heat P.C.
• Generates less heat during hydration & therefore gain of strength is

slower.
• In standards a maximum value of C3S & C3A & a minimum value for
C2S are placed.
• It is used in mass-concrete and hot- weather concreting.

Type III High Early Strength Cements

Moderate and Low Heat Cements
• Moderate heat and low heat cements minimize heat generation in massive elements
or structures such as (left) very thick bridge supports, and (right) dams.

Type V Portland Cement

• Type V: Sulfate Resistant P.C.
• Used in construction where concrete will be subjected to external

sulfate attack – chemical plants, marine & harbor structures.
• During hydration C3A reacts with gypsum & water to form ettringite.
In hardened cement paste calcium-alumino-hydrate can react with
calcium&alumino sulfates, from external sources, to form ettringite
which causes expansion & cracking.
• C-H and sulfates can react & form gypsum which again causes
expansion & cracking.
• * In Type V C3A is limited to 5%.

Type II & Type V

Sulfate Resistant
Cements
• Concrete exposed to high-sulfate soils

Outdoor Sulfate Test
Type V Cement Type V Cement

W/C-ratio = 0.65 W/C-ratio = 0.39

Type IA, IIA, IIIA: Air Entrained Portland Cement
• Only difference is adding an air- entraining agent to the

cement during manufacturing to increase freeze-thaw
resistance by providing small sized air bubbles in concrete.

Composition for Cements
Average Notes
ASTM Type & Name Compound
of P.C. Composition
C3S C2S C3A C4AF
Type I - O.P.C. 49 25 12 8 General Purpose
For Moderate Heat
of Hydration
Type II - Modified 46 29 6 12
Type III - High C3S&C3A increased,
Early Strength C2S decreased
56 15 12 8
Type IV - Low
Heat P.C.
30 46 5 13 C2S increased
Type V - Limit on
Sulfate C3A≤5%,
43 36 4 12
Resistant P.C. 2C3A+C4AF≤2
5%

(Amount of iron and

magnesium oxides are
minimized to negligible)


Blended Cements










• Soundness of cement is the property by virtue of which the cement does not undergo any
appreciable expansion (or change in volume) after it has set, thus eliminating any chances of
disrupting the mortar or concrete.



Heat Evolution during cement hydration







1 Portlandcement

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CHAPTER CONSTRUCTION

What is Portland Cement

• Portland cement is a hydraulic cement composed primarily of hydraulic

Dr Mohamad El Dandachy Beirut Arab University Fall 2018-2019 1-2

Sources of Raw Materials

• Based on raw materials proportions, many types of cement exist.

Dr Mohamad El Dandachy Beirut Arab University Fall 2018-2019 1-3

THE CEMENT MANUFACTURING PROCESS

Dr Mohamad El Dandachy Beirut Arab University Fall 2018-2019 1-4

THE CEMENT MANUFACTURING PROCESS

Dr Mohamad El Dandachy Beirut Arab University Fall 2018-2019 1-5

THE CEMENT MANUFACTURING PROCESS

Dr Mohamad El Dandachy Beirut Arab University Fall 2018-2019 1-7

Background: Portland Cement Clinker Components,Oxides

Chemical Composition & Industrial Process

Preparing row materials

Lime stone Sand

Weighing , kiln feeding & burning

Phases of clinker for different types of Portland cements

Adding proper ratio of gypsum & grinding

Type I Type IIII TypeIIIIII

Dr Mohamad El Dandachy Beirut Arab University Fall 2018-2019 1-9

Formation of Chemical Reactions.

Fe2O3 AL2O3 CaO

Dr Mohamad El Dandachy Beirut Arab University Fall 2018-2019 1 - 10

Effect of changes in Fe2O3

Dr Mohamad El Dandachy Beirut Arab University Fall 2018-2019 1 - 11

Effect of changes in SiO2

Dr Mohamad El Dandachy Beirut Arab University Fall 2018-2019 1 - 12

Cement Compounds & Hydration

Dr Mohamad El Dandachy Beirut Arab University Fall 2018-2019 1 - 13

Cement Phases & rate of releasing heat of hydration.

Dr Mohamad El Dandachy Beirut Arab University Fall 2018-2019 1 - 14

Effect of Heat of hydration on durability

• Cement heat of hydration is one of the most important factors affecting

Dr Mohamad El Dandachy Beirut Arab University Fall 2018-2019 1 - 15

Hydration of cement phases.

3days 7days 28days

Dr Mohamad El Dandachy Beirut Arab University Fall 2018-2019 1 - 16

Heat of Hydration of Pure Compounds

Dr Mohamad El Dandachy Beirut Arab University Fall 2018-2019 1 - 17

The requirement of ASTM C 150 varies in the

Type II production needs more accuracy in Quality

Dr Mohamad El Dandachy Beirut Arab University Fall 2018-2019 1 - 18

Effects of cement chemical components & physical

Strength Cement composition (C3S, C2S and C3A), loss on ignition,

C3A content is the most important component affecting properties of concrete,

Dr Mohamad El Dandachy Beirut Arab University Fall 2018-2019 1 - 20

Types of Portland Cement (ASTM C 150)

I1 General purpose cement, when there are no extenuating conditions

II2 Aids in providing moderate resistance to sulfate attack

III When high-early strength is required

IV3 when low heat of hydration is required`

V4 When high sulfate resistance is required

IIA4 A type II cement containing an integral air-entraining agent

IIIA4 A type III cement containing an integral air-entraining agent

Dr Mohamad El Dandachy Beirut Arab University Fall 2018-2019 1 - 21

Standard Cements (ASTM)

• Type II: Modified Portland Cement

Dr Mohamad El Dandachy Beirut Arab University Fall 2018-2019 1 - 22

• High Early Strength P.C. Strength development is rapid.

Type IV: Low Heat P.C.

• Generates less heat during hydration & therefore gain of strength is