UNIT 3

DETERMINATION OF SETTING TIME OF

HYDRAULIC CEMENT

Cement that is used in the construction industry can be classified mainly into two
kinds of cement namely Hydraulic Cement and Non-Hydraulic Cement.
Hydraulic Cement
Hydraulic cements are inorganic materials that have the ability to react with water
under ambient conditions to form a hardened and water-resistant product. The
most common cements are those based on calcium silicates, such as the
Portland cements.
Hydraulic cement which is a type of cement that sets very quickly and hardens
with the addition of water. It is the most commonly used cement at present.

Hydraulic Cement Non-Hydraulic Cement

Difference of Hydraulic Cement and Non-hydraulic Cement

HYDRAULIC CEMENT NON-HYDRAULIC CEMENT

Non-Hydraulic Cement is composed

Hydraulic Cement is made out of
of lime, gypsum plaster and
limestone, clay and gypsum.
oxychloride.
Hydraulic Cement hardens when there
 is a chemical reaction between
anhydrous cement powder with water. Non-Hydraulic Cement should be kept
The hydrates that are formed are not dry to attain strength.
soluble in water. It retains its strength
and hardness below water
Hydraulic Cement hardens under
water or when in contact with wet Non-Hydraulic Cement should be kept
weather. Hence it is suitable to work dry to attain strength
with in any climatic conditions
Hydraulic cement is used in multiple
Non hydraulic cement is becoming
applications like concrete, mortar in
redundant and obsolete due to the
masonry, swimming pools, marine
long duration of time taken for setting
construction, foundations, manholes,
of cement
reservoirs to name a few
Hydraulic Cement is made out of Non-Hydraulic Cement is composed
limestone, clay and gypsum of lime, gypsum plaster and
oxychloride.

Nowadays, usually different blends of modern Portland cement are commercially

referred to as hydraulic cement. Composed of hydraulic calcium silicates
(generally containing calcium sulfate), hydraulic cement is a non-corrosive, non-
rusting and non-shrink substance widely used in construction. This type of
cement is especially good for structures that are constantly in contact with water
because it is impermeable to water.

History and Development of Hydraulic Cement

Hydraulic cement was first used by the Romans in the middle age when “hydraulic
cement” was just volcanic ashes mixed with lime. In the 18th century, James
Parker patented the Roman cement, which gained popularity but was replaced by
Portland cement in the 1850s.

In the 19th century, Frenchman Louis Vicat laid the foundation for the chemical
composition of Portland cement while in Russia, Egor Cheliev published the use,
advantages, and methods of making cement. Joseph Aspdin brought Portland
cement to the market in England and his son, William Aspdin, developed the
“modern” Portland cement, which was soon in quite high demand.

But the real father of Portland cement is considered to be Isaac Charles

Johnson, who contributed immensely to the development of hydraulic cement by
publishing the process of developing meso-Portland cement in the kiln. Since
then, hydraulic cement has gone through extensive development to be produced
as the refined product seen today. Different blends of hydraulic cement are now
available to suit the particular needs of a construction project.
Chemical Composition of Hydraulic Cement
The four main components of hydraulic cement are

1. Belite (2CaO·SiO2)
2. Alite (3CaO·SiO2)
3. Tricalcium aluminate/ Celite (3CaO·Al2O3)
4. Brownmillerite (4CaO·Al2O3·Fe2O3)

The mechanical properties of cement are given by the silicates (belite, alite)
whereas the last two ingredients are required for the liquid phase in the
production process inside the kiln. Certain additives are also needed for special
properties such as greatly reduced setting and curing time, prevention of
shrinking, being able to be used underwater etc. The exact chemistry of the
reactions responsible for the production of cement is still a subject of research.

How Hydraulic Cement Works

Hydraulic cement’s working principle is based on the process of hydration, which

means the product hardens when water is added. Certain substances present in
hydraulic cement initiate reactions due to the application of water, causing the
mixture to set and harden very quickly with reduced curing time. The nature of
these chemical products makes hydraulic cement impervious to water damage
and further chemical attacks. Hence, this type of cement is suitable for
construction of structures in close contact with or submerged in water.

Another chief property of hydraulic cement is its strength. Tricalcium silicate and
dicalcium silicate present in such type of cement undergo the following reactions
upon addition of water:
Tricalcium silicate + water → calcium silicate hydrate + other chemical products
Dicalcium silicate + water → calcium silicate hydrate +other chemical products

The main product of these reactions, calcium silicate hydrate, has a network of short
fibers that increases the strength of the product greatly, also making it water-tight.

When to Use Hydraulic Cement

The right type of cement is to be selected based on the nature of the construction
work. Different blends of hydraulic cement contain varying ratios of chemical
components to suit specific needs.

Hydraulic cement is highly suitable for projects that require quick setting and less
curing time. However, it only gives a short window of time to work with it before it
hardens, so it is recommended to apply hydraulic cement only for projects that can
be done in 10-15 mins with a moderate amount of cement mix prepared at a time.

Its ability to provide strength is immense, so hydraulic cement can be used for

the construction of highly durable structures. The cement is not flexible, so it can
only be used to provide mechanical support to structures.
For constructing underwater structures, hydraulic cement has almost no
alternative. Being impermeable to water, it can be used in constructing structures
that are in constant contact with water. This type of cement does not corrode or
rust, hence it retains its strength even when submerged in water. It is also
extremely useful for water-proofing.

If the construction requires high durability but the location is in an extremely cold
climate or on a frozen surface, applying hydraulic cement is not commendable in
such circumstances unless certain measures are taken to ensure durability.

Hydraulic cement does not shrink like normal cement, and some blends even
expand upon hardening. This type expanding hydraulic cement is very useful for
sealing concrete leaks and repair work. Sealing cracks with hydraulic cement will
hold for many years, but it is not a permanent fix. For very fine cracks, caulk
might be a better solution than hydraulic cement. Again, hydraulic ce ment will not
solve problems caused due to condensation and not leaking.  

Hydraulic cement is very useful for the construction of:

 Footings and foundation

 Heavy construction
 Walls, floor, stairway
 Levee walls, sea walls, retaining walls
 Bridges, culverts
 Abutments, fortifications
 Monolithic concrete houses, concrete block houses
 Tower substructures
 Dams, breakwaters
 Sewers
 Electric ducts
 Water pipes
 Irrigation ditches, filter beds
 Cisterns, reservoirs
 Road foundations, paved roads, sidewalks
 Tunnels
 Railroads, ties, turntables, trestle belts
 Posts, fence and fence posts, mileposts, electric poles, telephone poles
 Curb and gutters
 Coefficient of expansion in concrete
 Columns and pillars
 Fountains
 Waterproofing 
 Prison cells
 Chimneys
 Fire proofing, fire tests
 Sealing cracks
 Adhesive for building blocks
Hydraulic cement is also used for various specialized purposes.

 Foundation repair
 Basement crack repair
 Basement leak stopper
 Repair Cracks in Concrete Walls, Floors, and Driveways

Preparation

 The surface on which the cement is to be applied should be clean. Dirt, oil,
grease and loose particles will prevent the cement from adhering to the
surface properly.
 It is imperative for the temperature to be maintained between 45°F (7°C)
and 90°F (32°C) during initial curing since the cement will not be durable
on frozen surfaces.
 The area should be saturated for 24 hours before applying cement there.
 Small cracks and holes should be enlarged prior to the cement
application. V-shaped cuts are to be avoided.

Mixing Cement

 A mechanical mixer with rotatory blades is recommended for mixing the

cement to get a uniform mix.
 The mixer should be saturated and drained of excess water prior to
mixing.
 Following the manufacturer’s instruction, the required amount of water is
to be added to the proper amount of dry hydraulic cement. However, once
it begins to set, water should not be added anymore.
 It is recommended that small amounts of cement be mixed at a time since
it hardens very quickly and has to be placed within 10-15 minutes.
 The cement mix should be blended at a relatively low speed.

Applying Hydraulic Cement

 The hydraulic cement mix should be applied as quickly as possible.

 Excessive blending will cause bleeding and segregation.
 Any other additives or admixtures should not be added unless mentioned in
the manufacturer’s instructions.

TYPES OF HYDRAULIC CEMENT

The three main types of cement that are most commonly used are Portland, blended
and hydraulic, but Portland and blended cements are actually hydraulic cement. In
fact, most types of cement used in construction are hydraulic.

1. Hydraulic cement:

 Type GU: General Use

 Type HE: High Early Strength
 Type MS: Moderate Sulfate Resistance
 Type HS: High Sulfate Resistance
 Type MH: Moderate Heat of Hydration
  Type LH: Low Heat of Hydration

2. Portland cement:

 Type I, Type IA: general purpose cements

 Type II, Type IIA: contain no more than 8% tricalcium aluminate
 Type III, Type IIIA: similar to Type I but has higher early strength
 Type IV: develops strength over longer periods of time, used in special
type of structures that require heat to be generated from hydration
 Type V: high sulphate resistance, contains no more than 5% tricalcium
aluminate

3.  Blended cement:

 Type IS (X): Portland blast furnace slag cement

 Type IP (X): Portland-pozzolan cement

ADVANTAGES OF HYDRAULIC CEMENT

 Hydraulic Cement is easy to work with, even for beginners.

 Hydraulic Cement sets and hardens fast. So desirable strength can be
achieved quickly.  
 As hydraulic Cement is waterproof, it can be used for structures
submerged underwater
 Non-corrosive, non-rusting and non-shrinking substance.
 Hydraulic Cement uses is high as it is a cost-effective solution.
 Can be used for durable concrete repairs.
 Can be used in vertical applications. 
 Can be painted within just 1 hour of being applied
 Can be used for sealing basement or other concrete leaks, waterproofing
and fireproofing.
 Setting time can be expedited by adding hot water and retarded with cold
water

DISADVANTAGES OF HYDRAULIC CEMENT

 Hardens very fast, so it must be used within 10-15 minutes of mixing. 

 This type of cement Cannot be used on frozen surfaces, or in areas where
the temperature drops drastically within 48 hours. 
 Not flexible, hence only suitable for providing mechanical support. 
 Not recommended to be used when the temperature is below 48°F. 
 Impermeable to water.

Considerations

Non-hydraulic cement was created first, but its limitations have propelled
hydraulic cement's use in today's construction industry. Hydraulic cement's ability
to harden underwater has made it the main type of cement used for those types
of projects. Hydraulic cement is also preferred for minor repair work such as
plugging holes and leaks in basements.

SIGNIFICANCE OF INITIAL AND FINAL SETTING TIME OF CEMENT

Cement is a widely used material for making mortar and concrete for construction
and building projects.
Setting time of cement paste is that the interval during which the cement paste
losses its plasticity after adding water in cement.

When cement is mixed with water, it starts hydrating with water and makes
cement paste. This cement paste can be molded into any desired shape due to
its plasticity. With this time, cement continues reacting with water. Then slowly,
cement starts losing its elasticity and starts to harden. After some times, the
cement paste will completely harden. This complete cycle is called the setting
time of cement paste.

Initial setting time of cement possess a primary role in strength and it is

mandated that cement paste is placed in position before it crosses initial setting
time that is approximately 30 minutes. It should not be disturbed until the final
setting time is reached that is around 600 minutes to attain complete rigidity and
tensile strength for ordinary Portland cement. This is the reason for the
importance of determining the initial and final setting times.
1. Initial set
The time elapsed between the moments when water is added to the
cement to the time when the square needle penetrates a depth of 33 to 35
 mm from the top of the mold. The initial setting time should not be less
than 30 minutes for Ordinary Portland Cement

2. Final set.

Occurs when the cement has hardened to the point at which it can sustain
some load. The final setting time is the time elapsed between the moment
the water is added to the cement, and the time when the paste has
completely lost its plasticity and has attained sufficient firmness to resist
certain definite pressure.

The setting time of cement is influenced by factors such as:

 percentage of water,
 the fineness of cement
 the presence of salts in sand
 amount of kneading the paste,
 temperature and humidity of the environment/atmospheric conditions

Important things to remember about Setting Time of Cement

1. It is necessary that initial setting time of cement should not be quick.

There should be sufficient time to transport and place the concrete before
it becomes too rigid. In the second case, too long a setting period tends to
slow up the work unduly, also it might postpone the actual us of the
structure because of the inadequate strength at the desired age.

2. Setting of cement should not be confused with hardening, which refers to

the gain in mechanical strength after the certain degree of resistance to
the penetration of a special attachment pressed into it.

3. Determination of the setting time is the time required for concretizing of

cement paste to a designed consistency.

4. During setting of cement, the initial chemical reaction of cement with water
indirectly related to form aluminum-silicate compound.

5. Initial setting time of cement paste is regarded as the time which the
cement can be molded in any desired shape without losing its strength.

6. Initial setting time of cement is the time when the hardening of the cement
starts and the cement paste starts losing its plasticity. We have the only
time available for mixing the paste and placing it in position.

7. Initial setting time of cement is important for transportation, placing and

compaction of cement paste.

8. Determination of initial setting time duration is required to delay the

process of hydration or hardening.

9. Final setting time of cement is regarded as the maximum time when the
cement paste completely losses its plasticity and becomes hard.
 10. This is the time taken for the cement paste to reach its optimum strength
to reach the highest tensile strength possible by the cement paste and
attain the shape of the mold in which it is cast.

11. Determination of final setting time facilitates safe removal of forms.

Determination of initial and final setting time of cement is important because

different types of cement have diffirent hydration and hardening time.

VICAT APPARATUS
Determine Setting Time of Cement (Vicut Apparatus)
Instruments:
Vicat Apparatus
Weighing balance
Gauging trowel
measuring cylinder
stop watch.

Material:

Ordinary Portland cement

Water

Procedure:
 Take 400 grams of cement for making a paste
 Prepare paste of weighted quantity of cement and water. Volume of water
added is 0.85 times the water required to give a paste of standard
consistency for preparation of test block.
 Maintain the time of gauging, gauging time is not less than 3 minutes and
not more than 5 minutes. The gauging must be completed before any sign
of setting occurs.
 Start a stop-watch at the instant water is added to the cement. The
gauging times starts from the time of adding water to the dry cement.
 The mould should be a non-porous plate. Fill the mould with the paste.
  After completely filling the mould, smoothen the surface of the paste,
making it level with the top of the mould. Slightly shake the mould to
remore the air.

a. Initial Setting Time of Cement

 Place th mould under the rod bearing the needle. (needle for determining
the initial setting time)
 Lower the needle slightly until it comes in contact with the surface of the
test block and quickly release, allowing it to penetrate the test block.
 At the start, the needle will completely penetrate the test block.
 Repeat this procedure until the needle fails to penetrate the block to the
5.0± 0.5 mm from the bottom of the mould.

 The period elapsing between the time when water is added to the cement
and the time at which the needle fails to penetrate the test block to the 5.0
± 0.5 mm from the bottom of the mould is called the initial setting time.

b. Final Setting Time of Cement

 To determine the final setting time, the first needle is replaced by the
(needle for determining the final setting time) needle with annular
attachment.

 When applying the needle gently to the surface of the mold, the needle
makes an impression thereon.

 Cement has finally set if the needle fails to make an impression on the
sureface of the test block.

 The period elapsing between the time when water is added to the cement
and the time at which the needle fails to make an impression on the
surface of the test block is called the final setting time.

Test Results

Initial Setting Time of Cement – note down the time, when needle fails
to penetrate 5 – 7 mm from the bottom of the test block.

Final Setting Time of Cement – note down the time when the needle
fails to make and impression on the surface of the test block.

Points to be taken cared of during the test

 Clean apparatus shall be used for the experiments

  Temperature and Humidity – experiments shall be conducted at 27 oC ±
2oC temperature and 65 ±5 percent of the relatuve humidity of the
laboratory.
 All appliances shall be free from vibration during the test.
 Take care of the needle; it should keep staight during the experiment.
 If there are any scum forming on the surface of the test block, use the
underside of the block for the determination.
Frequency of Determining Setting Time of Cement
 Setting time test is conducted per every 50 MT cement used and also
when the source, type and brand of cement is changed.
 Change frequency may be changed according to different standard
guidelines.

For an ordinary Portland cement, the initial setting time should not be less than
30 minutes while the final setting time should not be more than 600 minutes.