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A cement is a binder, sets and hardens and can bind other materials together.
Cements used in construction can be characterized as being either hydraulic or non-hydraulic,
depending upon the ability of the cement to be used in the presence of water.
Non-hydraulic cement will not set in wet conditions or underwater, rather it sets as it dries and
reacts with CO2 of the air. Example: Slaked lime. It can be attacked by some aggressive chemicals
after setting.
CaCO3 → CaO + CO2
The calcium oxide is then spent (slaked) mixing it with water to make slaked lime:
CaO + H2O → Ca(OH)2
Once the water in excess from the slaked lime is completely evaporated (called setting), the
carbonation starts:
Ca(OH)2 + CO2 → CaCO3 + H2O
This reaction takes a significant amount of time because the partial pressure of carbon dioxide in
the air is low. The carbonation reaction requires the dry cement to be exposed to air, for this
reason the slaked lime is a non-hydraulic cement and cannot be used under water. This whole
process is called the lime cycle.
Hydraulic cement is the one which sets due to hydration. They are quite durable in water and safe
from chemical attack. Example: Portland Cement. This allows setting in wet condition or
underwater and further protects the hardened material from chemical attack.
The chemical process for hydraulic cement found by ancient Romans used volcanic ash (activated
aluminium silicates). Presently cheaper than volcanic ash, fly ash from power stations, recovered as
a pollution control measure, or other waste or by products are used as pozzolanas with plain
cement to produce hydraulic cement. Pozzolanas can constitute up to 40% of Portland cement.
The most important uses of cement are as a component in the
production of mortar in masonry, and of concrete, a
combination of cement and an aggregate to form a strong
building material.
In other words:
Portland Cement (P.C>) → Gypsum+Portland Cement Clinker
(pulverizing)
Portland Cement Clinker → Calcareous & Clayey Materials
(burning)
Paste → P.C. + Water
Mortar → P.C. + Water + Sand
Concrete → P.C. + Water + Sand + Gravel
RAW MATERIALS OF P.C.
1) Calcareous Rocks (CaCO3 > 75%)
• Limestone
• Marl
• Chalk
• Marine shell deposits
• ~350-650°C→decomposition of
clay→SiO2&Al2O3
• ~600°C→decomposition of MgCO3→MgO&CO2
(evaporates)
• ~900°C→decomposition of CaCO3→CaO&CO2
(evaporates)
• ~1250-1280°C→liquid formation & start of
compound formation.
• ~1280°C→clinkering begins.
• ~1400-1500°C→clinkering
• CaO→limestone
• SiO2-Al2O3→Clay
• Fe2O3→Impurity in Clays
• SO3→from gypsum→not from the clinker
The amount of oxides in a P.C. Depend on the proportioning of
the raw materials and how well the burning is done in the kiln.
The chemical composition is found by chemical analysis.
A typical analysis of O.P.C.
MgO+H2O→MH
C+H→CH volume expansion & cause cracking.
ASTM C 150 → M<6%
free C < 3%
Alkalies (Na2O & K2O) may cause some dificulties if the cement is
used with certain types of reactive aggregates in making concrete.
The alkalies in the form of alkaline hydroxides can react with the
reactive silica of the aggregate & resulting in volume expansion
after hardening. This process may take years.
If cement is exposed to air, water & CO2 are absorbed & by heating
the cement upto 1000°C loose these two substances.
Belite (2CaO·SiO2);
Alite(3CaO·SiO2);
Celite(3CaO·Al2O3);
Brownmillerite (4CaO·Al2O3·Fe2O3).
%C2S=2.867(%S)-0.7544(%C3S)
%C3A=2.650(%A)-1.692(%F)
%C4AF=3.043(%F)
Ex:Given the following oxide composition of a portland cement
clinker.
CaO=64.9% SiO2=22.2%
Al2O3=5.8% Fe2O3=3.1% MgO=4%
Using Bogue’s eqn’s calculate the compound composition of the P.C.
clinker?
C3S=4.071*64.9-7.6*22.2-6.718*5.8-1.43*3.1=52.1%
C2S=2.876*22.2-0.7544*52.1=24.5%
C3A=2.65*5.8-1.692*3.1=10.1%
C4AF=3.043*3.1=9.4%
As hydration takes place at the surface of the cement particles, it is the
surface area of cement particles which provide the material available
for hydration. The rate of hydration is controlled by fineness of
cement. For a rapid rate of hydration a higher fineness is necessary.
However,
Blaine Apparatus
SETTING
Setting refers to a change from liquid state to solid
state. Although, during setting cement paste acquires
some strength, setting is different from hardening.
Vicat Needle
Setting can be obtained by using the vicat apparatus.
In fact several cement types are available and most of them have
been developed to ensure durability and strength properties to
concrete.
It should also be mentioned that obtaining some
special properties of cement may lead to
undesirable properties in another respect. For this
reason a balance of requirements may be necessary
and economic aspects should be considered.
Rocklike Material
Ingredients
– Portland Cement
– Course Aggregate
– Fine Aggregate
– Water
– Admixtures (optional)
Type III - High Early Type IV - Low Heat of Hydration
Chemical admixtures
- Accelerating admixtures: Compounds added to cement to decrease its setting time
and to improve the early strength developments - Used in cold-weather concreting - A
25% of strength gain observed at the end of three days - CaCl2 (less than 2% by weight
of cement); Not recommended for cold weather concreting; Triethanolamine; Sodium
thiocyanate; Acetyl alcohol; Esters of carbonic and boric acids; Silicones - Problems:
Increased heat of hydration, also leads to corrosion of steel
- Retarding admixtures: Added to concrete to increase its setting times - Used in hot
weather applications - Sodium/calcium triethanolamine salts of hydrogenated adipic
or gluconic acid - Problem: early strength of concrete reduced
- Water-reducing admixtures and super plasticizers used to reduce the amount of
water used in concrete mixes - High range water reducers reduce the water required
for mixing by 12% or greater - Added to improve the consistency/workability of
concrete and increase the strength - Water reducers: Lignosulphates, hydroxylated
carboxylic acids, carbohydrates - Superplasticizers: Suphonated melamine/naphtalene
formaldehyde condensates
3.1 CONSTITUENT MATERIALS AND PROPERTIES (Cont’d)
- Fly ash: By-product of coal from electrical power plants - Finer than cement -
Consists of complex compounds of silica, ferric oxide and alumina - Increases the
strength of concrete and decreases the heat of hydration - Reduces alkali
aggregate reaction.
- Silica fume: By-product of electric arc furnaces - Size less than 0.1μm - Consists
of non-crystalline silica - Increases the compressive strength by 40-60%
Improperly consolidated Concrete
3.2 MAKING AND TESTING OF CONCRETE (Cont’d)
Grades
40, 50, 60
Steel Yield Strength
(in thousands of psi)