14-11-2023

LECTURE OUTLINE

➢ History of Cement

Building Materials ➢ Cement

➢ Raw Materials

Chapter 4: Cement ➢ Manufacturing Process

11/14/2023 1 11/14/2023 2

1
 14-11-2023

History of cement

• Portland cement is a successor to a hydraulic

lime that was first developed by John Smeaton in
1756 when he was called in to erect the
Eddystone Lighthouse off the coast of Plymouth ,
Devon, England.

• The next development, taking place about1800 in

England and France, was a material obtained by
burning nodules of clayey limestone.

the Eddystone Lighthouse off the coast of Plymouth , Devon,

11/14/2023 3 11/14/2023 4 England.

2
 14-11-2023

11/14/2023 5 11/14/2023 6

3
 14-11-2023

Composition of Ordinary Portland Cement

11/14/2023 7 11/14/2023 8

4
 14-11-2023

Uses of Cement Uses of Cement

Cement concrete foundation

11/14/2023 9 11/14/2023 10
https://cdn.britannica.com/12/116012 -050-6747AAA2/pouring-concrete-foundation.jpg

5
 14-11-2023

Uses of Cement Uses of Cement

11/14/2023 11 11/14/2023 12

6
 14-11-2023

Properties of Cement
consistency test of cement
(1)Physical properties of cement: follow ing are the important physical properties of a good cement w hich
primarily depends on chemical composition, thoroughness of burning & fineness of grinding:
(I) It gives strength to the masonry. • The consistency test of cement is an
(II) It is an excellent binding material. essential test that determines the
(III) It is easily w orkable.
amount of water required to make a
cement paste of standard consistency.
(IV) It offers good resistance to the moisture
(V) It possesses a good plasticity.
• The standard consistency of cement
(VI) It stiffens or hardens early. paste is defined as the percentage of
(VII) A thin paste of cement w ith w ater should feel sticky betw een fingers. water added To the 300gm weight of
(VIII) Cement throw n in w ater should sink & should not float on the surface. cement. which will permit a Vicat
(IX) The particles should have uniformity of fineness. plunger having a 50 mm length and 10
(X) The consistency of cement should be checked w ith Vicat apparatus. mm diameter to penetrate in cement
(XI) The initial setting tim e for ordinary cement is about 30 m inutes.
paste to a depth of 33-35 mm from the
top of the mold.
(XII) Final setting time for cement is about 10 hours.
(XIII) Cem ent should be tested for soundness using Le Chatleier apparatus.
• Reference: Consistency Test of Cement
IS Codes – IS: 5513-1976, IS: 4031 ( Pat
4 ) – 1988,

11/14/2023 13 11/14/2023 14

7
 14-11-2023

consistency test of cement Soundness of Cement

Significance of Soundness of Cement

• The followings are the different types of
consistency and their corresponding • The testing of the soundness of cement, to ensure that the cement does
depth of penetration:
not show any appreciable subsequent expansion of prime importance.
• Dry or stiff consistency: The depth of
penetration is less than 5 mm. • The unsoundness is occurring mainly due to an excess lime that could
• Normal consistency: The depth of
be combined with acidic oxide at the kiln.
penetration is between 5 to 7 mm.
• Soft consistency: The depth of • inadequate burning or insufficient fineness of grinding
penetration is between 7 to 10 mm.
• Very soft consistency: The depth of • high a proportion of magnesium content or calcium sulfate
penetration is between 10 to 15 mm.
• Fluid consistency: The depth of • high percentage of gypsum leads to an expansion and consequent
penetration is more than 15 mm.
disruption of the set cement paste.

11/14/2023 15 11/14/2023 16

8
 14-11-2023

Properties of Cement
Soundness of Cement IS Code for soundness cement Test is IS:4031-Part 3-1988
(2)Mechanical properties of cement:
(I)The compressive strength at the end of 3 days should not be less than 11.5 N/mm2 & that at the end of 7
days should not be less than 17.5 N/mm2.
(II)The tensile strength at the end of 3 days should not be less than 2 N/mm2 and that at the end of 7 days
should not be less than 2.50 N/mm2.

(3)Chemical properties of cement:

(I)The ratio of percentage of alumina to iron oxide should not be less than 0.66.
(II)The ratio of percentage of lime to alumina, iron oxide & silica know n as Lime saturation factor (LSF) should
not be less than 0.66 & should not be more than 1.02.
(III)Total loss on ignition should not be more than 4%
(IV)Total Sulphur content should not be more than 2.75%
(V)Weight of insoluble residue should not be more than 1.50%
(VI)Weight of magnesia should not exceed 5%.

11/14/2023 17 11/14/2023 18

9
 14-11-2023

Cement Manufacturing Process Manufacturing process -I

11/14/2023 19 11/14/2023 20

10
 14-11-2023

Manufacturing process - II Manufacturing process -III

11/14/2023 21 11/14/2023 22

11
 14-11-2023

11/14/2023 23 11/14/2023 24

12
 14-11-2023

Ultratech Cements Tadipatri Andhrapradesh

11/14/2023 25 11/14/2023 26

13
 14-11-2023

Types of Cement : Uses and Grades Types of Cement : Uses and Grades

1) Ordinary Portland Cement 3) Rapid Hardening cement

Thi s is the most commonly us ed cement i n construction projects worldwide. It's a versatile cement that Ra pi d-hardening cement is a type of hydraulic cement that's s pecially designed to gain strength quickly.
ca n be us ed i n a va riety of a pplications, from general construction to precast concrete products. OPC i s Ra pi d-hardening cement is used in situations where fast-setting concrete is required, s uch a s in the
known for i ts strength, durability, a nd workability, ma king it s uitable for a va riety of construction cons tructi on of pavements, precast concrete products, and repair work. It has a higher early s trength
a pplications. It's commonly used in the construction of buildings, bridges, roads, a nd other structures. compa red to OPC, a l lowing s tructures to be put i nto service faster.
OPC i s versatile a nd can be used i n combination with other ma terials, such a s aggregates, to crea te
di fferent types of concrete mixes. 4) Extra Rapid Hardening Cement
Extra Ra pi d Ha rdening Cement i s a type of hydraulic cement that's similar to ra pid-hardening cement,
2) Portland Pozzolana Cement but i t ga i ns strength even faster. It's ma de by gri nding Ordinary Portl and cement cl inker wi th a higher
Portl a nd Pozzolana cement (PPC) i s a type of hydraulic cement that's made by blending Portl and cement a mount of calcium chloride. This combination a ccelerates the s etting time a nd early s trength gain of the
wi th pozzolanic ma terials, s uch a s fly a sh or s ilica fume. The pozzolanic materials i mprove the cement. Extra ra pid-hardening cement i s used i n s ituations where fast-setting concrete with high early
worka bility a nd durability of the cement, ma king i t s uitable for a vari ety of construction a pplications. s trength is required, s uch as i n cold weather conditions or emergency repair work. It's commonly us ed
PPC i s commonly us ed i n home building construction a nd mass concrete structures, s uch as dams and i n the construction of airport runways, i ndustri al fl oors, a nd precast concrete products.
bri dges, where durability i s a cri tical factor.

11/14/2023 27 11/14/2023 28

14
 14-11-2023

Types of Cement : Uses and Grades Types of Cement : Uses and Grades

5) Quick Setting Cement 7) Sulphate Resisting Cement

Qui ck-s etting cement i s a type of hydraulic cement that's designed to set a nd harden quickly. It a ids Sulphate-resisting cement is a type of hydrauli c cement tha t's designed to resist the da ma ging effects of
ti me-sensitive projects such a s the repair of wa ter pipes, s ewers, and tunnels. Its combination of sulpha te salts present i n soil and groundwa ter. Sul pha te-resistant cement is commonl y used in
ma teri als a ccelerates the s etting ti me of the cement, a llowing it to rea ch i ts initial s et in just a few cons truction projects where the s oil or groundwa ter has a hi gh sulpha te content, s uch as i n coastal
mi nutes, s imilar to tha t of fast s etting concrete. a rea s, mines, and ca nal linings, retaining walls.
8) Blast Furnace Slag Cement
6) Low Heat Cement Blas t furna ce sla g cement, also known as slag cement, is a type of hydrauli c cement made by mi xing
Low hea t cement is a type of hydraulic cement that's specially designed to produce l ess heat during the Portland cement clinker wi th granulated blas t furna ce sla g. The slag is a byproduct of the i ron-making
hydra ti on process. It's made by reducing the amount of tri calcium a luminate by 6%. Thi s results i n process a nd is ground into a fine powder, whi ch is then mi xed wi th Portland cement. This combi nati on
s l ower strength gain and l ower heat of hydration, ma king i t i deal for use i n large concrete s tructures that resul ts i n a cement wi th lower heat of hydra tion, better worka bility, and improved durabili ty. Blas t
a re prone to cra cking due to heat buildup. Low-heat cement i s commonly used i n the construction of furna ce slag cement is commonl y used in mass concrete projects , s uch as dams and bridges , as well as in
da ms , nuclear power plants, a nd large-mass concrete s tructures. the cons truction of high-rise buildings a nd industrial structures.

11/14/2023 29 11/14/2023 30

15
 14-11-2023

Types of Cement : Uses and Grades Types of Cement : Uses and Grades

9) High Alumina Cement 11) Coloured Cement

Hi gh Al umina cement is a type of hydraulic cement that's made by melting and gri nding bauxite and lime Coloured cement, also known as pi gmented cement, is a type of hydrauli c cement tha t's mi xed wi th
together. The resulting cement has a n excellent level of strength and durability.high alumina cement is pi gments (5 to 10% pigment) to a chieve a ra nge of colours . The pi gments used in coloured cement can
commonl y used in the construction of refractory concrete, which can withstand high temperatures and be s yntheti c or natural and a re a vailable in a va riety of sha des. Col oured cement is used pri ma ril y for
ha rs h chemical environments. It's a lso used in the construction of chemical plants, furnaces, and kilns, decora ti ve purposes , s uch as i n the cons tructi on of concrete countertops , floori ng, a nd pa vi ng.The use
where i ts resistance to high temperatures and corrosive chemicals makes it a n i deal choice. of col oured cement ca n enhance the a esthetic a ppeal of a project a nd gi ve i t a unique look.

10) White cement 12) Air entraining Cement

Whi te cement a s i ts name s uggests has a high degree of whiteness. White cement is used primarily for Ai r entraining cement is a hydrauli c cement tha t contains ai r-entraining a gents , such as resins , gl ues a nd
decora tive purposes, such a s in the constructi on of a rchitectural elements, precast concrete products, sodium sal ts , to crea te mi cros copi c ai r bubbles wi thi n the concrete mi x. Ai r-entraining cement requi res
a nd terra zzo flooring. It ca n a lso be used in combination with pigments to produce a wide ra nge of less wa ter to a chieve a speci fi c consis tency than ordina ry Portland cement and other types of cement.
col oured concrete finishes. It's commonl y used in cons truction projects tha t requi re fros t resis tance, such as concrete pa vements ,
bri dges, a nd buildings l ocated in cold cl imates.

11/14/2023 31 11/14/2023 32

16
 14-11-2023

Types of Cement : Uses and Grades Types of Cement : Uses and Grades

13) Expansive cement 15) Portland Limestone cement

Expansi ve cement is a type of hydra uli c cement tha t's designed to expand slightl y after setting. Portland limes tone cement (PLC) is a type of blended cement tha t's ma de by inter-gri ndi ng Portla nd
Expansi ve cement is commonl y used in cons truction projects where a ti ght fi t is required, s uch as cement clinker a nd 5 to 15% li mestone. PLC has simila r properties to OPC, but i t typi call y has a lower
precast concrete uni ts and bridge bea rings . It's also used i n grouting a nd shotcrete a ppli ca tions , where ca rbon footpri nt and genera tes less heat duri ng the hydra tion process . PLC is commonl y used in
the expa nsion can help fill voids a nd gaps . Expa nsi ve cement ca n also be used to compensate for the cons truction projects where sus tainabili ty is a concern, such as green buildings a nd infras tructure. It's
s hri nkage in concrete due to temperature cha nges or dryi ng. also sui table for use i n general-purpose concrete appli ca tions , such as pa vements , founda tions , a nd
14) Hydrographic cement preca st units.
Hydrographi c cement is a specialised type of Portland cement tha t's designed to set and ha rden
underwa ter. It's ma de by blending Portland cement clinker wi th special additi ves tha t help i t hydra te a nd
set even in the presence of wa ter. Hydrographi c cement is commonl y used in ma rine and underwa ter
cons truction projects , s uch as building da ms , bridges , and underwa ter tunnels . It's also used i n the
cons tructi on of s wimming pools, water storage tanks, a nd s ewage treatment plants.

11/14/2023 33 11/14/2023 34

17
 14-11-2023

Types of Cement : Uses and Grades Types of Cement : Uses and Grades

In addition to the different types of cement, there are also different grades of cement available in the 3) 53 Grade Cement
market. The most commonly used grades of cement in India are 33, 43, and 53-grade cement. These grades 53 gra de cement is the highest gra de of cement available i n India. It has a compressive strength of 53 N/mm²
refer to the compressive strength of cement after 28 days of curing. a fter 28 da ys of curing. This type of cement i s s uitable for use i n construction projects where high s trength is
1) 33 Grade Cement requi red, such a s in the construction of high-rise buildings, da ms, a nd heavy-duty i ndustrial s tructures. It has
33 gra de cement is commonly used for general constructi on work a nd plastering. It has a compressive a hi gher compressive strength than both 33 a nd 43-grade cement, making i t more durable and l ong-lasting.
s trength of 33 N/mm² a fter 28 da ys of curi ng. This type of cement is s uitable for use i n construction projects Sui ta ble for concrete mi x above M25.
where the requirement for high s trength i s not cri tical. It i s not s uitable for concrete mi x a bove M20.
2) 43 Grade cement
43 gra de cement is the most commonly used grade of cement in India. It has a compressive s trength of 43
It's important to note that higher grades of cement tend to have a higher heat of
N/mm² a fter 28 da ys of curing. It's s uitable for use i n construction projects where moderate to high strength hydration, which can result in the cracking of concrete if not properly managed.
i s required, s uch as plain concrete or pl astering works. It is a lso used to make precast i tems such a s tiles, Therefore, it's important to use the appropriate grade of cement for the intended
bl ocks, pipes, etc. It has a higher compressive s trength tha n 33-gra de cement a nd is s uitable for medium-
application and follow the manufacturer's recommendations for use and curing.
s ca l e construction projects. It is s uitable for concrete mi x up to M30.

11/14/2023 35 11/14/2023 36

18
 14-11-2023

Conclusion:

• Choosing the right type of cement is essential for the success of any construction

project.

• Each type of cement has unique properties that make it suitable for specific

applications.

• By understanding the different types of cement and their uses, you can make an

informed decision about which type of cement to use for your next construction

project.

11/14/2023 37

19