ARAB ACADEMY FOR SCIENCE, TECHNOLOGY AND MARITIME

TRANSPORT

COLLEGE OF ENGINEERING

CONSTRUCTION AND BUILDING ENGINEERING DEPARTMENT

CB352

CONSTRUCTION MATERIALS

LECTURE NOTES

CEMENTS IN CONSTRUCTION

By

Prof. Nabil H. El-Ashkar

Professor of Structural Engineering,

Construction & Building Engineering Department, AASTMT

September, 2017
ARAB ACADEMY FOR SCIENCE, TECHNOLOGY & MARITIME TRANSPORT
COLLEGE OF ENGINEERING & TECHNOLOGY FALL SEMESTER 2017
CB352: CONSTRUCTION MATERIALS Prof. NABIL H. EL-ASHKAR

Cements
Cements ..................................................................................................................................... 2
1 Introduction ........................................................................................................................ 3
2 Portland cement .................................................................................................................. 3
2.1 Definition of Portland cement ..................................................................................... 3
2.2 Manufacturing of Portland cement .............................................................................. 3
2.3 Some Definitions ........................................................................................................ 6
2.4 Composition of Portland cement ................................................................................. 7
2.4.1 Major Compounds of Portland cement................................................................. 7
2.4.2 Influence of the four major compounds on the properties of the cement paste ...... 7
2.5 Types of Portland cement ............................................................................................ 8
2.5.1 General................................................................................................................ 8
2.5.2 ASTM C150 ........................................................................................................ 8
2.5.3 EN 197 .............................................................................................................. 11
2.5.4 White Portland cement ...................................................................................... 11
2.6 Testing of Portland cement ........................................................................................ 12
2.6.1 Consistency of Standard Paste ........................................................................... 12
2.6.2 Setting Time ...................................................................................................... 12
2.6.3 Fineness of cement ............................................................................................ 12
2.6.4 Soundness ......................................................................................................... 13
2.6.5 Strength of Cement Mortar ................................................................................ 13
2.6.6 Flow Table test .................................................................................................. 13

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 1 Introduction

Generally, any binding material can be called cement as can be found in dictionaries (cement is a
binding element in Merriam Webster's Dictionary)

In Construction Cements can be classified into two types

1. Non-hydraulic Cements

 It does not need water for Hardening

 It needs Co2 for Hardening
 Examples: Gypsum, Lime …etc.

2. Hydraulic Cements

 It needs water for Hardening

 It does not need Co2 for Hardening
 Examples: Ground cement, Portland cement, High Alumina cement …etc.

2 Portland cement
2.1 Definition of Portland cement

ASTM C150 defines Portland cement as a

hydraulic cement produced by pulverizing
clinker consisting essentially of hydraulic
calcium silicates. Clinkers are 5 to 25 mm
diameter nodules of a sintered material which is
produced when a raw mixture of limestone and
clay is heated to a high temperature.

Cosmatka et al., 2003

2.2 Manufacturing of Portland cement

Steps for manufacturing Portland cement:

1. The raw materials (limestone and clay) are crushed

2. The proper proportions are then mixed together (either dry or wet)
3. The mix is then fed and burned in a large rotary kiln at a temperature up to 1450°C rotary
kiln when the material sinter and partially fuses into balls known as clinker
4. The clinker is then cooled and ground to the desired fineness.
5. During grinding gypsum is added 2-5% to control the time of setting.

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Figure 2-2: Steps in the modern DRY process manufacture of Portland cement

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Figure (2-3): Steps in the modern WET process manufacture of Portland cement

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2.3 Some Definitions

Hydration: The reaction between cement and water

Heat of hydration: Hydration Reaction of Portland cement compounds is an exothermic reaction

Amount of heat of hydration depends on:
The chemical composition
The fineness of cement
The temperature

Setting: is the term used to describe the stiffening of the cement paste. OR it can refer to the
change from a fluid to a to rigid stage

Hardening: is the process of gaining the strength of the cement paste

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2.4 Composition of Portland cement

The Portland cement is composed of several oxides such as

Oxide Name Chemical abbreviation Manufacturing Abbreviation
`Lime CaO C
Silica SiO2 S
Alumina Al2O3 A
Ferrite Fe2O3 F
Magnesia MgO M

2.4.1 Major Compounds of Portland cement

Portland cement consists of four major compounds:

1. Di-Calcium Silicate C2S - 2CaO. SiO2

2. Tri-Calcium Silicate C3S - 3CaO. SiO2

3. Tri-Calcium Aluminates C3A - 3CaO. Al2O3

4. Tetra Calcium Aluminates Ferrite C4AF - 4CaO. Al2O3. Fe2O3

2.4.2 Influence of the four major compounds on the properties of the cement
paste
The influence of the four major compounds of Portland cement on the properties of the hydrated
cement is shown below:

1. Di-Calcium Silicate C2S - 2CaO SiO2

 Slow down the rate of hydration

 Reduce the rate of evolution of heat of hydration
 High cementing value
 Gain most of its strength in 28 days

2. Tri-Calcium Silicate C3S - 3CaO. SiO2

 Relatively faster rate of hydration

 Nominal rate of evolution of heat of hydration
 High cementing value
 Gain most of its strength in 7 days

3. Tri-Calcium Aluminates C3A - 3CaO. Al2O3

 very fast rate of hydration

 very high rate of evolution of heat of hydration
 Low cementing value
 Gain most of its strength in only 1 day

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 4. Tetra Calcium Aluminates Ferrite C4AF - 4CaO. Al2O3. Fe2O3

 Slow down the rate of hydration

 Reduce the rate of evolution of heat of hydration
 Low cementing value
 Gain most of its strength in 28 days

2.5 Types of Portland cement

See the Tables

2.5.1 General

There are different standards for classification of Portland cement. The two major standards are the
ASTM C150 used primarily in the U.S. and European EN-197. EN 197 cement types CEM I, II,
III, IV, and V do not correspond to the similarly-named cement types in ASTM C 150.

2.5.2 ASTM C150

There are five types of Portland cements with variations of the first three according to ASTM
C150.

Type I Portland cement is known as common or general purpose cement. It is generally assumed
unless another type is specified. It is commonly used for general construction especially when
making precast and precast-prestressed concrete that is not to be in contact with soils or ground
water. The typical compound compositions of this type are:

55% (C3S), 19% (C2S), 10% (C3A), 7% (C4AF), 2.8% MgO, 2.9% (SO3), 1.0% Ignition loss, and
1.0% free CaO.

A limitation on the composition is that the (C3A) shall not exceed fifteen percent.

Type II is intended to have moderate sulfate resistance with or without moderate heat of hydration.
This type of cement costs about the same as Type I. Its typical compound composition is:

51% (C3S), 24% (C2S), 6% (C3A), 11% (C4AF), 2.9% MgO, 2.5% (SO3), 0.8% Ignition loss, and
1.0% free CaO.

A limitation on the composition is that the (C3A) shall not exceed eight percent which reduces its
vulnerability to sulfates. This type is for general construction that is exposed to moderate sulfate
attack and is meant for use when concrete is in contact with soils and ground water especially in
the western United States due to the high sulfur content of the soil. Because of similar price to that
of Type I, Type II is much used as a general purpose cement, and the majority of Portland cement
sold in North America meets this specification.

Note: Cement meeting (among others) the specifications for Type I and II has become commonly
available on the world market.

Type III is has relatively high early strength. Its typical compound composition is:

57% (C3S), 19% (C2S), 10% (C3A), 7% (C4AF), 3.0% MgO, 3.1% (SO3), 0.9% Ignition loss, and
1.3% free CaO.

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This cement is similar to Type I, but ground finer. Some manufacturers make a separate clinker
with higher C3S and/or C3A content, but this is increasingly rare, and the general purpose clinker is
usually used, ground to a specific surface typically 50-80% higher. The gypsum level may also be
increased a small amount. This gives the concrete using this type of cement a three day
compressive strength equal to the seven day compressive strength of types I and II. Its seven day
compressive strength is almost equal to types I and II 28 day compressive strengths. The only
downside is that the six month strength of type III is the same or slightly less than that of types I
and II. Therefore the long-term strength is sacrificed a little. It is usually used for precast concrete
manufacture, where high 1-day strength allows fast turnover of molds. It may also be used in
emergency construction and repairs and construction of machine bases and gate installations.

Type IV Portland cement is generally known for its low heat of hydration. Its typical compound
composition is:

28% (C3S), 49% (C2S), 4% (C3A), 12% (C4AF), 1.8% MgO, 1.9% (SO3), 0.9% Ignition loss, and
0.8% free CaO.

The percentages of (C2S) and (C4AF) are relatively high and (C3S) and (C3A) are relatively low. A
limitation on this type is that the maximum percentage of (C3A) is seven, and the maximum
percentage of (C3S) is thirty-five. This causes the heat given off by the hydration reaction to
develop at a slower rate. However, as a consequence the strength of the concrete develops slowly.
After one or two years the strength is higher than the other types after full curing. This cement is
used for very large concrete structures, such as dams, which have a low surface to volume ratio.
This type of cement is generally not stocked by manufacturers but some might consider a large
special order. This type of cement has not been made for many years, because Portland-pozzolan
cements and ground granulated blast furnace slag addition offer a cheaper and more reliable
alternative.

Type V is used where sulfate resistance is important. Its typical compound composition is:

38% (C3S), 43% (C2S), 4% (C3A), 9% (C4AF), 1.9% MgO, 1.8% (SO3), 0.9% Ignition loss, and
0.8% free CaO.

This cement has a very low (C3A) composition which accounts for its high sulfate resistance. The
maximum content of (C3A) allowed is five percent for Type V Portland cement. Another limitation
is that the (C4AF) + 2(C3A) composition cannot exceed twenty percent. This type is used in
concrete that is to be exposed to alkali soil and ground water sulfates which react with (C3A)
causing disruptive expansion. It is unavailable in many places although its use is common in the
western United States and Canada. As with Type IV, Type V Portland cement has mainly been
supplanted by the use of ordinary cement with added ground granulated blast furnace slag or
tertiary blended cements containing slag and fly ash.

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 Table: ASTM C150 Classification of Portland Cement
Type Description Properties Uses and Applications Typical % of Major Compounds
C2S C3S C3A C4AF
I Ordinary Portland  Typical  For general purpose construction 19 55 10 7
Cement [Not larger
than15 %]
II Moderate Sulfate  Moderate Heat  When moderate heat of hydration 24 56 6 11
Resistance – Evolution evolution is needed [Between
Moderate Heat of 5 - 8 %]
 For concrete exposed to moderate
Hydration Cement  Moderate Sulfate sulfate attack
OR resistance  For mass concrete
[Modified Cement]  For hot weather concreting
 Seawater Resistance  For seawater Resistance

III High Early Strength  Finer Cement particles  When high early strength is needed 19 57 12 7
Cement
 Faster Hydration  For fast removal of forms

 Higher heat of  When higher heat of hydration is

hydration evolution needed

 High early strength  For concrete in cold weather

IV Low Heat Cement  Lower Heat Evolution  When lower heat of hydration is 49 28 5 12
[Oil Well Cement] needed [Not larger [Not larger
 Slow Hydration than 35 %] than 7 %]
 For oil wells
 For hot weather concreting
 For mass concrete
V Sulfate Resisting  Higher sulfate  For sulfate resisting concrete 43 38 3 9
Cement resistance structures. [Not larger
than 5 %]
2.5.3 EN 197

EN 197-1 defines 5 classes of common cement that comprise Portland cement as a main
constituent. These classes differ from the ASTM classes.

Comprising Portland cement and up to 5% of minor additional

Cem I Portland cement
constituents
Portland-composite
Cem II Portland cement and up to 35% of other single constituents
cement
Cem III Blastfurnace cement Portland cement and higher percentages of blastfurnace slag
Cem IV Pozzolanic cement Portland cement and up to 55% of pozzolanic constituents
Cem V Composite cement Portland cement, blastfurnace slag and pozzolana or fly ash

Constituents that are permitted in Portland-composite cements are blastfurnace slag, silica fume,
natural and industrial pozzolans, silicious and calcareous fly ash, burnt shale and limestone.

2.5.4 White Portland cement

Main article: White Portland cement

White Portland cement differs physically from the gray form only in its color, and as such can
fall into many of the above categories (e.g. ASTM Type I, II and/or III). However, its
manufacture is significantly different from that of the gray product, and is treated separately.
2.6 Testing of Portland cement
2.6.1 Consistency of Standard Paste

By trial and error, the standard paste consistency is measured as the water content percentage
when the Vicat needle drop to the bottom of the mold to a distance of 6 ± 1 mm. This water
content ranges from 26% to 33%
- Needed for the determination of the initial and final setting times and for the Le Chatlier
soundness test.
- It is measured using Vicat apparatus

2.6.2 Setting Time

Setting: is the term used to describe the stiffening of the cement paste. OR it can refer to the
change from a fluid to a to rigid stage

Initial Setting Time (IST)

IST: is the time from adding the water needed for standard paste consistency to the cement until
the paste is stiffened sufficiently for the initial setting needle to penetrate no more than 5 ± 1 mm
from the bottom of the container.
Or IST: is the time from the moment the cement is mixed with the water to the moment the
initial setting time needle penetrate the standard cement paste to a distance of no more than 5 ± 1
mm from the bottom of the container.

Final Setting Time (FST)

FST: is the time needed from adding the amount of water for standard paste consistency to the
cement until the paste is stiffened sufficiently for the final setting needle to penetrate no more
than 0.5 mm from the cement paste surface without leaving the circular mark or impression on
the paste surface.

2.6.3 Fineness of cement

 The rate of hydration depends on the fineness

of cement
 The rate of strength gaining is depending on
the fineness of cement
 The rate of heat evolution depends on the
fineness of cement

Measuring the fineness of cement is done throw

two methods:
1. The specific surface area using the Blain apparatus to measure the surface area of the
cement particles using the air permeability method.
2. Using the sieve No. 170 Retained do not
exceed 10%

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2.6.4 Soundness

 It is essential that cement paste once it has set does not undergo a large change in volume
 Expansion may take place due to delayed or slow hydration or other reactions of some
compounds present in the hardened cement such as free lime, magnesia and calcium sulfate.
 The soundness of cement is tested in an accelerated manner by using a device called Le
Chatelier apparatus.
 The bracket is filled with cement past with standard consistency and covered with two glass
plates and the distance between the indictor is measured d1. The whole assembly is
immersed in water bath and the water is brought to boiling in 30 mins. After boiling for 3
hrs the assembly is taken out of water and left for cooling. Then the distance between the
indicator is measured again d2.

 The expansion of the cement = d2-d1 must not exceed 10 mm. ESS & ENV

2.6.5 Strength of Cement Mortar

 Uses cubes of 50 cm2 cross sectional area in ESS and Bs or 5*5*5 cm cubes in ASTM or
40*40*160 mm prism in EN Standards.

 According to BS 4550, the ratio between the cement to the sand by weight is 1:3 and the
water to cement ratio is 0.4 or the mass of the water in the mix is 10%. Cured and tested at 3
and 7 days.

 The used sand is a standard sand

2.6.6 Flow Table test

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