Slide 1

Review of Cement

Portland, Blended, and Other Hydraulic Cements

Slide 2

Primary Components of Raw Materials Necessary for Portland Cement Manufacture

Calcium Silica Alumina Iron

Portland, Blended, and Other Hydraulic Cements

Materials used in the manufacture of portland cement must contain appropriate proportions of calcium, silica, alumina, and iron components

Slide 3

Calcium

Iron

Silica
Calcium silicate Cement rock Clay Fly ash Fullers earth Limestone Loess Marl Ore washings Quartzite Rice-hull ash Sand Sandstone Shale Slag Traprock

Alumina

Sulfate

Alkali waste Blast-furnace flue dust Aragonite Clay Calcite Iron ore Cement-kiln dust Mill scale Cement rock Ore washings Pyrite cinders Chalk Shale Clay Fullers earth Limestone Marble Marl Seashells Shale Portland, Blended, Slag

and Other Hydraulic Cements

Aluminum-ore Anhydrite refuse Calcium Bauxite sulfate Cement rock Gypsum Clay Copper slag Fly ash Fullers earth Granodiorite Limestone Loess Ore washings Shale Slag Staurolite

Table 2-1. Sources of Raw Materials Used in Manufacture of Portland Cement Sulfate, often in the form of gypsum, is added during the grinding of the clinker to regulate the setting time of the cement and to improve shrinkage and strength development properties.

Slide 4

Quarry

Portland, Blended, and Other Hydraulic Cements

Fig. 2-6. Limestone, a primary raw material providing calcium in making cement, is quarried near the cement plant. (59894) Fig. 2-7. Quarry rock is trucked to the primary crusher. (59893)

Slide 5

Portland, Blended, and Other Hydraulic Cements

Fig. 2-8. Rotary kiln (furnace) for manufacturing portland cement clinker. Inset view inside the kiln. (58927, 25139)

Slide 6

Clinker

Gypsum

Portland, Blended, and Other Hydraulic Cements

Fig. 2-9. Portland cement clinker is formed by burning calcium and siliceous raw materials in a kiln. This particular clinker is about 20 mm (34 in.) in diameter. (60504) Fig. 2-11. Gypsum, a source of sulfate, is interground with portland clinker to form portland cement. It helps control setting, drying shrinkage properties, and strength development. (60505)

Slide 7

Portland, Blended, and Other Hydraulic Cements

(3)

Fig. 2-10. Process of clinker production from raw feed to the final product (Hills 2000).

Slide 8

Types of Portland Cement

ASTM C 150 (AASHTO M 85)
I IA II IIA Normal Normal, air-entraining Moderate sulfate resistance Moderate sulfate resistance, airentraining III High early strength IIIA High early strength, air-entraining IV Low heat of hydration V High sulfate resistance

Portland, Blended, and Other Hydraulic Cements

Slide 9

Performance of Concretes Made with Different Cements in Sulfate Soil

Portland, Blended, and Other Hydraulic Cements

Fig. 2-13. (top) Performance of concretes made with different cements in sulfate soil. Type II and Type V cements have lower C3A contents that improve sulfate resistance.

Slide 10

Performance of Concretes Made with Different W/C-Ratios in Sulfate Soil

Portland, Blended, and Other Hydraulic Cements

Improved sulfate resistance results from low water to cementitious materials ratios as demonstrated over time for concrete beams exposed to sulfate soils in a wetting and drying environment. Shown are average values for concretes containing a wide range of cementitious materials, including cement Types I, II, V, blended cements, pozzolans, and slags

Slide 11

Type II & Type V Sulfate Resistant Cements

Portland, Blended, and Other Hydraulic Cements

Fig. 2-14. Moderate sulfate resistant cements and high sulfate resistant cements improve the sulfate resistance of concrete elements, such as (left to right) slabs on ground, pipe, and concrete posts exposed to high-sulfate soils. (68985, 52114, 68986)

Slide 12

Outdoor Sulfate Test

Type V Cement W/C-ratio = 0.65 Type V Cement W/C-ratio = 0.39

Portland, Blended, and Other Hydraulic Cements

Fig. 2-15. Specimens used in the outdoor sulfate test plot in Sacramento, California, are 150 x 150 x 760-mm (6 x 6 x 30-in.) beams. A comparison of ratings is illustrated: (top) a rating of 5 for 12-year old concretes made with Type V cement and a water-to-cement ratio of 0.65; and (bottom) a rating of 2 for 16-year old concretes made with Type V cement and a water-to-cement ratio of 0.39 (Stark 2002). (68840, 68841)

Slide 13

Moderate and Low Heat Cements

Portland, Blended, and Other Hydraulic Cements

Fig. 2-16. Moderate heat and low heat cements minimize heat generation in massive elements or structures such as (left) very thick bridge supports, and (right) dams. Hoover dam, shown here, used a Type IV cement to control temperature rise. (65258, 68983)

Slide 14

Type III High Early Strength Cements

Portland, Blended, and Other Hydraulic Cements

Fig. 2-17. High early strength cements are used where early concrete strength is needed, such as in (left to right) cold weather concreting, fast track paving to minimize traffic congestion, and rapid form removal for precast concrete. (65728, 59950, 68668)

Slide 15

White Portland Cement

Portland, Blended, and Other Hydraulic Cements

Fig. 2-18. White portland cement is used in white or light-colored architectural concrete, ranging from (left to right) terrazzo for floors shown here with white cement and green granite aggregate (68923), to decorative and structural precast and cast-in-place elements (68981), to building exteriors. The far right photograph shows a white precast concrete building housing the ASTM Headquarters in West Conshohocken, Pennsylvania. Photo courtesy of ASTM.

Slide 16

Blended Hydraulic Cement ASTM C 595

General a hydraulic cement consisting of two or more inorganic constituents, which contribute to the strength gaining properties of cement.
Portland, Blended, and Other Hydraulic Cements

Slide 17

Blended Cements

Clinker Gypsum Portland cement Fly ash Slag Silica Fume Calcined Clay

Portland, Blended, and Other Hydraulic Cements

Fig. 2-19. Blended cements (ASTM C 595, AASHTO M 240, and ASTM C 1157) use a combination of portland cement or clinker and gypsum blended or interground with pozzolans, slag, or fly ash. ASTM C 1157 allows the use and optimization of all these materials, simultaneously if necessary, to make a cement with optimal properties. Shown is blended cement (center) surrounded by (right and clockwise) clinker, gypsum, portland cement, fly ash, slag, silica fume, and calcined clay. (68988)

Slide 18

Blended Hydraulic Cements

ASTM C 595 (AASHTO M 240)
Type IS Type IP Type P Type I(PM) Portland, Blended, and Other Hydraulic Cements Type S Type I(SM) Portland blast-furnace slag cement Portland-pozzolan cement Portland-pozzolan cement Pozzolan-modified portland cement Slag cement Slag-modified portland cement

Slide 19

Hydraulic Cements ASTM C 1157

Portland, Blended, and Other Hydraulic Cements

First performance specification for hydraulic cements Cements meet physical performance test requirements rather than prescriptive restrictions on ingredients or cement chemistry as in other cement specifications. Provides for six types

Slide 20

Hydraulic Cement
ASTM C 1157
Type GU Type HE Type MS Type HS Type MH
Portland, Blended, and Other Hydraulic Cements

Type LH

General use High early strength Moderate sulfate resistance High sulfate resistance Moderate heat of hydration Low heat of hydration

Slide 21

Cement Applications
Resistance to Moderate High Low heat Moderate High alkali-silica Cement sulfate General heat of early of sulfate reactivity specification purpose hydration strength hydration resistance resistance (ASR) ASTM C 150 portland cements II (moderate heat option) IS(MH) IP(MH) I(PM)(MH) I(SM)(MH) Low alkali option

III

IV

II

ASTM C 595 blended hydraulic cements

IS IP I(PM) I(SM) S, P

P(LH)

IS(MS) IP(MS) P(MS) I(PM)(MS) I(SM)(MS) MS HS

Low reactivity option

Portland, Blended, ASTM C 1157 and Other Hydraulic hydraulic GU cements Cements

MH

HE

LH

Option R

Table 2-3. Applications for Commonly Used Cements Check the local availability of specific cements as all cements are not available everywhere. The option for low reactivity with ASR susceptible aggregates can be applied to any cement type in the columns to the left. For ASTM C 1157 cements, the nomenclature of hydraulic cement, portland cement, airentraining portland cement, modified portland cement, or blended hydraulic cement is used with the type designation.

Slide 22

Special cements
White portland cements, ASTM C 150 White masonry cements, ASTM C 91 Masonry cements, ASTM C 91 Mortar cements, ASTM C 1329 Plastic cements, ASTM C 1328 Expansive cements, ASTM C 845 Oil-well cements, API-10 Water-repellent cements

Type
I, II, III, V M, S, N M, S, N M, S, N M, S

Application
White or colored concrete, masonry, mortar, grout, plaster, and stucco White mortar between masonry units Mortar between masonry units, plaster, and stucco Mortar between masonry units Plaster and stucco

E-1(K), E-1(M), E-1(S) Shrinkage compensating concrete A, B, C, D, E, F, G, H Grouting wells Tile grout, paint, and stucco finish coats Early strength and repair

Portland, Blended, and Other Hydraulic Regulated-set Cements cements

Table 2-4. Applications for Special Cements Portland cement Types I, II, and III and blended cement Types IS, IP, and I(PM) are also used in making mortar. Portland cement Types I, II, and III and blended cement Types IP, I(SM) and I(PM) are also used in making plaster.

Slide 23

Special cements
Cements with functional additions, ASTM C 595, ASTM C 1157 Finely ground (ultrafine) cement Calcium aluminate cement Magnesium phosphate cement Geopolymer cement Ettringite cements Sulfur cements

Type

Application
General concrete construction needing special characteristics such as; water-reducing, retarding, air entraining, set control, and accelerating properties Geotechnical grouting Repair, chemical resistance and high temperature exposures Repair and chemical resistance General construction, repair, waste stabilization Waste stabilization Repair and chemical resistance

Portland, Blended, Rapid hardening hydraulic and Other Hydraulic cement Cements

VH, MR, GC

General paving where very rapid (about 4 hours) strength development is required

Table 2-4. Applications for Special Cements

Slide 24

Portland Cement Compound Hydration Reactions (Oxide Notation)

+ 11 H2O 2 (3CaOSiO2) Water Tricalcium silicate 2 (2CaOSiO2) Dicalcium silicate 3CaOAl2O3 Tricalcium aluminate 2 (3CaOAl2O3) Tricalcium aluminate 3CaOAl2O3 Tricalcium aluminate + 9 H2O Water + 3 (CaOSO32H2O) Gypsum = 3CaO2SiO28H2O + 3 (CaOH2O) Calcium silicate Calcium hydroxide hydrate (C-S-H) = 3CaO2SiO28H2O + CaOH2O Calcium silicate Calcium hydroxide hydrate (C-S-H) + 26 H2O Water = 6CaOAl2O33SO332H2O Ettringite = 3 (4CaOAl2O3SO312H2O) Calcium monosulfoaluminate = 4CaOAl2O313H2O Tetracalcium aluminate hydrate = 6CaOAl2O3Fe2O312H2O Calcium aluminoferrite hydrate

+ 6CaOAl2O33SO332H2O + 4 H2O Ettringite Water + CaOH2O Calcium hydroxide + 12 H2O Water + 2 (CaOH2O) Calcium hydroxide

Portland, Blended, 4CaO Al2O3Fe2O3 + 10 H2O and Other Tetracalcium Hydraulic Water Cements aluminoferrite

Table 2-5. Portland Cement Compound Hydration Reactions (Oxide Notation) Note: This table illustrates only primary transformations and not several minor transformations. The composition of calcium silicate hydrate (C-S-H) is not stoichiometric (Tennis and Jennings 2000).

Slide 25

Type of portland cement I II III IV

Average Chemical composition, % SiO2 20.5 21.2 20.6 22.2 Al2O3 Fe2O3 5.4 4.6 4.9 4.6 3.9 4.1 2.6 3.5 2.8 5.0 4.2 0.3 CaO 63.9 63.8 63.4 62.5 63.8 66.7 MgO 2.1 2.1 2.2 1.9 2.2 0.9 SO3 3.0 2.7 3.5 2.2 2.3 2.7 Na2Oeq 0.61 0.51 0.56 0.36 0.48 0.18

V 21.9 Portland, Blended, and Other Hydraulic White 22.7 Cements

Table 2-6. Chemical Composition Cements*

Slide 26

Type of portland cement I II III IV

Average potential compound composition, % C3S 54 55 55 42 C2S 18 19 17 32 22 18 C3A 10 6 9 4 4 10 C4AF 8 11 8 15 13 1

Blaine fineness m2/kg 369 377 548 340 373 482

V 54 Portland, Blended, and Other Hydraulic White 63 Cements

Table 2-6. Compound Composition and Fineness of Cements

Slide 27

Heat of Hydration at 7 Days

Type I Type II Type II cement cement Moderate heat cement % of Type I 100 99 75 Type III Type IV Type V cement cement cement 106 67 89

Portland, Blended, and Other Hydraulic Cements

Table 2-8. ASTM C 186 Heat of Hydration for Selected Portland Cements from the 1990s, kJ/kg

Slide 28

Bulk Density
Bulk density of cement varies between 830 kg/m3 (52 lb/ft3)
and

1650 kg/m3 (103 lb/ft3).

Portland, Blended, and Other Hydraulic Cements

Fig. 2-48. Both 500-mL beakers contain 500 grams of dry powdered cement. On the left, cement was simply poured into the beaker. On the right, cement was slightly vibratedimitating consolidation during transport or packing while stored in a silo. The 20% difference in bulk volume demonstrates the need to measure cement by mass instead of volume for batching concrete. (68970)

Slide 29

Transporting Cement

Portland, Blended, and Other Hydraulic Cements

Fig. 2-52. Portland cements are shipped from the plant silos to the user in bulk by (left to right) rail, truck, or water. (59899, 59355, 59891)