DURABILITY OF CONCRETE STRUCTURES

CHAPTER - 6

Selection Of Cement
6.1 It is necessary to use cement of appropriate grade and type for specific applications and environment conditions. Various type of cement produced in India are shown in table 6.1. Table 6.1 Various type of cement produced in India
S N 1 Cement Variety OPC (Ordinary Portland Cement) PPC(Portland Pozzolana Cement) PBFSC (Portland Blast Furnace Slag Cement) Others Rapid Hardening Cement Low Heat Cement Sulphate Resisting Cement Super sulphated Cement As per code Gd-33 IS:269-1989 Gd-43 IS:8112-1989 Gd-53 IS: 12269-1987 IS :1489-1991 IS: 455-1989 Quantity in million tonnes. (Yr : 1996-97) 48.4 70% 13.6 19% 7.33 0.60 IS:8041-1990 IS :12600-1989 IS :12330-1988 1S:6909-1990 TOTAL 10% 1%

2 3 4

70.00

6.2 Major Compounds in Cement: In all the Portland Cements, there are four major compounds. The variation in percentage composition of compounds influences the properties of cement. These compounds are given in table 6.2 below: Table 6.2 Composition of cement
SN Name of compound Tricalcium Silicate Dicalcium Silicate Tricalcium Aluminate Oxide composition 3CaO.SiO2 2CaO.SiO2 Abbreviation Approx. Percentage 45-55% Function

C3S C2S

20-30%

3CaO.AI2O3

C3A

6-10%

Tetracalcium Aluminoferrite

4CaO.AI2O3Fe 2O3

C4AF

15-20%

Mainly responsible for early strength (1 to 7 days) Mainly responsible for later strength (7 days and beyond) C3A increases rate of hydration of C3S. C3A gives flash set in absence of gypsum It hydrates rapidly but its contribution to strength is uncertain and generally very low.

DURABILITY OF CONCRETE STRUCTURES

6.3 The physical and chemical characteristics of various cements are given in Table 6.3 & 6.4 Table 6.3 Physical characteristics of various types of cement
Sr. No. Type of Cement Fineness (m2 / Kg) Min 225 Soundness by Le Cha- Auto telier Clave (max.) max mm % 10 0.8 Setting time (minutes) Initial Final Min Max 30 600 Compressive strength 1 3 7 28 day days days days Min. Min Min Min Mpa Mpa Mpa Mpa NS 16 22 33

10

11

33 grade OPC (IS: 269-1989) 43 grade OPC (IS: 8112-1989) 53 grade OPC (IS: 122691987) Sulphate Resisting Cement (IS : 123301988 ) Portland Pozzolana Cement (IS: 1489-1991) Part I Rapid Hardening Cement (IS: 8041-1990) Slag Cement (IS: 455-1989) Super Sulphated Cement (IS: 6909-1990) Low Head Cement (IS:126001989) Masonry Cement (IS:34661988) IRS-T40

225

10

0.8

30

600

NS

23

33

43

225

10

0.8

30

600

NS

27

37

53

225

10

0.8

30

600

NS

10

16

33

300

10

0.8

30

600

NS

16

22

33

325

10

0.8

30

600

16

27

NS

NS

225

10

0.8

30

600

NS

16

22

33

400

NS

30

600

NS

15

22

30

320

10

0.8

60

600

NS

10

16

35

10

90

1440

NS

NS

2.5

370

0.8

60

600

NS

NS

37.5

NS

NS-Not specified. * residue on 45 Micron IS sieve, Max, Percent (by wet sieving) is 15.

DURABILITY OF CONCRETE STRUCTURES

Table 6.4 Chemical characteristics of various types of cement
Sr. No. Type of cement Lime saturation factor (%) 0.66Min 1.02Max . Alumina Iron ratio (%)Min Insoluble residue (%) Max Magnesi a (%) Max 6 Sulphuric anhydride Loss on igniton (%) Max 5

33 grade OPC (IS:269-1989)

0.66

43 grade OPC (IS: 81121989) 53 grade OPC (IS:122691987) Sulphate Resisting Cement (IS:123301988) Portland Pozzolana Cement (IS: 14891991)PartI Rapid Hardening Cement (IS: 8041-1990) Slag Cement (IS:455-1989) Super Sulphated Cement (IS:69091990) Low Heat Cement (IS: 12600-1989)

0.66 Min 1.02Max

0.66

0.8 Min 1.02Max

0.66

0.66Min 1.02Max

NS

2.5%Max. When C3A is 5 or less. 3% Max. when C3A is greater than 5 2.5%Max. When C3A is 5 or less. 3% Max. when C3A is greater than 5 2.5%Max. When C3A is 5 or less. 3% Max. when C3A is greater than 5 2.5%Max

NS

NS

X+4( 100 - X ) / 100

3% Max

0.66Min 1.02Max

0.66

7 8

NS NS

NS NS

4 4

8 10

2.5%Max. When C3A is 5 or less. 3% Max. when C3A is greater than 5 3% Max 6%Min

5 NS

NS

0.66

10

IRS-T40

0.8 Min. 1.02Max

0.66

2.5% Max. When C3A is 5 or less. 3% Max. when C3A is greater than 5 3.5% Max.

X - Declared percentage of fly ash.

NS - Not specified.

DURABILITY OF CONCRETE STRUCTURES

6.4 Important properties and draw backs in Indian specifications: i) Initial setting time: As per Indian standard, the minimum initial setting time is 30 minutes. Considering the hot weather conditions prevailing in India, it is all the more necessary to insist on a higher initial setting time for cement e.g. at least 60 minutes. ii) Chemical properties: The chloride content is a very important requirement affecting the durability of concrete and is missing in IS specification. iii) Fineness of cement: IS code provides for a minimum specific surface of 225M2/Kg except for Portland Pozzolana Cement. Most of the Indian cement manufacturers resort to producing cement with increased fineness even higher than 300 presumably to improve the compressive strength of cement. This is not desirable in hot weather concreting. It is, therefore, necessary to lay down upper limit of fineness while ordering cement or framing contract conditions for concrete works. The upper limit should be around 280. iv) When should a cement be rejected: The table 6.5 gives list of major defects in cement in respect of various properties . IS does not specify. Table 6.5 SN 1 Property Strength lower limit 28 days 7 days Strength- Upper limit 28 days Setting time Soundness Sulphate Content Chloride Content Deviation from the requirements - 2.5 N/sq.mm - 2.0N/sq.mm Not specified -15 minutes +1mm +0.5% +0.01%

2 3 4 5 6

v) Heat of hydration: Heat of hydration should be specified for the cements for hot weather concreting it should be (i) 7 days <270 Kj/Kg and for 28 days < 320Kj/Kg. For cold weather it should be more . 6.5 Factors affecting choice of cement: Following factors govern choice of cement. Durability Characteristics Functional requirement - Deflection, crack width etc. Design parameters- Strength, fineness, setting time requirement etc. Speed of construction- Time for construction etc. Environmental Conditions- Ground conditions, soluble salts, sulphates, Chemical plants etc.

DURABILITY OF CONCRETE STRUCTURES

6.6 Suitability of various types of cement: i) 33 grade OPC: It is used for normal grade of concrete upto M-20, plastering, flooring, grouting of cable ducts in PSC works etc. The fineness should be between 225 and 280. ii) 43 grade OPC: It is the most widely used general purpose cement. For concrete grades upto M-30, precast elements. For marine structures but C 3A should be between 5 - 8%.

iii) 53 grade OPC: For concrete grade higher than M-30, PSC works, bridge, roads, multistoried buildings etc. For use in cold weather concreting. For marine structures but C 3A should be between 5 - 8%. iv) Portland Slag Cement (PSC) i.e. OPC + granulated slag: It gives low heat of hydration. The slag should be more than 50% and upto 70%. It is used for ; Marine and off shore structures- very high chloride and sulphate resistant. Sewage disposal treatments works Water treatment plants Constructions which are expected to be attacked by dissolved chlorides and sulphate ions. Should be mainly used for all future structures. v) Portland Pozzolana Cement: IS: 1489(part-I) - 1991 (using flyash): It gives low heat of hydration and reduces the leaching of calcium hydroxide. This cement should be used only after proper evaluation. This should be tested as per IS: 1489 (Pt I) 1991. It is used for : hydraulic structures- dams, retaining walls Marine structures Mass concrete works- like bridge footings under aggressive conditions Masonry mortar and plastering.

vi) SRC- Sulphate Resisting Cement: (C3A < 3%) Sulphate Resisting Portland Cement is a type of Portland Cement in which the amount of tricalcium aluminate (C3A) is restricted to lower than 5% and 2C 3A + C4AF lower than 25%. The SRC can be used for structural concrete wherever OPC or PPC or Slag Cement are usable under normal conditions. The use of SRC is particularly beneficial in such conditions where the concrete is exposed to the risk of deterioration due to sulphate attack, for example, in contact with soils and ground waters containing excessive amounts of sulphates as well as for concrete in sea water or exposed directly

DURABILITY OF CONCRETE STRUCTURES

to sea coast . The IS 456 (revised draft code) has made elaborate provisions for use of particular type of cement against different percentages of soluble sulphate salts. These provisions are given in table 6.6 below: Table 6.6 Class In soil Total SO3 % 1 2 3 4 5 <0.2 0.2-0.5 0.5-1.0 1.0-2.0 >2 Concentration of Sulphates expressed as SO3 In ground water SO3 In 2:1 (g/L) water : soil extract (g/L) <1.0 <0.3 1.0-1.9 0.3-1.2 1.9-3.1 3.1-5.0 >5.0 1.2-2.5 2.5-5.0 >5.0 Type of cement

OPC,PSC or PPC OPC,PSC or PPC SSC or SRC SSC or SRC PSC or PPC SSC or SRC SRC or SSC with protective coating.

The use of SRC is recommended for following applications: Foundations, piles Basement and underground structures Sewage and water treatment plants Chemical factories Suitable for underground works where Sulphate is present in the Soil and water. Attention: i) Sulphate resisting cement is not suitable where there is danger of chloride attack. This will cause corrosion of rebar. ii) If both Chlorides and Sulphates are present, Ordinary Portland Cement with C3A between 5& 8 should be used. Sulphate resistance of cements : Chemical resistance of various types of cement in different environmental conditions is given in table 6.7 . Table 6.7 Type of Cement Ordinary Portland Chemicals resistance to sulphates Moderate High Very High C3A <8% C3A <5% C3A =0% 2C3A+C4AF<25% C4AF< 20% or or C4AF +C2F<25% C4AF +C2F<20% No special C3A <6% C3A < 3.5% prescription Slag > 36% Slag > 70% C 3A < 2%

Pozzolana Slag

DURABILITY OF CONCRETE STRUCTURES

vii) Low heat portland cement : Low Heat Portland Cement is particularly suited for making concrete for dams and many other types of water retaining structures, bridge abutments, massive retaining walls, piers and slabs etc. In mass concreting, there is often considerable rise in temperature because of the heat produced as the cement sets and hardens. The shrinkage which occurs on subsequent cooling sets up tensile stresses in the concrete, may result in cracking. The use of low heat cement is advantageous since it evolves less heat than OPC. This cement is not available in the market on regular basis and has to be obtained on specific orders. viii) Rapid hardening cement : The Rapid Hardening Cement is used for repair and rehabilitation works and where speed of construction and early completion is required due to limitations of time, space or other reasons. The cement is to be used in cold weather concreting i.e. temp < 5 0C. Rapid hardening cement is basically OPC but its fineness is 3250 cm 2/gm against 2250cm2/gm in case of OPC. The compressive strength after 1 day is 16 N/mm2 and that of 3 days 27N/mm 2. These days higher grade OPC are available in the country to meet these requirements and therefore, this cement is not being manufactured and marketed on regular basis. The characteristics of this cement can be effectively met by only good quality 53 grade OPC. ix) Hydrophobic portland cement : Hydrophobic Portland Cement is manufactured on special requirement for high rainfall areas to improve the shelf life of the cement. The cement particles are given a chemical coating during manufacturing which provides water repelling property and the cement is not affected due to high humidity and can be stored for a longer period . This has to be obtained on special order from the cement manufactures. x) IRS-T 40 special grade cement : IRS-T 40 Special Grade Cement is manufactured as per specification laid down by Ministry of Railways under IRS-T 40:1985. It is a very finely ground cement with high C 3S content designed to develop high early strength required for manufacture of concrete sleeper for Indian Railways. This cement can also be used with advantage for other applications where high strength concrete is required. This cement can be used for prestressed concrete elements, high rise buildings, high strength concrete etc. 7. Summary i ii If both Cl - and SO3 are present ; use blended cement (OPC + GGBFS) If only Cl- like Sea water - never use Sulphate Resistant Cement . Cl- diffusion is maximum in sulphate Resistant Cement. Use blended Cement. The C 3A content should be between 5-8%. Use low heat OPC. (OPC 30% +GGBFS 70%) is the best combination. If SO3 present: C3A < 5. Use sulphate resistant cement (which is equal to grade 33 OPC in strength). High strength and sulphate resistance do not go together, or use blended cement with GGBFS or fly ash.

iii

DURABILITY OF CONCRETE STRUCTURES

For high grade concrete > 100 Mpa, use OPC53 (30-40%) +GGBFS (>50% ) + Silica fumes (10%), with w/c around 0.30. Curing is very important. It must start within half an hour. v For better plaster use OPC 33 : GGBFS as 1: 2. Plastering by Grade 53 or OPC will cause shrinkage cracks. vi The cement should not have very high fineness. vii For grouting of cables use only Gd 33 cement with fineness less than 260. viii Ground soil and quality of water (especially in case of sea and marine structures), should be examined and specifications for the cement to be used for the structure should be decided at the planning stage itself. ix The percentage of mineral admixtures in blended cement should be as under: GGBFS > 50% (upto 70%) Fly Ash > 10 % (upto 25%) Silica Fumes = 8 to 10%. Attention: The rate of development of strength is slow in case of blended cement i.e. Portland pozzolana cement and Portland slag cement etc., as compared to ordinary Portland cement. This aspect should be taken care while planning to use blended cement. Accordingly, stage of prestressing period of removal of form work and period of curing etc. should be suitably increased. iv