Contents

What is cement? ............................................................................................................................... 1 Importance of cement in construction ......................................................................................... 1 Types of cement ................................................................................................................................ 2 Portland Pozzolana Cement (PPC) ................................................................................................ 3 Portland Slag Cement (PSC) .......................................................................................................... 3 Some important requirements to be met by various types of cement ........................................ 3 Composition of Portland cement...................................................................................................... 4 The basic components of cement are: ......................................................................................... 4 Role of compounds on properties of cement ............................................................................... 5 Heat of Hydration ......................................................................................................................... 5 Comparative table of heat of hydration produced at the end of 90 days.................................... 6 What is hydration of cement? ...................................................................................................... 6 Selection of cement .......................................................................................................................... 6 Test on cement ................................................................................................................................. 8 Manufacture of Cement ................................................................................................................... 9 Storage of cement............................................................................................................................. 9 Plant and Machinery ....................................................................................................................... 10

What is cement?
Cement is a fine powder, which when mixed with water undergoes chemical change and thereafter allowed to set and harden is capable of uniting fragments or masses of solid matter together to produce a mechanically strong material. Cement can be used as binding material with water, for bonding solid particles of different sizes like bricks, stones or aggregate to form a monolith. Cements used in construction of buildings and civil engineering works contain compounds of lime, silica and alumina as their principal constituents and can be called as complex compounds.

Importance of cement in construction

Today, cement is a very important building material used in the construction industry. It was in 1824 that cement, as we know it today was developed. Joseph Aspdin of England first patented the manufacture of a very improvised type of cementitious material for building construction in

1824. The hardened cement paste resembled the natural stone occurring at Portland in England. Hence it was named as Portland cement. Cement has replaced all other binding materials, for example, clay and lime, which ruled high for hundreds of years, in construction from last century. The reason being that, cement is the strongest binding material amongst clay, lime and cement. Cement is now used in many construction trade items like Plain Concrete, Reinforced Concrete, Mortar, Plaster, Grouts, Paints and in Pre-cast Elements. In an ordinary building construction the cement accounts to about 15-17% of the cost of construction. In some other major constructions like concrete roads and bridges, it is very much more.

Some of the reasons for its popularity and universal acceptance are listed below:
a. Cement can be produced in large volumes in controlled condition, packed and transported b. Cement is several times stronger binding material than lime and clay c. It can be mixed and used at will with locally available materials at site d. When stored properly in ordinary atmosphere does not deteriorate for reasonably longer time e. When mixed with water, starts setting and acquires sufficient strength in a day or two, where as other binding materials require much longer time f. When water is added to quick lime, lot of heat is generated, but in case of cement, heat generated is unnoticeable and comparatively much lesser g. It can withstand compressive stresses well. Where tension and shear stresses occur it gives good bond to steel reinforcement and transfers excess stresses to steel h. It is produced from the materials like limestone, hematite, bauxite, clay, etc which are abundantly available in the upper crust of the earth

Types of cement
There are many types of cement in the market to suit every need. Some of them which are included in the revised IS : 456-2000 are as follows: Ordinary Portland Cement 33, 43, 53 grade (OPC), 53-S (Sleeper Cement) Portland Pozzolana Cement (PPC), both Fly Ash and Calcined Clay based Rapid Hardening Portland Cement Portland Slag Cement (PSC) Sulphate Resisting Portland Cement (SRC) Low Heat Portland Cement Hydrophobic Cement Even though only Ordinary Portland Cement is graded according to strength, the other cements too have to gain a particular strength. 33, 43 and 53 grade in OPC indicates the compressive strength of cement after 28 days when tested as per IS: 4031-1988, eg, 33 Grade means that 28

days of compressive strength is not less than 33 N/mm2 (MPa) . Similarly for 43 grade and 53 grade the 28 days compressive strength should not be less than 43 and 53 MPa respectively. 43 and 53 grade are also being introduced in PPC and PSC shortly by the Bureau of Indian Standards (BIS)

Portland Pozzolana Cement (PPC)

PPC is manufactured by inter grinding OPC clinker with 15-35% of pozzolanic material. Pozzolanas are essentially siliceous or aluminous material, which in itself possesses no cementitious properties, which will be in finely divided form and in the presence of moisture react with calcium hydroxide, liberated in the hydration process, at ordinary temperature, to form compounds possessing cementitious properties. The pozzolanic materials generally used are fly ash or calcined clay. PPC produces less heat of hydration and offers greater resistance to attack of aggressive environment, gives long-term strength and enhances the durability of structures.

Portland Slag Cement (PSC)

PSC is obtained by mixing blast furnace slag, cement clinker and gypsum and grinding them together to get intimately mixed cement. The quantity of slag varies from 30-70%. The gain of strength of PSC is somewhat slower than OPC. Both PPC and PSC will give more strength than that of OPC at the end of 12 months. PPC and PSC can be used in all situations where OPC is used, but are preferred in mass construction where lower heat of hydration is advantageous or in marine situations and structures near seacoast or in general for any structure where extra durability is desired. The other types of cement listed above are for special purpose and their nomenclature indicates the purpose for which they are preferred. The following table gives the codal requirements at a glance.

Some important requirements to be met by various types of cement

S Type no cement of IS Code Fineness Setting Time in Soundness Compressive Strength m2/kg minutes MPa (min) Initial Final Le Auto 3 days 7 days 28 days (min.) (max.) Chatelier Clave (mm) (%) 269 1989 8112 1989 : 225 : 225 30 30 600 600 10 10 0.8 0.8 16 23 22 33 33 43 in

1 2

OPC 33 OPC 43

3 4

OPC 53

12269 : 225 1987

30 30

600 600

10 10

0.8 0.8

27 16

37 22

53 33

PPC (flyash 1489 : 300 based) 1991 (Part 1) PSC (slag) SRC White Cement 455 2002 : 225

5 6 7 8

30 30 30 30

600 600 600 600

10 10 10 10

0.8 0.8 0.8 0.8

16 10

22 16 19.8

33 33 29.7

12330 : 225 1988 8042 1989 : 225 : 325

RHC (Rapid 8041 Hardening 1990 Cement)

27

16 @ 1 day

Composition of Portland cement

The basic components of cement are:
SiO2 Al2O3 Fe2O3 CaO MgO SO3 17-25 % 4-8% 0.5-0.6 % 61-63 % 0.1-4.0 % 1.3-3.0 %

Na2 + K2O 0.4-1.3 % Cl IR 0.01-0.1% 0.6-1.75 %

There are four major compounds in cement and these are known as C2S, C3S, C3A & C4AF, and their composition varies from cement to cement and plant to plant. In addition to the above, there are other minor compounds such as MgO, TiO 2, Mn2O3, K20 and N2O. They are in small quantity. Of these K2O and Na2O are found to react with some aggregates and the reaction is known as Alkali Silica Reaction (ASR) and causes disintegration in concrete at a

later date. The silicates C3S and C2S are the most important compounds and are mainly responsible for the strength of the cement paste. They constitute the bulk of the composition. C3A and C4AF do not contribute much to the strength., but in the manufacturing process they facilitate combination of lime and silica, and act as a flux. In a typical Portland cement, the composition of mineralogical compounds could be Table 1 : The extent of chemical compounds in cement S no Compound 1 2 3 4 5 C3S C2S C3A C4AF Freelime Composition as % 48-52 % 22-26 % 6-10 % 13-16 % 1-2 %

Role of compounds on properties of cement

Characteristic Setting Hydration C3S Quick Rapid C2S Slow Slow Lower C3A Rapid Rapid Higher C4AF Higher

Heat Liberation Higher (Cal/gm) 7 days Early Strength

Not much High up to Low up to beyond 1 Insignificant 14 days 14 days day High at later Moderate at stage after later stage 14 days -

Later Strength

Heat of Hydration
Most of the reactions occurring during the hydration of cement are exothermic in nature (heat is generated). This heat is called heat of hydration. It is desirable to know the heat producing

capacity of cement in order to choose the most suitable cement for a given purpose. For Ordinary Portland Cement, half of the total heat is liberated between 1-3 days, about th in 7 days and nearly 90% in 28 days. The rate at which the heat is produced is important for practical purposes. It may lead to cracks if not properly dissipated. The sum total heat produced, if spread over a longer period can be dissipated to a greater degree with fewer problems. The hydration of C3S produces higher heat as compared to the hydration of C2S. Fineness of cement also affects the rate of heat development. The heat of hydration generated is generally as follows at 28 days.

Comparative table of heat of hydration produced at the end of 90 days

S Heat of hydration (calories per Compound no gram) 1 2 3 4 C3S C2S C3A C4AF 100-110 50-60 300-315 95-105

It may be seen that the heat produced by C3S is twice that of C2S and that by C3A is still higher. It follows that, reducing the proportions of C3S and C3A, the heat of hydration and its rate can be reduced.

What is hydration of cement?

When water is added to cement, the paste is formed due to chemical reaction, which hardens into rock like mass over a period of time. Compounds like C3S and C2S react in the presence of moisture and fully hydrated reaction can be expressed as 2C3S +6H -> C3S2H3 +3Ca(OH)2 2C2S +4H -> C3S2H3 +Ca(OH)2 C3S2H3 (Calcium Silicate Hydrate) becomes a hard mass over a period of time and normally called as C-S-H gel. While C3S contributes to most of the strength development during the first two weeks, C2S influences gain of strength after two weeks. However, in the long term (over a year) the contribution to strength is same for equal individual weight.

Selection of cement
The type of cement selected should be appropriate for the intended use. Functional requirement

of the structure, design parameters, speed of construction, durability characteristics, environmental condition are some of the major factors which affect selection of cement for appropriate application. The suggested uses of various cements are given in the following table.

S no Type of cement 1 OPC 33

End Use Used for general civil construction works under normal/mild environmental conditions. OPC 33 grade is normally not used where high grade concrete is required due to limitations of its strength. Nowadays this variety is not generally produced Nowadays 43 grade is being used widely for general construction work. However, 43 grade OPC is gradually being replaced by blended cements. Used in RCC and pre-stressed concrete of higher grades, cement grouts, instant plugging mortars etc. where initial higher strength is the criteria Slag PSC provides better protection against chloride and sulphate attack. PSC is preferred over OPC for usage in constructions where the structures are susceptible to sulphate and chloride attack. eg Marine structure, structures near the sea, sewage disposal treatment works, water treatment plants, etc

OPC 43

OPC 53

Portland Cement (PSC)

Portland Pozzolana PPC makes concrete more impermeable, denser as Cement (PPC) compared to OPC. The long-term strength of PPC is higher compared to OPC. PPC produces less heat of hydration and offers greater resistance to the attack of aggressive waters than normal OPC. PPC can be used for all types of construction. Sulphate Portland (SRC) Resisting IIn SRC, amount of C3A is restricted to lower than 5% and Cement 2C3A + C4AF lower than 25%. SRC can be used for Foundation, Piles, Basements, Underground structures, sewage and water treatment plants and coastal works, where Sulphate attack due to water or soil is anticipated

Low Heat Portland Low heat Portland cement is particularly suitable for making Cement mass concrete for dams and many other types of water retaining structures, bridge abutments, massive retaining walls, piers and slabs, etc Rapid Hardening The Rapid hardening cement is used for repair and Cement (RHC) rehabilitation works and where speed of construction and early completion is required due to limitations of time, space

or other reasons 9 Hydrophobic Portland Cement It is manufactured under special requirement for high rainfall areas to improve the shelf life of 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 longer period. Due to abundant availability of cement in all parts of the country, this cement is very rarely produced these days. White Portland Cement is made from raw materials containing very little iron oxide and manganese oxide. Burning in the kiln is done with furnace oil or gas instead of coal. Limited quantities of certain chemicals, which improve whiteness of cement, are added during manufacturing. This type of cement is generally meant for non-structural works. It is used for architectural purposes such as mosaic tiles, wall paintings, GRC and special effects.

10

White Cement

Test on cement
The usual tests carried out for cement are for chemical and physical requirements. They are given in relevant Indian Standards. IS 4031 (different parts) and IS 4032. The chemical standards gives permissible limits for insoluble residue, loss of ignition and other compounds and impurities like Magnesium Oxide, Sulphate, etc. The physical requirements are for fineness, soundness, setting time and compressive strength. These are mostly conducted at a laboratory. A field engineer is advised to purchase a reputed brand of cement from an authorized dealer, and ask for the test certificate. He can conduct a few field tests at the site itself for ascertaining the quality of cement. Check at random that the packing bags are fresh and that the bags are machine stitched Check that the bag displays Indian Standards mark and number to which it conforms. Check the manufacturing week and the year on the bag Open the bag and take a good look at cement, there should be no lumps Check that the colour of cement is uniform Check for setting. Take some quantity of cement, make it to a paste, place it on a plate and give it a square shape. Immerse the same slowly in to a bucket of water. Check that it has not lost shape and that it hardens after 24hrs

Manufacture of Cement
Portland cements are made by grinding a mixture of limestone, clay and other corrective materials, viz. Laterite, Bauxite,etc. Essential constituents mainly are Lime, Silica, Alumina and Iron Oxide. The process of manufacturing consists of grinding of raw materials into fine powder, mixing them intimately and burning in a kiln at about 1400 deg. C. The resultant product is called Clinker. Clinker is cooled, ground to fine powder with gypsum. The end product is cement.

Storage of cement
The binding property and strength of cement depends upon its capacity for chemical reaction, which can take place in the presence of water. Cement tends to absorb moisture, and react with it chemically. Basic requirement is that cement should not come in contact with water or moisture till it is put to use. If it comes in contact, it will react and form lumps. Then it loses its reactivity and this in turn will result in less strength. The site engineer should bear in mind that even the atmospheric moisture is sufficient for deterioration of cement. Hence cement should be stored in such a manner that no moisture or dampness is allowed to reach cement either from the ground or from the environment. Cement loses strength as it ages. Approximate reduction in strength with age (in standard water tight storage condition) Age months 3 6 12 in

Sr no 1 2 3

Loss of strength in % 5 to 10 20-30 30-40

Note: BIS prescribes that cement should be used within 90 days of its production. In case it is used at a later date then it should be tested before use.

Good axioms of proper inventory management are: Buy only the quantity required for the week or for the fortnight Please see that cement bag is not torn

 No windows/ventilators should be allowed in godown, if unavoidable, it should be kept closed all the time Do not allow workers to use hooks or sharp tools to lift the bags Do not allow workers to use hooks or sharp tools to lift the bags The cement should be stored in a godown built with minimum 300mm plinth height Check whether the roof of the shed leaks, if so, repair it Always store cement away from the wall Do not store cement directly on the floor. Use wooden planks/pallets or polythene sheets Place cement bags one layer lengthwise and one layer widthwise (header and stretcher style) for better stability of the pile Always adopt first in first out approach (FIFO system). Sometimes, when the cement bag is brought down, it may appear hard (pack lumps) because of the load of the bags above it. Roll the bag two to three times before opening it.

Plant and Machinery

UltraTech Concrete is manufactured at state-of-the-art computerized automatic batching & mixing plants with contemporary technology. Some of the special features of our plants are: 1. Entire process is fully computerized, leaving no scope for human errors. All the control systems are Windows based. 2. Cement and other raw material are checked as per our quality plan. 3. All the raw materials are stacked in separate bins and are stored under cover so that aggregates are not exposed to direct sunlight and environment pollution. 4. Cement, Fly ash, Slag etc. are stored in separate silos for better control on recipe. 5. Handling of fly ash and slag are done from closed bunkers to silos directly. 6. Separate weigh-batchers are provided for each ingredient like cement, water, admixtures and aggregates. The weighing is done on sophisticated electronic weigh batchers. Precise weighing of all materials is done through electronic load cells made up of special alloys. 7. Homogeneous mixing of concrete is ensured by use of special high-efficiency mixers like pan-type or turbo-twin shaft mixers. 8. A fully equipped onsite plant laboratory is available at each plant. 9. A Sprinkler system is installed to ensure temperature control of aggregates in hot

weather. 10. In line with Groups focus towards environment and eco-friendliness all silos are installed with bag filters and level indicators to avoid any kind of pollution. 11. Processes are in place for effective and periodic maintenance and calibration of all critical components. 12. Laser sensor and moisture control are used for a stringent quality assurance. 13. Well trained and experienced engineers are available at every plant to take care of the quality of concrete