cement -introduction-types

cement mortar – types and application

market forms of cement
A CEMENT IS A BINDER, OR A BINDING
MATERIAL, A SUBSTANCE THAT SETS AND
HARDENS AND CAN BIND OTHER MATERIALS
TOGETHER WHEN ADDED WITH WATER OR
OTHER INCREDIENTS
Portland cement is the most common type of cement in general use around the
world. This cement is made by heating limestone (calcium carbonate) with other
materials (such as clay) to 1450 °C in a kiln, in a process known as calcination,
whereby a molecule of carbon dioxide is liberated from the calcium carbonate to
form calcium oxide, or quicklime, which is then blended with the other materials
that have been included in the mix to form calcium silicates and other
cementitious compounds.

The resulting hard substance, called 'clinker', is then ground with a small amount
of gypsum into a powder to make 'Ordinary Portland Cement', the most
commonly used type of cement (often referred to as OPC). Portland cement is a
basic ingredient of concrete, mortar and most non-specialty grout.

The most common use for Portland cement is in the production of concrete.
Concrete is a composite material consisting of aggregate (gravel and sand),
cement, and water.

As a construction material, concrete can be cast in almost any shape desired, and
once hardened, can become a structural (load bearing) element. Portland cement
may be grey or white.
Components of Cement Comparison of Chemical and Physical Characteristics

Portland
Property
Cement

SiO2 content (%) 21.9

Al2O3 content (%) 6.9

Fe2O3 content (%) 3

CaO content (%) 63

MgO content (%) 2.5

SO3 content (%) 1.7

TYPES
Types of Cement Composition Purpose

Rapid Hardening Cement Increased Lime content Attains high strength in early days it is used in
concrete where form work are removed at an
early stage.
Quick setting cement Small percentage of aluminium sulphate Used in works is to be completed in very short
as an accelerator and reducing period and concreting in static and running water
percentage of Gypsum with fine grinding
Low Heat Cement Manufactured by reducing tri-calcium It is used in massive concrete construction like
aluminate gravity dams
Sulphates resisting It is prepared by maintaining the It is used in construction exposed to severe
Cement percentage of tricalcium aluminate sulphate action by water and soil in places like
below 6% which increases power against canals linings, culverts, retaining walls, siphons
sulphates etc.,
Blast Furnace Slag It is obtained by grinding the clinkers It can used for works economic considerations is
Cement with about 60% slag and resembles more predominant.
or less in properties of Portland cement
High Alumina Cement It is obtained by melting mixture of It is used in works where concrete is subjected to
bauxite and lime and grinding with the high temperatures, frost, and acidic action.
clinker it is rapid hardening cement with
initial and final setting time of about 3.5
and 5 hours respectively
White Cement It is prepared from raw materials free It is more costly and is used for architectural
from Iron oxide. purposes such as pre-cast curtain wall and facing
panels, terrazzo surface etc.,
Coloured cement It is produced by mixing mineral They are widely used for decorative works in
pigments with ordinary cement. floors
Pozzolanic Cement It is prepared by grindin pozzolanic It is used in marine structures, sewage works,
clinker with Portland cement sewage works and for laying concrete under
water such as bridges, piers, dams etc.,
Air Entraining Cement It is produced by adding indigenous air This type of cement is specially suited to improve
entraining agents such as resins, glues, the workability with smaller water cement ratio
sodium salts of Sulphates etc during the and to improve frost resistance of concrete.
grinding of clinker.
Hydrographic cement It is prepared by mixing water repelling This cement has high workability and strength
chemicals
 Types Of Cement and Respective Indian Standards
Reference Indian
SlNo Types Of Cement
Standard
1 Ordinary Portland Cement 33 Grade IS:269
2 Ordinary Portland Cement 43 Grade IS:8112
3 Ordinary Portland Cement 53 Grade IS:12269
4 Rapid Hardening Cement IS:8041
5 Extra Rapid Hardening Cement —
6 Sulphate Resisting Cement IS:12330
7 Portland Slag Cement IS:455
8 Quick Setting Cement —
9 Super Sulphated Cement IS:6909
10 Low Heat Cement IS:12600
11 Portland Pozzolana Cement (Fly ash based) IS:1489 P-1
12 Portland Pozzolana Cement (Calcined based) IS:1489 P-2
13 Air Entraining Cement —
14 Coloured Cement: White Cement IS:8042
15 Hydrophobic Cement IS:8043
16 Masonry Cement IS:3466
17 Expansive Cement —
18 Oil Well Cement IS:8229
19 Rediset Cement —
20 Concrete Sleeper Grade Cement IRS-R 40
21 High Alumina Cement IS:6452
22 Very High Strength Cement —
Varieties of Cement in India
There are some varieties in cement that always find good demand in the market. To know
their characteristics and in which area they are most required,

the details given below.

Portland Blast Furnace slag cement (PBFSC): The rate of hydration heat is found
lower in this cement type in comparison to PPC. It is most useful in massive construction
projects, for example - dams.

Sulphate Resisting Portland Cement: This cement is beneficial in the areas where
concrete has an exposure to seacoast or sea water or soil or ground water. Under any such
instances, the concrete is vulnerable to sulphates attack in large amounts and can cause
damage to the structure. Hence, by using this cement one can reduce the impact of
damage to the structure. This cement has high demand in India.

Rapid Hardening Portland Cement: The texture of this cement type is quite similar to
that of OPC. But, it is bit more fine than OPC and possesses immense compressible
strength, which makes casting work easy.
Ordinary Portland Cement (OPC): Also referred to as grey cement or OPC, it is
of much use in ordinary concrete construction. In the production of this type of
cement in India, Iron (Fe2O3), Magnesium (MgO), Silica (SiO2), Alumina
(AL2O3), and Sulphur trioxide (SO3) components are used.
Portland Pozolona Cement (PPC): As it prevents cracks, it is useful in the
casting work of huge volumes of concrete. The rate of hydration heat is lower in
this cement type. Fly ash, coal waste or burnt clay is used in the production of this
category of cement. It can be availed at low cost in comparison to OPC.
Oil Well Cement: Made of iron, coke, limestone and iron scrap, Oil Well Cement
is used in constructing or fixing oil wells. This is applied on both the off-shore and
on-shore of the wells.
Clinker Cement: Produced at the temperature of about 1400 to1450 degree
Celsius, clinker cement is needed in the construction work of complexes, houses
and bridges. The ingredients for this cement comprise iron, quartz, clay, limestone
and bauxite.
White cement: It is a kind of Ordinary Portland Cement. The ingredients of this
cement are inclusive of clinker, fuel oil and iron oxide. The content of iron oxide
is maintained below 0.4% to secure whiteness. White cement is largely used to
increase the aesthetic value of a construction. It is preferred for tiles and flooring
works. This cement costs more than grey cement.
 CEMENT MORTAR
• Mortar is a mixture of materials which is used
to hold building materials such as brick or
stone together. It is composed of a thick
mixture of water, sand, and cement. The
water is used to hydrate the cement and hold
the mix together. The water to cement ratio is
higher in mortar than in concrete in order to
form its bonding element
The ratio of sand to cement is about 2:1 or 3:1 or 4:1 or
5:1
or AS PER NEED
Mix the dry ingredients.
Pour the required quantity of sand to the prepared floor where the mortar mixture has to be
prepared. Add the required quantity of cement in the ratio needed on the spreaded sand
and Mix the dry ingredients thoroughly two or three times until the mixture is ready in dry
state.
Add water to the dry ingredients.
Once you have mixed the dry ingredients thoroughly, add a little
water, then distribute the water by carefully mixing with a spade
or other tool. Keep adding water until the mortar reaches the
proper consistency. It should be smooth and spreadable, but
should not drip or run off your spade when you lift it. If you add
too much water, you can adjust by adding more cement and sand.
Once you have mixed the mortar

Clean your mixing tools at this time so that the mortar does not
cure on the tool.

Run clear water over the tool and rub with your gloved hand until
all the mortar is removed.
Use the cement mortar. Apply the mortar within about two hours of mixing
it. If you wait longer than that, it will likely have cured too much to use, but
the curing time can be extended by adding retarders and by keeping the
mortar cool or cold. Once the mortar begins to set and harden, do not
attempt to thin the mix by adding more water.
Properties of Good Mortar

It should be capable of developing good adhesion with the building units

such as bricks, stones etc.
It should be capable of developing the designed stresses.
It should be capable of resisting penetration of rain water.
It should be cheap.
It should be durable
It should be easily workable
It should not affect the durability of materials with which it comes into
contact.
It should set quickly so that speed in construction may be achieved.
The joints formed by mortar should not develop cracks and they should be
able to maintain their appearance for a sufficiently long period.
 Market form of cement
1. Ultra tech
2. Chettinad
3. Coramandel
4. Ramco
5. Shankar
6. Bharthi
7. Vijay
8. Amma cement….. etc
 Grades of cement
• Suitability of various types of cement:
• Selection of cement based on suitability for various concreting environment is important for durability
considerations of structures. Thus, making wise choice of cement type for particular construction site, prevents
structure from deteriorating and saves much repair and rehabilitation cost later. Following are the suitability of
various cements for different environmental conditions:
• 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 C3A should be between 5 – 8%.
• iii) 53 grade OPC:
• For concrete grade higher than M-30, PSC works, bridge, roads, multi-storied buildings etc.
• For use in cold weather concreting.
• For marine structures but C3A should be between 5 – 8%.
• iv) Portland Slag Cement (PSC)
• It is OPC + granulated slag cement. 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:
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 to sea coast.
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.
Not Suitable for:
Sulphate resisting cement is not suitable where there is danger of chloride attack. This will cause corrosion of
rebar.
If both Chlorides and Sulphates are present, Ordinary Portland Cement with C3A between 5 & 8 should be used.
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. temperature < 5oC. Rapid hardening cement is
basically OPC but its fineness is 3250 cm2/g against 2250cm2/g in case of OPC. The compressive
strength after 1 day is 16 N/mm2 and that of 3 days 27 N/mm2. 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
 Unit -5

components of buildings
Primary physical and
Structural components of buildings
Masonry walls are the most durable part of any building or
structure. They provide strength,, durability to the structure and
also helps to control indoor and outdoor temperature. It
separates a building from outside world.
Masonry is the word used for construction with mortar as a
binding material with individual units of bricks, stones, marbles,
granites, concrete blocks, tiles etc. Mortar is a mixture of binding
material with sand. Binding materials can be cement, lime, soil or
any other.
The durability and strength of masonry wall construction
depends on the type and quality of material used and
workmanship.
Based on the type of individual units used for masonry walls and
their functions, the types of masonry walls are:
1. Load Bearing Masonry Walls:
Load bearing masonry walls are constructed with bricks, stones or concrete blocks.
These walls directly transfer loads from the roof to the foundation. These walls can be
exterior as well as interior walls. The construction system with load bearing walls are
economical than the system with framed structure

The thickness of load bearing walls is based on the quantity of load from roof it has to
bear. For example a load bearing wall with just a ground floor can have its outer walls of
230mm, while with one or more floors above it, based on occupancy type, its thickness
may be increased.
The load bearing walls can be reinforced or unreinforced masonry walls.
2. Reinforced Masonry Walls:
Reinforced masonry walls can be load bearing walls or non-load bearing walls. The use of
reinforcement in walls helps it to withstand tension forces and heavy compressive loads.
The un-reinforced masonry walls are prone to cracks and failure under heavy
compressive loads and during earthquakes. They have little ability to withstand lateral
forces during heavy rain and wind. Cracks also develop in un-reinforced masonry walls
due to earth pressure or differential settlement of foundations.

To overcome such problems, reinforced masonry walls are used. Reinforcement in walls
are at required intervals both horizontally and vertically is used. The size of
reinforcement, their quantity and spacing are determined based on the loads on the
walls and structural conditions.
3. Hollow Masonry Walls:
Hollow or Cavity masonry walls are used to prevent moisture reaching the interior of
the building by providing hollow space between outside and inside face of the wall.
These walls also helps in temperature control inside the building from outside wall as
the hollow space restricts heat to pass through the wall.

When the wall is exposed to moisture for a sustained period and penetrates through
the outer face, the water reaches the cavity or the hollow space and flows down. Then
they are drained through the weep holes to the exterior of the building. These hollow
spaces may be coated with water repellent coating or damp-proofing to further
reduce the ingress of moisture.
4. Composite Masonry Walls:
These walls are constructed with two or more
units such as stones or bricks and hollow
bricks. This type of masonry wall construction
is done for better appearance with economy.
In composite masonry walls, two wythes of
masonry units are constructed bonding with
each other. While one wythe can be brick or
stone masonry while the other can be hollow
bricks. A wythe is a continuous vertical section
of masonry one unit in thickness.

These wythes are interconnected either by

horizontal joint reinforcement or by using steel
ties.
5. Post-tensioned Masonry Walls:
Post-tensioned masonry walls are constructed
to strengthen the masonry walls against the
forces that may induce tension in the wall such
as earthquake forces or wind forces.
These walls are constructed from the
foundation level and post-tensioning rods are
anchored into the foundation. These rods are
run vertically between the wythes or in the
core of concrete masonry units.

After the masonry wall construction is

completed and cured, these rods are
tensioned and anchored on the steel place at
the top of the wall.