Portland Cement
Portland Cement
Portland Cement
PORTLAND CEMENT
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CLINKER GYPSUM
PRODUCTION STEPS
1) Raw materials are crushed, screened &
stockpiled.
2) Raw materials are mixed with definite
proportions to obtain “raw mix”. They are
mixed either dry (dry mixing) or by water (wet
mixing).
3) Prepared raw mix is fed into the rotary kiln.
4) As the materials pass through the kiln their
temperature is rised upto 1300-1600 °C. The
process of heating is named as “burning”. The
output is known as “clinker” which is 0.15-5
cm in diameter.
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~350-650°C→decomposition of
clay→SiO2&Al2O3
~600°C→decomposition of MgCO3→MgO&CO2
(evaporates)
~900°C→decomposition of CaCO3→CaO&CO2
(evaporates)
~1280°C→clinkering begins.
~1400-1500°C→clinkering
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CHEMICAL COMPOSITION
OF P.C.
Portland cement is composed of four
major oxides (CaO, SiO2, Al2O3, Fe2O3
≥90%) & some minor oxides. Minor refers
to the quantity not importance.
CaO→limestone
SiO2-Al2O3→Clay
Fe2O3→Impurity in Clays
SO3→from gypsum→not from the clinker
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CaO (C), SiO2 (S), Al2O3 (A) & Fe2O3 are the
major oxides that interact in the kiln & form the
major compounds.
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MgO+H2O→MH
C+H→CH volume expansion & cause
cracking.
ASTM C 150 → M<6%
free C < 3%
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COMPOUND COMPOSITION
OF P.C. (OR CLINKER)
Oxides interact with eachother in the kiln
to form more complex products
(compounds). Basically, the major
compounds of P.C. can be listed as:
Name Chemical Formula Abbreviations
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Methods of Determining
Compound Composition
Each grain of cement consists of an intimate
mixture of these compounds.
They can be determined by:
1) Microscopy
2) X-Ray Diffraction
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Assumptions
1) The chemical reactions in the kiln
proceeded to equilibrium.
2) Compounds are in pure form such as C3S
& C2S
3) Presence of minor compounds are
ignored.
4) Ferrite phase can be calculated as C4AF
5) All oxides in the kiln have taken part in
forming the compounds.
%C3S=4.071(%C)-7.6(%S)-6.718(%A)-
1.43(%F)-2.852(%Ś)
%C2S=2.867(%S)-0.7544(%C3S)
%C3A=2.650(%A)-1.692(%F)
%C4AF=3.043(%F)
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C3S=4.071*64.9-7.6*22.2-6.718*5.8-
1.43*3.1=52.1%
C2S=2.876*22.2-0.7544*52.1=24.5%
C3A=2.65*5.8-1.692*3.1=10.1%
C4AF=3.043*3.1=9.4%
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Influence of Compound
Composition on Characteristics
of P.C.
P.C.+water→the compounds in the cement
undergo chemical reactions with the water
independently, and different products result from
these reactions.
C3S C2S C3A C4AF
Average Compound
ASTM Type & Name Composition
of P.C.
C3S C2S C3A C4AF
Type I - O.P.C. 49 25 12 8 General Purpose
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Hydration of P.C.
Hydration: Chemical reactions with water.
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- w/c ratio
capillary porosity
- degree of hydration
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If there is no gypsum→flash-set
more gypsum→ettringite
formation increases
which will cause cracking
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C4AŚH12 or C4FŚH12
C6AŚ3H32 or C6FŚ3H32
HEAT OF HYDRATION
Hydration process of cement is accompanied by
heat generation (exothermic).
As concrete is a fair insulator, the generated
heat in mass concrete may result in expansion &
cracking. This could be overcome by using
suitable cement type.
It could also be advantages for cold wheather
concreting.
The heat of hydration of OPC is on the order of
85-100 cal/gr.
About 50% of this heat is liberatedwithin 1-3
days & 75% within 7 days.
By limiting C3S&C3A content heat of hydration
can be reduced.
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C3A 207
Heat of
C4AF 100 Hydration(cal/gr)=120
*(%C3S)+62*(%C2S)+
207*(%C3A)+100*(C4A
F)
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FINENESS OF CEMENT
As hydration takes place at the surface of
the cement particles, it is the surface area
of cement particles which provide the
material available for hydration. The rate of
hydration is controlled by fineness of
cement. For a rapid rate of hydration a
higher fineness is necessary.
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However,
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Sieving
Blaine Apparatus
SETTING
Setting refers to a change from liquid state to
solid state. Although, during setting cement
paste acquires some strength, setting is different
from hardening.
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Gillmore Needle
Vicat Needle
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Flash-set
Abnormal Settings
False-set
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SOUNDNESS OF CEMENT
Soundness is defined as the volume stability of cement
paste.
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STRENGTH OF CEMENT
Strength tests are not carried out on neat
cement pastes, because it is very difficult
to form these pastes due to cohesive
property of cement.
P P
1”
1”
σt=P/1in2
Difficult test procedure
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P
4cm
4cm
L
C
σf=(M*C)/I
M:maximum moment
I:moment of inertia
C:distance to bottom fiber from C.G.
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3) Compression Test:
i) Cubic Sample ii)Flexural Sample after it
is broken
P
4cm 4cm
4cm
P
σc=P/A
σc=P/A A=4x4
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SPECIAL CEMENTS
Portland Pozzolan Cement (P.P.C.)
By grinding & blending P.C.
Clinker+Pozzolan+Gypsum
P.P.C. Produces less heat of hydration &
offers higher sulfate resistance so it can
be used in marine structures & mass
concrete.
However, most pozzolans do not
contribute to strength at early ages.
The early strength of PPC is less.
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Hydraulic Cement
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EN 197-1
2000
CEM cements
CEM I – Portland Cement
CEM II – Portland Composite
Cement
CEM III – Portland Blast Furnace
Slag Cement
CEM IV – Pozzolanic Cement
CEM V – Composite Cement
27 different cements
EN 197-1
CEM cements :
– Binding property is mainly due to hydration of
calcium-silicates
– Reactive C + Reactive S > 50%
Clinker, major and minor mineral admixtures
– Clinker + Major + Minor = 100% (mass) + Gypsum
– Major > 5% by mass
– Minor ≤ 5% by mass
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EN 197-1
Mineral Admixtures
K : Clinker
D : Silica Fume
P : Natural Pozzolan
Q : Calcined Natural Pozzolan
T : Calcined Shale
W : Class – C Fly Ash
V : Class – F Fly Ash
L : Limestone (Organic compound < 0.5%)
LL : Limestone (Organic compound < 0.2%)
S : Granulated Blast Furnace Slag
EN 197-1
Composition
A : Lowest amount of mineral admixture
B : Mineral admixture amount is > A
C : Mineral admixture amount is > B
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EN 197-1
Composition
CEM I : Portland Cement
95-100% K + 0-5% Minor
EN 197-1
Composition
CEM II : Portland Composite Cement
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EN 197-1
Composition
CEM III : Portland Blast Furnace Slag Cement
EN 197-1
Composition
CEM IV : Pozzolanic Cement
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EN 197-1
Composition
CEM V : Composite Cement
Strength Classes
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Name - Example
CEM II / A – P 42.5 N
CEM II / A – P 42.5 R
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