Chapte

er‐5

BINDIN
NG MATER
RIALS

1. CEM
MENT

 Lim
me and clay have been used
u as cem
menting mateerial on consstruction thrrough
many centuriees
 Ro
omans are co
ommonly givven credit fo
or developm
ment of cemeent
 Jo
oseph Aspedin (UK) was the first to introduce ceement in 182
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 ement is a powdered form used as binding matterial in morrtar and concrete
Ce
ettc.
 Also fills voidss in between
n fine and co
oarse aggreggate
 Th
he concretee produced from cement resemb
bled the co
olour of naatural
lim
mestone quarried in Po
ortland, UK.. Therefore,, it is also called “Ord
dinary
Po
ortland Cement” (OPC)
 ement is paccked in bags of 50kg havving volume 0.0347 m3 (1.23
Ce ( cft app
prox)

Joseph Asp
pedin OPC samplle

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1.1. Chemical composition of cement

 The three main constituents of cement are lime, silica and alumina
 In addition, most cement also contain small proportion of ferrous oxide,
magnesia etc.
 Gypsum also plays a very important role in controlling the rate of hardening
of the cement.

Ingredients Percentage Function

Lime (Calcium Oxide, CaO) 60 to 65% Strength
Silica (SiO2) 20 to 25% Strength
Alumina (Aluminum Oxide, 4 to 8% Quick setting
Al2O3)
Ferrous Oxide (Fe2O3) 2 to 4% Colour
Magnesia (Magnesium Oxide, 1 to 3% Hardness
(MgO)
Gypsum (Calcium Sulphate, 2 to 8% Rate of hardening
CaSO4)

1.2. Manufacture of cement

1.2.1. Dry Process

 All raw materials are ground separately to fine powder in absence of water
and then are mixed together in the desired proportions and the resultant
material is fed into kiln for burning process
 In rotary kiln coal or burning oil is used as fuel which increased the
temperature from 1700 to 1900oC.
 The resultant product consists of grey hard balls called “clinker”
 Clinker is cooled, ground to fine powder and mixed with gypsum.
 Gypsum is added to control the “setting of cement”. If not added, the
cement will set immediately after mixing of water leaving no time for
concrete placing.

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 1.2.1.1. Advantages
 Less fuel consumption
 Unit cost of product can be reduced

1.2.1.2. Disadvantages
 Achieved low quality of product

1.2.2. Wet Process

 Raw materials (Clay‐Silica, Alumina) is purified by washing and is then mixed
with crushed limestone in proper proportion to get raw slurry (semi liquid
form) which is then introduced to kiln for burning.

1.2.2.1. Advantages
 Better quality can be produced
 Dust emission can be reduced

1.2.2.2. Disadvantages
 Fuel and power consumption are high

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1.2.3. Bogue compounds
 The compounds formed in the burning process have the properties of setting
and hardening in the presence of water
 These compounds are also known as Bogue compounds named after R. H.
Bogue who identified them
 Le‐Chatelier and Tornebohm referred these compounds as Alite (C3S), Belite
(C2S), Celite (C3A) and Felite (C4AF)
 The Bogue compounds are:
Principal mineral compounds Formula Name Symbol
in Portland Cement
Tri‐calcium silicate 3CaO.SiO2 Alite C3S
Di‐calcium silicate 2CaO.SiO2 Belite C2S
Tri‐calcium aluminate 3CaO.Al2O3 Celite C3A
Tetra‐calcium alumino ferrite 4CaO.Al2O3.Fe2O3 Felite C4AF

 See the youtube video link below for this topic

https://www.youtube.com/watch?v=dyxL_BvkhJg

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1.3. Grades of cement

Source: www.britannica.com

 ASTM stands for “American Society for Testing and Materials”

 ACI stands for “American Concrete Institute”

1.4. Setting time of cement

 Initial set: Occurs when the paste begins to stiffen considerably

 Final set: Occurs when the cement has hardened to the point at
which it can sustain some load

1.5. Hydration of cement

 The chemical reaction between cement and water is known as hydration of

cement.
 This reaction proceeds slowly for 2 to 5 hours
 Heat is liberated during hydration process

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1.6. Storage of cement

 Portland cement is kept is bag of 50kg (0.035 m3)

 Can be stored for short period of time in moist and damp free place
 Must be above from floor and away from walls

1.7. Hazardous Aspects of Cements

 Portland cement is caustic, so it can cause chemical burns.

 The powder can cause irritation or, with severe exposure, lung cancer,
 Environmental concerns are the high energy consumption required to mine,
manufacture, and transport the cement, and the related air pollution,
including the release of greenhouse gases (e.g., carbon dioxide), dioxin, NOx,
SO2, and particulates

1.8. Types of cement

1.8.1. Ordinary Portland Cement
 It is the most commonly used cement type with no special characteristics

1.8.2. Rapid hardening cement

 It attains same strength in 3 days which an ordinary cement may attain in 7
days
 The higher strength at early stage is due to finer grinding, as fines of cement
will expose greater surface area for the action of water
 It is subjected to large shrinkage and water requirement for workability is
more
 Its costs about 10% more than the ordinary cement
 Concrete made can be safely exposed to frost since it matures more quickly
 It is suitable for repair of roads and bridges and when load is applied in short
period of time

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1.8.3. Sulphate resisting Portland cement
 Modified form of OPC, manufactured to resist the suphates
 It require longer period for curing
 It develops strength slowly

1.8.4. Quick setting cement

 Adding small percentage of Aluminum sulphate which accelerate the setting
action
 Gypsum content is reduced
 Sets faster than OPC
 Initial setting time 5 minutes and final setting time 30 minutes

1.8.5. Low Heat Cement

 Low percentage of C3S and high C2S to keep heat generation low
 Very low rate of developing strength as rate of C3S content is low
 Better resistance to chemical attack than OPC

1.8.6. Portland puzzolana cement

 OPC and Pozzolana (Calcined clay, Surkhi and Fly ash) ground together
 Used in marine works and mass concreting
 Ultimate strength is more than OPC
 Low shrinkage on drying
 Water tightness

1.8.7. Portland slag cement

 Produced by Portland cement clinker, gypsum and granulated blast furnace
slag
 Blackish grey in colour

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  Lesser heat of hydration
 Offers good resistance to the attack of sulphate

1.8.8. High Alumina Cement

 Characterized by its dark colour, high heat of hydration and resistance to
chemical attach
 Raw material used are limestone and bauxite
 Initial setting time of 4 hours final setting time of 5 hours

1.8.9. Air‐entering cement

 OPC with small quantity of air entraining materials (oils, fats, fatty acids)
ground together
 Air is entrained in the form of tinny air bubbles which enhance workability
and reduce segregation and bleeding
 It resists freeze‐thaw damage

1.8.10. Super‐sulphated cement

 Heat of hydration is considerable lower

 It also resist to sulphate attack
 Suitable for marine structure and mass concrete

1.8.11. Expansive cement

 The main difference is the increase in volume when it settles

 In repair work, it is essential that the new concrete should be tight fitting in
the old concrete. This can be done through use of this cement
 A small percentage of this cement in concrete will not let it crack.

1.8.12. Coloured cement

 Suitable pigments used to achieve desired color

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  Pigment used should be durable under light, sun and weather

1.8.13. White cement

 OPC with pure white colour produced with white chalk or clay free from iron
oxide
 Instead of coal, oil fuel is used for burning

1.9. Testing of Cement

i. Cement Fineness Test
ii. Setting time test
iii. Heat of Hydration Test
iv. Standard Consistency Test
v. Soundness Test
vi. Chemical Composition Test

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2. LIME

2.1. Introduction

 It is a cementing/binding material
 Until the invent of cement, lime was used as the cementing material in
construction
 Most of the ancient palace, temples monuments etc are being built with lime
 Still at places, where lime is available locally and during the shortage of
cement lime provided an economical alternative to cement
 Usually lime in free state is not found in nature
 The raw form of lime CaO is calcium carbonate CaCO3 (lime stone, chalk or
marble)
 Calcium carbonate is obtained from calcinations (heating of solids to a high
temperature) of lime stone.
CaCO3 + Heat ‐‐‐‐‐‐‐‐‐‐ CaO + CO2
 Quicklime can be hydrated i.e. combined with water
CaO + Water ‐‐‐‐‐‐ Ca(OH)2 [Slacked lime] + Heat
 Visit: https://www.youtube.com/watch?v=0kZXFvI4kCU
https://www.youtube.com/watch?v=9LDG9cnGlDo

2.2. Uses of lime

 Used for making mortar and plastering for masonry work

 It is used for whitewashing and for serving as a base coat for distempering
 Used in production of artificial stone, lime‐sand brick, foam silicate, products
etc.
 Used in metallurgical industry
 Used in production of glass

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  Used as chemical raw material in the purification of water and for sewage
treatment

2.3. Lime vs. cement

Property Lime Cement

Color White or grayish white Dark grey or grayish brown
Slaking Slaking takes place on Hardening takes place on
adding water adding water
Setting It sets slow It sets rapidly by reacting
with water
Hardening Slow Rapid
Compressive strength Less High
Cost Low High
Use Suitable for ordinary Suitable for all construction
construction works

2.4. Types of lime

 Different types of lime are obtained depending upon the chemical
composition of the lime stone used in manufacturing of quick lime

2.4.1. Poor lime (lean lime)

 It is obtained by heating limestone of high purity
 It contains from 10 to 40% impurities which are insoluble in acids such as
sand and stones
 Contains more than 30% clay
 It takes longer to slake
 Poor binding material
 Its expansion is less than that of rich
 Setting and hardening is very slow
 Its color varies from yellow to grey
 It gives poor and inferior mortar and is recommended for less important
structure

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  Mostly used for plastering

2.4.2. Hydraulic Lime

 It is obtained from lime stone containing 5 to 30% clay
 It slakes on difficulty
 Does not shrink or crack on setting
 Used as substitute for cement particularly for new building foundation

2.4.3. Rich (Pure or Fat Lime)

 It is obtained by calcinations of limestone of high purity (more than 95%
CaoCO3)
 Used for white washing

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References:

1. https://owlcation.com/stem/Fossils‐and‐Sedimentary‐Rocks
2. https://www.shetlandamenity.org/sedimentary‐rocks
3. Building Materials, 3rd Revised Edition by S.K. Duggal
4. Building Construction and material by Gurcharan Singh
5. http://civil.emu.edu.tr/courses/civl284/4%20Aggregates.pdf
6. http://www.free‐ed.net/free‐
ed/Resources/Trades/Construction/ConcreteMasonry/default.asp?uNum=1
&iNum=0203
7. http://file.scirp.org/Html/1‐1110099_52491.htm
8. https://theconstructor.org/building/classification‐of‐aggregates‐size‐
shape/12339/
9. http://www.jsg.utexas.edu/tyzhu/files/Some‐Useful‐Numbers.pdf (For
values of rock)
10. http://civilengineeringmaterials2012.blogspot.com/2013/08/manufacturing
‐of‐bricks‐part‐iii‐drying.html (Kilns)
11. https://www.agg‐net.com/resources/articles/recycling‐waste/exploring‐
the‐synthetic‐aggregates‐alternative (Synthetic aggregates)
12. http://www.engr.psu.edu/ce/courses/ce584/concrete/library/materials/agg
regate/aggregatesmain.htm (Aggregate %age in concrete)
13. https://www.slideshare.net/SameerNK/cement‐24025240 (Cement)
14. https://www.britannica.com/technology/cement‐building‐
material/Extraction‐and‐processing#ref609165 (Cement)
15. https://www.engineeringcivil.com/what‐is‐the‐purpose‐of‐adding‐gypsum‐
in‐cement.html (Gypsum)
16. https://theconstructor.org/concrete/types‐concrete‐applications/19779/
(Types of concrete)
17. https://civilstudents.com/category/concrete‐technolgy/ (Defects in
concrete)
18. https://www.youtube.com/watch?v=dyxL_BvkhJg (Manufacturing of
cement)

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19. https://www.slideshare.net/MADNANARSHAD/m‐hamid‐presentation
(cement)
20. https://www.slideshare.net/LATIFHYDERWadho/cement‐ppt (cement)
21. https://www.slideshare.net/BhaswatiSharma1/1‐cement‐ppt (types of
cement)

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