Pensyarah

Prof. Madya Dr. Mohammad Ismail

Fakulti Kejuruteraan Awam
Universiti Teknologi Malaysia
2009
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 Water Cement

Aggregate
Admixture
(fine + coarse)

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 CEMENT
• INTRODUCTION
– Common construction material, the properties may
be predetermined by design, selection of
constituent materials, and quality control
– The constituent materials of concrete are
• cement, aggregates, water and admixtures
– Ingredients mixed → molded → hydration →
concrete

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 Cement
• Cement is any material that binds or unites
– essentially like glue.
• In civil engineering or construction, the
word cement or “cementitious material”
refer to an ingredient in concrete, mortar
or grout

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 Cement

Is the product obtained by grinding clinker

formed by burning raw-materials
(argillaceous and calcareous) primarily
consisting of lime (CaO), silicate (SiO2),
alumina (Al2O3), and iron oxide (Fe2O3)

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 Advantages/ Kebaikan
• Cheap
• Flexibility - (concrete, mortar, grout…)
• Finishes/ Penyudah - versatile
• Compression strength – high
• Protection/ Mengawal - keluli

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 Disadvantages
• Low tensile strength/ Brittle (Rapuh)/
• High density/ Berat
• Deteriorate (Boleh rosak) – suceptable to
frost/ chemical attack

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 Characteristic of cement

• Setting and hardening when mix to a

paste with water
• Cohesive and Adhesive

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 History of Portland Cement

• 1824 – patented by Joseph Aspdin

• Materials to produce cement were found
on the English Isle of Portland
• Thus, called PORTLAND CEMENT

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 Cement
• Argillaceous + Calcareous
Silica Lime
Alumina
Ferum oxide

Argillaceous – clay, sandstone, shale

Calcareous – limestone, chalk

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 Cement
• Hydraulic cement – able to set and harden
under water e.g. OPC, Slag Cement, ggbs

• Non-Hydraulic cement – will not set and

harden under water but require air to
harden e.g. lime, gypsum

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 Manufacturing Process
Two processes:
• Wet Process – softer materials (clay +
chalk)

• Dry Process – harder materials (shale +

limestone)

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Steps in manufacturing process

1. Grinding and mixing of raw materials

2. Burning in a rotary kiln
3. Cooling, grinding and sieving
4. Storing, packing and distributing

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Manufacturing Process

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 Wet Process
1. Materials being ground and mixed with
the correct proportions

2. The mixture in a slurry form is fed into a

rotary kiln where it is heated/burnt to a
temperature of 1500 oC to form clinker

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 Wet Process
3. Cooling and grinding – Gypsum (CaSO4)
is added during the grinding process to
prevent flash setting
4. Storing – stored in silo

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 Burning (wet process)
• 100 oC – water is driven off
• 850 oC – limestone changes to calcium
oxide and CO2 is liberated
• 1500 oC – CaO reacts with SiO2 to form
Calcium Silicate CS
• CaO reacts with other compounds to form
Calcium Aluminat (CA) and Calcium
Aluminoferit (CAF)

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 Dry Process
• The process is relatively the same as wet
process except in dry process the raw materials
(harder materials) are mixed in dry condition.

• Small amount of water is added to form 12mm in

diameter ‘balls’

• The ‘balls’ are burnt in a rotary kiln and the

chemical reactions are the same as wet process

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 Types of Portland Cement
Ordinary Portland Cement (OPC)
Kursus Forensik Kejuruteraan
Rapid Hardening Portland Cement (RHPC)
Pembinaan
Sulphate Resisting Portland Cement (SRPC)
Pegawai
Modified BPR Malaysia
Portland Cement (MPC)
Low Heat 2Portland
Ogos – Cement
7 Oktober 2004
(LHPC)
Hotel SeriCement
Portland-Blastfurnace Malaysia
(PBC)
Johor
Portland-Pozzolan Bahru(PPC)
Cement
Others
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Cement differing in chemical
composition may exhibit
different properties when
hydrated

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 Ordinary Portland Cement
• By far the most common cement used in
general concrete construction when there
is no exposure to sulphates in the soil or
groundwater
• Minimum fineness of 225 m2/kg
• Rate of hardening is moderate
• Standards; BS 12, MS 522

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 Rapid Hardening Portland Cement
(RHPC)
• Rapid strength gain due to higher C3S content
(70%)
• Minimum fineness of 325 m2/kg
• Used when formwork is to be removed early for
reuse or where sufficient strength for further
construction is required quickly
• Should not be used in mass concrete
construction or in large structural sections
because of its higher rate of heat development

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 RHPC
• For construction at low temperatures, the use of
RHPC may provide a satisfactory safeguard
against early frost damage

• The setting time and chemical composition of

RHPC and OPC is relatively the same

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 Sulphate Resisting Portland Cement
• This cement has low C3A (3.5%) content so as to
avoid sulphate attack from outside the concrete
• Minimum fineness of 250 m2/kg
• Active salts are magnesium and sodium sulphates

• Sulphate attack is greatly accelerated if

accompanied by wetting and drying (splash zone)
• The heat develop by SRPC is not much higher than
the low-heat cement, which is an advantage

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 Portland-Blastfurnace Cement
• Made by intergrinding or blending Portland
cement clinker with granulated blastfurnace slag
• Known as slag cement
• Slag contains lime, silica and alumina, but not in
the same proportions as in Portland cement
• Minimum fineness of 275 m2/kg
• Early strength are generally lower than OPC but
later strength are similar or even higher

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Cont.
• Typical uses are in mass concrete because of
low heat of hydration and in seawater
construction due to better sulphate resistance
(lower C3A content) than with the OPC

• The amount of slag replacement between 25 to

70% of the mass of the mixture

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 Portland-Pozzolan Cement
• Made by intergrinding or blending pozzolans
with Portland cement
• A pozzolan is a siliceous or siliceous and
aluminous material which itself possesses little
or no cementitious value BUT in finely divided
form and in the presence of moisture, chemically
react with Ca(OH)2 - liberated during the
hydration of Portland cement to form compounds
possessing cementitious properties

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Cont.
• Portland-Pozzolan cement gain strength
slowly and therefore require curing over a
comparatively a long period, but the long-
term strength is high

• Amount replacement between 25 to 40%

• More durable than OPC

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 Principal Compounds of
Portland Cement
Compound Chemical formula Abb. Percent Rate of
(range) reaction
with water
Tricalcium 3CaO.SiO2 C 3S 35-65% Medium
silicate

Dicalcium 2Cao.SiO2 C 2S 15-40% Slow

silicate

Tricalcium 3CaO.Al2O3 C3 A 0-15% Fast

Aluminate

Tetracalcium 4CaO.Al2O3.Fe2O3 C4AF 6-20% Medium

Aluminoferrite

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 Alkalis in Cement
• Na2O and K2O
• May cause problem – Alkali
Silica Reaction

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 PROBLEMS
1. What are the three main compounds in the raw
materials for the manufacture of cement
CaO, Clay or shale Silica SiO2 and Alumina Al2O3)
(limestone or chalk

2. What is the purpose of adding gypsum to

cement (add 2-5% gypsum to retard the setting time of cement)

3. What are the four major compounds of

portland cement
4. Which is the most reactive compound in
portland cement
5. Name a nonhydraulic cement
6. Name two hydraulic cement

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Terima Kasih

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