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    CH1 - Cement - Part1

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    Eilmoh
    Cement is manufactured from limestone and clay or shale. There are two processes - wet and dry. The raw materials are heated to high temperatures to form clinker, which is then ground with gypsum. The major compounds in cement are tricalcium silicate (C3S), dicalcium silicate (C2S), tricalcium aluminate (C3A), and tetracalcium aluminoferrite (C4AF). When water is added, they hydrate and harden to form calcium silicate hydrate (CSH) and calcium hydroxide (CH). C3S provides early strength while C2S provides later strength. C3A reacts quickly but needs gy

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    CH1 - Cement - Part1

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    Eilmoh
    29 views22 pages
    Cement is manufactured from limestone and clay or shale. There are two processes - wet and dry. The raw materials are heated to high temperatures to form clinker, which is then ground with gypsum. The major compounds in cement are tricalcium silicate (C3S), dicalcium silicate (C2S), tricalcium aluminate (C3A), and tetracalcium aluminoferrite (C4AF). When water is added, they hydrate and harden to form calcium silicate hydrate (CSH) and calcium hydroxide (CH). C3S provides early strength while C2S provides later strength. C3A reacts quickly but needs gy

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    CH1- Cement- Part1_f4d0a66b3d5b1946a0a38b28bef1f345

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    Cement is manufactured from limestone and clay or shale. There are two processes - wet and dry. The raw materials are heated to high temperatures to form clinker, which is then ground with gypsum. The major compounds in cement are tricalcium silicate (C3S), dicalcium silicate (C2S), tricalcium aluminate (C3A), and tetracalcium aluminoferrite (C4AF). When water is added, they hydrate and harden to form calcium silicate hydrate (CSH) and calcium hydroxide (CH). C3S provides early strength while C2S provides later strength. C3A reacts quickly but needs gy

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    29 views22 pages

    CH1 - Cement - Part1

    Uploaded by

    Eilmoh
    Cement is manufactured from limestone and clay or shale. There are two processes - wet and dry. The raw materials are heated to high temperatures to form clinker, which is then ground with gypsum. The major compounds in cement are tricalcium silicate (C3S), dicalcium silicate (C2S), tricalcium aluminate (C3A), and tetracalcium aluminoferrite (C4AF). When water is added, they hydrate and harden to form calcium silicate hydrate (CSH) and calcium hydroxide (CH). C3S provides early strength while C2S provides later strength. C3A reacts quickly but needs gy

    Copyright:

    © All Rights Reserved
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    of 22

    Chapter I : Cement

    Contents:

    1.1 Introduction
    1.2 Manufacture of Portland Cement
    1.3 Basic chemistry of Cement
    1.4 Hydration of Cement and Related Properties
    1.5 Cement Tests
    1.6 Structure of Hydrated Cement
    1.7 Types of Portland and Other Hydraulic Cements and Their Uses

    1
    1.1 Introduction

    Romans were the first to use concrete.

    Hydraulic Cement ( Portland Cement)


    It is the cement that set and hardens inside water as
    well as in air.

    Portland Cement:
    Obtained from processing and heat treatment of
    calcareous, argillaceous, or other silica, alumina and
    iron oxide, then grinding and addition gypsum..

    2
    1.2 Manufacture of Portland Cement

    The production stages of Portland cement is represented by


    the flow chart shown in Fig 1.1.

    Raw Materials:

    Cement is manufactured From:

    limestone ( or chalk )  CaCO3

    Clay or shale  silica, Alumina

    3
    Two Processes of Manufacture

    a. Wet Manufacture Using water

    b. Dry Manufacture Without water

    4
    Wet Process

    5
    Dry Process

    6
    Heat Treatment

    100C  Free moisture evaporate



    600C  Clay  Al2O3, SiO2

    1000C  Limestone [CaCO3]  CaO (quick lime)



    Major
    Products
    1950 C  n1 CaO.n2AL2O3

    n1 CaO. n2 SiO2

    7
    Minor Compounds

    MgO, TiO2, Mn2O3, K2O, and Na2O

    The Clinker  Cooled  Ground to Fine Powder

    Gypsum ( CaSO4.2H2O) added to prevent flash set. Its


    content is measured through SO3 Content.

    8
    1.3 Basic Chemistry of Cement

    Four Compounds are regarded as the major constituents of cement :

    Name Chemical Formula Shorthand Notation

    Tricalcium Silicate 3CaO.SiO2 C3S

    2CaO.SiO2 C2S
    Dicalcium Silicate
    3CaO.Al2O3 C3A
    Tricalcium Aluminate

    Tetracalcium 4CaO.Al2O3.Fe2O3 C4AF


    Alumino-ferrite

    Alite : Impure tricalcium silicate ( C3S )

    Blite : Impure dricalcium silicate ( C2S )


    9
    The calculation of the potential composition of Portland
    cement is given by R.H. Bogue’s equations, given as :

    C3S = 4.07 (CaO) - 7.60 (SiO2) - 6.72 (Al2O3) - 1.43 (Fe2O3) - 2.85 (SO3)

    C2S = 2.87 (SiO2) - 0.754 ( C3S)

    C3A = 2.65 (Al2O3) - 1.69 (Fe2O3)

    C4AF = 3.04 (Fe2O3)

    The brackets represent the percentage of the given oxides.

    10
    Example
    Calculate the Bogue’s composition of the cement with the
    oxide composition given as: “These Values are obtained
    when analyzing a Cement Sample”

    SiO2 = 22.4% CaO=68.2% Fe2O3= 0.3%


    AL2O3= 4.6% SO3=2.4% Free lime = 3.3%

    Solution
    C3S = 4.07 (68.2) - 7.60 (22.4)-6.72(4.6)-1.43(0.3)-2.85(2.4) = 69.2 %

    C2S = 2.87 (22.4)-0.754(69.2) = 12.15 %

    C3A = 2.65(4.6)-1.69(0.3) = 11.68 %

    C4AF= 3.04 (0.3) = 0.91%

    11
    Typical compostion of portland cement

    Oxide % Oxide % Compounds %


    CaO 63 C3A 10.8
    **IR 1
    Sio2 20 C3S 54.1
    * LI 2
    AL2O3 6 C2S 16.6
    Other 1/2
    Fe2O3 3 C4AF 9.1

    MgO 1.5 Minor -


    Calculated
    SO3 2 Compounds

    K2O 0.5

    Na2O 0.5
    12
    *Loss of Ignition :

    Extent of carbonation and hydration of free lime and free


    magnesia due to the exposure of cement to the atmosphere
    ( maximum. allowed is 4%)

    **Insouble Residue :

    Measure of adulteration of cement, largely arising from


    impurities in gypsum ( maximum allowed is 1.5% ).

    13
    1.4 Hydration of Cement

    Tricalcium Silicates

    2C3S + 7H  C3S2H4 + 3CH H= -502 KJ/mole (1.1)

    Tricalcium Water Calcium Calcium


    silicate silicate hydroxide
    hydrate

    CSH: Poorly crystalline material


    CH: Crystalline material

    14
    Dicalcium Silicates

    Calcium
    Water hydroxide
    2C2S + 5H  C3S2H4 + CH
    Calcium H=-260 KJ/mole (1.2)
    Dicalcium
    silicate
    silicate
    hydrate

    C2S hydrates in a similar manner as C3S, but much more


    slowly because it is less reactive compound .

    15
    Tricalcium Aluminate
    The primary initial reaction of C3A with water in the
    presence of a plentiful supply of gypsum is :

    Tricalcium Aluminate
    C3A +26 H → C3AH6 H=-867 KJ/mole (1.3)

    C3AH6 +3(CaSO4.2H2O) + 19 H →
    C6ASH31+Volume Expansion (1.4)
    gypsum Tricalcium sulfo-aluminate
    Used to prevent Hydrate get: Ettringate
    flash set
    Consumptions of Sulfates

    Monosulfoaluminate: harmless
    compound

    16
    Tetracalcium Aluminoferrite

    The reaction of C4AF with water is as follows:

    Tricalcium
    Aluminate

    C4AF +(6+n) H → C3AH6 + C3FHn H=-419 KJ/mole (1.5)

    Regarding Sulfate Resistance


    C3A has poor (SR) because Ca(OH)2 converts sulfates into
    gypsum by ion exchange:

    1
    Na 2 So4  Ca ( OH )2  CaSO4 + 2Na(OH)
    1 2 2

    Gypsum attacks C3A hydration products forming Ettringite inside


    17
    hardened concrete, resulting in volume expansion and cracking.
    Uncombined Oxides

    Hydrates as usual :
    These reactions cause volume
    CaO + H2O  Ca(OH)2 expansions which happen after
    MgO + H2O  Mg(OH)2 concrete (Paste) hardens.

    18
    Properties of Cement Compounds

    C3S and C2S (80-85%)


    responsible for giving strength for the cement paste

    C3A (10-12%)
    Little or no contribution to cement paste strength at early ages
    Reacts with sulfates; therefore, forming sulphoaluminate
    (Ettringate). The latter expands upon absorption of water causing
    concrete cracking
    Facilitates the combination of lime and silica during manufacture
    of cement.

    C4AF (3 - 9 %)
    Does not affect the behavior of cement paste significantly
    Reacts with gypsum  Calcium sulphoferrite
    19
    Amount of gypsum added to the clinker depends on :

    C3A content (2.5% for 5% or less of C3A) or (3% for more than
    5% of C3A).
    Alkali Content.
    Increasing cement fineness ( increase fineness leads to higher
    rate of reactivity of C3A).
    Desirable rate of reaction at early age (proportional to C3A).

    Minor Compounds
    MgO, TiO2, Mn2O3, alkalis ( K2O and Na2O)
    Reacts with aggregates causing disintegration of concrete
    Affect the rate of strength gain.

    20
    Properties of Cement Compounds

    The major compounds hydrate at different Reaction Rate (RR),


    evolving different Heats of Hydration (HH). Resulting gel will have
    some Cementing Value (CV). Its Sulfate Resistance (SR) Varies.

    Compound RR HH CV SR

    C3S Medium moderate Good early strength Not good

    C2S Slow Small Good Later strength Good

    C3A Fast Large Not good But acts as Very Bad


    Catalyses

    C4AF Slow Small Poor Not Bad

    21
    Strength development of major cement compounds over curing period.

    Compressive Strength (MPa)

    Curing Time (Days)


    22

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