CEMENT

CE 406
Construction Materials and Testing

Bobadilla, Calimutan, Capio, Marasigan, & Perez

BSSE 3201
 CONTENT

01
Definition
02History
03
Manufacture

04
Composition &
05
Application
06
Cement Testing
Properties
 DEFINITION
Cements, of this kind are finely ground powders that, when mixed
with water, set to a hard mass. Setting and hardening result from
hydration, which is a chemical combination of the cement
compounds with water that yields submicroscopic crystals or a gel-
like material with a high surface area.

Cement is a binding agent that sets and hardens to adhere to

building units such as stones, bricks, tiles, etc. Cement generally refers
to a very fine powdery substance chiefly made up of limestone
(calcium), sand or clay (silicon), bauxite (aluminum) and iron ore, and
may include shells, chalk, marl, shale, clay, blast furnace slag, slate.

01
The origin of hydraulic
cements goes back to ancient
Greece and Rome. The HISTORY
materials used were lime and
a volcanic ash that slowly
reacted with it in the
presence of water to form a
hard mass. THE TERM CEMENT,
MEANWHILE, DERIVES
Volcanic ash mined near FROM THE LATIN WORD
what is now the city of
Pozzuoli, Italy, was CAEMENTUM, WHICH
particularly rich in MEANT STONE CHIPPINGS
essential aluminosilicate
minerals, giving rise to the SUCH AS WERE USED IN
classic pozzolana cement ROMAN MORTAR.
of the Roman era.
 20TH CENTURY
cement manufacture
spread worldwide. By 2019
China and India had
become the world leaders
1756 1800 in cement production,
followed by Vietnam, the
Developed by John In England and France, United States, and Egypt.
Smeaton when he was a material obtained by
called in to erect the burning nodules of
Eddystone Lighthouse clayey limestone
off coast of Plymouth,
Devon, England.

1824
The invention of portland
cement is attributed to 1850
Joseph Aspdin of Leeds, Real prototype was
Yorkshire, England. Took produced by Isaac Charles
out a patent for a material Johnson in Southeastern
that was produced from a England
synthetic mixture of
limestone and clay

01
 Brief History of
HYDRAULIC CEMENT
 Brief History of
PORTLAND CEMENT
 MANUFACTURE
OF CEMENT

CRUSHING AND BLENDING BURNING BLENDING

GRINDING

1 2 3 4
CRUSHING
& GRINDING
All except soft materials are first crushed, often in two
stages, and then ground, usually in a rotating, cylindrical
ball, or tube mills containing a charge of steel grinding
balls. This grinding is done wet or dry, depending on the
process in use, but for dry grinding the raw materials first
may need to be dried in cylindrical, rotary dryers. Soft
materials are broken down by vigorous stirring with water
in wash mills, producing a fine slurry, which is passed
through screens to remove oversize particles.
BLENDING
A first approximation of the chemical composition
required for a particular cement is obtained by selective
quarrying and control of the raw material fed to the
crushing and grinding plant. Finer control is obtained by
drawing material from two or more batches containing
raw mixes of slightly different composition. In the dry
process these mixes are stored in silos; slurry tanks are
used in the wet process. Thorough mixing of the dry
materials in the silos is ensured by agitation and vigorous
circulation induced by compressed air.
BURNING
The earliest kilns in which cement was burned
in batches were bottle kilns, followed by
chamber kilns and then by continuous shaft
kilns. The shaft kiln in a modernized form is still
used in some countries, but the dominant
means of burning is the rotary kiln. These kilns
—up to 200 metres (660 feet) long and six
metres in diameter in wet process plants but The fuel for firing may be pulverized coal, oil, or
shorter for the dry process—consist of a steel, natural gas injected through a pipe. The
cylindrical shell lined with refractory materials. temperature at the firing end ranges from
about 1,350 to 1,550 °C (2,460 to 2,820 °F),
depending on the raw materials being burned.
GRINDING
The clinker and the required amount of gypsum are ground to a fine powder in horizontal mills
similar to those used for grinding the raw materials. The material may pass straight through the
mill (open-circuit grinding), or coarser material may be separated from the ground product and
returned to the mill for further grinding (closed-circuit grinding).
 DRY WET

In the wet method, a slurry is

In the dry method, dry created by adding water to
raw materials are properly proportioned raw
proportioned before materials prior to them being
being ground into a fine ground, blended and fed into
powder, blended, then the upper end of a tilted and
fed dry into a kiln. rotating cylindrical kiln, where
their rate of passage is
controlled by the kiln's slope
and rotational speed.
 CEMENT MANUFACTURING
INDUSTRIES IN THE WORLD
According to the global cement directory,
there are about 2273 active cement
production plants in the world. Some of the
leading cement manufacturers are
LafargeHolcim, Anhui Conch, China National
Building Materials, HeidelbergCement,
Cemex, Italcementi, China Resources
Cement, Taiwan Cement, Eurocement, and
Votorantim.

The top three cement producers of

Among the developed capitalist countries, the leading
the world as recorded in 2010 are the
producers of cement are USA, France, Italy, and Germany. Iran,
USA, China, and India. Among these
now the top producer in the Middle-East, occupies the third
countries, China alone manufactures
position in the world for cement manufacture. Asian and
about 45% of the total worldwide
African countries are also progressive in the production of
production of cement.
cement.
EXTRACTION & PROCESSING
RAW MATERIALS EMPLOYED IN THE MANUFACTURE
OF CEMENT ARE EXTRACTED BY QUARRYING IN THE
CASE OF HARD ROCKS SUCH AS LIMESTONES,
SLATES, AND SOME SHALES, WITH THE AID OF
BLASTING WHEN NECESSARY.

THE EXCAVATED MATERIALS ARE TRANSPORTED

TO THE CRUSHING PLANT BY TRUCKS, RAILWAY
FREIGHT CARS, CONVEYOR BELTS, OR ROPEWAYS.
MANUFACTURE OF CEMENT
Four stages in the manufacture of Portland cement:

Crushing and grinding the raw materials

Blending the materials in the correct proportions
Burning the prepared mix in a kiln
Grinding the burned product, known as “clinker,”
together with some 5 percent of gypsum
CLASSIFICATION OF CEMENTS
1.Natural cement

burning limestone containing 20-40% clay and crushing it to powder.

brown in colour and sets very quickly when mixed with water.

2. Artificial cement
portland cement
ordinary portland cement
rapid hardening cement
low heat cement
special cements
quick setting cement
high alumina cement
blast furnace cement
calcium chloride cement
white cement
coloured cement
expanding cement
super sulphate cement
sulphate resisting cement
RAW MATERIALS COMPOSITION

A HYDRAULIC CEMENT IS A MATERIAL CAPABLE OF

SETTING, HARDENING AND REMAINING STABLE UNDER
WATER.

PORTLAND CEMENT IS A HYDRAULIC CEMENT

COMPOSED MAINLY OF CALCIUM SILICATES, OBTAINED
BY HEATING A MIXTURE OF LIMESTONE AND CLAY IN A
KILN AT 1400-1600 °C.
PROPERTIES
THE COMMONEST CALCAREOUS RAW MATERIALS
ARE LIMESTONE AND CHALK, BUT OTHERS, SUCH AS
CORAL OR SHELL DEPOSITS, ALSO ARE USED.

CLAYS, SHALES, SLATES, AND ESTUARINE MUDS ARE THE

COMMON ARGILLACEOUS RAW MATERIALS. MARL, A
COMPACT CALCAREOUS CLAY, AND CEMENT ROCK
CONTAIN BOTH THE CALCAREOUS AND ARGILLACEOUS
COMPONENTS IN PROPORTIONS THAT SOMETIMES
APPROXIMATE CEMENT COMPOSITIONS.

KAOLIN, A WHITE CLAY THAT CONTAINS LITTLE

IRON OXIDE, IS USED AS THE ARGILLACEOUS
COMPONENT FOR WHITE PORTLAND CEMENT.
COMPONENTS OF PORTLAND CEMENT
SLAG CEMENT
The granulated slag made by the
rapid chilling of suitable molten
slags from blast furnaces forms
the basis of another group of
constructional cements. A
mixture of portland cement and
granulated slag, containing up to
65 percent slag, is known in the
English-speaking countries as
portland blast-furnace (slag)
cement.
HIGH-ALUMINA CEMENT
High-alumina cement is a rapid-
hardening cement made by fusing at
1,500 to 1,600 °C (2,730 to 2,910 °F) a
mixture of bauxite and limestone in a
reverberatory or electric furnace or in
a rotary kiln.

High-alumina cement gains a high

proportion of its ultimate strength
within 24 hours and has a high
resistance to chemical attack. It also
can be used in refractory linings for
furnaces. A white form of the
cement, containing minimal
proportions of iron oxide and silica,
has outstanding refractory properties.
EXPANDING AND
NON-SHRINKING
CEMENT
Expanding and nonshrinking
cements expand slightly on
hydration, thus offsetting the small
contraction that occurs when fresh
concrete dries for the first time.
Expanding cements were first
produced in France about 1945. The
American type is a mixture of
portland cement and an expansive
agent made by clinkering a mix of
chalk, bauxite, and gypsum.
GYPSUM
PLASTERS

Gypsum plasters are used for

plastering, the manufacture of
plaster boards and slabs, and in one
form of floor-surfacing material.
These gypsum cements are mainly
produced by heating natural
gypsum
 CEMENTS MAY BE USED ALONE BUT THE NORMAL
USE IS IN MORTAR AND CONCRETE IN WHICH THE
CEMENT IS MIXED WITH INERT MATERIAL KNOWN AS
AGGREGATE.

MORTAR IS CEMENT MIXED WITH SAND OR CRUSHED

STONE THAT MUST BE LESS THAN APPROXIMATELY 5 MM
(0.2 INCH) IN SIZE. CONCRETE IS A MIXTURE OF CEMENT,
SAND OR OTHER FINE AGGREGATE, AND A COARSE
AGGREGATE THAT FOR MOST PURPOSES IS UP TO 19 TO 25
MM (0.75 TO 1 INCH) IN SIZE.

MORTARS ARE USED FOR BINDING BRICKS,

BLOCKS, AND STONE IN WALLS OR AS SURFACE
RENDERINGS.
Concrete is used for a large variety of
constructional purposes.

Mixtures of soil and portland cement

are used as a base for roads.

Portland cement also is used in the

manufacture of bricks, tiles, shingles,
pipes, beams, railroad ties, and various
extruded products.
1. ORDINARY
PORTLAND CEMENT
Ordinary Portland cement is the
most widely used type of cement,
which is suitable for all general
concrete construction. It is the
most commonly produced and
used type of cement around the
world, with annual global
production of around 3.8 million
cubic meters per year. This
cement is suitable for all kinds of
concrete construction.
 2. PORTLAND
POZZOLANA CEMENT
(PPC)
Portland pozzolana cement is
prepared by grinding pozzolanic
clinker with Portland cement. It is
also produced by adding
pozzolana with the addition of
gypsum or calcium sulfate or by
intimately and uniformly
blending Portland cement and
fine pozzolana.
3. RAPID HARDENING
CEMENT
Rapid hardening cement attains
high strength in the early days; it
is used in concrete where
formworks are removed at an
early stage and are similar to
ordinary portland cement (OPC).
This cement has increased lime
content and contains higher c3s
content and finer grinding, which
gives higher strength
development than OPC at an
early stage.
4. QUICK SETTING
CEMENT
The difference between the quick
setting cement and rapid
hardening cement is that quick-
setting cement sets earlier. At the
same time, the rate of gain of
strength is similar to Ordinary
Portland Cement, while quick
hardening cement gains strength
quickly. Formworks in both cases
can be removed earlier.
 5. LOW HEAT
CEMENT
Low heat cement is produced by
maintaining the percentage of
tricalcium aluminate below 6% by
increasing the proportion of C2S. A small
quantity of tricalcium aluminate makes
the concrete to produce low heat of
hydration. Low heat cement suitable for
mass concrete construction like gravity
dams, as the low heat of hydration,
prevents the cracking of concrete due to
heat.
 6. SULFATES
RESISTING CEMENT
Sulfate resisting cement is used to
reduce the risk of sulfate attack on
concrete and thus is used in the
construction of foundations where the
soil has high sulfate content. This
cement has reduced the contents of
C3A and C4AF.
 7. BLAST FURNACE
SLAG CEMENT
Blast furnace slag cement is obtained by
grinding the clinkers with about 60%
slag and resembles more or less in
properties of Portland cement. It can be
used for works where economic
considerations are predominant.
 8. HIGH ALUMINA
CEMENT
High alumina cement is obtained by
melting a mixture of bauxite and lime
and grinding with the clinker. It is a
rapid hardening cement with initial and
final setting time of about 3.5 and 5
hours, respectively.
 9. WHITE CEMENT

It is prepared from raw materials free

from Iron oxide and is a type of ordinary
portland cement, which is white. It is
costlier and is used for architectural
purposes such as precast curtain wall
and facing panels, terrazzo surface, etc.
and for interior and exterior decorative
work like external renderings of
buildings, facing slabs, floorings,
ornamental concrete products, paths of
gardens, swimming pools, etc.
 10. COLORED
CEMENT
It is produced by mixing 5- 10% mineral
pigments with ordinary cement. They
are widely used for decorative works on
floors.
 11. AIR ENTRAINING
CEMENT
Air entraining cement is produced by
adding indigenous air-entraining agents
such as resins, glues, sodium salts of
sulfates, etc. during the grinding of
clinker.
 12. EXPANSIVE
CEMENT
Expansive cement expands slightly with
time and does not shrink during and
after the time of hardening. This cement
is mainly used for grouting anchor bolts
and prestressed concrete ducts.
13. HYDROGRAPHIC
CEMENT
Hydrographic cement is prepared by
mixing water-repelling chemicals and
has high workability and strength. It has
the property of repelling water and is
unaffected during monsoon or rains
 CEMENT TESTING
fineness. consistency.

compressive
setting time. strength.

heat of
soundness.
hydration

chemical
tensile strength
composition

01
 CEMENT TESTING
The fineness of cement is responsible for the
rate of hydration and rate of evolution of heat
and hence on the rate of gain of strength.
fineness.

The fineness of cement can be

determined by the following
tests:
1. Sieve Test or
2. Air Permeability Test

PROCEDURE
https://youtu.be/e9993eh8?
si=xTfnqt17Z37yPbwt

01
 CEMENT TESTING
The consistency of cement is the minimum
consistency

water requirement to start the chemical

reaction between water and cement.
This test helps to identify the minimum water
required to make the cement paste.

the test is commonly

conducted using the Vicat
apparatus, and it's often
referred to as the Vicat
consistency test.
PROCEDURE
https://youtu.be/PlbCpJqWqwU?
si=Jsj17HC4Dou7HJAW.

01
 CEMENT TESTING
It evaluates the time required for cement to
lose its plasticity and gain strength.
setting time.
1. Initial Testing
2. Final Testing

According to standard
guidelines, the initial setting
time for Ordinary Portland
Cement (OPC) should be less
than 30 minutes, while the
final setting time should not
exceed 600 minutes.

PROCEDURE
https://youtu.be/3tKuexK4zto?
si=RkAqoRiO3J-wGRTc

01
 CEMENT TESTING
The most common strength test, compressive
strength, is carried out on a 50 mm (2-inch) cement
mortar test specimen. The test specimen is
subjected to a compressive load (usually from a
compressive

hydraulic machine) until failure. This loading

strength.

sequence must take no less than 20 seconds and

no more than 80 seconds.

IS 4031 (Part 6) – 1988

IS 4031 – Methods of Physical Tests for Hydraulic
Cement
Part 6 – Determination of Compressive Strength
of Hydraulic Cement Other than Masonry
PROCEDURE Cement
https://youtu.be/t4RDdn6rOwU?
si=jJREtiFzaueSLObO.
01
 CEMENT TESTING

The Soundness Test is performed

soundness.

to detect the presence of

uncombined lime and magnesia
in cement. This test is conducted
in Le Chatelier’s apparatus

Soundness of cement can be defined

as its ability to retain its volume after it
PROCEDURE gets hardened. This means that a
properly sound cement will undergo
https://youtu.be/KntJtqXqjUI?
minimum volume change after it
si=I8ax1s1seDxwskyQ
converts into the hardened state.

01
 CEMENT TESTING
heat of hydration

The heat of hydration test of cement is used

to determine the amount of heat liberated
by the cement during its hydration reaction
with water. Heat of hydration of cement test
helps in some of the concreting applications
like mass concreting and cold weather
concreting.

IS 4031 (Part 9) – 1988

IS 4031 Methods of Physical Tests for
Hydraulic Cement
PROCEDURE Part 9 Determination of Heat of
https://youtu.be/k02fOFB2-iQ?si=- Hydration
Ij_69pKV7_Lmten

01
 CEMENT TESTING
Tensile tests on briquettes, shaped like a
figure eight thickened at the centre, were
formerly used but have been replaced or
tensile strength.

supplemented by compressive tests on

cubical specimens or transverse tests on
prisms.

IS 4031 (Part 9) – 1988

IS 4031 Methods of Physical Tests for
Hydraulic Cement
Part 9 Determination of Heat of
Hydration

PROCEDURE
https://youtu.be/C5h9nfufG9Y?
si=q6M7rUfWwbu8TI4q

01
 CEMENT TESTING
Chemical composition test of cement determines
the proportion of various constituents present in the
cement specimen. The proportion of these
composition.

constituents should fall under the standard range of

chemical

cement constituents.

IS 4032 – 1985 – Methods of Chemical Analysis of

Hydraulic Cement

1. Loss on ignition test

2. Silica test
3. Combined ferric oxide and alumina test
4. Ferric oxide test
5. Calcium oxide test
6. Magnesia test
7. Sulfuric anhydride test
8. Insoluble residue test
01
 THE 3 MAJOR CEMENT SPECIFICATIONS
AND THEIR CEMENT TYPES

ASTM C150/AASHTO M 85 ASTM C595/AASHTO M 240 ASTM C1157

1. Type I 1. Type IS 1. Type GU

2. Type II 2. Type IP 2. Type HE
3. Type III 3. Type IL 3. Type MS
4. Type IV 4. Type IT 4. Type HS
5. Type V 5. Type MH
Type IP(MS) , (HS), (MH) 6. Type LH
Types IA, IIA, and IIIA