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Types of cement
There are about 19 types of cement are available and under the 19 th cement namely High
Strength Cement, there are 5 types available.95
- Ordinary Portland Cement (OPC) is considered to be the most one among the types of
cement.2
- Before the year 1987 there used to be only one grade of Ordinary Portland Cement, with
an International Standard no. of IS 269-1976.
- After the 1987, still better and higher grades of cements were introduced to our country.
- This type of Cement (OPC) can be classified to a three grades system which usually
depending upon on the strength tested at 28 days as per specification of IS 4031-1988.
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standards/
- Grade-33
- Grade-43
- Grade-53
(a) Grade-33:
If the 33 Grade Cement, if tested at 28 days should not be less than 33N/ mm 2
and it is certified by IS 269:1989.
(b) Grade-43:
When strength of cement tested after 28 days with having not less than 43N/mm2, then it
is termed as called 43 grade cement.
- The total production of OPC Grade-43 accounts for 50% of the total cement
production in India, as it is used most time by most people
OPC is being used in as below:
(c) Grade-53:
- This kind of cement, if tested for its the strength at 28 days is not less than 53N/
mm2, This is being certified by IS 12269:1987.
- This grade Cement well is known for its rich quality and long time durability.
- It is mostly preferred for making Air Runways, ordinary Concrete Roads for public
use and also for making Bridges.
- This cement is used mostly for precast items such as paving blocks, tiles, building
blocks, etc.
- As above this cement is also used for Reinforced cement (RC) concrete work.
The bad point of view is that the manufacturing of OPC tend to decrease all over the world due
as the popularity of blended cement is increasing very speedily, due to
With increasing technological advancement, now it has become possible to upgrade the
quality of cement through the use of:
Though the high grade cement are costlier than the ordinary cement, it is used for
making stronger concrete. When this cement ism used than the low grad one , there can be 10-
20% savings in cement consumption apart form the other hidden benefits.
- As it is clear from the name the cement, it suggests Rapid Hardening leading to s higher
rate of development of strength, which is done at the age of 3 days, however, the time taken
for OPC to develop the similar strength is about 7 days.
The Raw Materials used for the Manufacturing of Rapid Hardening Cement is as follows:
- Limestone
- Shale
- Gypsum
- Coke
- First the Limestone and shale are heated at the extremely high temperature which resltsin
cement clinker.
- Then the finely grinded Gypsum is added in small quantity to the cement clinker to
produce Rapid Hardening Cement.
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So, it is a dry process with which the Rapid Hardening Cement is produced. The
cement should be stored in dry place, if not the quality decreases with slow pause due to
the reason of premature action of carbonation and of hydration.
- High fitness of grinding of RHC with specific surface must not be not less than 3250
sq.cm per gram.)
Disadvantage of R H C:
- If required a higher fineness of cement particles, then it needs greater surface area for
water to act on.. Due to the presence of the C3S in higher proportion which results in
quicker hydration.
It known that the RHC gives out greater heat due to hydration in the early period
and that was the reason why RHC should not be recommended for the use of mass
concrete construction.
- It can safely be used in industries which are manufacturing concrete products like slabs,
electric poles. The advantage was that moulds can be released quickly.
- It is mostly preferred use for cold weather concreting, as the rapid release of heat during
hydration quickly protects the concrete against freezing.
There are many Companies which are in the business of Producing Rapid Hardening Cement:
- JK Cement company
These companies cater the needs for the local use as well as for export to other countries.
- Extra Rapid Hardening Cement should not be ventured to be stored for more than one
month.
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Functions of Extra Rapid Hardening Cement:
- After placing, during the early period of hydration, a large amount of heat is evolved in
very short period of time.
- The strength of ERHC is about 25% higher than the strength recorded in the RHC even at
the aging of one or two days.
- When considering the strength of ERHC which is 10-20% higher than the strength of
RHC at the aging of 7 days.
- The dis-advantage of this cement is that the gain of strength disappear with passing age
and thus at age of 90 days, the strength of ERHC becomes almost similar to that of OPC.
- There is a record of a small amount of initial corrosion in the strength of ERHC, but
since, the corrosion is not progressive, the use of ERHC not harmful.
- It is a must if the concrete was made by using ERHC, which must be transported and
placed in compacted within a span of 20 minutes of time.
- .When Such of the cement have low C3A and as well low of C4AF content then it is
called Sulphate Resisting Cement.
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the raw material. Ferrous Oxide (Fe2O3) can be added to the mixture, to increase the
content of C4AF.
- Under the International Standard Code (ISC), total content of C4AF and C3A should not
be more than 25 per cent.
- It is used in such concrete for the foundation and basement where the soil is rich in
sulphates.
- This kind of cement is used in fabrication of concrete pipes which are usually buried
inside the marshy areas of soils bearing Sulphate
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- Grind the Portland Cement Clinker along with gypsum and add to the granulated blast
furnace separately followed by mixing them thoroughly.
- The physical properties of PSC is much similar to that of ordinary Portland cement.
- It resist the chlorides, soils and water which are containing more of Sulphates or alkali
metals alumina and iron. As well. It is also resistant to acidic waters and hence, can be
used under marine constructions.
The manufacturing of PSC is process where they utilize the blast furnace slag which is a
waste product from blast furnace.
The development of PSC has been on the increasing to total cement production output
of in India. It provided a scope for profitable use of a waste product to save economy. During
1998-99, India had produced 10% of PSC to the total cement production.
The variation in the Quantity of Portland Slag Cement- when the the quantity of Portland
Slag Cement is mixed with Portland clinker varies from country to country. About 25% to 65 %
of the quantity of PSC is mixed with Portland clinker and thus quantity may reach up to the
maximum of 85%.
In order to meet the increasing market demand, a separate grinding of each of the
constituent of Portland Slag Cement is done, so as to easily add the slag clinker into the finished
cement.
Recently, , under the Sewage disposal project at Bandra in Mumbai, where they have
used 70% ground granulated blast furnace slag and along with 30% cement made grout and used
for filling up of the trench around sewer with 3.5 m dia. Which is embedded at about 40m
below MSL.
- It is as similar as of the OPC in respect to fitness, time for setting, soundness with
adequate strength.
- The time taken for the hardening of PSC in concrete is slower than that of OPC for the
first 28 days, and afterwards, the rate of hardening of PSC increases. Thus at the age of
twelve months, the strength of PSC becomes similar or even more than that of OPC.
- There is a lower heat of hydration of Portland blast furnace cement as that of OPC. So,
the PSC could be very well used in the large scale concreting schemes.. In cold weather
conditions, the heat of hydration of PSC if low, along with low rate of strength it may
lead to damage due to frost.
- PSC exhibits least diffusivity to the chloride ions and such slag cement results in better
resistance to corrosion of reinforced steel.
It was pointed out frequently, that the only glassy granulated slag can be used for cement
manufacturing. To prepare this type of slag first the blast furnace slag is chilled rapidly by
pouring into stream with lots of water in order to prevent it from crystallizing and thus solidifies
it as glass. This product is named as glassy granulated blast furnace slag.
Air-cooled crystallized slag cannot be used for cement preparations.
- Generally a combination of 70% GGBS and 30% OPC is preferred for a good quality
GGBS.
- The quality of Resistance to the chemical attack could be enhanced through use of
GGBS in the concrete.
- Resistance to the acid attack can also be enhanced by using GGBS in concrete.
- Resistance to Sulphate and chloride attack may be possible by using GGBS in concrete.
- Risk of resulting early age thermal cracking can also be minimized by the use of GGBS.
3.6 QUICK SETTING CEMENT100
- This quick setting property can be achieved by the reduction of gypsum content during
clinker grinding.
- It is used mostly in under water construction, where, pumping of water is involved, where
it reduces the time taken for pumping and makes it economical.
The product is ground still finer to that of OPC with specific surface is not less than
4000 CM2 per gm101.
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In BelgiumiIt is extensively used in the name of ―CimentMetallurgiqueSursulfate‖. In
France it is called as ―cimentsursulfate‖.
- This kind of cement is found to be more sensitive to the reduction process undertaken
during the storage.
- It posses a low heat of hydration of at 40 to 45 calories/gm at the aging of 7 days and 45-
50 calories/gm at 28 days.
- It posses a high Sulphate resistance quality and thus preferred to be used in foundation
where chemically aggressive conditions existing.
- It is also highly resistant to sea water and thus used in marine works.
- The ratio of water / cement at the time of use of Super Sulphated Cement should not be
less than 0.5 because Super Sulphated Cement combines with more water on hydration.
Wet curing should not be followed more than 3 days after casting as premature drying
results in the formation of undesirable surface which is found to be powdery.
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- LHC is certified by the code of IS 12600:1989.
LHC is being made by the addition of Tri-calcium aluminates and Silicate in Ordinary
Portland Cement102.
Thus Low Heat Cement is particularly suited for making concrete for dams and many
other type of-
- Through the reduction of the contents of C3S and C3A and increasing the content of C2S,
the property of low heat hydration is achieved.
- When the temperature is reduced leads to retarding the action of of hardening and
produces high rate of heat.
- The specification as prescribed the Indian Standard Institute, the volume of heat of
hydration should be as follows:
- There should be more than 3200 sq.cm/ gm specific surface of Low Heat
- The strength of this kind of cement is much low to that of Ordinary Portland
- Other characters such as time for setting and soundness are similar as that of
Ordinary Portland Cement.
- IT helps in reducing the potential for thermal cracking in thick concrete sections.
- Possess later-age-concrete strengths.
- It has the quality of work ability and pump ability with large pours.
This type of Portland Pozzolana Cement being is manufactured by the inter grading of
Ordinary Portland Cement clinker mixing with 15 to 35 % of pozzolanic material103.
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ordinary temperature. This pozzolanic material forms a compound which possess cementing
property.
The pozzolanic material is useful in the manufacturing of PPC in calcined clay or fly
ash.
Fly ash, as it is known, found to be a waste material produced in the thermal power
station which uses the powdered coal as a fuel. Fly ashes are collected in electrostatic
precipitator.
Properties of PPC:
- The PPC produces lower rate of heat on hydration.
- The quality of the PPC is that it reduces the leaching of calcium hydroxide when the
same is used in hydraulic structures.
- The strength of PPC is expected to be similar to that of OPC only when at the later ages
provided, when the concrete is cured under the moist condition for a sufficient period of
time.
- If the PPC is the manufactured by using the right quality and type of pozzolanic material,
the PPC can be inferior to OPC in any way except for the rate of development of strength
up to 7 days.
Portland Pozzolanic Cement is useful and can be replaced at all places, wherever, the
OPC is used. In fact, technically PPC is found to be more advantages than OPC when made by
using optimum percentage and right quality of fly ash or pozzolanic material. Following are the
advantages of PPC:
- Portland pozzolanic cement is reported to be more economical as the clinker which used
usually is costly and here it is replaced by cheaper pozzolanic material which is very
cheap.
- PPC with more of permeability quality, the reason being that the soluble calcium
hydroxide is converted into insolublecementing products. It gives long durability, under
the marine and hydraulic constructions.
- PPC and OPC are almost similar in the production of calcium hydroxide.
- PPC due to the presence of pozzolanic action and additionally being finer than OPC
improves distribution of the pore size and reduces the micro cracks at transition zone.
- As the fly ash is finer and of low in density, PPC gives more volume of mortar than OPC.
The PPC os considered for its bulk volume rather than the OPCin the 50kg bags.
- The long term strength of PPC through couple of months is higher than that of OPC,
provided, if enough moisture is available for continued pozzolanic action.
- The possession of increased permeability of PPC increases the resistance to corrosion.
The above stated advantages are due to mainly slow conversion of calcium hydroxide
In one of the investigation it was found that 20 % calcium hydroxide was present in one
Disadvantages of PPC:
- The rate of development of strength is found to be initially slower than that of OPC.
The 75 thermal power stations located over all through India. They produce over sixty
million tons of fly ash from all the stations, however, the quality of such fly ash is un-
satisfactory for the production of PPC.
In Western Countries, the fly ashes out of the thermal power plants are further processed
to make it more suitable for the manufacture of PPC.
In India due to lack of awareness on the poor quality of fly ash, PPC is not much popular
as compared to other types.
During the year 1998-1999, out of the total cement production, 19 % was that of PPC
and 10 % slag cement. Experts have recommending to muse more of blended cement for
sustainable development of any country.
The Government of India has established a mission mode organization called ―FLY ASH
MISSION‖ for the promotion of the use of fly ash in the manufacture of PPC.
In India, for the reason of shortage of electrical power, many of the cement industries
have set up their own thermal power plants installed to cater their immediate needs. They use
their own fly ash for manufacturing PPC. These industries take special care to produce fly ash of
good quality. The PPC thus produced by these industries have superior physical and chemical
properties that could match the BIS Standard.
- Suraksha Industry
- In India, PPC is almost termed to be equal to the 33 Grade of OPC and some brands of
the PPC, which are considered to be as good as 53 Grade OPC.
- Many cement manufactures have requested BIS to grade PPC like OPC and keep the
limit specified as upper on the fly ash content is from 25% to 35%.
- Now the BIS has enhanced the standard of fly ash content in PPC from 10-25% to 15-
35%.
Application of PPC:
- PPC can be put to use wherever OPC is used, except at places where early high strength
is required.
- PPC requires sufficient quantity of moisture for continued pozzolanic activity. So the
longer curing is the longer is the desirable.
- For mass concrete structures like dam, bridge and even for thick foundation.
This kind of cement is made by mixing with agent which allows Air-entraining with
Ordinary Portland Cement clinker at the time of grinding104.
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The below given are the various air-entraining agents can be used:
- Calcium lingo sulphate which is obtained during the process of sulphite in paper making.
- Calcium salts of glues and other some kind of proteins used in the treatment of animal
hides.
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- Additives such as animal and vegetable fats, oil and their acids can also be used
successfully.
- Wetting agents like aluminium powder and hydrogen peroxide can be used.
It is to be noted that the above agents are used in powder or liquid forms to an extent of
Only 0.025-0.1% by weight of cement clinker.
- These air bubbles can modify the quality of concrete on its workability, etc
- Thus the air bubbles could modify the properties of hardened concrete in respect of
resistance to frost action.
- Limestone which contains 96% CaCo3 and iron oxide of less than 0.07%.
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concrete/white-cement
- China clay with iron content of apprximately 0.72-0.8%.
- Silica Sand
- Iron ore
- Nickel
- Titanium
- Chromium
- Vanadium
- Fluorspar as flux
- Selenite as retarder
- Strength of white cement is found to be much higher than that was recorded in IS Code
8042 of 1989.
- As per the ISI standard scale, whiteness of the white cement should not be less than
70%.
- The Hunters scale Value of the whiteness of white cement is generally 90%.
White cement are produced by many companies including ACC cements, JK Cement etc.
Hydrophobic cement is produced by grinding the OPC clinker with substances of water-
repellant which forms a film of acid of oleic and stearic. The water-repellant film around the
cement particle reduces the quality of cement storage and transporting or during the other un-
favourable conditions106.
The water-repellant film entrains certain amount of air in the concrete that helps to
improves the work ability of concrete. The film is broken out during the mixture of OPC clinker
and above named acid is put in the mixer to exposing the cement particle for normal hydration
process.
After grinding the OPC clinker, the particles of cement is applied as spray in one
direction and film forming of acid of oleic and stearic, or pentachlorophenol, or calcium oleate
from another direction in such a way that every cement particle is coated with a very thin film of
water repellant material.
- Hydrophobic cement do not lose its strength like Ordinary Portland Cement in
unfavourable conditions too.
- The water repellant film of hydrophobic cement protects from the bad effect of moisture
during the storage and transportation.
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Manufacturing of Masonry Cement:
Masonry Cement is made of by the combination materials with such qualities that when
this combination taken for mortar, which retains all properties of lime and removes all the ill
properties of cement mortar. Masonry cement also contains some quantity of air-entraining
agent and mineral mixtures for improving the plasticity and water receptivity107.
Generally concrete is made with Ordinary Portland Cement, which shrinks while setting
due to loss of free water. Besides, during the process of drying, shrinkage takes place in which
the concrete shrinks continuously for a long time. The property of shrinkage of cement proves to
be a disadvantage for grouting anchor bolts and grouting of machine foundations. Hence, here it
is better to use such type of cement which does not shrinks while hardening and thereafter108.
This is the actual requirement for the invention cement for grouting machines such cement which
undergoes no change in volume after drying is called Expansive Cement.
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sheet.pdf?sfvrsn=4
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Manufacturing of Expansive Cement:
(a) Shrinkage Compensating Cement is used in concrete when it induces compressive stress
which offsets the tensile stress due to the srinkage.
(b) Self Stressing Cement: This cement creates compressive stress after drying shrinkage
which gives some sort of pre-stressing effect in the tensile.
It is prepared following the directions of Indian Railways under IRS - T40:1985 with
C3S content109.
- It is also used for high rise buildings and high strength concrete such as multi-storied
buildings.
- It is certified by IS 8229:1986.
The following are the raw materials such as Limestone, Iron Ore, Coke, Iron scrap,
Procedure:
Where Oil Wells are drilled deeply through sedimentary rocks. There can be seen a
space between steel casing and rock formation in the oil well. The slurry used as seal off the
gaps in rock formation. Also used for to sealling the other fissures and cavities in the
sedimentary rock layer in order to prevent the escape of oil or gas from the annular space. The
cement slurry has to be pumped in such a position at such a depth, where the prevailing
temperature may be up to 175ºC and the pressure required may go up to 1300 kg/cm2. This type
of cement slurry is pumped to seal the cavities found in the oil well, hence these cement is called
Oil Well Cement110.
- This cement slurry is made as sufficiently as mobile which will flow to cover all cavities for
several hours and then hardened rapidly.
- This cement resist corrosive condition from Sulphur gases or from water dissolved salts.
These agents blocks quick setting and maintain for mobile condition favouring
penetration of slurry to all fissures and cavities.
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- Sometimes there is added some workability increasing agents to increase the mobility of
cement slurry, by adjusting the composition of compound of cement.
Each type of the OWC grade cement is used as per the requirement for a particular range of
Sulphate environment, temperatures, pressures and depths of oil well.
- JK Cement ltd
As discussed earlier, many types of admixtures were used to prepare different types of
cement to meet the growing demand for sector the sectors such as infrastructure development.
For e.g. high alumina cement, though, found to be good for early strength, but it shows
gradual decrease in strength when exposed to hot and humid conditions. This posed a big
question for the concrete industry as to how to repair the concrete roads and pavements rapidly
with out loss of time111.
In the PCA of USA, they have investigated on cement which could give high strength in
few hours without showing any such retrogression as stated in above example. Thus-
―REDISET‖ Cement was the result of investigation in USA. The Associated Cement
Company in India developed similar to that of above cement and named it as ―REDISET‖
Cement.
- Its strength found to be as similar as to that of OPC concrete after one day or three days.
The strength that is achieved by using the normal concrete after seven days, the same
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- Since, Rediset releases a lot of heat after laying, which is in-fact advantageous in winter
concreting.
- Rate of shrinkage is the fastest in this cement, but, the total shrinkage is similar to that of
OPC concrete.
- The only negative point is that sulphate resistance of Rediset is very poor.
- Useful where the need for high early strength (three to four hours) concrete and mortar.
- It forms into ceramic bonds at the high temperature and thus acts as bonding material
when added in refractory cartable.
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- It possess a high resistance to chemical corrosion, hence, it is widely used in
construction of water pipes, sewage pipes, factory drains, coastal and marine
constructions and used as well in factory chimneys.
These aluminates are the causes for the high strength to High Alumina Cement concrete
but they are meta-stable and at the normal temperature it converts into more stable product such
as :
The changes that took place in composition directly reduces the strength of High Alumina
Cement concrete. With the release of water, the crystal which is like a hexagonal form changes
to cubical form resulting in to the increased porosity of concrete. These e above changes are all
depended upon the temperature, water, cement ratio and chemical environment, this change in
the chemical composition is called conversion. Various experiments suggest that the temperature
plays a dominant role in the conversion. Higher the temperature faster is the rate of conversion.
Higher the cement water ratio, greater is the rate of conversion.
The innovation attempted on the high strength cement resulted in the production of
Macro-defect-free cement (MDF).
Many defects are present in conventional mixed cement pastes, due to the
entrapped air and results insufficient dispersion. Such defects tend to limit the strength of
concrete. Whereas, Macro-defect-free (MDF) contains no such defects113.
After a continues research, the high strength cement resulted in the production of
a new material called Densely Packed System (DPS). It contains homogeneously
arranged ultra-fine particles.
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Manufacturing process of Densely Packed System-
- With Normal Portland cement the ultra-fine silica fume is mixed. The size of Particles of
the Portland cement should be from 0.5 to 100 and that of Silica fume varies from 0.005
to 0.5. Silica fume is added at 5 to 25 %. A compressive strength of 270 Mpa has to be
achieved with silica fume substituted paste.
The requirement of high early strength of concrete becomes imminent. Sometimes this
kind of cement is needed for emergency repairs. This requirement has lead to the development of
rapid setting and hardening of cement which gives to give materials very high early strength.
Before 1970, there existed an uncertainties for the strength of hydrated cement paste.
The potential strength of cement paste could not be achieved due to considerable porosity after
hydration of cement. This defect led to the innovation of new approach called ―Warm Pressing‖
method to develope high strength of cement concrete114.
Warm Pressing Method: It is the method wherein the heat and pressure are applied at the
same time to the cement paste. In some cases, the strength of cement concrete was gained by
applying pressure alone. Warm pressing Portland cement and calcium aluminate cement both
have the compressive strength of 650 Mpa and tensile strength of about 68 Mpa.
- Homogeneous and very fine micro structure having a porosity as low as 1-7% are
generated.
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- Lithium salts are used as accelerators, resulting in high early strength of cement and a
marginal decrease in the later strength.
Strength as high as- 04Mpa in 1 hour and it will be 27 Mpa in 3 hours, which goes to 49
Mpa in 1 day.
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- Finely powdered di-sodium tetraborate (Borax).
- Water.
For repair purpose the dead burnt magnesite and sand mixture is added into cold
phosphate and along with borax solution (at 12–15ºC) and a allowed for mixing for one minute.
This mixture is for air cured and is ready for opening traffic within 4-5 hours.