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Definition:
Cement is a hydraulic binder and is defined as a finely ground inorganic
material.
It is mixed with water to form mortar or mixed with sand, gravel,
and water to make concrete.
Hardens by hydration reactions and processes which, after hardening
retains it's strength and stability even under water.
Cement used in construction is characterized as hydraulic or non-
hydraulic :
CEMENT
MANUFACTURING
PROCESS
Clinker
Grinded
As an agent to
control the rate of
freezing cement.
Al203 Responsible for quick setting, if in excess, it lowers the strength 3-8
Mg0 Imparts color and hardness. If in excess, it causes cracks in mortar 0.5-4
and concrete and unsoundness
TYPES OF CEMENT
Ordinary Portland Cement (OPC)
It is a cementing material resembling a natural stone quarried from Portland in U.K.
Portland cement may be defined as a product obtained by finely pulverizing clinker.
The ordinary Portland cement has been classified as 33 Grade (IS269:1989), 43
Grade (IS 8112:1989), and 53 Grade (IS 12669-1987). The physical requirements of
all these three types of cement are almost same except for compressive strength
IS:10262 has classified the OPC grade-wise from A to F based on 28 day
compressive strength as follows.
Category Strength(MPa)
A 32.5 – 37.5
B 37.5 – 42.5
C 42.5 – 47.5
D 47.5 – 52.5
E 52.5 – 57.5
F 57.5 – 62.5
Accordingly the 33, 43 and 53 grades of cement correspond to categories A, C and
E, respectively. However, most of the 43-grade cements available in the market fall in
category D and that 53-grade cements in category F.
TYPES OF CEMENT
Cements of unique characteristics for desired performance in a given environment are being
manufactured by changing the chemical composition of OPC or by using additives, or by using
different raw materials. Some of the cements available in the market are as follows:
Uses: It is suitable for repair of roads and bridges and when load is applied in a short period
of time.
High Alumina Cement (IS: 6452):
This is not a type of Portland cement and is manufactured by fusing 40 per cent
bauxite, 40 per cent lime, 15 per iron oxide with a little of ferric oxide and silica,
magnesia, etc. at a very high temperature. The alumina content should not be less
than 32%.
Properties: It is not quick setting: initial setting time (minimum) is 30 minutes, even
up to 2 hours. The final setting time should not exceed 600 minutes. It attains
strength in 24 hours, high early strength, high heat of hydration and resistance to
chemical attack. Compressive strength after one day is 30.0 N/mm2 and after 3 days
it is 35.0 N/mm2. After setting and hardening, there is no free hydrated lime as in
the case of ordinary Portland cement. The fineness of the cement should not be less
than 225 m2/kg. The cement should not have expansion more than 5 mm.
Uses: It is resistant to the action of fire, sea water, acidic water and sulphates and is
used as refractory concrete, in industries and is used widely for precasting. It should
not be used in places where temperature exceeds 18°C.
AGGREGATES
Definition
• Aggregates are one of construction materials which are mixed with
binding material (cement) to produce mortar or concrete.
• Aggregates are used as filler in mortar and concrete and also to reduce
their cost.
Depending upon the size of their particles aggregates are classified as:
(1) Fine aggregates
(2) Coarse aggregates
FINE AGGREGATES
Reinforced Cement 20 mm
Concrete work
i.e. beams, columns, wall,
etc
Flooring 10 mm
Admixtures
Steel link
Reinforcement
tie wire
Making and placing concrete
Concreting process involves the following process:
5) Curing 4) Compacting
concrete concrete
1) Mixing of concrete
Mixing of
concrete
Machine
Hand mixing
mixing
Operated electrically or
driven by oil engines
2) Transporting concrete
Concrete should be handled from the place of mixing to
the place of final deposit as rapidly as practical by
methods which will prevent the segregation or loss of any
of the ingredients.
If the segregation does occur during transport, the
concrete should be remixed before being placed.
Method of transporting and placing concrete which
are used widely, are:
- Wheel barrows
- Power barrows
- Dumpers and trucks
- Monorail system
- Elevating towers and hoists
- cranes
- Belt conveyers and Boom conveyers
- Truck mixers
3) Placing concrete
The concrete should be placed and compacted.
Before concrete is placed, it should be ensured that the
forms are rigid, in their correct position, well cleaned
and oiled.
Oiling of these forms will prevent the concrete from sticking
to it, and it will then be easier to remove the forms when they
are no longer required.
Concrete should not be poured into the forms only at one
point, but should be uniformly spread on all the sides for
better compaction.
4) Compacting concrete
The density and consequently, the strength and durability
of concrete depend upon this operation.
Concrete should be thoroughly compacted during the
operation of placing and thoroughly worked around the
reinforcement & into corners of the form work.
Concrete is compacted by vibration.Vibrators are of three
general types:
a) Internal Vibrators,
b) External Vibrators,
c) Surface Vibrators.
Internal vibrator
External vibrator
Surface vibrator
4) Curing concrete
Curing is one of the most essential operation in which
concrete is kept continuously damp/wet for some days
to enable the concrete to gain more strength.
Curing replenishes the loss of moisture from the concrete
due to evaporation, absorption and heat of reactions.
The period of curing depends upon atmospheric
conditions such as temperature, humidity and wind velocity.
The normal period is between 7 and 10 days.
There are several methods of curing the concrete:
- Covering the exposed surface with a layer of sacking,
canvas, hessian or similar absorbant materials, and
keeping them continuously wet.
- Thoroughly wetting the surface of concrete, and then keeping
it covered with a layer of suitable water proof material.
- Curing with the help of steam or hot water, resulting
in rapid development of strength.
steam or hot water
Hessian/canvas