MODULE-1

CEMENT
Cement act as a binding material and if forms a paste with water and hold CA &
FN together to form a solid mass.
Most of the concrete work done with ordinary Portland cement.
Cement is prepared by mixing calcareous (chalk, lime stone )&
argillaceous(clay ) materials.
What are the properties of cement?
 It gives strength to the masonry
 It gives an excellent binding material
 It is easily workable
 It is posses a good plasticity
 It is stiffness or hardness early

Ingredients of cement
 Cement is manufactured through a closely controlled chemical
combination of calcium, silicon, aluminium, iron and other ingredients.
 Common materials used to manufacture cement include limestone,
shells, and chalk or marl combined with shale, clay, slate, blast furnace
slag, silica sand, and iron ore.
What are ingredients used in production of cement?
 Silica
 Lime
 Alumina
 Sulphur /sulfur
 Iron oxide
 Magnesium oxide
What is the purpose of adding gypsum in cement?
 Gypsum is a mineral and is hydrated calcium sulphate in chemical
form. Gypsum plays a very important role in controlling the rate of
hardening of the cement. During the cement manufacturing process,
upon the cooling of clinker, a small amount of gypsum is introduced
during the final grinding process.
 Gypsum is added to control the “setting of cement”. If not added, the
cement will set immediately after mixing of water leaving no time for
concrete placing.
 gypsum increases setting time of cement. so that it settle slowly and
become harder and that does not contain air spaces.
Chemical composition
Uses of cement
 Cement is used for the preparation of cement mortar, cement concrete
and reinforced cement concrete.
 Cement mortar is used for masonry work, plastering and pointing.
 Cement concrete used in RCC for roof slabs, columns, water tanks,
dams, foundations, railway sleepers etc.
 Cement is used in the manufacture of dust bins, posts, pipes, garden
benches, flower pots etc.
 Cement mortar is used for all most all decorative and aesthetic works.
Properties of cement
 Fineness:

 Setting time:

 Soundness:

 Heat of hydration:

 Setting & Hardening of Cement

 Compressive strength:

 Specific gravity

Heat of hydration:
 The reaction of cement and water is known as hydration due to this
hydration cement paste gives binding properties to the concrete.

 During the process, lots of gasses are evolved namely C3S, C2S, C3A,
C4AF these chemical compounds which are known by the name
Bogue’s compounds
 Initial setting time not more than 30 minutes(opc)
 Final setting time not grater than 10 hrs (opc)
HYDRATION OF CEMENT
•When cement is mixed with water this process is known as hydration of
cement. During the process lots of gasses are evolved namely
c3s,c2s,c3A,c4AF.
1. solution mechanisms (early strength )
2. solid mechanisms(later strength)
Tricalcium silicate (c3s):
 C3s readily react with water produce more heat of hydration responsible
for early strength .
  Cement with more c3s is better for cold weather conditions
 C3s produces lesser quantity of c-s-H gel and more calcium hydroxide
(ca(oH)2)
 calcium hydroxide is soluble in water and gets reached out making
concrete porous.
 So cement with more c3s is not preferable for hydraulic structure .
Dicalcium silicate (c2s):
 C2s hydrates slowly ,generates less heat of hydration ,responsible for
ultimate strength of concrete .
 calcium hydroxide its forms 20 -25 % volume of solids in hydrated
cement paste.
 It react with sulphate in soil or water to form calcium sulphate which
react with C3A, causing deterioration of concrete. This is known as
sulphate attack
TESTING OF CEMENT
1.FILED TEST
 colour
 physical property
 presence of lumps
 strength.
2.LABORATORY TEST:
 Fineness test
 Standard consistency
 Initial setting time
 Final setting time
 Compressive strength test
 Soundness test
Quick Setting Cement
 This type of cement is manufactured by reducing the amount of gypsum
and adding small amount of aluminum sulphate to accelerate setting time
of cement.

 As the name suggests, it is used where the works needs to be done

quickly

 Applications
In Underwater Constructions. In Cold and Rainy Weather Conditions
Blended cement
 Blended cements is obtained by mixing OPC with mineral admixtures or
additives like fly ash, slag or silica fumes.
 Blended cements are now being considered superior as compared to
conventional opc category of cements.
 Advantages of blended cement
1. It reduces water demand and therefore water-cement ratio can be
reduced.
 2. It improves workability for the same water content.

3. The blended cements are finer as compared to OPC, therefore the

permeability of concrete is less. This results into improved
durability.

 Environmental advantages

1. Energy saving: Blended cements are obtained by adding mineral

admixtures with OPC. The energy, which would have otherwise
been utilized for production of OPC, is thus saved. This saving is
to the tune of 0.8 to 1.2 MWH/ton of cement.
2. Conservation of natural resources: The used mineral
admixtures are the waste products of thermal and steel plants. By
using these products, we are conserving the precious minerals
like lime stone, clay and silica etc.
3. Pollution control: By reducing the production of cement,
pollution is also controlled as cement is an energy intensive
product. It has been estimated that 7% of total pollution is only
due to cement production which can proportionately be reduced
if more blended cement is used.

AGGREGATES
Aggregate is general term applied to those inert or chemically inactive materials
which are bonded by cement and water to form concrete.

•Aggregate are the important constituents in concrete.

•They give body to the concrete, reduce shrinkage and effect in economy.

•Its constitutes 70 to 75% of volume of concrete

• mainly two types of aggregates :

1. fine aggregate

2. coarse aggregate

Classification
1.Classification based on geological origin
2. Classification based on size
3. Classification based on shape
4. Classification based on surface texture.

1.Classification based on geological origin

 It can be natural or artificial.
  Almost all natural aggregate materials originate from bed rocks.

 There are three kinds of rocks, namely, igneous, sedimentary and

metamorphic.

 Natural eg: sand, crushed rocks.

 Artificial eg: air cooled slag, broken bricks.

2.Classification based on size
 Aggregates are divided into two categories from the consideration of
size.
I ) Coarse aggregate
(ii ) Fine aggregate.
 The size of aggregate bigger than 4.75 mm is considered as coarse
aggregate and aggregate whose size is 4.75 mm and less is considered as
fine aggregate its determined from sieve analysis
 Course aggregate (crushed stone, gravel)
 Fine aggregate (sand)
 Course aggregate:
 It makes concrete strong and tough.
3.Classification based on shape
 The shape of aggregates is an important characteristic since it affects the
workability of concrete.

 Round shape (eg: river or sea shore gravel)

 Irregular or partially rounded

 Angular (sharp edges : crushed rock of all types.

 Flaky: thick is very less compared to its length

4.Classification based on surface texture.
 Glassy

 Smooth

 Rough

 Crystalline

 Honeycomb
Characteristics of aggregates
 Cleanliness :

 Surface texture

 Bond strength or strength of aggregate

 Hardness
  Specific gravity

 Bulk density

 Porosity and absorption of water by aggregate

 Bulking of fine aggregates

 Deteriorates substance presents in aggregates

 Soundness of aggregates

 Grading of aggregates
Cleanliness :
 It should be clean from impurities, if organic impurities presents it will
affects the strength of concrete.
 Organic impurities can be tested by colouring test .
 Presence of slit and clay causes shrinkage, increases the permeability
also affects bond strength.
 The presences of slit and clay should be below 4% for fine aggregate
and 1 % for coarse aggregates.
 Presences of salt will affects setting property.
 Aggregate which contain more than 3% should be washed away.
 Salt content causes efflorescence
Surface texture:
 Surface texture is the property, the measure of which depends upon the
relative degree to which particle surfaces are polished or dull, smooth or
rough.
 Rough textured and elongated particles require more cement paste to
produce workable concrete.
Bond strength or strength of aggregate :
 Aggregate crushing value :is the relative measure of resistance of an
aggregate sample under gradually applied compressive load.

Aggregate crushing value

This test helps to determine the aggregate crushing value of coarse aggregates as
per IS: 2386 (Part IV) – 1963.
 The apparatus used is
 Cylindrical measure and plunger,
 Compression testing machine
 IS Sieves of sizes – 12.5mm, 10mm and 2.36mm
Procedure to determine Aggregate Crushing Value
i) The aggregates passing through 12.5mm and retained on 10mm IS
Sieve are oven-dried at a temperature of 100 to 110oC for 3 to 4hrs.

ii) The cylinder of the apparatus is filled in 3 layers, each layer tamped
with 25 strokes of a tamping rod.

iii) The weight of aggregates is measured (Weight ‘w1’).

 iv) The surface of the aggregates is then levelled and the plunger
inserted. The apparatus is then placed in the compression testing
machine and loaded at a uniform rate so as to achieve 40t load in 10
minutes. After this, the load is released.

v) The sample is then sieved through a 2.36mm IS Sieve and the fraction
passing through the sieve is weighed (Weight ‘w2’).

vi) Two tests should be conducted.

• Aggregate crushing value = (w2/w1) x 100 %.

Aggregate impact value

This test is done to determine the aggregate impact value of coarse aggregates
as per IS: 2386 (Part IV) – 1963.
• The apparatus used for determining aggregate impact value of coarse
aggregates is
Impact testing machine
• IS Sieves of sizes – 12.5mm, 10mm and 2.36mm,
• A cylindrical metal
• A tamping rod
• Oven.
• Preparation of Sample

i) The test sample should confirm to the following grading:

Passing through 12.5mm IS Sieve
Retain on 10mm IS Sieve
ii) The sample should be oven-dried for 4hrs. at a temperature of 100 to
110oC and cooled.
iii) The measure should be about one-third full with the prepared aggregates
and tamped with 25 strokes of the tamping rod.
A further similar quantity of aggregates should be added and a further
tamping of 25 strokes given. The measure should finally be filled to
overflow, tamped 25 times and the surplus aggregates struck off, using a
tamping rod as a straight edge.
The net weight of the aggregates in the measure should be determined to the
nearest gram (Weight ‘A’).
Procedure to determine Aggregate Impact Value
i) The cup of the impact testing machine should be fixed firmly in position
on the base of the machine and the whole of the test sample placed in it and
compacted by 25 strokes of the tamping rod.

ii) The hammer should be raised to 380mm above the upper surface of the
aggregates in the cup and allowed to fall freely onto the aggregates. The test
sample should be subjected to a total of 15 such blows, each being delivered
at an interval of not less than one second.
Hardness
• Defined as the resistance to bear by abrasion
• Test are :
• Deval attraction
 • Dorry abrasion
• Los angles test
Los angles test
• Take 5 kg of sample for grading A, B, C & D and 10 kg for grading E, F
& G.
• Prepared sample is placed in the abrasion-testing machine.
• A specified number of steel spheres are then placed in the machine and
the drum is rotated for 500 revolutions at a speed of 30 - 33 revolutions
per minute (RPM).
• The material is then separated into material passing the 1.70 mm (No.
12) sieve and material retained on the 1.70 mm (No. 12) sieve.
• Dry the sample in an oven.
• Calculate % of loss due to Abrasion by calculating the difference
between the retained material (larger particles) compared to the original
sample weight.
The difference in weight is reported as a percent of the original weight and
called the "percent loss
Specific gravity
• Specific gravity = wt of substance of given volume
wt of water of same volume
• Bulk specific gravity : the ratio of wt in air of given volume of material
to the weight in an equal volume of distilled water at the same standard
temp.
• Apparent specific gravity : its the ratio of wt of aggregate dried in oven
at 100*c to 110*c to the wt of water occupying a same volume as that by
solid.
Test of specific gravity
• A = A1-A2= wt of saturated aggregates
• B= wt of saturated surface dry
• C= wt of oven dried aggregates
• Specific gravity = C/C-A
• Water absorption = (B-C/C)* 100
• Specific gravity of cement = 3.15
• Sand =2
• Granite =2.8
• Gravel =2.6
• Specific gravity of aggregates ranges from 2.6 to 2.8
• A = A1-A2= wt of saturated aggregates
• B= wt of saturated surface dry
• C= wt of oven dried aggregates
• Specific gravity = C/C-A
• Water absorption = (B-C/C)* 100
• Specific gravity of cement = 3.15
• Sand =2
• Granite =2.8
• Gravel =2.6
• Specific gravity of aggregates ranges from 2.6 to 2.8
Bulk density
• Weight of aggregates that would be fill a unit volume. It affects the
concrete behaviour such as mix design , workability and unit weight
• Net wt of aggregate in kg
• Capacity of container in L =kg/l
Absorption
• Its affects mix design ,strength of concrete .
• Take some aggregate and oven dry and then it is placed in a tank filled
with water for one day .and taken out that time wt of aggregate increase.
• Increase in wt = (B-A/A) * 100 = water absorption .
Bulking of fine aggregates
• The moisture presents in the fine aggregates cause increase in its volume
known as Bulking fine aggregates.
• Moisture in the fine aggregates develops a film around the sand particles
. Due to surface tension.
• it pushes the sand particles apart occupying greater volume .
• bulking of sand affects the mix proportion .
• Bulking increases with increase in moisture content up to a certain limit
and beyond that the further increase in moisture content results in
decrease in volume. When the fine aggregate is completely saturated it
does not show any bulking. Fine sand bulks more as compared to coarse
sand,

How to Determine Percentage of Bulking?

• The extent of bulking can be estimated by a simple field test.
• Fill a sample of moist fine aggregate (sand) into a measuring cylinder in
the normal manner. Note down the level, say h1.
• Pour water into a measuring cylinder and completely cover the sand with
water and shake it.
• Since the volume of the saturated sand is the same as that of the dry
sand, the saturated sand completely offsets the bulking effect. Note
down the level of sand, say h2.
• Subtract the final level h2 from initial level h1 (i.e. h1-h2), which shows
the bulking of sand under test.
• Calculate percentage of bulking using formula given below.
• Percentage of bulking = [(h1-h2)/h2]*100