INGREDIENTS OF CONCRETE:

1.CEMENT

UNIT-1
Concrete Technology
Concrete= Cement + Coarse Aggregates+ Fine Aggregate+ water
INTRODUCTION
• Cement is the binding material
• a substance used for construction that sets, hardens, and
adheres to other materials to bind them together
• used to bind, fine aggregate, coarse aggregate and
admixture with appropriate amount of water.
• Portland cement is invented in 1924 by an ordinary mason
Joseph Aspdin in Leeds (England). He was given patent for
manufacturing this cement.
• The cement was called Portland because of its colour
resemblance to various types of sandstone found in
Portland.
• The basic or conventional type of cement is called OPC i.e.
Ordinary Portland Cement.
Binding action by Cement
Chemical Composition of CEMENT:
Chemical Compounds Percentage in cement

Lime (Cao) 60-70

Silica(Sio2) 17-25

Alumina(Al203) 3-8

Magnesia(Mgo) 1-4

Iron oxide (fe2O3) 0.5-6

Calcium Sulfate(CaSO4) 3-5

Sulfur Trioxide(SO3) 1-3

Alkaline (Na2O+K2O) 0.5-1.3

FUNCTION OF INGREDIENTS

• Lime: Lime is calcium oxide or calcium hydroxide.

• The presence of lime in a sufficient quantity is required to form
silicates and aluminates of calcium.
• Deficiency in lime reduces the strength of property to the
cement.
• Deficiency in lime causes the cement to set quickly.
• Excess lime makes cement unsound.
• The excessive presence of lime causes the cement to expand
and disintegrate
FUNCTION OF INGREDIENTS
• Silica: Silicon dioxide is known as silica, chemical formula SiO2.
•The sufficient quantity of silica should be present in cement to
dicalcium and tricalcium silicate.
•Silica imparts strength to cement.
•Silica usually presents to the extent of about 30 percent cement.
• Alumina: Alumina is Aluminum oxide. The chemical formula is Al2O3.
•Alumina imparts quick setting property to the cement.
•Clinkering temperature is lowered by the presence of the requisite
quantity of alumina.
•Excess alumina weakens the cement.
• Magnesia: Magnesium Oxide. The chemical formula is MgO.
• Magnesia should not be present more than 2% in cement.
• Excess magnesia will reduce the strength of the cement.
FUNCTION OF INGREDIENTS

• Iron oxide: Chemical formula is Fe2O3.

• Iron oxide imparts color to cement.
• It acts as a flux.
• greenish grey colour substance.
• Calcium Sulfate: Chemical formula is CaSO4
• This is present in cement in the form of gypsum(CaSO4.2H2O)
• It slows down or retards the setting action of cement.
• Sulfur Trioxide: Chemical formula is SO3
• It should not be present for more than 2%.
• Excess Sulfur Trioxide causes the cement to unsound.
• Alkaline:
• It should not be present more than 1%.
• Excess Alkaline matter causes efflorescence.
NOTE- Temperatures are kept about 1400-1500° C. The modules are converted into
dark greenish balls and the product obtained in the kiln, known as clinker, is of
varying size 5 to 20 mm. The clinkers are very hot when coming out of this zone.
Dry Process Wet process

1. Mixing of Raw materials in wash mill with 35 to 50%

1. Mixing of raw material in dry state in blenders.
water.

2. The dry materials exiting the mill are called “kiln 2. Materials exiting the mill are called “slurry” and have
feed”. flowability characteristics.

3. Fuel consumption is low i.e., 100 kg of coal per tonne 3. Fuel consumption is high i.e., 350 kg of coal per
of cement produced tonne of cement produced

4. Cost of production is less. 4. Cost of production is high

5. Capital cost (Cost of establishment) is comparatively

5. Capital cost is high due to blenders.
less

6. Size of the kiln needed for manufacturing of cement 6. Size of the kiln needed for manufacturing of cement
is smaller. is bigger.

7. Difficult to control mixing of Raw materials, so it is 7. Raw material can be mixed easily, so a better
difficult to obtain a better homogeneous material. homogeneous material can be obtained
BOUGE’S COMPOUNDS

• The oxides present in the raw materials interact with one another
in the kiln at high temperature to form more complex compounds
called Bouge’s Compounds.
• The identification of the major compound is largely based on the
work of R.H.Bogue. And other and so it is often referred as ‘ Bogue’s
Compounds’ or Bogue’s Composition.
BOUGE’S COMPOUNDS
BOUGE’S COMPOUNDS

• In addition to four major compound there exists minor compounds,

such as MgO, TiO2, Mn2O3, K2O, Na2O.
• Two of the minor compounds of interest are K2O, Na2O, known as
alkalies. They have been found to react with some aggregates, the
product of this reaction causing disintegration of concrete, and also
have been found to affect strength of cement.

• Tricalcium silicate(C3S) =ALITE ,

• Dicalcium silicate(C2S)= BELITE
• Tricalcium aluminate(C3A)= CELITE
• Tetracalcium alumino ferrite(C4AF)= FELITE (very high heat of
hydration)
PROPERTIE’S OF BOUGE’S COMPOUNDS
Reactions of Bouge’s Compounds

1. Tricalcium silicate + Water--->Calcium silicate hydrate+Calcium hydroxide +

heat
2 Ca3SiO5 + 7 H2O ---> 3 CaO.2SiO2.4H2O (C-S-H)+ 3 Ca(OH)2 + 173.6kJ

2. Dicalcium silicate also affects the strength of concrete through its hydration.
Dicalcium silicate reacts with water in a similar manner compared to tricalcium
silicate, but much more slowly. The heat released is less than that by the
hydration of tricalcium silicate because the dicalcium silicate is much less
reactive.
Dicalcium silicate + Water--->Calcium silicate hydrate + Calcium hydroxide
+heat
2Ca2SiO4 + 5 H2O---> 3 CaO.2SiO2.4H2O (C-S-H) + Ca(OH)2 + 58.6 kJ

3. C3A + H2O ---> CaO.Al2O3.H2O ( C3 AH6)( for flash set) (Ettrignite)+ Low heat

4.C4AF+ H2O--->CaO.Fe2O3.H2O ( higher resistance to sulphates)+ Low heat

POZZOLANIC CEMENT/PPC

• Pozzolanic cements are mixtures of portland cement and a

pozzolanic material that may be either natural or artificial.
• The natural pozzolanas are mainly materials of volcanic origin but
include some diatomaceous earths.
• Artificial materials include fly ash, burned clays, and shales.
• Pozzolanas are materials that though not cementitious in
themselves, contain silica (and alumina) in a reactive form able to
combine with lime in the presence of water to form compounds with
cementitious properties.
 PROPERTIES OF CEMENT
• Fineness of Cement: The size of the particles of the cement is its
fineness. The fineness of cement is determined by using 90 µm IS sieve.
The required fineness of good cement is achieved through grinding the
clinker in the last step of cement production process. As hydration rate
of cement is directly related to the cement particle size, fineness of
cement is very important.
• Soundness of Cement: Soundness refers to the ability of cement to not
shrink upon hardening. Good quality cement retains its volume after
setting without delayed expansion, which is caused by excessive free
lime and magnesia.
• Setting Time of Cement
• Cement sets and hardens when water is added. This setting time can
vary depending on multiple factors, such as fineness of cement, cement-
water ratio, chemical content, and admixtures. Cement used in
construction should have an initial setting time that is not too low and a
final setting time not too high. Hence, two setting times are measured:
Initial set: When the paste begins to stiffen noticeably (typically occurs
within 30-45 minutes)
Final set: When the cement hardens, being able to sustain some load
(occurs below 10 hours).
 PROPERTIES OF CEMENT
• Loss of Ignition: Heating a cement sample at 900 - 1000°C (that is, until a
constant weight is obtained) causes weight loss. This loss of weight upon
heating is calculated as loss of ignition. Improper and prolonged storage or
adulteration during transport or transfer may lead to pre-hydration and
carbonation, both of which might be indicated by increased loss of ignition.
• Bulk density: When cement is mixed with water, the water replaces areas
where there would normally be air. Because of that, the bulk density of
cement is not very important. Cement has a varying range of density
depending on the cement composition percentage.For OPC it is
approximately 1440 Kg/m3
• Heat of Hydration: When water is added to cement, the reaction that takes
place is called hydration. Hydration generates heat, which can affect the
quality of the cement and also be beneficial in maintaining curing
temperature during cold weather. On the other hand, when heat generation
is high, especially in large structures, it may cause undesired stress. The heat
of hydration is affected most by C3S and C3A present in cement, and also by
water-cement ratio, fineness and curing temperature. The heat of hydration
of Portland cement is calculated by determining the difference between the
dry and the partially hydrated cement (obtained by comparing these at 7th
and 28th days).
• Consistency of cement:
Hydration of cement
• The concrete (or specifically, the cement in it) needs moisture to
hydrate and cure (harden). When concrete dries, it actually stops
getting stronger.
• The reaction of anhydrous cement with the water added during the
concrete or mortar preprations/productions is called HYDRATION
OF CEMENT & heat libated during the reactions is called HEAT OF
HYDRATION.
• Concrete with too little water may be dry but is not fully reacted. The
properties of such a concrete would be less than that of a wet
concrete. The reaction of water with the cement in concrete is
extremely important to its properties and reactions may continue for
many years.
Hydration of cement

• Portland cement consists of five major compounds and a few minor

compounds. The composition of a typical portland cement is listed
by weight percentage in Table
•
Cement Compound Weight Percentage(%) Chemical Formula

Tricalcium silicate 50 Ca3SiO5 or 3CaO.SiO2

Dicalcium silicate 25 Ca2SiO4 or 2CaO.SiO2

Tricalcium aluminate 10 Ca3Al2O6 or 3CaO

.Al2O3
Tetracalcium 10 Ca4Al2Fe2O10 or
aluminoferrite 4CaO.Al2O3.Fe2O3

Gypsum 5 CaSO4.2H2O
Hydration of cement
• The equation for the hydration given by:
1. Tricalcium silicate + Water--->Calcium silicate hydrate+Calcium hydroxide +
heat
2 Ca3SiO5 + 7 H2O ---> 3 CaO.2SiO2.4H2O (C-S-H)+ 3 Ca(OH)2 + 173.6kJ

2. Dicalcium silicate also affects the strength of concrete through its

hydration. Dicalcium silicate reacts with water in a similar manner compared
to tricalcium silicate, but much more slowly. The heat released is less than
that by the hydration of tricalcium silicate because the dicalcium silicate is
much less reactive.
Dicalcium silicate + Water--->Calcium silicate hydrate + Calcium hydroxide
+heat
2 Ca2SiO4 + 5 H2O---> 3 CaO.2SiO2.4H2O (C-S-H) + Ca(OH)2 + 58.6 kJ

3. C3A + H2O ---> CaO.Al2O3.H2O ( C3 AH6)( for flash set) (Ettrignite)+ Low
heat

4.C4AF+ H2O--->CaO.Fe2O3.H2O ( higher resistance to sulphates)+ Low heat

RATE OF HEAT EVOLUTION:Hydration of cement
Hydration Of Bouge’s Compounds
Consistency Of Cement
• The standard consistency of cement is that consistency, which permit
the vicat plunger to penetrate to a point 5 to 7mm from the bottom
of the vicat mould when tested.
• The consistency of cement paste is defined as the percentage of
water requirement of cement paste at which the viscosity of paste in
such a way that it determines the amount of water needed to make a
paste. It is necessary to determine consistency because the amount
of water affects the setting time of the cement.
• It determines the minimum amount of water required by the cement
sample to start its hydration process
• Determined in the percentage of water as per cement mass.
 FIELD TEST OF CEMENT
• Date of Manufacturing: As the strength of cement reduces with age, the date
of manufacturing of cement bags should be checked. The shelf life of cement is 3 months.
• Cement Color: The color of cement should be uniform. It should be typical cement color
i.e. gray color with a light greenish shade.
• Whether Hard Lumps are formed: Cement should be free from hard lumps. Such lumps
are formed by the absorption of moisture from the atmosphere.
• Temperature inside Cement Bag: If the hand is plunged into a bag of cement, it should be
cool inside the cement bag. If hydration reaction takes place inside the bag, it will become
warm.
• Smoothness Test: When cement is touched or rubbed in between fingers, it should give a
smooth feeling. If it felt rough, it indicates adulteration with sand.
• Water Sinking Test: If a small quantity of cement is thrown into the water, it should float
some time before finally sinking.
• The smell of Cement Paste: A thin paste of cement with water should feel sticky between
the fingers. If the cement contains too much-pounded clay and silt as an adulterant, the
paste will give an earthy smell.
• Glass Plate Test: A thick paste of cement with water is made on a piece of a glass plate
and it is kept under water for 24 hours. It should set and not crack.
• Block Test: A 25mm × 25mm × 200mm block of cement with water is made. The block is
then immersed in water for three days. After removing, it is supported 150mm apart and a
weight of 15kg uniformly placed over it. If it shows no sign of failure the cement is good.