Wachamo university

College of engineering and technology

Construction technology and management dep’t

# Detail note blended cement types

Blended Cement Types
i. Introduction

Blended cement is a type of cement that combines ordinary Portland cement (OPC) with
supplementary cementitious materials (SCMs) such as fly ash, slag, silica fume, or natural
pozzolans. This innovative blend is designed to improve the performance, sustainability, and cost-
efficiency of traditional cement used in construction. The development and adoption of blended
cement have become increasingly important as the construction industry faces challenges related to
resource depletion, environmental concerns, and the demand for more durable and efficient
building materials. The primary motivation behind the creation of blended cement is its ability to
reduce the environmental footprint of construction projects. Cement production is one of the
leading sources of carbon dioxide emissions globally, primarily due to the calcination process in
clinker production. By incorporating industrial by-products such as fly ash, a residue from coal-
fired power plants, and ground granulated blast-furnace slag (GGBS) from steel production,
blended cement significantly reduces the reliance on energy-intensive clinker. This results in lower
CO2 emissions and makes blended cement an eco-friendly alternative to traditional cement. In
addition to its environmental benefits, blended cement offers enhanced performance
characteristics. The use of SCMs can improve the workability, durability, and chemical resistance
of concrete. Structures made with blended cement exhibit greater resistance to sulfate attack,
chloride ingress, and alkali-silica reactions, which are critical for long-term durability, particularly
in harsh environments. The incorporation of pozzolanic materials also contributes to the long-term
strength development of concrete, making it suitable for infrastructure projects such as bridges,
dams, and high-rise buildings. The economic advantages of blended cement should not be
overlooked. By partially substituting expensive clinker with readily available industrial by-
products, blended cement often proves to be more cost-effective than traditional OPC.
Additionally, the improved durability and reduced maintenance requirements of concrete made

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with blended cement contribute to long-term savings for builders and infrastructure managers.
Blended cement is available in various types, depending on the combination and proportion of
SCMs used. For example, fly ash-based cement (known as Portland Pozzolana Cement or PPC) is
widely used in residential and commercial construction. Slag-based cement (Portland Slag Cement
or PSC) is popular for structures exposed to aggressive environmental conditions. Engineers and
builders can choose the most appropriate blend based on project requirements and environmental
considerations. Blended Cement is a uniform blend of Portland cement and fly ash or slag that
complies with the requirements specified in Australian Standard AS 3972 for Type GB (Blended)
cement. It also complies with the AS 3972 requirements for Type SL (Shrinkage Limited) and
Type SR (Sulfate Resisting) cements.

ii. Types of Blended Cement

This specification applies to the following types of blended cement that generally are intended for
use as indicated.
Type IS—Portland blast-furnace slag cement.
Type IP—Portland-pozzolan cements.
Type IL—Portland-limestone cements.
Type IT—Ternary blended cement.

Blended cements are categorized based on the types and proportions of supplementary materials
added to the base Portland cement. Blended cement is produced by mixing ordinary Portland
cement (OPC) with supplementary cementitious materials (SCMs) such as fly ash, slag, silica
fume, or natural pozzolans. The combination enhances cement properties and sustainability.
Blended cement is increasingly used in construction for its economic, environmental, and
performance benefits.

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I. Portland Pozzolana Cement (PPC)

Type IP cement, or Portland-pozzolan cement, incorporates pozzolanic materials, such as

volcanic ash, fly ash, or silica fume, into the traditional Portland cement mixture. Pozzolans
react with calcium hydroxide to form additional cementitious compounds, leading to increased
strength and reduced permeability. This makes Type IP cement highly suitable for projects
requiring enhanced durability, such as dams, pavements, and high-rise buildings. Additionally,
the use of pozzolanic materials contributes to sustainability by repurposing industrial
byproducts and reducing greenhouse gas emissions. Portland Pozzolana Cement is made by
mixing pozzolanic materials, such as fly ash or calcined clay, with Portland cement. Pozzolans
enhance the chemical resistance and reduce the permeability of the cement, making it less
prone to chemical attacks. PPC generates less heat during hydration, making it suitable for
massive construction projects like dams, canals, and hydraulic structures. Additionally, it is
commonly used in buildings in coastal areas where corrosion risk is high.

 Composition: Made by blending OPC with 15% to 35% pozzolanic materials such as fly ash,
volcanic ash, or calcined clay.
 Properties: Improves durability and resistance to aggressive environments, including sulfate
attack.
II. Portland Slag Cement (PSC)

Type IS cement, also known as Portland blast-furnace slag cement, is a blend of Portland
cement and granulated blast-furnace slag. The addition of slag, a byproduct from iron
production, enhances the durability and sustainability of the cement. This type of cement is
particularly beneficial in reducing permeability, improving sulfate resistance, and enhancing
workability. Due to its reduced carbon footprint and increased strength over time, Type IS
cement is widely used in large-scale infrastructure projects such as bridges, highways, and
marine structures. Portland Slag Cement is produced by blending ordinary Portland cement
with ground granulated blast furnace slag (GGBFS). This slag is a by-product of the steel
manufacturing process. PSC is known for its high sulfate resistance and low heat of hydration,

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making it ideal for marine structures, mass concrete works like dams, and road pavements. Its
durability in aggressive environments makes it a popular choice for long-lasting infrastructure.

 Composition: Blended with granulated blast furnace slag (25% to 70%).

 Properties: Offers excellent resistance to chemical attacks, improved workability, and
lower heat of hydration.
III. Silica Fume Blended Cement

Portland Limestone Cement incorporates finely ground limestone into the cement mixture. The
inclusion of limestone improves the cement's workability and reduces its environmental impact by
lowering the clinker content. PLC is often used for general construction projects, masonry work,
and plastering, offering moderate strength development with a reduced carbon footprint.

 Composition: Contains silica fume, usually in the range of 5% to 10% of the total blend.
 Properties: High strength, reduced permeability, and enhanced resistance to chemical
attack.
IV. Ternary Blended Cement

Ternary blended cement contains two different supplementary materials in addition to Portland
cement, such as a combination of slag and fly ash or silica fume. This unique composition provides
superior strength, excellent resistance to chemical attacks, and reduced heat of hydration. Ternary
blended cement is often used for high-performance concrete applications and in structures exposed
to aggressive environmental conditions.

 Composition: Combination of OPC with two SCMs, such as fly ash and slag or silica fume
and slag.
 Properties: Provides superior durability, reduced heat of hydration, and improved chemical
resistance.

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iii. Benefits of Blended Cements

Blended cement is a modern innovation in the construction industry, produced by mixing ordinary
Portland cement (OPC) with supplementary cementitious materials (SCMs) such as fly ash, slag,
silica fume, or pozzolanic materials. This combination improves the performance, durability, and
environmental footprint of concrete. Below are the key benefits of blended cement. Blended
cements offer numerous advantages over traditional Portland cement. They reduce the carbon
footprint of construction due to lower clinker usage, making them more environmentally
sustainable. Their improved durability and resistance to chemical attacks ensure the longevity of
structures. Additionally, blended cements often exhibit better workability, leading to easier
handling and finishing.

i. Enhanced Durability

Blended cement improves the long-term durability of concrete by enhancing resistance to chemical
attacks, weathering, and environmental factors.

 Sulfate Resistance: Ideal for structures exposed to aggressive environments such as

wastewater plants and coastal areas.
 Reduced Permeability: Minimizes water and chemical infiltration, protecting the structure
from damage.
ii. Better Workability and Finish

The fine particles of supplementary materials in blended cement improve the workability and
surface finish of concrete.

 Improved Flow: Easier to handle, place, and compact concrete.

 Smooth Surface: Provides a high-quality finish, reducing surface imperfections.

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iii. Heat of Hydration Reduction

Blended cement generates less heat during the hydration process compared to OPC.

 Crack Prevention: Reduced thermal stress minimizes the chances of cracks in mass
concrete applications.
 Ideal for Massive Structures: Suitable for dams, bridges, and large foundations.
iv. Increased Strength Development

Blended cement offers better long-term strength development.

Gradual Strength Gain: While initial strength may be lower, blended cement gains higher
strength over time.
High-Performance Concrete: Ideal for high-strength concrete applications in large
infrastructure projects.
v. Eco-Friendly and Sustainable

The production of blended cement has a lower environmental impact than traditional OPC.

Reduced Carbon Footprint: Uses industrial by-products, reducing clinker content and CO2
emissions.
Waste Management: Utilizes materials like fly ash and slag that would otherwise end up in
landfills.
vi. Cost-Effective Solution

Blended cement provides cost advantages in construction projects.

Material Savings: The replacement of OPC with SCMs lowers raw material costs.
Maintenance Savings: Improved durability reduces repair and maintenance costs over time.

vii. Improved Resistance to Chemical Attacks

Structures made with blended cement exhibit higher resistance to aggressive chemical
environments.

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Corrosion Protection: Reduces the risk of steel reinforcement corrosion in concrete.

Protection from Chlorides: Ideal for marine and industrial environments.
viii. Sustainable Construction Practices

Blended cement supports sustainable construction goals.

Resource Conservation: Reduces the dependence on limestone and fossil fuels used in OPC
production.
Green Building Certifications: Helps projects meet green building standards like LEED.
ix. Versatile Applications

Blended cement can be used in a variety of construction applications.

 Marine Structures: Ideal for bridges and docks exposed to saltwater.

 High-Performance Structures: Suitable for high-strength and industrial concrete
applications.
 Mass Concrete Projects: Used in dams, roads, and foundations.

iv. Applications of Blended Cements

Blended cement is a highly versatile construction material, making it an ideal choice for a wide
range of applications across various industries. Its unique composition, which often includes
supplementary cementitious materials such as fly ash, slag, or silica fume, enhances its durability,
strength, and sustainability. The adaptability of blended cement makes it suitable for a variety of
construction projects, ranging from residential buildings to large-scale infrastructure
developments. Below are some of the key applications of blended cement:

i. Domestic Construction

Blended cement is extensively used in residential construction due to its superior workability,
durability, and resistance to environmental factors. It is commonly utilized in:

 Foundations and footings to provide a strong and stable base for houses and buildings.

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 Walls and columns, ensuring long-lasting structural integrity.

 Roof slabs and floors, offering enhanced durability and improved resistance to cracks.
 Driveways, patios, and walkways, delivering a smooth finish and increased lifespan.

ii. Major Engineering Projects

Blended cement is an essential component in large-scale infrastructure and engineering projects,

where high strength and long-term performance are critical. These projects include:

Bridges and flyovers, where resistance to harsh weather conditions and heavy loads is
crucial.
Dams and reservoirs, ensuring excellent water resistance and durability.
High-rise buildings, offering structural strength while reducing environmental impact.
Tunnels and underground structures, providing resistance to sulfate attack and moisture
penetration.

iii. Pre-Cast Concrete Applications

Blended cement is widely used in the production of pre-cast concrete elements, which require high
durability and an excellent off-form finish. Applications in this category include:

 Pre-cast beams, columns, and panels, ensuring uniformity in construction.

 Concrete pipes and manholes, offering superior resistance to environmental degradation.
 Pre-fabricated walls and flooring systems, enabling faster construction with improved
quality.
 Architectural elements such as decorative panels, providing aesthetic appeal with structural
stability.

iv. Stabilization and Pavement Recycling for Road Construction

Blended cement plays a crucial role in road construction and stabilization projects by enhancing
the strength and longevity of pavement structures. Key applications include:

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 Soil stabilization, improving the load-bearing capacity of weak soils.

 Pavement recycling, where old road materials are rejuvenated and strengthened.
 Base and sub-base layers in highways, ensuring improved resistance to heavy traffic loads.
 Concrete roads and sidewalks, offering better performance compared to asphalt
alternatives.

v. Mining Applications

The mining industry benefits from blended cement’s durability and resistance to harsh conditions.
Common applications include:

 Backfilling operations, where blended cement is used to fill mined-out voids.

 Structural support for tunnels and underground excavations, providing enhanced stability.
 Concrete linings in mining shafts and passageways, preventing collapse and water ingress.
 Slurry containment systems, ensuring safe handling and disposal of mining waste.

vi. Specialist Formulations

Blended cement is an essential component in specialized formulations used in various construction

and repair applications. These include:

Adhesives: Used in tile fixing, ensuring strong bonding and resistance to moisture.
Renders: Providing a durable, smooth, and weather-resistant finish for exterior and interior
walls.
Mortars: Used for bricklaying and plastering, offering improved bonding and durability.
Grouts: Essential in filling gaps and voids, ensuring high strength and minimal shrinkage in
construction projects.

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5.Concrete Properties
A. Chemical Composition
Blended Cement of the type specified shall conform to the applicable chemical requirements
prescribed in Table

A. The chemical requirements in this table are applicable to all air-entrained cement equivalents.
B. It is permissible to exceed the values in the table for SO3 content, provided it has been
demonstrated by Test Method C1038 that the cement with the increased SO3 will not develop
expansion exceeding 0.020 % at 14 days. When the manufacturer supplies cement under this
provision, supporting data shall be supplied to the purchaser.
C. Insoluble residue maximum limit does not apply to ternary blended cements.
D. For ternary blended cements with limestone, loss on ignition is a maximum of 10.0 % by mass

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B. Physical Properties
Blended Cement—Blended cement of the type specified shall conform to the applicable physical
requirements prescribed in Table

i. The specimens shall remain firm and hard and show no signs of distortion, cracking, checking,
pitting, or disintegration when subjected to the autoclave expansion test.
ii. The time of setting of cements containing a user-requested accelerating or retarding functional
addition need not meet the limits of this table, but shall be stated by the manufacturer.

C. Effect of Excess Water Addition on Concrete

Compressive strength

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Compressive Strength Development

Compressive strength development in Portland cement concrete is affected by a number of factors
such as the physical and chemical properties of the cement, water cement ratio, admixtures, curing
and environmental conditions. The following graph depicts the indicative compressive strength
development of General Purpose Blended Cement concrete over time.

Conclusion
Blended cement is an innovative and sustainable alternative to traditional Portland cement,
offering enhanced performance, durability, and environmental benefits. It is produced by
intergrinding or blending Portland cement with supplementary cementitious materials (SCMs)
such as fly ash, slag, silica fume, or natural pozzolans. These materials not only improve the
properties of the cement but also contribute to reducing the carbon footprint associated with
cement production by utilizing industrial by-products and reducing clinker content. There are
several types of blended cement, each designed to meet specific construction needs. Pozzolanic
cement contains pozzolans, which enhance durability and resistance to sulfate attack. Slag cement,
made with granulated blast-furnace slag, improves workability and long-term strength. Fly ash-
based cement increases cohesion and reduces permeability, making it ideal for massive concrete
structures. Other specialized blends are designed for applications requiring improved sulfate
resistance, lower heat of hydration, or higher resistance to chemical attacks. The benefits of
blended cement extend beyond performance. The incorporation of SCMs leads to improved

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workability, reduced heat generation, and increased resistance to alkali-silica reactions, ultimately
enhancing the longevity of structures. Additionally, by reducing the demand for clinker, blended
cement plays a crucial role in promoting sustainability by lowering greenhouse gas emissions and
conserving natural resources.

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# Meaning, purpose and applications of Alumina Cement,

Expansive Cement and other types of cements
1. Meaning, purpose and applications of Alumina Cement,
A. Meaning of Alumina Cement (High Alumina Cement)

Alumina cement, also known as high-alumina cement (HAC), is a specialized type of cement
distinguished by its high aluminum oxide (Al2O3) content, which typically ranges between 35%
and 80%. Unlike ordinary Portland cement (OPC), which primarily contains calcium silicates,
alumina cement is composed mainly of calcium aluminates. This unique composition gives it
distinct properties that make it highly valuable for specific construction applications. Alumina
cement, also known as calcium aluminate cement (CAC), is a unique and specialized binding
material that possesses remarkable properties, making it distinct from ordinary Portland cement. Its
origin dates back to the early 20th century when scientists sought a cementitious material capable
of withstanding high temperatures, rapid setting, and extreme chemical conditions. Through years
of research and experimentation, they discovered that a cement with a high percentage of alumina
exhibited superior strength and durability, leading to the development of alumina cement. One of
the most striking features of alumina cement is its rapid setting time. When mixed with water, it
hydrates quickly, achieving significant strength within hours rather than days. This characteristic
proves advantageous in emergency repair works, where structures or equipment need to be
operational within a short period. Additionally, it is used in cold weather concreting, as its quick
setting properties prevent the risk of frost damage during construction. Beyond its fast-setting
nature, alumina cement is known for its remarkable resistance to sulfate and acidic environments.
Traditional Portland cement tends to deteriorate when exposed to acidic substances or sulfate-rich
soils, whereas alumina cement maintains its integrity even in such harsh conditions. This makes it
an ideal choice for constructing sewage systems, marine structures, and chemical storage facilities,
where resistance to corrosive elements is crucial.

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Composition and Manufacturing

Alumina cement is produced by fusing a mixture of bauxite (an aluminum-rich ore) and limestone
in a rotary kiln or electric arc furnace at temperatures exceeding 1,400°C. The molten clinker is
then rapidly cooled and ground into a fine powder to create the final cement product. The primary
constituents of alumina cement include mono calcium aluminate (CaAl2O4) and other calcium
aluminates, which are responsible for its rapid strength gain and refractory properties.

Properties of Alumina Cement

1. Rapid Hardening: One of the most significant advantages of alumina cement is its ability to
achieve high early strength. It can develop compressive strength within 24 hours, making it
suitable for time-sensitive construction projects.
2. High Refractoriness: Due to its high alumina content, alumina cement can withstand extreme
temperatures, often exceeding 1,500°C. This makes it a preferred choice for refractory
applications such as kiln linings and foundry molds.
3. Resistance to Sulfate Attack: Unlike OPC, which is susceptible to sulfate attack, alumina
cement exhibits superior resistance to sulfate-rich environments, making it ideal for marine and
sewage infrastructure.
4. Corrosion and Chemical Resistance: Alumina cement has excellent resistance to acids,
alkalis, and aggressive chemicals, making it suitable for chemical plants, wastewater treatment
facilities, and industrial flooring.
5. Dimensional Stability: Despite its fast setting nature, alumina cement exhibits minimal
shrinkage and good volume stability, reducing the risk of cracking.

B. Purpose of alumina

Alumina cement, also known as calcium aluminate cement (CAC), serves a distinct and vital
purpose in the construction and industrial sectors.

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1. Designed for specialized applications, it provides exceptional performance in environments

where ordinary Portland cement would fail. Its purpose extends across multiple industries, each
benefiting from its unique properties, such as rapid setting, high-temperature resistance, and
chemical durability.
2. One of the primary purposes of alumina cement is its ability to withstand extreme heat. Unlike
Portland cement, which can weaken under high temperatures, alumina cement remains stable
and retains its strength even when exposed to intense heat. This makes it an ideal choice for
refractory applications, such as furnace linings, kiln structures, and fireproofing in industrial
plants. In these environments, maintaining structural integrity under thermal stress is crucial,
and alumina cement delivers superior performance.
3. Another important use of alumina cement is its rapid-setting capability. This feature is
particularly valuable in emergency repairs and time-sensitive construction projects. When
infrastructure needs immediate reinforcement, such as repairing damaged bridges, roads, or
industrial machinery, alumina cement provides a quick and reliable solution. Its ability to
achieve high strength within hours rather than days ensures that structures can be restored and
operational in minimal time.
4. In addition to its heat resistance and fast setting properties, alumina cement is highly resistant
to chemical attacks, particularly from sulfates and acids. This makes it indispensable in
environments where exposure to aggressive substances is common. For instance, sewage
treatment plants, marine structures, and chemical processing facilities frequently utilize
alumina cement to prevent deterioration caused by corrosive materials. Unlike traditional
cement, which can degrade over time in such conditions, alumina cement maintains its
integrity, ensuring long-term durability.
5. Cold weather construction also benefits from the unique properties of alumina cement.
Traditional cement can be vulnerable to frost damage if not properly managed in low
temperatures. However, due to its fast hydration process, alumina cement generates heat as it
sets, allowing it to cure effectively even in cold environments. This makes it particularly useful
for projects in regions where freezing temperatures pose challenges to conventional cement-
based construction.

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6. Despite its many advantages, alumina cement does have some limitations. One challenge is the
conversion phenomenon, where long-term strength reduction can occur due to changes in its
hydrated compounds. However, engineers and construction professionals mitigate this issue by
designing concrete mixes with appropriate reinforcement techniques and additives to enhance
its stability and longevity.

C. Applications of Alumina Cement

1. Refractory and High-Temperature Applications: Due to its excellent heat resistance,

alumina cement is widely used in refractory concretes, furnace linings, and other high-
temperature industrial structures.
2. Rapid Repair Work: The fast setting and high early strength properties make alumina cement
ideal for emergency repair of roads, bridges, airport runways, and railway tracks.
3. Sewer Infrastructure: Because of its sulfate resistance, alumina cement is used in the
construction of sewage systems, drainage pipes, and wastewater treatment plants where
exposure to aggressive chemicals is common.
4. Chemical and Industrial Flooring: Alumina cement is often used in industrial flooring and
storage tanks in chemical plants due to its durability against harsh chemicals.
5. Underwater Construction: Since it sets quickly and resists sulfate attack, alumina cement is
well-suited for underwater construction, including ports, docks, and marine structures.

Limitations and Precautions

Despite its advantages, alumina cement has some limitations. One major concern is its
vulnerability to conversion, a process where the hydrated calcium aluminates gradually transform
into more stable forms, leading to a loss of strength over time. This phenomenon is accelerated
under high temperatures and humidity. As a result, alumina cement is not commonly used in
structural applications where long-term strength is critical. To mitigate this issue, engineers often
use blended compositions or reinforcement techniques. Additionally, alumina cement is more
expensive than OPC, making it a less economical choice for general-purpose construction. Its rapid
setting time also requires skilled handling and precise mixing to avoid premature hardening.

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2. Meaning, purpose and applications of Expansive Cement

A.Meaning of Expansive Cement

Expansive cement is a specialized type of hydraulic cement designed to counteract shrinkage

that occurs during the drying and hardening process of conventional cement. Unlike ordinary
Portland cement, which experiences volume reduction due to water loss and chemical
reactions, expansive cement undergoes a controlled expansion, ensuring dimensional stability
in structures. This unique property makes it an essential material for applications requiring
crack resistance, durability, and structural integrity. The primary purpose of expansive cement
is to mitigate shrinkage-related issues that can lead to structural weaknesses, cracks, and
durability concerns. In traditional cement, shrinkage occurs as the concrete sets and water
evaporates, causing internal stresses that result in cracks. Expansive cement, however, expands
slightly as it hydrates, compensating for shrinkage and reducing the likelihood of cracking.
This characteristic is particularly useful in large concrete structures, slabs, pavements, and
repair works where long-term stability is critical. Expansive cement achieves its unique
properties through the incorporation of expansive agents such as calcium sulfo aluminate,
calcium hydroxide, and calcium oxide. When mixed with water, these compounds react and
form ettringite, a crystalline substance that expands during the early stages of setting. This
controlled expansion counteracts the natural tendency of concrete to shrink, ensuring better
adhesion and bond strength in structural applications. The ability of expansive cement to
maintain its volume makes it a preferred choice in projects requiring seamless construction
joints, such as bridges, tunnels, and water-retaining structures. One of the key advantages of
expansive cement is its role in reducing the formation of cracks in reinforced concrete
structures. Cracking is a common issue in conventional concrete, leading to maintenance
challenges and potential structural failures over time. By compensating for shrinkage,
expansive cement improves the durability and lifespan of concrete structures, making it an
ideal choice for hydraulic structures like dams, reservoirs, and canal linings. The expansion

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property also enhances the bond between concrete and reinforcing steel, increasing overall
strength and performance.

B. Purpose of Expansive Cement

Expansive cement serves a crucial role in modern construction by addressing one of the most
common challenges in concrete structures—shrinkage. Unlike ordinary Portland cement, which
tends to shrink as it dries and hardens, expansive cement undergoes a controlled expansion,
reducing the formation of cracks and enhancing the overall durability of structures. This unique
property makes it an essential material for various construction applications that demand high
structural integrity, longevity, and minimal maintenance.

1. One of the primary purposes of expansive cement is to mitigate the effects of shrinkage-
induced cracking. When traditional cement cures, the loss of water and subsequent chemical
reactions result in volume reduction, leading to tensile stresses that can cause cracks.
Expansive cement counteracts this shrinkage by slightly increasing in volume during
hydration, thus preventing internal stress buildup. This property is particularly beneficial for
large concrete structures, such as bridges, tunnels, and slabs, where even minor cracks can
compromise long-term performance.
2. Another important function of expansive cement is its ability to enhance the bond strength
between concrete and reinforcement materials. By expanding slightly during the setting
process, the cement ensures better adhesion with embedded steel reinforcements, reducing the
risk of separation or weak joints. This makes it a preferred choice in reinforced concrete
applications, including structural beams, columns, and heavy-duty industrial floors where high
tensile strength is required.
3. Expansive cement is also widely used in the construction of hydraulic structures such as dams,
reservoirs, and water-retaining structures. These applications require materials that can
withstand continuous exposure to moisture and fluctuating environmental conditions without

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compromising their structural integrity. The expansion properties of this cement help maintain
joint stability and prevent leakage, ensuring the durability of such critical infrastructure.
4. Additionally, expansive cement is beneficial in grouting and anchoring applications. Its
controlled expansion allows grout to tightly fill voids and cavities, creating a strong bond
between different structural components. This property is particularly useful for securing
anchor bolts, machine foundations, and repair works in existing concrete structures. Precast
concrete elements also benefit from the dimensional stability of expansive cement, which helps
maintain precise alignment and prevents shrinkage-related distortions.

C.Applications of Expansive Cement

Expansive cement is widely used in construction and industrial applications where crack
prevention, joint stability, and structural durability are essential. Its unique ability to expand
during hydration makes it a preferred choice for projects that require minimal shrinkage and
high long-term performance. The following are some of the key applications of expansive
cement in modern engineering and construction.

1. One of the most common applications of expansive cement is in large concrete structures,
including bridges, tunnels, and highways. These infrastructures are prone to shrinkage-
induced cracking, which can compromise their integrity over time. By using expansive cement,
engineers can reduce the formation of cracks, thereby enhancing the durability and safety of
these critical structures. The controlled expansion helps maintain the stability of joints and
reduces the need for frequent maintenance.
2. Expansive cement is also extensively used in hydraulic structures such as dams, reservoirs,
and canals. These structures are continuously exposed to water and fluctuating environmental
conditions, making them susceptible to leaks and cracks. The expansive properties of this
cement ensure that joints remain tight and watertight, minimizing water seepage and enhancing
the lifespan of these vital constructions. Additionally, the cement’s resistance to sulfate attack
makes it highly suitable for water-retaining structures.

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 Wachamo university
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Construction technology and management dep’t

3. Another significant application of expansive cement is in precast concrete elements. Precast

components, such as columns, beams, and panels, require precise dimensional stability to
ensure proper fitting during assembly. Expansive cement helps maintain the desired shape and
size of precast elements, preventing shrinkage-related distortions. This makes it an ideal
material for manufacturing high-quality prefabricated concrete products used in various
construction projects.
4. In industrial settings, expansive cement is used for grouting and anchoring applications. It is
commonly employed to secure anchor bolts, machinery bases, and foundation structures. Its
controlled expansion allows grout to completely fill voids and gaps, ensuring a strong and
stable bond between different structural components. This feature is particularly useful in
heavy industrial plants and facilities where machinery requires a firm foundation to withstand
operational vibrations and loads.
5. Another important use of expansive cement is in repair and rehabilitation projects. When
restoring existing concrete structures, cracks and damaged sections need to be filled with a
material that prevents further deterioration. Expansive cement-based repair mortars and grouts
are ideal for this purpose, as they compensate for shrinkage, bond well with the old concrete,
and enhance structural integrity. This makes it an excellent choice for repairing bridges,
buildings, and pavements with minimal disruption.
6. Additionally, expansive cement is used in tunnel linings and underground construction. The
ability of the cement to expand and maintain tight joints is crucial in these applications, as it
prevents water ingress and enhances the strength of underground structures. This application is
particularly beneficial in metro rail projects, underground storage facilities, and mining
operations where stability and durability are paramount.

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 Wachamo university
College of engineering and technology
Construction technology and management dep’t

MIXING DESIGN

#1. Use ACI 211.1 Mix Design Method

The 28-day compressive strength of an air-entrained
concrete is expected to attain 30 MPa, The slump should be
between 25-75 mm and the maximum aggregate size should
not exceed 20 mm a shape of subangular with crushed
particles. The properties of the materials are as follows:
 Cement : Type I, specific gravity = 3.15
 Coarse Aggregate: Bulk specific gravity (SSD) = 2.65;
absorption capacity = 0.7%; dry rodded unit weight = 1650
kg/m3, ; surface moisture = 1.6%
 Fine Aggregate: Bulk specific gravity (SSD) = 2.7;
absorption capacity = 1.8%; fineness modulus = 2.65;
surface moisture = 4%.
 Pozzolan = Silica fume 10% and GGFBS 15% of cement
with specific gravity of and 2.35, respectively.
 Water – reducer admixtures with specific gravity of 1.25 and
reduces water demand by 15% when used at a dosage rate of

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 Wachamo university
College of engineering and technology
Construction technology and management dep’t

8 g per Kg of cement
Solution
Step 1. Strength Requirement
 Since no statistical data is given
The 28-day compressive strength of an air-entrained concrete is expected to attain
30 MPa, which Specified compressive strength, f'c is btween 21 and 35 mpa
f’cr =f' c + 8.5……………………………..from tabel
f’cr = 30 + 8.5 = 38.5 MPa.
Step 2. Workability Requirement
 Slump is given to be between 25 mm and 75 mm
Step 3. Maximum size of Aggregate
A nominal maximum size aggregate of 20 mm is given
Step 4. Selection of water and air content
The required water content for a 75-mm slump air-entrained concrete with
20-mm aggregate size is about 193 Kg/m3 and 1.5% respectively.

Water, Kilograms per cubic meter of concrete, for indicated sizes of

aggregate
Slump, mm 12.5 37.5
9.5 mm 19 mm 25 mm 50 mm 75 mm 150 mm
mm mm
Non-air-entrained concrete
25 to 50 207 199 190 179 166 154 130 113
75 to 100 228 216 205 193 181 169 145 124

150 to 175 243 228 216 202 190 178 160 -

Appropriate amount of entrapped air in non-air-

3.0 2.5 2.0 1.5 1.0 0.5 0.3 0.2
entrained concrete, percent
Air-entrained concrete

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 Wachamo university
College of engineering and technology
Construction technology and management dep’t

25 to 50 181 175 168 160 150 142 122 107

75 to 100 202 193 184 175 165 157 133 119
150 to 175 216 205 197 184 174 166 154 -
Recommended average total air content, percent, for
level of exposure:
Mild exposure 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0
Moderate exposure 6.0 5.5 5.0 4.5 4.5 4.0 3.5 3.0
Severe exposure 7.5 7.0 6.0 6.0 5.5 5.0 4.5 4.0

From the give data the value of nominal aggregate size =20mm is not
obtained directly from the table; which is between 19mm and 25mm
nominal aggregate size. The value of the water is obtained by
interpolation.
Agg Water/ kg/ m3 of concrete, for indicated sizes of aggregate

19 184
20 X
25 175
(20-19)/ (20-25) =(X-184)/(X-175)
X=182.5kg/m3……the amount of water for a given agg size 20mm
However, since the aggregate shape is rounded gravel, the mixing water
would be = 182.5 – 12 = 170.5 Kg/m3

• Also, the water reducers would also result in reduction of

15%.
• Thus, the final water content would be:

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 Wachamo university
College of engineering and technology
Construction technology and management dep’t

170.5 – (15% of 170.5) = 144.925 Kg/m3.

Step 5. Determination of W/C (W/B)

From above work our required compressive of concrete is

obtained which is 38.5mpa
The water cement is obtained by above table which is
between 35 and 41mpa on air entrained concrete column.
fcr w/c
35 0.4

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 Wachamo university
College of engineering and technology
Construction technology and management dep’t

38.5 X
41 0.32
By interpolation we can determine the value of X which is the water cement ratio of
a concrete with required compressive strength of 38.5mpa.
(38.5-35)/(38.5-41)=(X-0.4)/(X-0.32)
X=0.3533
The W/C ratio of a given concrete is 0.3533
Step 6. Calculation of Cement (SCM)
W B= W water / W/B = 144.925 Kg/m3/0.3533= 410.204kg/m3
Silica fume 10% =410.204kg/m3*0.1=41.0204kg/m3
GGFBS 15%=410.204kg/m3*0.15=61.53kg/m3
WCement =410.204-41.0204-61.53 =307.65kg/m3

Now Compare the cement amount with the minimum cement quantities in the
Table below for structural requirements, and take the maximum value,
Nominal maximum size of Cementing
aggregate, mm (in.) materials, Kg/m3 (lb/yd3)*
37.5 (11/2) 280 (470)
25 (1) 310 (520)
19 (3/4) 320 (540)
12.5 (1/2) 350 (590)
9.5 (3/8) 360 (610)

By interpolation mechanism the weight of cement is 318.33kg/m3

Take max =307.65kg/m3
=318.33kg/m3
Therefore the WCement is 318.33kg/m3

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 Wachamo university
College of engineering and technology
Construction technology and management dep’t

Step 7. Calculation of amount of C. A

Nominal maximum size of Bulk volume of dry-rodded coarse aggregate per unit volume of
aggregate, mm (in.) concrete for different fineness moduli of fine aggregate
2.40 2.60 2.80 3.00
9.5 (3/8) 0.5 0.48 0.46 0.44
12.5 (1/2) 0.59 0.57 0.55 0.53
19 (3/4) 0.66 0.64 0.62 0.6
25 (1) 0.71 0.69 0.67 0.65
37.5 (11/2) 0.75 0.73 0.71 0.69
50 (2) 0.78 0.76 0.74 0.72
75 (3) 0.82 0.8 0.78 0.76
150 (6) 0.87 0.85 0.83 0.81

For a aggregate size of 20mm, fineness moduli of fine agg is 2.65

From the table given above the nominal dimension of concrete 20mm
is not in the range of table which is between 19mm and 25mm; the
volume of coarse agg can be calculated by double interpolation.
Agg fineness moduli
size 2.6 2.65 2.8
19 0.64 0.62
20 X1 =0.65 X X2 =0.63
25 0.69 0.67
1. 20-19/20-25=X1-0.64/X1-0.69 X1=0.65
2. 20-19/20-25=X2-0.62/X2-0.67 X2 =0.63
3. Now determine the volume of coarse agg for fineness moduli of
2.65
Interpolate the fineness moduli with X1 & X2

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 Wachamo university
College of engineering and technology
Construction technology and management dep’t

(2.65-2.6)/(2.65-2.8)=(X-0.65)/(X-0.63)
0.0315-0.05X=0.15X-0.0975
0.2X=0.129
X=0.645m3
The bulk volume of CA (of 20-mm size) recommended when using
sand with fineness 2.65 is 0.645m3.
Step 8. Calculation of the amount (rate) Admixture
A dosage rate of 8 g per Kg of cement is recommended
W admixture= 0.008*410.204kg/m3= 3.3kg/m3
Step 9. Calculation of fine aggregate content
Dry mass Vm = wm/(SGm*ρw)
Vcement = 318.33/3.15*1000 = 0.101 m3
Vsilica = 41.0204/1.87*1000 = 0.022 m3
VGGFBS=61.53/2.35*10=0.0262
Vwater =144.925/1000 = 0.145 m3
VCA = 1061.53/2.65*1000 = 0.4 m3
Vadmixture =3.282/1.25*1000 = 0.00263 m3
VF.A = 1 - (0.101 + 0.022 + 0.0262+ 0.145 + 0.4+0.00263) = 0.303m3
wF.A. = 0.251*2.6*1000 = 818.56kg/m3
Step 10. Moisture Adjustment
A. Aggregate adjustment
Coarse Agg moisture content is 1.6 % and FA moisture content of 4 %. is
given

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 Wachamo university
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Construction technology and management dep’t

WCA = 1061.53+1.6% of 1061.53 = 1061.53+(0.016x1061.53)

=1061.53*1.016= 1078.51 Kg.
WFA = 818.56+4%of 818.56=818.56+(0.04x818.56) = 818.56*1.04= 851.3 Kg.
B. Water adjustment
Water absorption, CA = 0.5%, F.A.=0.6%
Surface moisture contributed by
CA = 1.6% - 0.7% = 0.9 %. = 0.009
FA= 4% - 1.8% = 2.2 %. = 0.022
Thus, the estimated requirement for added water becomes:
= 144.925– (1061.53*0.009)-( 818.56*0.022)
=144.925-27564
=117.36kg/m3
#2. Use British DoE Mix Design Method
Design a concrete mix to obtain a characteristic compressive strength (fc) = 28 MPa at 7 days, with
a 5% defective rate, assume that 15 previous results are available. The design requirements are as
follows:
 Slump required = 30–60 mm. Maximum w/c ratio should be 0.48,
 the Maximum aggregate size, = 20 mm (uncrushed),
 Fine aggregate: absorption= 2.7%, Moisture content = 0.5%, Fineness modulus, FM =2.9.
 Portland cement class = 52.5., minimum cement content = 360 kg/m3
 Coarse aggregate: Absorption = 3.5%, Moisture content = 1.3%;
Answer
Step 1: determine target mean strength
fm= fc+k.s
kc=1.65 …………..defective rate =5%
s=8………………………number of results =15 and fc= 28mpa

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 Wachamo university
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Construction technology and management dep’t

fm= 28+ 1.65x8

fm= 41.2mpa
step2: identify water cement ratio
 Cement class= 42.5
 Aggregate type is uncrushed
 7 days Compressive strength is 37mpa
From the curve read off the w/c ratio for a target mean strength of 37mpa, w/c=0.62
Step3: calculate the free water content
 For uncrushed aggregate, maximum size of aggregate = 20mm
 Slump= from 30-60mm
Therefore, From the table the mixing water content= 180kg/m3
Step 4: calculate the cement content
w/c= W
C
C= W = 180 kg/m3 = 290.322kg/m3
w/c 0.62

therefore, the cement content is 360kg/m3

step 5: find the weight of total aggregate
 assume an average value of specific gravity for uncrushed aggregate = 2.6
 from the graph wet density of concrete for uncrushed aggregate and 180kg/m3 of free water
content= 2380 kg/m3
Wt of TA= 2380-(360+180)
=1840 kg/m3
Step 6 : calculate weight of fine aggregate
 maximum aggregate size= 20mm
 slump= 60mm
 w/c=0.62
 F.M=2.9

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 Wachamo university
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Construction technology and management dep’t

 From the graph F.A= 42%

Then, F.A content = Wt of T.A x Wt of F.A
= 1840 x 0.42
=772.8 kg/m3
Step 7: moisture adjustment
A) Aggregate adjustment
CA moisture content= 1.3%
F.A moisture content= 0.5%
WCA= 1041+ (0.013*1041) = 1054.53kg
WFA= 772.8 + 0.5% (772.8)
= 754+ 0.005*754 = 776.67 kg
B) Water adjustment
 Water absorption of CA= 3.5%
 Water absorption of FA=2.7%
 Surface moisture contributed by
CA= 1.3%- 3.5% = -2.2% = 0.022
FA= 0.5-2.7 = -2.2% = 0.022
Thus the estimated requirement for added water becomes
=180-(772.8*0.022)-(1054.53*0.022)
= 180- (-17) –(-23.2)
= 180-6.2)
=173.8kg/m3

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 Wachamo university
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Reference
1. Blended Cement, Green, Durable &Sustainable 2022
2. Blended Hydraulic Cement, Environmental Product Declaration, Per Astm C219 And
Specified In Astm C595, Astm C1157, Aashto M 240, Or Csa A3001
3. Evaluating Properties Of Blended, Cements For Concrete Pavements, Kejin Wang Assistant
Professor
4. Moscow State University Of Civil Engineering, Yaroslavskoe Shosse, 26, Moscow, 29337,
Russia
5. Astm Designation: C595/C595m – 12

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