portland, blended, and other hydraulic cements

Portland, Blended, and Other Hydraulic Cements


Oldest Concrete Found To Date

dates around 7000 BC

— a lime concrete floor found during the construction of a road at Yiftah El in Galilee, Israel.


Beginning of the Industry

Portland cement was first patented in 1824

Named after the natural limestone quarried on the Isle of Portland in the English Channel


Portland Cement First Produced North America

1871— Coplay, Pennsylvania

Canada

1889 — Hull, Quebec


Primary Components of Raw Materials Necessary for Portland Cement Manufacture

Calcium Silica Alumina Iron


Calcium Iron Silica Alumina Sulfate

Alkali waste

AragoniteCalciteCement-kiln dust

Cement rock

ChalkClayFuller’s earth

LimestoneMarbleMarlSeashellsShaleSlag

Blast-furnace flue dust

ClayIron oreMill scaleOre washings

Pyrite cinders

Shale

Calcium silicateCement rockClayFly ashFuller’s earthLimestoneLoessMarlOre washingsQuartziteRice-hull ashSandSandstoneShaleSlagTraprock

Aluminum-ore refuse

BauxiteCement rock

ClayCopper slagFly ashFuller’s earth

Granodiorite

LimestoneLoessOre washings

ShaleSlagStaurolite

Anhydrite

Calcium sulfate

Gypsum


Quarry


Traditional Manufacture of Portland Cement

1. Stone is first reduced to 125 mm (5 in.) size, then to 20 mm (3/4 in.), and stored.


2. Raw materials are ground to powder and blended.

or

2. Raw materials are ground, mixed with water to form slurry, and blended.


3. Burning changes raw mix chemically into cement clinker.


4. Clinker with gypsum is ground into portland cement and shipped.


Dry Process Manufacture of Portland Cement

1. Stone is first reduced to 125 mm (5 in.) size, then to 20 mm (3/4 in.), and stored.


2. Raw materials are ground, to powder and blended.


3. Burning changes raw mix chemically into clinker. Note four stage preheater, flash furnaces, and shorter kiln.


4. Clinker with gypsum is ground into portland cement and shipped


Clinker

Gypsum


Process of Clinker Production

(1)


(2)


(3)


Portland Cement

By definition —

a hydraulic cement produced by pulverizing clinker consisting essentially of hydraulic calcium silicates, usually containing one or more of the forms of calcium sulfate as an interground addition.


Types of Portland Cement

I Normal

IA Normal, air-entraining

II Moderate sulfate resistance

IIA Moderate sulfate resistance, air-entraining

III High early strength

IIIA High early strength, air-entraining

IV Low heat of hydration

V High sulfate resistance

ASTM C 150 (AASHTO M 85)


Performance of Concretes Made with Different Cements in Sulfate Soil


Performance of Concretes Made with Different W/C-Ratios in Sulfate Soil


Type II & Type V Sulfate Resistant Cements


Outdoor Sulfate Test

Type V CementW/C-ratio = 0.65

Type V CementW/C-ratio = 0.39


Moderate and Low Heat Cements


Type IIIHigh Early Strength Cements


White Portland Cement


Blended Hydraulic Cement

ASTM C 595General —

a hydraulic cement consisting of two or more inorganic constituents, which contribute to the strength gaining properties of cement.


Blended Cements

Clinker Gypsum Portland cement Fly ash Slag Silica Fume Calcined Clay


Blended Hydraulic Cements

Type IS Portland blast-furnace slag cement

Type IP Portland-pozzolan cement

Type P Portland-pozzolan cement

Type I(PM) Pozzolan-modified portland cement

Type S Slag cement

Type I(SM) Slag-modified portland cement

ASTM C 595 (AASHTO M 240)


Hydraulic Cements ASTM C 1157 First performance specification

for hydraulic cements Cements meet physical

performance test requirements rather than prescriptive restrictions on ingredients or cement chemistry as in other cement specifications.

Provides for six types


Hydraulic Cement

Type GU General use

Type HE High early strength

Type MS Moderate sulfate resistance

Type HS High sulfate resistance

Type MH Moderate heat of hydration

Type LH Low heat of hydration

ASTM C 1157


Cementspecificatio

n

Cement Applications

General

purpose

Moderate

heat of hydratio

n

High early

strength

Low

heat ofhydratio

n

Moderate

sulfateresistanc

e

High sulfate

resistance

Resistance to

alkali-silica

reactivity (ASR)

ASTM C 150(AASHTO M

85)portland cements

I

II (modera

teheat

option)

III IV II VLow

alkalioption

ASTM C 595(AASHTO M

240)blendedhydrauliccements

ISIP

I(PM)I(SM)S, P

IS(MH)IP(MH)I(PM)(MH)I(SM)(MH)

P(LH)

IS(MS)IP(MS)P(MS)I(PM)(MS)I(SM)(MS)

Low reactivity

option

ASTM C 1157

hydrauliccements

GU MH HE LH MS HS Option R


Special cements Type ApplicationWhite portland cements, ASTM C 150

I, II, III, V White or colored concrete, masonry, mortar, grout, plaster, and stucco

White masonry cements, ASTM C 91

M, S, N White mortar between masonry units

Masonry cements, ASTM C 91

M, S, N Mortar between masonry units, plaster, and stucco

Mortar cements, ASTM C 1329

M, S, N Mortar between masonry units

Plastic cements, ASTM C 1328

M, S Plaster and stucco

Expansive cements, ASTM C 845

E-1(K), E-1(M), E-1(S)

Shrinkage compensating concrete

Oil-well cements, API-10

A, B, C, D, E, F, G, H

Grouting wells

Water-repellent cements

Tile grout, paint, and stucco finish coats

Regulated-set cements

Early strength and repair


Special cements Type ApplicationCements with functional additions, ASTM C 595 (AASHTO M 240), ASTM C 1157

General concrete construction needing special characteristics such as; water-reducing, retarding, air entraining, set control, and accelerating properties

Finely ground (ultrafine) cement

Geotechnical grouting

Calcium aluminate cement

Repair, chemical resistance and high temperature exposures

Magnesium phosphate cement

Repair and chemical resistance

Geopolymer cementGeneral construction, repair, waste stabilization

Ettringite cements Waste stabilizationSulfur cements Repair and chemical resistance

Rapid hardening hydraulic cement

VH, MR, GC

General paving where very rapid(about 4 hours) strength developmentis required


Masonry Cements

Type N — for Type O and Type N mortars and with portland cement for mortar Types S and M

Type S — for Type S mortar

Type M — for Type M mortar


Stucco using Masonry or Plastic Cements


Finely-Ground Cements

Grout penetration in soil


Expansive Cement Concrete


Drinking Water Applications


Chemical Compounds of Portland Cement


Hydration Products


Portland Cement Compound Hydration Reactions (Oxide Notation)

2 (3CaO•SiO2)

Tricalcium silicate

+ 11 H2O

Water

= 3CaO•2SiO2•8H2O

Calcium silicate

hydrate (C-S-H)

+ 3 (CaO•H2O)

Calcium hydroxide

2 (2CaO•SiO2)

Dicalcium silicate

+ 9 H2O

Water

= 3CaO•2SiO2•8H2O

Calcium silicate

hydrate (C-S-H)

+ CaO•H2O

Calcium hydroxide

3CaO•Al2O3

Tricalcium aluminate

+ 3 (CaO•SO3•2H2O)

Gypsum

+ 26 H2O

Water

= 6CaO•Al2O3•3SO3•32H2O

Ettringite

2 (3CaO•Al2O3)


+ 6CaO•Al2O3•3SO3•32H2O

Ettringite

+ 4 H2O

Water

= 3 (4CaO•Al2O3•SO3•12H2O)

Calcium monosulfoaluminate

3CaO•Al2O3


+ CaO•H2O

Calcium hydroxide

+ 12 H2O

Water

= 4CaO•Al2O3•13H2O

Tetracalcium aluminate hydrate

4CaO• Al2O3•Fe2O3

Tetracalcium aluminoferrite

+ 10 H2O

Water

+ 2 (CaO•H2O)

Calcium hydroxide

= 6CaO•Al2O3•Fe2O3•12H2O

Calcium aluminoferrite hydrate


SEMs of Hardened Cement Paste


Type ofportlandcement

Chemical composition, %

SiO2

Al2O

3

Fe2O

3

CaO MgO SO3 Na2Oeq

I (mean) 20.5 5.4 2.6 63.9 2.1 3.0 0.61

II (mean) 21.2 4.6 3.5 63.8 2.1 2.7 0.51

III (mean) 20.6 4.9 2.8 63.4 2.2 3.5 0.56

IV (mean) 22.2 4.6 5.0 62.5 1.9 2.2 0.36

V (mean) 21.9 3.9 4.2 63.8 2.2 2.3 0.48

White (mean)

22.7 4.1 0.3 66.7 0.9 2.7 0.18


Type ofportlandcement

Potential compound composition,%

Blaine fineness

m2/kgC3S C2S C3A C4AF

I (mean) 54 18 10 8 369

II (mean) 55 19 6 11 377

III (mean) 55 17 9 8 548

IV (mean) 42 32 4 15 340

V (mean) 54 22 4 13 373

White (mean) 63 18 10 1 482


Reactivity of Cement Compounds


Nonevaporable Water Contents

Hydrated cement

compound

Nonevaporable(combined) water

content(g water/g cement

compound)

C3S hydrate 0.24

C2S hydrate 0.21

C3A hydrate 0.40

C4AF hydrate 0.37

Free lime (CaO)

0.33


Scanning-Electron Micrograph of Powdered Cement


Fineness of Cement

ASTM C 204

ASTM C 115


Cement Fineness


Particle Size Distribution


Soundness Test

ASTM C 151 ASTM C 151 (AASHTO T 107 )(AASHTO T 107 )


Consistency of Cement PasteASTM C 187 ASTM C 187

(AASHTO T 129)(AASHTO T 129)

Vicat plungerVicat plunger


Consistency of Mortar

ASTM C 230 ASTM C 230 (AASHTO M 152) (AASHTO M 152)

and ASTM C 1437and ASTM C 1437

Flow tableFlow table


Setting TimeASTM C 191 ASTM C 191 (AASHTO M 131) (AASHTO M 131)

Vicat apparatusVicat apparatus


Setting TimeASTM C 266 ASTM C 266 (AASHTO M 154) (AASHTO M 154)

Gillmore needleGillmore needle


Setting Times for Portland Cements


Mortar Cubes

ASTM C 109 ASTM C 109 (AASHTO T 106) (AASHTO T 106)


Strength Development of Mortar Cubes


Strength Development Type I and II Cements


Strength Development Type III, IV, and V Cements


Heat of Hydration at 7 Days

Type I cement

Type II cement

Type II Moderate heat cement

Type III cement

Type IV cement

Type V cement

% of Type I

100 99 75 106 67 89


Heat Evolution


Density of CementLe Chatelier flask ( ASTM C 188 or Le Chatelier flask ( ASTM C 188 or AASHTO T 133) AASHTO T 133)

Helium Helium pycnometerpycnometer


Bulk Density

Bulk density of cement Bulk density of cement varies betweenvaries between

830 kg/m830 kg/m3 3 (52 lb/ft(52 lb/ft33))

andand

1650 kg/m1650 kg/m3 3 (103 lb/ft(103 lb/ft33).).


Thermal Analysis

Thermogravimetric analysis (TGA)

Differential Thermal Analysis (DTA)

Differential Scanning Calorimetry (DSC)


Differential Scanning Calorimetry Thermogram of a Cement Paste after (a) 15 min and (b) 24 h of Hydration


Virtual Cement Testing


Transporting Cement


Packaging and Storage


Videos 1/7

Cement TypesManufacturing Cement


Videos 2/7

Cement Hydration I Cement Hydration II


Videos 3/7

Cement Hydration Soundness


Videos 4/7

False SetSetting Time


Videos 5/7

Cement Fineness Cement Strength


Videos 6/7

Cement Hydration Simulation


Videos 7/7

Storage Cement Delivery

portland, blended, and other hydraulic cements

Documents

hydraulic cements4

hydraulic cementsbeginning

hydraulic cements2portland

hydraulic cements3portland

hydraulic cementsraw

hydraulic calcium silicates

isle of portland

cement clinker