Portland, Blended, and Other Hydraulic Cements Blended, and Other Hydraulic Cements Beginning of the Industry Portland cement was first patented in 1824 Named after the natural limestone

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 America1871— Coplay, Pennsylvania

■ Canada1889 — Hull, Quebec



Primary Components of Raw Materials Necessary for Portland Cement Manufacture

■ Calcium■ Silica■ Alumina■ Iron


AnhydriteCalcium

sulfateGypsum

Aluminum-ore refuse

BauxiteCement rockClayCopper slagFly ashFuller’s earthGranodioriteLimestoneLoessOre washingsShaleSlagStaurolite

Calcium silicateCement rockClayFly ashFuller’s earthLimestoneLoessMarlOre washingsQuartziteRice-hull ashSandSandstoneShaleSlagTraprock

Blast-furnace flue dust

ClayIron oreMill scaleOre washingsPyrite cindersShale

Alkali wasteAragoniteCalciteCement-kiln

dustCement rockChalkClayFuller’s earthLimestoneMarbleMarlSeashellsShaleSlag

SulfateAluminaSilica IronCalcium


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 sulfateas an interground addition.


Types of Portland Cement

ASTM C 150 (AASHTO M 85)

I NormalIA Normal, air-entrainingII Moderate sulfate resistanceIIA Moderate sulfate resistance, air-

entrainingIII High early strengthIIIA High early strength, air-entrainingIV Low heat of hydrationV High sulfate resistance



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 CementASTM C 595

General —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

ASTM C 595 (AASHTO M 240)

Type IS Portland blast-furnace slag cement

Type IP Portland-pozzolancement

Type P Portland-pozzolancement

Type I(PM) Pozzolan-modified portland cement

Type S Slag cement Type I(SM) Slag-modified portland

cement


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

ASTM C 1157

Type GU General useType HE High early strengthType MS Moderate sulfate

resistanceType HS High sulfate resistanceType MH Moderate heat of

hydrationType LH Low heat of hydration


Option RHSMSLHHEMHGU

ASTM C 1157

hydraulic

cements

Low reactivity

option

IS(MS)

IP(MS)

P(MS)

I(PM)(MS)

I(SM)(MS)

P(LH)

IS(MH)

IP(MH)

I(PM)(MH)

I(SM)(MH)

IS

IP

I(PM)

I(SM)

S, P

ASTM C 595

(AASHTO M 240)

blended

hydraulic

cements

Low alkali

optionVIIIVIII

II (moderate

heat option)

I

ASTM C 150

(AASHTO M 85)

portlandcements

High sulfate

resistance

High early

strength

General

purpose

Cement

specification

Resistance to

alkali-silica

reactivity (ASR)

Moderate

sulfate

resistance

Low heat of

hydration

Moderate

heat of

hydration

Cement Applications

Portland, Blended, and Other Hydraulic Cements Early strength and repairRegulated-set cements

Tile grout, paint, and stucco finish coats

Water-repellent cements

Grouting wellsA, B, C, D, E, F, G, HOil-well cements, API-10

Shrinkage compensating concreteE-1(K), E-1(M), E-1(S)Expansive cements, ASTM C 845

Plaster and stuccoM, SPlastic cements, ASTM C 1328

Mortar between masonry unitsM, S, NMortar cements, ASTM C 1329

Mortar between masonry units, plaster, and stucco

M, S, NMasonry cements, ASTM C 91

White mortar between masonry units

M, S, NWhite masonry cements, ASTM C 91

White or colored concrete, masonry, mortar, grout, plaster, and stucco

I, II, III, VWhite portland cements, ASTM C 150

ApplicationTypeSpecial cements


Repair and chemical resistanceSulfur cements

General paving where very rapid

(about 4 hours) strength development

is required

VH, MR, GCRapid hardening hydraulic cement

Waste stabilizationEttringite cements

General construction, repair, waste

stabilizationGeopolymer cement

Repair and chemical resistanceMagnesium phosphate cement

Repair, chemical resistance and high temperature exposures

Calcium aluminate cement

Geotechnical groutingFinely ground (ultrafine) cement

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

Cements with functional

additions,

ASTM C 595 (AASHTO M 240),

ASTM C 1157

ApplicationTypeSpecial cements


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)

= 4CaO•Al2O3•13H2O

Tetracalcium aluminate hydrate

+ 12 H2O

Water

+ CaO•H2O

Calcium hydroxide

3CaO•Al2O3

Tricalciumaluminate

= 6CaO•Al2O3•Fe2O3•12H2O

Calcium aluminoferrite hydrate

+ 2 (CaO•H2O)

Calcium hydroxide

+ 10 H2O

Water

4CaO• Al2O3•Fe2O3

Tetracalciumaluminoferrite

= 3 (4CaO•Al2O3•SO3•12H2O)

Calcium monosulfoaluminate

+ 4 H2O

Water

+ 6CaO•Al2O3•3SO3•32H2O

Ettringite

2 (3CaO•Al2O3)

Tricalciumaluminate

= 6CaO•Al2O3•3SO3•32H2O

Ettringite

+ 26 H2O

Water

+ 3 (CaO•SO3•2H2O)

Gypsum

3CaO•Al2O3

Tricalciumaluminate

+ CaO•H2O

Calcium hydroxide

= 3CaO•2SiO2•8H2O

Calcium silicate

hydrate (C-S-H)

+ 9 H2O

Water

2 (2CaO•SiO2)

Dicalcium silicate

+ 3 (CaO•H2O)

Calcium hydroxide

= 3CaO•2SiO2•8H2O

Calcium silicate

hydrate (C-S-H)

+ 11 H2O

Water

2 (3CaO•SiO2)

Tricalcium silicate


SEMs of Hardened Cement Paste



Portland, Blended, and Other Hydraulic Cements 0.18

0.48

0.36

0.56

0.51

0.61

Na2Oeq

2.70.966.70.34.122.7White (mean)

2.32.263.84.23.921.9V (mean)

2.21.962.55.04.622.2IV (mean)

3.52.263.42.84.920.6III (mean)

2.72.163.83.54.621.2II (mean)

3.02.163.92.65.420.5I (mean)

SO3MgOCaOFe2O3Al2O3SiO2

Chemical composition, %Type of

portland

cement


Potential compound composition,%

White (mean)

V (mean)

IV (mean)

III (mean)

II (mean)

I (mean)

4821101863

3731342254

3401543242

548891755

3771161955

3698101854

Blaine fineness

m2/kgC4AFC3AC2SC3S

Type of

portland

cement


Reactivity of Cement Compounds


Nonevaporable Water Contents

0.33Free lime (CaO)

0.37C4AF hydrate

0.40C3A hydrate

0.21C2S hydrate

0.24C3S hydrate

Hydrated cement

compound

Nonevaporable

(combined) water content

(g water/g cement compound)



Scanning-Electron Micrograph of Powdered Cement


Fineness of CementASTM C 204

ASTM C 115


Cement Fineness


Particle Size Distribution


Soundness Test

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


Consistency of Cement PasteASTM C 187 ASTM C 187 (AASHTO T 129)(AASHTO T 129)

VicatVicat plungerplunger


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 Time

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

VicatVicat apparatusapparatus


Setting Time

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

GillmoreGillmore needleneedle


Setting Times for Portland Cements


Mortar Cubes

ASTM CASTM C 109 109 (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

106

Type III cement

67

Type IV cement

89

Type V cement

75

Type II Moderate heat cement

99100% of Type I

Type II cement

Type I cement


Heat Evolution



Density of Cement

Le Le ChatelierChatelier flask ( ASTM Cflask ( ASTM C 188 or 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

■ Thermogravimetricanalysis (TGA)

■ Differential Thermal Analysis (DTA)

■ Differential Scanning Calorimetry (DSC)


Differential Scanning CalorimetryThermogram 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 Blended, and Other Hydraulic Cements Beginning of the Industry Portland cement was first patented in 1824 Named after the natural limestone

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