Portland, Blended, and Other Hydraulic Cements

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Portland, Blended, and Other Hydraulic Cements
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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.

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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

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Portland Cement First Produced

• North America
• 1871 Coplay, Pennsylvania
• Canada
• 1889 Hull, Quebec

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Primary Components of Raw Materials Necessary for
Portland Cement Manufacture

• Calcium
• Silica
• Alumina
• Iron

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Calcium Iron Silica Alumina Sulfate
Alkali waste Aragonite Calcite Cement-kiln dust Cement rock Chalk Clay Fullers earth Limestone Marble Marl Seashells Shale Slag Blast-furnace flue dust Clay Iron ore Mill scale Ore washings Pyrite cinders Shale Calcium silicate Cement rock Clay Fly ash Fullers earth Limestone Loess Marl Ore washings Quartzite Rice-hull ash Sand Sandstone Shale Slag Traprock Aluminum-ore refuse Bauxite Cement rock Clay Copper slag Fly ash Fullers earth Granodiorite Limestone Loess Ore washings Shale Slag Staurolite Anhydrite Calcium sulfate Gypsum
Blast-furnace flue dust Clay Iron ore Mill scale Ore washings Pyrite cinders Shale Calcium silicate Cement rock Clay Fly ash Fullers earth Limestone Loess Marl Ore washings Quartzite Rice-hull ash Sand Sandstone Shale Slag Traprock Aluminum-ore refuse Bauxite Cement rock Clay Copper slag Fly ash Fullers earth Granodiorite Limestone Loess Ore washings Shale Slag Staurolite Anhydrite Calcium sulfate Gypsum
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Quarry
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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.
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• Raw materials are ground to powder and blended.

or 2. Raw materials are ground, mixed with water
to form slurry, and blended.
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3. Burning changes raw mix chemically into cement
clinker.
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4. Clinker with gypsum is ground into portland
cement and shipped.
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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.
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1. Raw materials are ground, to powder and blended.

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3. Burning changes raw mix chemically into
clinker. Note four stage preheater, flash
furnaces, and shorter kiln.
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4. Clinker with gypsum is ground into portland
cement and shipped
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Clinker
Gypsum
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Process of Clinker Production
(1)
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(2)
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(3)
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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.

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Types of Portland Cement
ASTM C 150 (AASHTO M 85)

• 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

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Performance of Concretes Made with Different
Cements in Sulfate Soil
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Performance of Concretes Made with Different
W/C-Ratios in Sulfate Soil
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Type II Type V Sulfate Resistant Cements
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Outdoor Sulfate Test
Type V Cement W/C-ratio 0.65
Type V Cement W/C-ratio 0.39
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Moderate and Low Heat Cements
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Type IIIHigh Early Strength Cements
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White Portland Cement
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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.

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Blended Cements

• Clinker
• Gypsum
• Portland cement
• Fly ash
• Slag
• Silica Fume
• Calcined Clay

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Blended Hydraulic Cements
ASTM C 595 (AASHTO M 240)
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
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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

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Hydraulic Cement
ASTM C 1157

• 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

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Cement specification Cement Applications Cement Applications Cement Applications Cement Applications Cement Applications Cement Applications Cement Applications
Cement specification General purpose Moderate heat of hydration High early strength Low heat of hydration Moderate sulfate resistance High sulfate resistance Resistance to alkali-silica reactivity (ASR)
ASTM C 150 (AASHTO M 85) portland cements I II (moderate heat option) III IV II V Low alkali option
ASTM C 595 (AASHTO M 240) blended hydraulic cements IS IP 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 hydraulic cements GU MH HE LH MS HS Option R
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Special cements Type Application
White 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
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Special cements Type Application
Cements 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 cement General construction, repair, waste stabilization
Ettringite cements Waste stabilization
Sulfur cements Repair and chemical resistance
Rapid hardening hydraulic cement VH, MR, GC General paving where very rapid (about 4 hours) strength development is required
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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

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Stucco using Masonry or Plastic Cements
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Finely-Ground Cements
Grout penetration in soil
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Expansive Cement Concrete
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Drinking Water Applications
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Chemical Compounds of Portland Cement
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Hydration Products
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Portland Cement Compound Hydration Reactions (Oxide Notation) Portland Cement Compound Hydration Reactions (Oxide Notation) Portland Cement Compound Hydration Reactions (Oxide Notation) Portland Cement Compound Hydration Reactions (Oxide Notation)
2 (3CaOSiO2) Tricalcium silicate 11 H2O Water 3CaO2SiO28H2O Calcium silicate hydrate (C-S-H) 3 (CaOH2O) Calcium hydroxide
2 (2CaOSiO2) Dicalcium silicate 9 H2O Water 3CaO2SiO28H2O Calcium silicate hydrate (C-S-H) CaOH2O Calcium hydroxide
3CaOAl2O3 Tricalcium aluminate 3 (CaOSO32H2O) Gypsum 26 H2O Water 6CaOAl2O33SO332H2O Ettringite
2 (3CaOAl2O3) Tricalcium aluminate 6CaOAl2O33SO332H2O Ettringite 4 H2O Water 3 (4CaOAl2O3SO312H2O) Calcium monosulfoaluminate
3CaOAl2O3 Tricalcium aluminate CaOH2O Calcium hydroxide 12 H2O Water 4CaOAl2O313H2O Tetracalcium aluminate hydrate
4CaO Al2O3Fe2O3 Tetracalcium aluminoferrite 10 H2O Water 2 (CaOH2O) Calcium hydroxide 6CaOAl2O3Fe2O312H2O Calcium aluminoferrite hydrate
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SEMs of Hardened Cement Paste
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Type of portland cement Chemical composition, Chemical composition, Chemical composition, Chemical composition, Chemical composition, Chemical composition,
Type of portland cement SiO2 Al2O3 Fe2O3 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
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Type of portland cement Potential compound composition, Potential compound composition, Potential compound composition, Potential compound composition, Blaine fineness m2/kg
Type of portland cement C3S C2S C3A C4AF Blaine fineness m2/kg
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
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Reactivity of Cement Compounds
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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
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Scanning-Electron Micrograph of Powdered Cement
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Fineness of Cement
ASTM C 204
ASTM C 115
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Cement Fineness
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Particle Size Distribution
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Soundness Test

• ASTM C 151 (AASHTO T 107 )

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Consistency of Cement Paste

• ASTM C 187
• (AASHTO T 129)
• Vicat plunger

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Consistency of Mortar
ASTM C 230 (AASHTO M 152) and ASTM C 1437 Flow
table
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Setting Time
ASTM C 191 (AASHTO M 131) Vicat apparatus
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Setting Time
ASTM C 266 (AASHTO M 154) Gillmore needle
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Setting Times for Portland Cements
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Mortar Cubes
ASTM C 109 (AASHTO T 106)
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Strength Development of Mortar Cubes
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Strength Development Type I and II Cements
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Strength Development Type III, IV, and V Cements
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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
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Heat Evolution
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Density of Cement
Le Chatelier flask ( ASTM C 188 or AASHTO T 133)
Helium pycnometer
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Bulk Density
Bulk density of cement varies between 830 kg/m3
(52 lb/ft3) and 1650 kg/m3 (103 lb/ft3).
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Thermal Analysis

• Thermogravimetric analysis (TGA)
• Differential Thermal Analysis (DTA)
• Differential Scanning Calorimetry (DSC)

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Differential Scanning Calorimetry Thermogram of a
Cement Paste after (a) 15 min and (b) 24 h of
Hydration
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Virtual Cement Testing
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Transporting Cement
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Packaging and Storage
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Videos 1/7
Cement Types
Manufacturing Cement
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Videos 2/7
Cement Hydration I
Cement Hydration II
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Videos 3/7
Soundness
Cement Hydration
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Videos 4/7
Setting Time
False Set
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Videos 5/7
Cement Fineness
Cement Strength
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Videos 6/7
Cement Hydration Simulation
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Videos 7/7
Cement Delivery
Storage