Cement application in construction projects *Bhaskar Agate

Cement is the basic input material that is being used throughout the world to prepare the concrete for buildings, roads, pavements, ports, airports etc. etc. Manufacturing quality cement and quality concrete apparently look synonymous, but these two are separate sub ects and needs to be studied and understood independently in steps. !his brief paper or a form of small hand book shall focus only on"
#. Basic engineering properties of Cement $. !ypes of Cements % application in construction pro ects

&n understanding the aforesaid focused key areas through the given below bullet'te(ts tabulation write up, it should facilitate any civil pro ect engineer)manager to take an appropriate decision at planning stage or at the worksite of any civil construction pro ect* and to arrive at an apt solution to choose the right kind of cement for preparing a good and durable concrete. 1. Basic engineering properties of Cement Compressive strength development period +M,a -Megapascal. /ltimate strength +M,a -Megapascal. 0eat of hydration +Cal.)gm. &ther

!hese are the ma or characteristics that are required to be built in to any Cement before one would like to go for any concrete. 1or achieving these important engineering properties we need to understand the + 1.1 Properties of individual Cement Clinker compounds Engineering properties C3 !lite (Characteristics) Comp. strength dev.2apid period $' $3 days Clinker compounds / phases C" Belite C3! Celite 4low $5 ' 6 78 days 9ery rapid : hrs. ; < days

C#!$ $elite Bro%nmillerite =egligible

&ltimate strength 'eat of h(dration Cal. / gm. )ther

0igh

Medium

>ow

>ow

Medium >ow 9ery 0igh Medium #$8 :$ $8< #88 >eader >ess ,romotes ,romotes compo reactive than initial setting slow setting nent C?4 or hardening Adds to 4low 4usceptible to color of continuous sulphate attack cement hardening Catalyst for C?4 % C$4 formation

$ree lime * 1.+, causes e-pansion cracks in cement structure 0aving understood the tabulated intricacies and the importance of the each cement clinker compounds let us give a look to + ". .(pes of Cements / application in construction projects Cement with water is an adhesive Cements may be used alone -i.e., @neat,A as grouting materials. Mortar % concrete widely used Bricks, tiles, shingles, pipes, beams, railroad ties, and various e(truded products. Bifferent Cement verities available based on the above table =ow, how to decide about choosing of cementC &nce the above stated cement application basics are understood the ne(t step would be +. ".1 election of Cement for concrete construction Dhich are the -Eoverning factors. needs considerationsF Burability Characteristics 1unctional requirement ' Beflection, crack width etc. Besign parameters' 4trength, fineness, setting time requirement etc. -Cement Gngineering properties. 4peed of construction' !ime for construction etc. Gnvironmental Conditions' Eround conditions, soluble salts, sulphate, Chemical plants etc. Burability of concrete structure 4pecific applications

=ow one would like to align the cement engineering properties to that of concrete properties with +.. "." uita0ilit( of various t(pes of cements Dhere the required quality is built in to cement "."1 33 grade )PC1

Ht is used for normal grade of concrete up to M'$8, ,lastering, flooring, grouting of cable ducts in ,4C works etc. !he fineness should be between $$58 and $388 Blaines. "."" #3 grade )PC1 Ht is the most widely used general purpose cement. 1or concrete grades up to M'?8, precast elements. 1or marine structures but C?A should be between 5 ' 3I. Eenerate considerable heat of hydration and therefore not suitable for mass concrete

"."3 23 grade )PC1 1or concrete grade higher than M'?8, ,4C works, bridge, roads, multistoried buildings etc. 1or use in cold weather concreting. 1or marine structures but C?A should be between 5 ' 3I. "."# Portland lag Cement (P C) i.e. )PC 3 granulated slag1 ("2452,) (Blended/Composite) Ht gives low heat of hydration. !he slag should be more than 58I and up to <8I. Ht is used for* Marine and off shore structures' very high chloride and sulphate resistant. 4ewage disposal treatments works Dater treatment plants Constructions which are e(pected to be attacked by dissolved chlorides and sulphate ions. 4hould be mainly used for all future structures. Gquivalent to &,C with added features

"."2 Portland Po66olona Cement1 7 1 1#89(part47) 4 1991 (using fl( ash)1 (12432,) Ht gives low heat of hydration and reduces the leaching of calcium hydro(ide. !his cement should be used only after proper evaluation. !his should be tested as per H4" #J37 -,t H. ; #77#. Ht is used for " 0ydraulic structures' dams, retaining walls Marine structures Mass concrete works' like bridge footings /nder aggressive conditions Masonry mortar and plastering. "."5 :asonar( Cement

>)s K sand K hydrated lime Bricks bonding and plastering "."; <C4 ulphate <esisting Cement1 (C3! = 3,) 4ulphate 2esisting ,ortland cement -C?A. is restricted to lower than 5I and $C?A K CJA1 lower than $5I. !he 42C can be used for structural concrete wherever &,C or ,,C or 4lag Cement are usable under normal conditions Beneficial in such conditions where the concrete is e(posed to the risk of deterioration due to sulphate attack. Contact with soils and ground waters containing e(cessive amounts of sulphate as well as for concrete in sea water or e(posed directly to seacoast. "."8 "."9 <C4 ulphate <esisting Cement1 (C3! = 3,) /nderground and basements structures Dorks in coastal areas ,iles and foundations Dater and sewage treatment plants 4ugar, chemical, and fertiliLers factories ,etrochemical and food processing industries )il %ell Cement !P74> .(pe

 ".3+

!emperature at depths increases beyond #88MC. &,C sets instantly. C?A less than ?I 4etting time 78'#$8 minutes 4hould not set at high temperature Also attain #88 kgs)cmN or more in $J hrs. /sed in ,etroleum Hndustry ?o% alkali lo% heat Cement Best suited for mass concrete obs &ffered in both &,C and ,,C =ational 0ydro ,ower Corporation'Chamera pro ect Bams, piers, larger mass concrete

".31 7< /. #+41982(7ndian <ail%a(s td. pc.)4 pecial >rade Cement 0igh strength cement similar to 5? grade cement < Bays comp. strength ?<5 kgs.)cmN specified. 1ineness ?<88 cmN)gm. Cement shall not e(hibit false set C?A O #8I and C?4 O J5I min. /seful for railway concrete sleeper

".3" @hite Cement Chromium, Manganese, Hron, Copper, 9anadium, =ickel and !itanium impart colour to &,C !he amount of these in white cement is minimiLed as far as possible. Cr$&? is kept below 8.88?I Mn$&? is kept below 8.8?I, and 1e$&? is kept below 8.?5I in the clinker. !he other elements are usually not a significant problem. Paolin in place of conventional clay which is low in silica >imestone 1e$&? content below 8.#I >arge amount of sand must be ground below J5 micron particle siLe Ceramic balls in grinding operation /seful for decorative purpose *Driter has over ?3 years of e(perience in the cement industry heading the Cement ,lants including Quality Control division. 0e retired as Beputy Eeneral Manager -!ech.. at 0olcim 4wiss group -ACC >td.. Hndia and currently works

as Hndependent !rainer ; Euest)9isiting 1aculty. 0e conducted a session at Massachusetts Hnstitute of !echnology -MH!. Cambridge /4A for their eminent faculty and researchers in $8#$ on Cement ,roperties, manufacturing and Quality Control.