Portland, Blended and Other

Hydraulic Cement
Design and Control of Concrete Mixtures – Chapter 3
Overview
 Manufacture of portland cement
 Cement’s role in sustainability
 Types of cement
 Selecting and specifying cement
 Chemistry of portland cement
 Physical properties of cement
 Thermal analysis
 Virtual testing
 Transportation, packaging, and storage
Portland Cement
Portland Cement Manufacture
Manufacturing Process
Manufacturing Process
Manufacturing Process
Manufacturing Process
Cement Kiln
Kiln Reactions
Kiln Reactions
Kiln Reactions
Clinker
Mill Grinding
Cement’s Role in Sustainability
 Alternative Raw Materials
 Land Stewardship
 Solid Waste Reduction
 Energy and Fuel
 Tire-Derived Fuel
Alternative Raw Materials
 Slag
 Foundry sand
 Mill scale
 Fly ash
 Bottom ash
Land Stewardship
Solid Waste Reduction
 Cement Kiln Dust (CKD)
 Recycled into manufacturing process
 Other beneficial applications
 Soil solidification/Stabilization
 Waste solidification/Stabilization
Energy and Fuel

PCA 2009
Tire-Derived Fuel
Types of Portland Cement
 ASTM C150/AASHTO M 85
 Type I  Type II (MH) A

 Type IA  Type III

 Type II  Type IIIA

 Type IIA  Type IV

 Type II (MH)  Type V

Type I
Type II
Type II
Sulfate Resistance by Type

Stark 2002
Sulfate Resistance by W/C

Stark 2002
Type II (MH) and Type IV
Type III
Type V
Air-Entraining Portland Cements
 Type IA
 Type IIA
 Type II(MH)A
 Type IIIA
White Portland Cements
Blended Hydraulic Cements
Blended Hydraulic Cements
 ASTM C595/AASHTO M 240
 Type IS (X)
 Type IP (X)
 Type IT (AX)(BY)
Type IS
 Intergrinding of clinker and granulated slag
 Blending of portland and slag cements
 Combination

 Type IS (<70)
 Type IS (≥70)
Type IP
 Up to 40% by mass pozzolan
 Intergrinding, blending, or combination
Type IT
 Portland cement + 2 SCMs
 Requirements based on dominant SCM
Subcatagories
 A- air-entraining
 MS- moderate sulfate resistant
 HS- high sulfate resistant
 MH- moderate heat of hydration
 LH- low heat of hydration
Performance Based Hydraulic Cements
 ASTM C1157
 Type GU
 Type HE
 Type MS
 Type HS
 Type MH
 Type LH
Applications for Hydraulic Cement
Special Cements
Masonry and Mortar Cements
Plastic Cements
Finely-Ground Cements
Expansive Cements

(Pfeifer and Perenchio 1973).

Oil-Well Cements
 API Specification 10A
 Classes A through H
 Grade O – ordinary
 Grade MSR – moderate sulfate resistance
 Grade HSR – high sulfate resistance
Rapid Hardening Cements
 ASTM C1600
 Type URH
 Type VRH
 Type MRH
 Type GRH
Cements with Functional Additions
 ASTM C226
 Air-entraining additions
 ASTM C688
 Water-reducing
 Set-control
Water-Repellent Cements
 White or gray
 Reduce capillary water transmission
 Do not affect water vapor transmission
 Tile grouts, paint, stucco finish coats, specialty
precast units
Regulated-Set Cements
 Portland-based cement with functional
additions
 Set control
 Early strength development
Geopolymer Cements
 Inorganic hydraulic cement
 Alkali-activated alumino-silicate cement
 Zeolitic or polysilate cement
Calcium Aluminate Cements
 Not portland-based
 Applications:
 Chemical, heat, and corrosion resistant floors
 Repair
 Chemical conversion after placement
Natural Cements
 ASTM C10
 Used for historical restoration
Selecting and Specifying Cements

 Flexibility
 Availability
Canadian and European Cement Specifications
 CSA A3001
 Types GU, MS, MH, HE, LH and HS
 Blended option (b)
 Portland limestone cements (L)
 EN 197-1
 Types CEM I, II, III, IV, and V
Shorthand Notation for Oxides
 Cement chemist shorthand
 A = Al2O3 - alumina
 C = CaO – calcium oxide
 F = Fe2O3 – ferric oxide
 H = H2O - water
 M = MgO - magnesia
 S = SiO2 - silica
 S = SO3 - sulfate
Chemical Phases of Portland Cement
 Clinker phases:
 Tricalcium silicate – C3S
 Dicalcium silicate – C2S
 Tricalcium aluminate – C3A
 Tetracalcium aluminoferrite – C4AF
Chemical Phases of Portland Cement
 Sulfate forms:
 Anhydrous calcium sulfate – CS
 Gypsum – CSH2
 Calcium sulfate hemihydrate - CSH½
Primary Phases
Hydration
Hydration of Cement
Hydration Reactions
Cement Paste
Hydration Products

(adapted from Locher, Richartz, and Sprung 1976) (adapted from Tennis and Jennings 2000).
Composition and Fineness
Reactivity

(Tennis and Jennings 2000).

Calcium Sulfate
 Anhydrite, Hemihydrate, Gypsum
 Reacts with C3A to form ettringite
 Controls C3A setting to prevent flash set
Water (Evaporable and Nonevaporable)
Water (Evaporable and Nonevaporable)
Physical Properties of Cement
 Compressive strength  Consistency
 Setting time  Heat of hydration
 Early stiffening  Loss on ignition
 Particle size and  Density and relative
fineness density
 Soundness  Bulk density
Compressive Strength
Compressive Strength
Compressive Strength

Bhatty and Tennis (2008).

Compressive Strength

(Bhatty and Tennis 2008)

Setting Time

Bhatty and Tennis 2008

Early Stiffening
 False set
 Loss of plasticity without heat evolution
 Can be reversed by continued mixing
 Flash set (Quick set)
 Rapid, early loss of workability
 High heat evolution
 Cannot be reversed without adding water
Particle Size
 Fineness
 Blaine test- ASTM C204
Fineness
Soundness
 ASTM C151
Consistency
Consistency
Heat of Hydration
Heat of Hydration
Heat of Hydration
Heat of Hydration
Loss on Ignition
Density and Relative Density
Bulk Density
Thermal Analysis
Differential Scanning Analysis
Virtual Cement Testing
Transportation
Packaging
Storage
Hot Cement
 Mill grinding raises temperature
 Slow heat dissipation in storage
 May still be hot when delivered
 Tests show effect is negligible
Summary
 Manufacture of portland cement
 Cement’s role in sustainability
 Types of cement
 Selecting and specifying cement
 Chemistry of portland cement
 Physical properties of cement
 Thermal analysis
 Virtual testing
 Transportation, packaging, and storage
Questions