Unit 300984

Pavement Materials and Design

Lecture 3
Cements

Dr Qinghua Zeng
Email: [email protected]

References:
Part 4L Stabilising Binders
Australian Standard: General purpose and blended cements
Types and applications of cements (www.cementaustralia.com.au)1
 Cement
• Cement: an organic or inorganic binder

• Hydraulic vs non hydraulic:

o Hydraulic cement: set and harden when
mixed with water (Portland cement)

o Non hydraulic cement: does not harden

when exposed to water (lime, gypsum)

• Portland cement: a burnt mixture of limestone and

clay, or other materials (e.g., gypsum, fly ash, slag)

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 Production of Portland Cement
• Raw materials:
o calcareous materials: limestone, chalk, marl, sea shells

o argillaceous materials: clay, shale, slate

• Processes:
o Mixing: proportion and mix crushed raw materials
o Grinding: produce fine particles (10-30% under 90µm)
o Burning: materials sinter and partially fuse into clinker in a
rotary kiln (>1400oC)
o Cooling and grinding of clinker: produce fine powder
o Adding gypsum: prevent flash-setting of the cement

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Multiple steps of processes in the production of Portland cement
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(Mamlouk and Zaniewski, 2011)
Chemical change along the kiln in the production
of Portland cement (Midney et al, 2003) 5
 Chemical Composition of Portland Cement
• Oxide composition and its limit
Oxide Content (%)
CaO 60-67
SiO2 17-25
Al2O3 3-8
Fe2O3 0.5-6.0
MgO 0.1-4.0
Alkalis (Na2O, K2O) 0.2-1.3
SO3 1-3
(Neville and Brooks)

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 Chemical Composition of Portland Cement
• Main compounds and their functions
(Mamlouk and Zaniewski, 2006)

H=water,

C3S: contributes to the early strength development of hydrated cement paste

C2S: contributes to the late strength development of hydrated cement paste
C3A: undesirable since it makes hardened cement paste easy to be attacked by
sulfates, but it facilitates the combination of lime and silica during
cement manufacture
C4AF: reacts with gypsum and accelerates hydration of silicates
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 Bogue Equations
• Calculate the percentage of main compounds of
Portland cement from the given percentage of oxides

C3S = 4.07(CaO) – 7.60(SiO2) – 6.72 (Al2O3) –

1.43(Fe2O3) – 2.85(SO3)
C2S = 2.87(SiO2) – 0.754(3CaO.SiO2)
C3A = 2.65(Al2O3) – 1.69(Fe2O3)
C4AF = 3.04(Fe2O3)

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 Hydration of Cement
• Silicates and aluminates of Portland cement react with water
to form hydrates and then hardened cement paste.
o calcium silicate hydrate
2C3S + 6H = C3S2H3 + 3Ca(OH)2
2C2S + 4H = C3S2H3 + Ca(OH)2

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 Hydration of Cement
• Development of structure in Portland cement paste
Initial C-S-H phase

Formation of gels

Initial set
(development of
weak skeleton)

Initial set
(development of
rigid skeleton)

Hardening

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(Hover and Phillco 1990)
 Hydration of Cement
• Hydration is exothermic reaction which generates lots of heat.
o 1/3 of total heat released in 3 days
o 3/4 of total heat released in 7 days
o 90% of total heat released in 6 months

• In mass concrete, the high

level of heat generated must
be removed quickly to
Heat liberation from a setting
prevent internal cracks. cement (Shetty, 2005) 11
 Hydration of Cement
• Development of strength of cement compounds

(Bogue, 1955)
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Schematic representation of the formation and hydration of
Portland cement (Shetty, 2005) 13
 Other Materials in Cement
(1) Supplementary cementitious materials
• Fly ash
• Ground granulated iron blast-furnace slag
• Amorphous silica (fume silica)

Electric furnace for producing

Blast-furnace for making iron
silicon metal and alloys
and steel

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Coal-fired power station
 Other Materials in Cement
(1) Supplementary cementitious materials

Table specified requirements

Property Specification limits
Fly ash (AS3582.1) Slag Amorphous silica
Fine Medium Coarse (AS3582.1) (AS3582.1)
Fineness (<45 µm) >75% >65% >55%
Loss on ignition <4% <5% <6% <3% <6%
Sulfuric anhydride <3% <3% <3% <3%
(SO3)
Sulfide sulfur (S) <1.5%
Moisture content <1% <1% <1% <3%
Magnesia (MgO) <15%
Alumina (Al2O3) <18%
Manganese (MnO) <2%
Total iron (FeO) <1.5%
Total silica (SiO2) >85%
Insoluble residue <2%

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 Other Materials in Cement
(2) Limestone
• CaCO3 <75% is unacceptable
• CaCO3 between 75-80% is acceptable only if:
o clay<1.2%
o total organic carbon (TOC) <0.5%
• CaCO3 >80% is acceptable

(3) Calcium sulfate

• Sources:
o gypsum (calcium sulfate dihydrate, CaS4.2H2O)
o hemihydrate (CaSO4.1/2H2O)
o anhydrite (anhydrous calcium sulfate, CaSO4)
o by-product of industrial processes

• Specified requirement: >30% sulfuric anhydride (SO3)

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 Properties of Portland Cement
• Fineness (particle size)
o affects the rate of hydration, strength gain, and heat
evolution
o Measurement:
(1) sieving method: the percentage passing 45 µm
(2) air permeability: specific surface

• Strength (compressive)
o affected by water/cement (w/c) ratio, cement/fine
aggregate ratio, type and grading of final aggregate,
mixing and molding of specimen, curing conditions,
size and shape of specimen, moisture content, loading
conditions and ageing
o Measurement:
(1) specimen of cement mortar (cement + water + sand)
(2) time to be specified (1, 2, 3, 7, 28, 90 days) 17
 Properties of Portland Cement
• Setting time (the time from a fluid to a rigid state)
o affected by cement fineness, w/c ratio, and chemical
content (e.g., gypsum)
o initial setting time: the paste is beginning to stiffen
considerably and can no longer be molded, about 45
minutes to 1 hour
o final setting time: the cement has hardened to the point
at which it can sustain some load, about 10 hours

• Soundness (hydration expansion of volume after setting)

o Cement unsoundness is mainly caused by the hydration
of crystalline magnesia (MgO), hard-burned calcium
oxide (CaO), or both

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19
 Properties of Portland Cement
• Sulfate expansion (resistance of concrete to sulfate attack)
o Affected by mix design (w/c ratio, cement content),
construction practices (placing, compaction, curing), and
service conditions (type and concentration of sulfates,
duration of exposure, temperature)
o Measurement
(1) curing 7 days prior to exposure to sulfate solution
(2) specimen of cement mortar (cement + water + sand)
with w/c=0.5

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 Types of Cement
• General Purpose cement (Type GP)

• General Purpose Limestone cement (Type GL)

• General Purpose Blended cement (Type GB)

• Special purpose cements, including:

o High Early strength cement (Type HE)
o Low Heat cement (Type LH)
o Sulfate-Resisting cements (Type SR)
o Shrinkage Limited cements (Type SL)

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 Types of Cement
Table 3 Benefits and applications of major cement types.
Type of Benefits Applications
cement
Type GP • High versatility allowing use in• Domestic construction such as concrete slabs,
a wide variety of concrete driveways and footpaths
applications • Structural concrete such as pre-stressed
• Compatible with most slabs, columns and tilt-up walls
admixtures and supplementary • Pavers, blocks, panels and pipes
cementitious materials • Mining applications
• Major engineering and civil projects requiring
cement of high quality and consistency
• Specialty formulations such as adhesives,
renders, mortars and grouts
Type GB • Improved workability and • Domestic construction
pumpability • Major engineering projects
• Reduced water demand • Pre-cast concrete where high durability and
• Enhanced bleed control off-form finish are required
• Lower drying shrinkage and • Stabilisation including pavement recycling for
creep road construction
• Improved resistance to sulfate • Mining applications
attack and chloride penetration • Specialist formulations such as adhesives,
• Reduced potential for Alkali renders, mortars and grouts 22
Aggregate Reaction
 Types of Cement
Table 3 Benefits and applications of major cement types (cont.).
Type of Benefits Applications
cement
Type HE • Permits early stripping and • Suspended slabs – pre-stressed concrete to
faster turnaround times allow for early stressing
• Increased early strengths • Precast and tilt-up operations – buildings,
promoting speed of construction walls
• Allows early use of concrete • Cast-in place construction
applications in load bearing
situations and in cold weather
environments
• Potential reduction in labour
costs, overheads and building
cycle times
Type LH • Assists in minimising the • Constructing dams
potential for thermal cracking in • Large footings, large raft slabs, wind turbine
thick concrete sections plinths
• Significantly improved later-age • Very high strength concrete
concrete strengths
• Improved durability performance
• Increased workability and
pumpability with large pours 23
 Types of Cement
Table 3 Benefits and applications of major cement types (cont.)
Type of Benefits Applications
cement
Type SR • Provides maximum To minimise the risk of chemical attack resulting in concrete
resistance to chloride deterioration and structural failure, Sulfate Resisting
ions - minimising the Cement should be specified in the following applications:
risk of corrosion of • Abattoirs, piggeries, feedlots and food processing plants
reinforced steel • Geothermal areas
• Provides high level of • Sewerage treatment plants
concrete performance • Mines and other acidic soil environments
and structural integrity • Dairying, forestry, fishing and other environments with
in highly aggressive structures susceptible to chemical attack
sulfate and acidic
environments To minimise the risk of chloride induced corrosion in
• Increased workability reinforcing steel and to ensure long-term durability, Sulfate
and pumpability Resisting Cement should be specified in the following
• Significantly improved applications:
later-age concrete • Wharfs and marinas
strengths • Sea walls, dams and reservoirs
• Water and sewage pipelines and treatment plants
• Off-shore platforms
• Bridges and any other submerged structures in tidal24 and
splash zones
 Types of Cement
Table 3 Benefits and applications of major cement types (cont.)
Type of Benefits Applications
cement
Type SL • Assists in minimising drying • Concrete pavements
shrinkage of concrete • Suspended and on-ground slabs
• High level of consistency and • Bridges and overpasses
versatility • Pre and post-tension concrete elements
• Compatible with most admixtures
and supplementary cementitous
materials

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 Types of Cement
Table 1 Major cement types and composition (% by mass).

Cement Portland Type Mineral additionsb Minor additional Supplementary

type cement GPa constituentsc cementitious materials
(SCM)d
Fly ash or Limestone Fly ash Amorphous
slag and/or slag silica
Type GP 92.5-100 - 0-7.5 0-5 - -
Type GL 80-92 - - 8-20 0-5 - -
Type GB - <92.5 - - - >7.5 0-10
a If Type GB cement consists of Type GP and amorphous silica only, the proportion of Type GP
shall be 90% or above.
b For Type GP, the “mineral addition” may comprise limestone, fly ash or slag, or a combination of

these materials.
c The “minor additional constituents” addition forms part of the allowable amount of “mineral

addition” in the cement. The combined maximum of mineral additions and minor additional
constituents is 7.5% for Type GP cement and 20% for Type GL cement.
d Type GB cement may contain SCMs comprising either or both flay ash and slag at combined

level above 7.5%, and amorphous silica at a level not exceeding 10%.

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 Types of Cement
Table 2 Properties of major cement types#.
Type of Setting Soundne Cl SO3 Compressive Peak Sulfate Dry
cement time (h) ss (Max. (Max. strength (Min. temperature expansion shrinkage
%) %) MPa) rise (Max. oC) (Max. (Max.
Min. Max. 3 7 28 microstrain) microstrain)
days days days
Type GP 0.75 6 5 0.1 3.5 - 35 45 - - -
Type GL 0.75 10 5 0.1 3.5 - 20 35 - - -
Type GB 0.75 10 5 0.1 3.5 - 20 35 - - -
Type HE 0.75 6 5 0.1 3.5 25 40 - - - -
Type LH 0.75 10 5 0.1 3.5 - 10 30 23 - -
* *
Type SR 0.75 10 5 0.1 3.5 - - 750 -
* *
Type SL 0.75 10 5 0.1 3.5 - - - 750

#
Test methods of the properties:

•Setting time: AS/NZS2350.4

•Soundness: AS/NZ2350.5
•Cl: AS2350.2/AS3583.13
•SO3: AS2350.2
•Compressive strength: AS/NZS2350.11
•Peak temperature rise: AS2350.7
•Sulfate expansion (16 days): AS2350.14
•Drying shrinkage (28 days): AS2350.13

* Type
SL and Type SR cements shall comply with the strength requirements of either Type GP or Type GB,
depending on the nature of the cement.

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 Admixtures
• Admixture is a material other than cement,
aggregates and water.
• Admixture is added at the time of mixing of fresh
concrete (usually <5% of cement).

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 Admixtures
• Types: mineral admixtures and chemical admixtures

• Purposes of using admixtures

o To increase the workability of fresh concrete
o To accelerate or retard setting
o To reduce bleeding
o To increase the strength of hardened concrete
o To obtain concrete with less permeability
o To increase durability of concrete
o To save money

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 Mineral Admixtures
• Three main categories:
o Pozzolanic materials
o Cementitious materials
o Non-reactive materials (e.g., ground limestone, silica fume,
hydrated lime)

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 Chemical Admixtures
• Chemical admixtures is water soluble compounds.
• Three broad categories:
o Air-entraining agents: added primarily to improve the
resistance of concrete to freezing and thawing
o Set-controlling admixtures: added to control setting or
to induce early hardening
o Plasticizing admixtures: water-soluble polymers
designed to enhance workability by increasing slump, or
to reduce the water requirements for a desired workability

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 Summary
• Production and composition of cements
• Hydration of cements
• Properties of cements
• Types of cements and their applications
• Admixtures

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