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Portland, Blended, and Other Hydraulic Cements Slide 2 Oldest Concrete Found To Date n dates around 7000 BC a lime concrete floor found during the construction of a road at Yiftah El in Galilee, Israel. Slide 3 Portland, Blended, and Other Hydraulic Cements Beginning of the Industry n Portland cement was first patented in 1824 n Named after the natural limestone quarried on the Isle of Portland in the English Channel Slide 4 Portland, Blended, and Other Hydraulic Cements Portland Cement First Produced n North America 1871 Coplay, Pennsylvania n Canada 1889 Hull, Quebec Slide 5 Portland, Blended, and Other Hydraulic Cements Slide 6 Primary Components of Raw Materials Necessary for Portland Cement Manufacture n Calcium n Silica n Alumina n Iron Slide 7 Portland, Blended, and Other Hydraulic Cements CalciumIronSilicaAluminaSulfate 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 Slide 8 Portland, Blended, and Other Hydraulic Cements Quarry Slide 9 Portland, Blended, and Other Hydraulic Cements 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. Slide 10 Portland, Blended, and Other Hydraulic Cements 2.Raw materials are ground to powder and blended. or 2. Raw materials are ground, mixed with water to form slurry, and blended. Slide 11 Portland, Blended, and Other Hydraulic Cements 3.Burning changes raw mix chemically into cement clinker. Slide 12 Portland, Blended, and Other Hydraulic Cements 4. Clinker with gypsum is ground into portland cement and shipped. Slide 13 Portland, Blended, and Other Hydraulic Cements Slide 14 Slide 15 Slide 16 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. Slide 17 Portland, Blended, and Other Hydraulic Cements 2.Raw materials are ground, to powder and blended. Slide 18 Portland, Blended, and Other Hydraulic Cements 3.Burning changes raw mix chemically into clinker. Note four stage preheater, flash furnaces, and shorter kiln. Slide 19 Portland, Blended, and Other Hydraulic Cements 4. Clinker with gypsum is ground into portland cement and shipped Slide 20 Portland, Blended, and Other Hydraulic Cements Slide 21 ClinkerGypsum Slide 22 Portland, Blended, and Other Hydraulic Cements Process of Clinker Production (1) Slide 23 Portland, Blended, and Other Hydraulic Cements (2) Slide 24 Portland, Blended, and Other Hydraulic Cements (3) Slide 25 Portland, Blended, and Other Hydraulic Cements 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. Slide 26 Portland, Blended, and Other Hydraulic Cements Types of Portland Cement INormal IANormal, air-entraining IIModerate sulfate resistance IIAModerate sulfate resistance, air- entraining IIIHigh early strength IIIAHigh early strength, air-entraining IVLow heat of hydration VHigh sulfate resistance ASTM C 150 (AASHTO M 85) Slide 27 Portland, Blended, and Other Hydraulic Cements Slide 28 Performance of Concretes Made with Different Cements in Sulfate Soil Slide 29 Portland, Blended, and Other Hydraulic Cements Performance of Concretes Made with Different W/C-Ratios in Sulfate Soil Slide 30 Portland, Blended, and Other Hydraulic Cements Type II & Type V Sulfate Resistant Cements Slide 31 Portland, Blended, and Other Hydraulic Cements Outdoor Sulfate Test Type V Cement W/C-ratio = 0.65 Type V Cement W/C-ratio = 0.39 Slide 32 Portland, Blended, and Other Hydraulic Cements Moderate and Low Heat Cements Slide 33 Portland, Blended, and Other Hydraulic Cements Type III High Early Strength Cements Slide 34 Portland, Blended, and Other Hydraulic Cements White Portland Cement Slide 35 Portland, Blended, and Other Hydraulic Cements Blended Hydraulic Cement ASTM C 595 General a hydraulic cement consisting of two or more inorganic constituents, which contribute to the strength gaining properties of cement. Slide 36 Portland, Blended, and Other Hydraulic Cements Blended Cements n Clinker n Gypsum n Portland cement n Fly ash n Slag n Silica Fume n Calcined Clay Slide 37 Portland, Blended, and Other Hydraulic Cements Blended Hydraulic Cements Type ISPortland blast-furnace slag cement Type IPPortland-pozzolan cement Type PPortland-pozzolan cement Type I(PM)Pozzolan-modified portland cement Type SSlag cement Type I(SM)Slag-modified portland cement ASTM C 595 (AASHTO M 240) Slide 38 Portland, Blended, and Other Hydraulic Cements Hydraulic Cements ASTM C 1157 n First performance specification for hydraulic cements n Cements meet physical performance test requirements rather than prescriptive restrictions on ingredients or cement chemistry as in other cement specifications. n Provides for six types Slide 39 Portland, Blended, and Other Hydraulic Cements Hydraulic Cement Type GUGeneral use Type HEHigh early strength Type MSModerate sulfate resistance Type HSHigh sulfate resistance Type MHModerate heat of hydration Type LHLow heat of hydration ASTM C 1157 Slide 40 Portland, Blended, and Other Hydraulic Cements Cement specification Cement Applications 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) IIIIVIIV 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 GUMHHELHMSHSOption R Slide 41 Portland, Blended, and Other Hydraulic Cements Special cementsTypeApplication White portland cements, ASTM C 150 I, II, III, VWhite or colored concrete, masonry, mortar, grout, plaster, and stucco White masonry cements, ASTM C 91 M, S, NWhite mortar between masonry units Masonry cements, ASTM C 91 M, S, NMortar between masonry units, plaster, and stucco Mortar cements, ASTM C 1329 M, S, NMortar between masonry units Plastic cements, ASTM C 1328 M, SPlaster and stucco Expansive cements, ASTM C 845 E-1(K), E-1(M), E-1(S)Shrinkage compensating concrete Oil-well cements, API-10A, B, C, D, E, F, G, HGrouting wells Water-repellent cementsTile grout, paint, and stucco finish coats Regulated-set cementsEarly strength and repair Slide 42 Portland, Blended, and Other Hydraulic Cements Special cementsTypeApplication 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 cementsWaste stabilization Sulfur cementsRepair and chemical resistance Rapid hardening hydraulic cement VH, MR, GC General paving where very rapid (about 4 hours) strength development is required Slide 43 Portland, Blended, and Other Hydraulic 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 Slide 44 Portland, Blended, and Other Hydraulic Cements Stucco using Masonry or Plastic Cements Slide 45 Portland, Blended, and Other Hydraulic Cements Finely-Ground Cements Grout penetration in soil Slide 46 Portland, Blended, and Other Hydraulic Cements Expansive Cement Concrete Slide 47 Portland, Blended, and Other Hydraulic Cements Drinking Water Applications Slide 48 Portland, Blended, and Other Hydraulic Cements Chemical Compounds of Portland Cement Slide 49 Portland, Blended, and Other Hydraulic Cements Hydration Products Slide 50 Portland, Blended, and Other Hydraulic Cements Portland Cement Compound Hydration Reactions (Oxide Notation) 2 (3CaOSiO 2 ) Tricalcium silicate + 11 H 2 O Water = 3CaO2SiO 2 8H 2 O Calcium silicate hydrate (C-S-H) + 3 (CaOH 2 O) Calcium hydroxide 2 (2CaOSiO 2 ) Dicalcium silicate + 9 H 2 O Water = 3CaO2SiO 2 8H 2 O Calcium silicate hydrate (C-S-H) + CaOH 2 O Calcium hydroxide 3CaOAl 2 O 3 Tricalcium aluminate + 3 (CaOSO 3 2H 2 O) Gypsum + 26 H 2 O Water = 6CaOAl 2 O 3 3SO 3 32H 2 O Ettringite 2 (3CaOAl 2 O 3 ) Tricalcium aluminate + 6CaOAl 2 O 3 3SO 3 32H 2 O Ettringite + 4 H 2 O Water = 3 (4CaOAl 2 O 3 SO 3 12H 2 O) Calcium monosulfoaluminate 3CaOAl 2 O 3 Tricalcium aluminate + CaOH 2 O Calcium hydroxide + 12 H 2 O Water = 4CaOAl 2 O 3 13H 2 O Tetracalcium aluminate hydrate 4CaO Al 2 O 3 Fe 2 O 3 Tetracalcium aluminoferrite + 10 H 2 O Water + 2 (CaOH 2 O) Calcium hydroxide = 6CaOAl 2 O 3 Fe 2 O 3 12H 2 O Calcium aluminoferrite hydrate Slide 51 Portland, Blended, and Other Hydraulic Cements SEMs of Hardened Cement Paste Slide 52 Portland, Blended, and Other Hydraulic Cements Slide 53 Slide 54 Type of portland cement Chemical composition, % SiO 2 Al 2 O 3 Fe 2 O 3 CaOMgOSO 3 Na 2 O eq I (mean)20.55.42.663.92.13.00.61 II (mean)21.24.63.563.82.12.70.51 III (mean)20.64.92.863.42.23.50.56 IV (mean)22.24.65.062.51.92.20.36 V (mean)21.93.94.263.82.22.30.48 White (mean)22.74.10.366.70.92.70.18 Slide 55 Portland, Blended, and Other Hydraulic Cements Type of portland cement Potential compound composition,% Blaine fineness m 2 /kg C3SC3SC2SC2SC3AC3AC 4 AF I (mean)5418108369 II (mean)5519611377 III (mean)551798548 IV (mean)4232415340 V (mean)5422413373 White (mean)6318101482 Slide 56 Portland, Blended, and Other Hydraulic Cements Reactivity of Cement Compounds Slide 57 Portland, Blended, and Other Hydraulic Cements Nonevaporable Water Contents Hydrated cement compound Nonevaporable (combined) water content (g water/g cement compound) C 3 S hydrate0.24 C 2 S hydrate0.21 C 3 A hydrate0.40 C 4 AF hydrate0.37 Free lime (CaO)0.33 Slide 58 Portland, Blended, and Other Hydraulic Cements Slide 59 Scanning-Electron Micrograph of Powdered Cement Slide 60 Portland, Blended, and Other Hydraulic Cements Fineness of Cement ASTM C 204 ASTM C 115 Slide 61 Portland, Blended, and Other Hydraulic Cements Cement Fineness Slide 62 Portland, Blended, and Other Hydraulic Cements Particle Size Distribution Slide 63 Portland, Blended, and Other Hydraulic Cements Soundness Test ASTM C 151 (AASHTO T 107 ) Slide 64 Portland, Blended, and Other Hydraulic Cements Consistency of Cement Paste ASTM C 187 (AASHTO T 129) Vicat plunger Slide 65 Portland, Blended, and Other Hydraulic Cements Consistency of Mortar ASTM C 230 (AASHTO M 152) and ASTM C 1437 Flow table Slide 66 Portland, Blended, and Other Hydraulic Cements Setting Time ASTM C 191 (AASHTO M 131) Vicat apparatus Slide 67 Portland, Blended, and Other Hydraulic Cements Setting Time ASTM C 266 (AASHTO M 154) Gillmore needle Slide 68 Portland, Blended, and Other Hydraulic Cements Setting Times for Portland Cements Slide 69 Portland, Blended, and Other Hydraulic Cements Mortar Cubes ASTM C 109 (AASHTO T 106) Slide 70 Portland, Blended, and Other Hydraulic Cements Strength Development of Mortar Cubes Slide 71 Portland, Blended, and Other Hydraulic Cements Strength Development Type I and II Cements Slide 72 Portland, Blended, and Other Hydraulic Cements Strength Development Type III, IV, and V Cements Slide 73 Portland, Blended, and Other Hydraulic Cements Slide 74 Slide 75 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 75106 67 89 Slide 76 Portland, Blended, and Other Hydraulic Cements Heat Evolution Slide 77 Portland, Blended, and Other Hydraulic Cements Slide 78 Density of Cement Le Chatelier flask ( ASTM C 188 or AASHTO T 133) Helium pycnometer Slide 79 Portland, Blended, and Other Hydraulic Cements Bulk Density Bulk density of cement varies between 830 kg/m 3 (52 lb/ft 3 ) and 1650 kg/m 3 (103 lb/ft 3 ). Slide 80 Portland, Blended, and Other Hydraulic Cements Thermal Analysis n Thermogravimetric analysis (TGA) n Differential Thermal Analysis (DTA) n Differential Scanning Calorimetry (DSC) Slide 81 Portland, Blended, and Other Hydraulic Cements Differential Scanning Calorimetry Thermogram of a Cement Paste after (a) 15 min and (b) 24 h of Hydration Slide 82 Portland, Blended, and Other Hydraulic Cements Virtual Cement Testing Slide 83 Portland, Blended, and Other Hydraulic Cements Transporting Cement Slide 84 Portland, Blended, and Other Hydraulic Cements Packaging and Storage Slide 85 Portland, Blended, and Other Hydraulic Cements Videos 1/7 Cement Types Manufacturing Cement Slide 86 Portland, Blended, and Other Hydraulic Cements Videos 2/7 Cement Hydration I Cement Hydration II Slide 87 Portland, Blended, and Other Hydraulic Cements Videos 3/7 Cement Hydration Soundness Slide 88 Portland, Blended, and Other Hydraulic Cements Videos 4/7 False Set Setting Time Slide 89 Portland, Blended, and Other Hydraulic Cements Videos 5/7 Cement FinenessCement Strength Slide 90 Portland, Blended, and Other Hydraulic Cements Videos 6/7 Cement Hydration Simulation Slide 91 Portland, Blended, and Other Hydraulic Cements Videos 7/7 Storage Cement Delivery