CHAPTER - 3

Types of cement

There are about 19 types of cement are available and under the 19 th cement namely High
Strength Cement, there are 5 types available.95

3.1 ORDINARY PORTLAND CEMENT - OPC

- Ordinary Portland Cement (OPC) is considered to be the most one among the types of
cement.2

- It is being manufactured by the process of burning limestone which is the siliceous

material at 1400ºC and after burning it is grinded with Gypsum.

- Before the year 1987 there used to be only one grade of Ordinary Portland Cement, with
an International Standard no. of IS 269-1976.

- After the 1987, still better and higher grades of cements were introduced to our country.

- This type of Cement (OPC) can be classified to a three grades system which usually
depending upon on the strength tested at 28 days as per specification of IS 4031-1988.

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 - Grade-33
- Grade-43
- Grade-53

(a) Grade-33:

If the 33 Grade Cement, if tested at 28 days should not be less than 33N/ mm 2
and it is certified by IS 269:1989.

- This ordinary Portland Cement Grade 33 is more useful for-

- Mass concreting of large area

- Cement Concreting in Plain

- Plastering is the most prepared type using this cement

(b) Grade-43:

When strength of cement tested after 28 days with having not less than 43N/mm2, then it
is termed as called 43 grade cement.

- This kind of cement is in very high demand in India.

- The total production of OPC Grade-43 accounts for 50% of the total cement
production in India, as it is used most time by most people
OPC is being used in as below:

- Making of Precasted items like blocks, tiles, pipes, etc.

- Mostly used in the general Civil Engineering Constructions

 - For use in the Reinforced Cement Concrete work.

- It is also used in works like Plastering, Flooring etc.

- It is used in making Asbestos products such as sheets and pipes.

(c) Grade-53:

- This kind of cement, if tested for its the strength at 28 days is not less than 53N/
mm2, This is being certified by IS 12269:1987.

- This grade Cement well is known for its rich quality and long time durability.

This grade cement is used in the Following Applications:

- Used in the pre-stressed Components made of Concrete.

- It is mostly preferred for making Air Runways, ordinary Concrete Roads for public
use and also for making Bridges.

- This cement is used mostly for precast items such as paving blocks, tiles, building
blocks, etc.

- As above this cement is also used for Reinforced cement (RC) concrete work.

The bad point of view is that the manufacturing of OPC tend to decrease all over the world due
as the popularity of blended cement is increasing very speedily, due to

- The blended cement consume Low energy

- It results in less Environmental pollutions

- It is popular due to the cost and other technical reasons.

During the the Year 1998-99, the total cement production in India was 79 million tonnes,
out of which the OPC share was to the tune of 57 million tonnes i.e. 70 % of the total cement
production was OPC.

With increasing technological advancement, now it has become possible to upgrade the
quality of cement through the use of:

- Using high quality of limestone

- Using the advanced and Modern equipments

- By controlling the constituents online

- Through maintenance of size particle with better distribution

- Attempting for finer grinding

- Packing the cement in better method

Though the high grade cement are costlier than the ordinary cement, it is used for
making stronger concrete. When this cement ism used than the low grad one , there can be 10-
20% savings in cement consumption apart form the other hidden benefits.

3.2 RAPID HARDENING CEMENT (RHC):

 - The Rapid Hardening Cement is done which almost similar to Ordinary Portland
Cement96.

- It is again certified with IS 8041-1990 number.

- As it is clear from the name the cement, it suggests Rapid Hardening leading to s higher
rate of development of strength, which is done at the age of 3 days, however, the time taken
for OPC to develop the similar strength is about 7 days.

The Raw Materials used for the Manufacturing of Rapid Hardening Cement is as follows:

- Limestone

- Shale

- Gypsum

- Coke

The Process of Manufacturing of R H C is as Follows:

- First the Limestone and shale are heated at the extremely high temperature which resltsin
cement clinker.

- Then the finely grinded Gypsum is added in small quantity to the cement clinker to
produce Rapid Hardening Cement.

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 So, it is a dry process with which the Rapid Hardening Cement is produced. The
cement should be stored in dry place, if not the quality decreases with slow pause due to
the reason of premature action of carbonation and of hydration.

The Rapid Rate of Development of Strength of RHC is due to-

- The of content C3S is High level and lower level of C2S

- High fitness of grinding of RHC with specific surface must not be not less than 3250
sq.cm per gram.)

Disadvantage of R H C:

- If required a higher fineness of cement particles, then it needs greater surface area for
water to act on.. Due to the presence of the C3S in higher proportion which results in
quicker hydration.

It known that the RHC gives out greater heat due to hydration in the early period
and that was the reason why RHC should not be recommended for the use of mass
concrete construction.

What are the advantages and Uses of Rapid Hardening Cement:

- It is recommended for use where a very high early strength is needed.

- It is used generally for construction of road, pavements, where it becomes essential to

open the road for floating traffic quickly.

- It can safely be used in industries which are manufacturing concrete products like slabs,
electric poles. The advantage was that moulds can be released quickly.
 - It is mostly preferred use for cold weather concreting, as the rapid release of heat during
hydration quickly protects the concrete against freezing.

- It is generally preferable for pre-fabricated concrete construction.

There are many Companies which are in the business of Producing Rapid Hardening Cement:

- ACC cement company

- Gujarat Ambuja cement ltd

- JK Cement company

- Grasim Industries ltd

- Indian Cement Ltd.

These companies cater the needs for the local use as well as for export to other countries.

3.3 EXTRA RAPID HARDENING CEMENT

- It is prepared by adding CCl2 to the rapidly hardening cement. There should be only 2%
of calcium chloride by weight of the Rapid Hardening Cement97.

- Extra Rapid Hardening Cement should not be ventured to be stored for more than one
month.

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Functions of Extra Rapid Hardening Cement:

- ERHC fastens the setting and hardening process very fast.

- After placing, during the early period of hydration, a large amount of heat is evolved in
very short period of time.

Because of its character of quick hardening, it is mostly recommended in the the

process of concreting under the cold weather.

Strength of Extra Rapid Hardening Cement:

- The strength of ERHC is about 25% higher than the strength recorded in the RHC even at
the aging of one or two days.

- When considering the strength of ERHC which is 10-20% higher than the strength of
RHC at the aging of 7 days.

- The dis-advantage of this cement is that the gain of strength disappear with passing age
and thus at age of 90 days, the strength of ERHC becomes almost similar to that of OPC.

- There is a record of a small amount of initial corrosion in the strength of ERHC, but
since, the corrosion is not progressive, the use of ERHC not harmful.

- It is a must if the concrete was made by using ERHC, which must be transported and
placed in compacted within a span of 20 minutes of time.

3.4 SULPHATE RESISTING CEMENT (SRC):

- The sulphate resisting cement is certified by IS 12330:1988.

  Uses of Sulphate Resisting Cement :
To better understand the use of Sulphate Resisting Cement, we must study the process of
Sulphate attack.

- What is called sulphate Attack?

Generally, Sulphate mixes with both of free calcium hydroxide which sets the cement
making calcium sulphate and it reacts with hydrate of calcium aluminate leading the formation
of calcium sulphoaluminate98.

The volume of calcium sulphoaluminateis found to be of 227% of the volume of original

aluminates. Solid Sulphate usually do not attack the cement compound, but Sulphates in the
solution enters into the hardened concrete for attacking the calcium hydroxide resulting the
formation of hydrated calcium aluminate and hydrated silicates, which is called attack of
Sulphate.

- The attack of sulphate tend to increase provided, if it accompanied by alternate wetting

and drying in the structures which are either near or boarder to marine /tidal zones.

- For avoiding the attack, the use of C3A is found to be favourable

- .When Such of the cement have low C3A and as well low of C4AF content then it is
called Sulphate Resisting Cement.

- Silica is the main and high content of Sulphate Resisting Cement.

- C4AF denotes TetracalciumAlumino Ferrite in normal portland cement. C4AF varies

from 6% to 12% and since it is not capable of reducing the Aluminium Oxide (Al2O3) in

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 the raw material. Ferrous Oxide (Fe2O3) can be added to the mixture, to increase the
content of C4AF.

- Under the International Standard Code (ISC), total content of C4AF and C3A should not
be more than 25 per cent.

Where this cement found its Application:

- If the concrete is needed for a marine condition.

- It is used in such concrete for the foundation and basement where the soil is rich in
sulphates.

- This kind of cement is used in fabrication of concrete pipes which are usually buried
inside the marshy areas of soils bearing Sulphate

- It is used in concrete for construction of sewage treatment works.

3.5 PORTLAND SLAG CEMENT

- This come under the certification by IS 455:1989.

 `Production method of Portland Slag Cement.

It is usually obtained through mixing portland cement clinker, gypsum and
granulated blast furnace slag in a suitable proportion and then grinding which
leaves as the mixture99.

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 - Grind the Portland Cement Clinker along with gypsum and add to the granulated blast
furnace separately followed by mixing them thoroughly.

Properties of Portland Slag Cement :

- The physical properties of PSC is much similar to that of ordinary Portland cement.

- Addition, this cement has heat hydration at low.

- It resist the chlorides, soils and water which are containing more of Sulphates or alkali
metals alumina and iron. As well. It is also resistant to acidic waters and hence, can be
used under marine constructions.

Requirement of Portland Slag Cement:

The manufacturing of PSC is process where they utilize the blast furnace slag which is a
waste product from blast furnace.

Benefit of Portland Slag Cement :

The development of PSC has been on the increasing to total cement production output
of in India. It provided a scope for profitable use of a waste product to save economy. During
1998-99, India had produced 10% of PSC to the total cement production.

The variation in the Quantity of Portland Slag Cement- when the the quantity of Portland
Slag Cement is mixed with Portland clinker varies from country to country. About 25% to 65 %
of the quantity of PSC is mixed with Portland clinker and thus quantity may reach up to the
maximum of 85%.

In order to meet the increasing market demand, a separate grinding of each of the
constituent of Portland Slag Cement is done, so as to easily add the slag clinker into the finished
cement.
 Recently, , under the Sewage disposal project at Bandra in Mumbai, where they have
used 70% ground granulated blast furnace slag and along with 30% cement made grout and used
for filling up of the trench around sewer with 3.5 m dia. Which is embedded at about 40m
below MSL.

Characteristics of Portland Slag Cement:

- It is as similar as of the OPC in respect to fitness, time for setting, soundness with
adequate strength.
- The time taken for the hardening of PSC in concrete is slower than that of OPC for the
first 28 days, and afterwards, the rate of hardening of PSC increases. Thus at the age of
twelve months, the strength of PSC becomes similar or even more than that of OPC.

- There is a lower heat of hydration of Portland blast furnace cement as that of OPC. So,
the PSC could be very well used in the large scale concreting schemes.. In cold weather
conditions, the heat of hydration of PSC if low, along with low rate of strength it may
lead to damage due to frost.

Benefits of Portland Slag Cement:

- It reduces the heat of hydration.

- There is well defined refinement of pore structures.

- It reduces the permeability.

- There is increase in resistance to chemical attack.

- PSC exhibits least diffusivity to the chloride ions and such slag cement results in better
resistance to corrosion of reinforced steel.

Problems in the Use of Portland Slag Cement:

 In India, when Portland Slag Cement was first introduced, it was not easily accepted by
the users, because in some products of cement, they do not use right quality of slag.

It was pointed out frequently, that the only glassy granulated slag can be used for cement
manufacturing. To prepare this type of slag first the blast furnace slag is chilled rapidly by
pouring into stream with lots of water in order to prevent it from crystallizing and thus solidifies
it as glass. This product is named as glassy granulated blast furnace slag.
Air-cooled crystallized slag cannot be used for cement preparations.

Application of Ground Granulated Blast Furnace Slag (GGBS):

- The mixture of GGBS and OPC is considered to be equivalent to that of factory made
PSC.

- Making of concrete of with varying properties by varying the proportions of GGBS.

- Generally a combination of 70% GGBS and 30% OPC is preferred for a good quality
GGBS.

- The quality of Resistance to the chemical attack could be enhanced through use of
GGBS in the concrete.

- Resistance to the acid attack can also be enhanced by using GGBS in concrete.

- Resistance to Sulphate and chloride attack may be possible by using GGBS in concrete.

- GGBS concrete is mostly recommended in water retaining structures.

- Risk of resulting early age thermal cracking can also be minimized by the use of GGBS.
 3.6 QUICK SETTING CEMENT100

- As the name suggests, this cement sets very quickly.

- This quick setting property can be achieved by the reduction of gypsum content during
clinker grinding.

- These kind of quick setting of cement is to be mixed, placed and compacted.

Use of Quick Setting Cement

- It is used mostly in under water construction, where, pumping of water is involved, where
it reduces the time taken for pumping and makes it economical.

3.7 SUPER SULPHATED CEMENT

- It is certified under IS 6909: 1990.

Manufacturing Process of Super Sulphated Cement:

It can be manufactured through the process of by grinding the mixture of-

- Slag with 80- 85 % which must be granulated + 10-15 % of gypsum which should be
hard burnt + 5% the clinker of Portland cement.

The product is ground still finer to that of OPC with specific surface is not less than
4000 CM2 per gm101.
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 In BelgiumiIt is extensively used in the name of ―CimentMetallurgiqueSursulfate‖. In
France it is called as ―cimentsursulfate‖.

Properties of SuperSulphated Cement and Applications of Super Sulphated Cement:

- This kind of cement is found to be more sensitive to the reduction process undertaken
during the storage.

- It posses a low heat of hydration of at 40 to 45 calories/gm at the aging of 7 days and 45-
50 calories/gm at 28 days.

- It posses a high Sulphate resistance quality and thus preferred to be used in foundation
where chemically aggressive conditions existing.

- It is also highly resistant to sea water and thus used in marine works.

- Due its resistance to Sulphate, it is being recommended in areas where fabrication of

strong concrete pipes.

- The ratio of water / cement at the time of use of Super Sulphated Cement should not be
less than 0.5 because Super Sulphated Cement combines with more water on hydration.
Wet curing should not be followed more than 3 days after casting as premature drying
results in the formation of undesirable surface which is found to be powdery.

3.8 LOW HEAT CEMENT

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 - LHC is certified by the code of IS 12600:1989.

Manufacturing of Low Heat Cement :

LHC is being made by the addition of Tri-calcium aluminates and Silicate in Ordinary
Portland Cement102.

Advantages of Low Heat Cement:

- It posses a low heat of hydration.

- Hydration in cement is known to be an exothermic action which produces large quantities

of heat which causes cracks on concrete bodies.

Thus Low Heat Cement is particularly suited for making concrete for dams and many
other type of-

- Water retaining type of structures.

- Where it is needed for Bridge abutments.

- Massive retention of walls.

- Slabs for multi-use etc.

In mass concreting programmes, there is often considerable rise in temperature because

of heat produced as the cement sets and hardens. As the cooling of cement is done, shrinkage in
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the concrete sets up tensile stress that cause cracking. Thus here the use of Low Heat Cement
becomes advantageous.

How is the Low Heat Hydration Property is Achieved?

- Through the reduction of the contents of C3S and C3A and increasing the content of C2S,
the property of low heat hydration is achieved.

- When the temperature is reduced leads to retarding the action of of hardening and
produces high rate of heat.

- The specification as prescribed the Indian Standard Institute, the volume of heat of
hydration should be as follows:

- There should be less than 65 calories per gm at 7 days.

- It should be less than 75 calories per gm at 28 days.

Properties of Low Heat Cement:

- There should be more than 3200 sq.cm/ gm specific surface of Low Heat

- The strength of this kind of cement is much low to that of Ordinary Portland

Cement, which is not less than 16 Mp at the age of 7 days

- Other characters such as time for setting and soundness are similar as that of
 Ordinary Portland Cement.

Benefits of Low Heat Cement:

- IT helps in reducing the potential for thermal cracking in thick concrete sections.
- Possess later-age-concrete strengths.

- It has improved durability.

- It has the quality of work ability and pump ability with large pours.

3.9 PORTLAND POZZOLANA CEMENT (PPC)

- This kind of cement is being certified by IS 1489: 1991.

Method of Manufacturing of Portland Pozzolana Cement:

This type of Portland Pozzolana Cement being is manufactured by the inter grading of
Ordinary Portland Cement clinker mixing with 15 to 35 % of pozzolanic material103.

Mow let us know What is Pozzolanic Material?

A pozzolanic material is a siliceous or aluminous material which do not possess any

cementing properties. When the same materials is in the presence of water with of fine
powdered form, readily reacts with calcium hydroxide liberated during the hydration process at

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ordinary temperature. This pozzolanic material forms a compound which possess cementing
property.

The pozzolanic material is useful in the manufacturing of PPC in calcined clay or fly
ash.

Fly ash, as it is known, found to be a waste material produced in the thermal power
station which uses the powdered coal as a fuel. Fly ashes are collected in electrostatic
precipitator.

 Use of Fly Ash:

The Calcium silicate which produce huge quantity of calcium hydroxide which is almost
a useless material considering its strength or long durability. If such useless mass is converted
into a useful cementing product, it improves the quality of concrete. The use of fly ash plays
such a very dominating role.

 Properties of PPC:
- The PPC produces lower rate of heat on hydration.

- It offers superior resistance to the attack by forceful waters.

- The quality of the PPC is that it reduces the leaching of calcium hydroxide when the
same is used in hydraulic structures.

- PPC is found to be useful in marine as well as in and hydraulic constructions, including

mass concrete constructions.

- The strength of PPC is expected to be similar to that of OPC only when at the later ages
provided, when the concrete is cured under the moist condition for a sufficient period of
time.
 - If the PPC is the manufactured by using the right quality and type of pozzolanic material,
the PPC can be inferior to OPC in any way except for the rate of development of strength
up to 7 days.

Advantages of Portland Pozzolanic Cement:

Portland Pozzolanic Cement is useful and can be replaced at all places, wherever, the
OPC is used. In fact, technically PPC is found to be more advantages than OPC when made by
using optimum percentage and right quality of fly ash or pozzolanic material. Following are the
advantages of PPC:

- Portland pozzolanic cement is reported to be more economical as the clinker which used
usually is costly and here it is replaced by cheaper pozzolanic material which is very
cheap.

- PPC with more of permeability quality, the reason being that the soluble calcium
hydroxide is converted into insolublecementing products. It gives long durability, under
the marine and hydraulic constructions.

- PPC and OPC are almost similar in the production of calcium hydroxide.

- PPC produces a very low heat of hydration compared to other cements .

- PPC due to the presence of pozzolanic action and additionally being finer than OPC
improves distribution of the pore size and reduces the micro cracks at transition zone.
 - As the fly ash is finer and of low in density, PPC gives more volume of mortar than OPC.
The PPC os considered for its bulk volume rather than the OPCin the 50kg bags.

- The long term strength of PPC through couple of months is higher than that of OPC,
provided, if enough moisture is available for continued pozzolanic action.
- The possession of increased permeability of PPC increases the resistance to corrosion.

The above stated advantages are due to mainly slow conversion of calcium hydroxide

into cementing product in the hydrated cement paste.

In one of the investigation it was found that 20 % calcium hydroxide was present in one

Disadvantages of PPC:

- The rate of development of strength is found to be initially slower than that of OPC.

- Reduction in alkalinity helps in reduction of the resistance to corrosion of steel strength.

- The setting time of PPC is much longer.

Currant Status of PPC in India:

The 75 thermal power stations located over all through India. They produce over sixty
million tons of fly ash from all the stations, however, the quality of such fly ash is un-
satisfactory for the production of PPC.

In Western Countries, the fly ashes out of the thermal power plants are further processed
to make it more suitable for the manufacture of PPC.
 In India due to lack of awareness on the poor quality of fly ash, PPC is not much popular
as compared to other types.
During the year 1998-1999, out of the total cement production, 19 % was that of PPC
and 10 % slag cement. Experts have recommending to muse more of blended cement for
sustainable development of any country.

The Government of India has established a mission mode organization called ―FLY ASH
MISSION‖ for the promotion of the use of fly ash in the manufacture of PPC.

Industries Producing PPC in India:

In India, for the reason of shortage of electrical power, many of the cement industries
have set up their own thermal power plants installed to cater their immediate needs. They use
their own fly ash for manufacturing PPC. These industries take special care to produce fly ash of
good quality. The PPC thus produced by these industries have superior physical and chemical
properties that could match the BIS Standard.

Some of these Companies Using PPC are:

- Birla Plus Industry

- Silicate Cement Industry

- Birla Bonus Industry

- Suraksha Industry

How Grading of PPC is done:

 - In many countries PPC is graded similar to that of like OPC, however, depending upon
the strength at 28 days.

- In India, PPC is almost termed to be equal to the 33 Grade of OPC and some brands of
the PPC, which are considered to be as good as 53 Grade OPC.
- Many cement manufactures have requested BIS to grade PPC like OPC and keep the
limit specified as upper on the fly ash content is from 25% to 35%.

- Now the BIS has enhanced the standard of fly ash content in PPC from 10-25% to 15-
35%.

Application of PPC:

- PPC can be put to use wherever OPC is used, except at places where early high strength
is required.

- PPC requires sufficient quantity of moisture for continued pozzolanic activity. So the
longer curing is the longer is the desirable.

PPC is suitable for following applications:

- For hydraulic structures to be errected.

- For mass concrete structures like dam, bridge and even for thick foundation.

- For marine structures.

- For use in sewage disposal works.

 - Under water aggressive conditions.

- For even to masonry mortars and plastering.

3.10 AIR-ENTRAINING CEMENT

There is no record of certification by ISI to the Air Entraining Cement.

This kind of cement is made by mixing with agent which allows Air-entraining with
Ordinary Portland Cement clinker at the time of grinding104.

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The below given are the various air-entraining agents can be used:

- Alkali salts of wood resins.

- detergents of alkyl- aryl sulphonate type of synthetically made.

- Calcium lingo sulphate which is obtained during the process of sulphite in paper making.

- Calcium salts of glues and other some kind of proteins used in the treatment of animal
hides.

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 - Additives such as animal and vegetable fats, oil and their acids can also be used
successfully.

- Wetting agents like aluminium powder and hydrogen peroxide can be used.
It is to be noted that the above agents are used in powder or liquid forms to an extent of
Only 0.025-0.1% by weight of cement clinker.

 Characteristics of Air-Entraining Cement:

- During the mixing Air-Entraining Cement, it produces tough, which is tiny, a discrete
non-coalescing air bubbles on the body of concrete.

- These air bubbles can modify the quality of concrete on its workability, etc

- Thus the air bubbles could modify the properties of hardened concrete in respect of
resistance to frost action.

3.11 COLOURED CEMENT (WHITE CEMENT)

- White cement is certified under IS 8042:1989.

 Manufacturing of White Cement:

The types of Raw Materials needed for the production of white cement are105:

- Limestone which contains 96% CaCo3 and iron oxide of less than 0.07%.

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 - China clay with iron content of apprximately 0.72-0.8%.

- Silica Sand

- Iron ore

- Nickel

- Titanium

- Chromium

- Vanadium

- Fluorspar as flux

- Selenite as retarder

- Sea shells and coral

- Refined furnace oil as fuel

 Availability of Raw Material:

Particular type of limestone required for the production of white cement is available only
around Jodhpur of Rajasthan state, where two famous brands Birla White and JK White Cements
are manufactured and distributed.

 Properties of White Cement:

 - The properties of white cement are almost similar to that of OPC.

- White cement is ground finer than that of then grey cement.

- Strength of white cement is found to be much higher than that was recorded in IS Code
8042 of 1989.

- As per the ISI standard scale, whiteness of the white cement should not be less than
70%.

- The Hunters scale Value of the whiteness of white cement is generally 90%.

White cement are produced by many companies including ACC cements, JK Cement etc.

 Major Countries where White Cement is Exported from India are:

The white cement is regularly exported to many foreign countries.

 Application of White Cement:

The white cement is considered to be the best for the construction of Architectural
Projects, other Decorative Works, structures where vibrant colours are deemed good.

3.12 HYDROPHOBIC CEMENT

- This cement is certified by IS 8043-1991.

Manufacturing of Hydrophobic Cement

Hydrophobic cement is produced by grinding the OPC clinker with substances of water-
repellant which forms a film of acid of oleic and stearic. The water-repellant film around the
cement particle reduces the quality of cement storage and transporting or during the other un-
favourable conditions106.

The water-repellant film entrains certain amount of air in the concrete that helps to
improves the work ability of concrete. The film is broken out during the mixture of OPC clinker
and above named acid is put in the mixer to exposing the cement particle for normal hydration
process.

After grinding the OPC clinker, the particles of cement is applied as spray in one
direction and film forming of acid of oleic and stearic, or pentachlorophenol, or calcium oleate
from another direction in such a way that every cement particle is coated with a very thin film of
water repellant material.

 Properties and Advantages of Hydrophobic Cement:

- The natural properties of hydrophobic cement are the similar to that of OPC except that it
contains a small quantity of air bubbles, which increases the work ability of concrete.

- Hydrophobic cement do not lose its strength like Ordinary Portland Cement in
unfavourable conditions too.

- The water repellant film of hydrophobic cement protects from the bad effect of moisture
during the storage and transportation.

3.13 MASONRY CEMENT

- This cement is certified by IS 3466:1988.

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  Manufacturing of Masonry Cement:

Masonry Cement is made of by the combination materials with such qualities that when
this combination taken for mortar, which retains all properties of lime and removes all the ill
properties of cement mortar. Masonry cement also contains some quantity of air-entraining
agent and mineral mixtures for improving the plasticity and water receptivity107.

 Properties and Application of Masonry Cement:

With respect to ordinary mortar, lime mortar has more of strength and setting properties.
It has the workability, water retention capacity and shrinkage property along with extensibility.
Masonry cement, as the name suggests, is used for masonry construction mostly.

3.14 EXPANSIVE CEMENT

 Why Invention of Expansive Cement:

Generally concrete is made with Ordinary Portland Cement, which shrinks while setting
due to loss of free water. Besides, during the process of drying, shrinkage takes place in which
the concrete shrinks continuously for a long time. The property of shrinkage of cement proves to
be a disadvantage for grouting anchor bolts and grouting of machine foundations. Hence, here it
is better to use such type of cement which does not shrinks while hardening and thereafter108.

This is the actual requirement for the invention cement for grouting machines such cement which
undergoes no change in volume after drying is called Expansive Cement.

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sheet.pdf?sfvrsn=4

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  Manufacturing of Expansive Cement:

It is made by using an expanding agent along with a stabilizer. Sulphoaluminate clinker

at 8-20 parts is mixed with 100 parts of Portland cement and 15 parts of stabilizer as combination
of mixture Besides, this controlled curing of cement is also necessary since expansion takes
place during the long time as long as the concrete is moist. Thus manufacturing of expansive
cement truly requires the sufficient amount of skill and the needed experience.

 Types of Expansive Cement:

Some of the types of costly cement are-

(a) Shrinkage Compensating Cement is used in concrete when it induces compressive stress
which offsets the tensile stress due to the srinkage.

(b) Self Stressing Cement: This cement creates compressive stress after drying shrinkage
which gives some sort of pre-stressing effect in the tensile.

3.15 SPECIAL GRADE CEMENT – IRS- T 40

It is prepared following the directions of Indian Railways under IRS - T40:1985 with
C3S content109.

 Advantages and Applications:

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 - It is designed such a way that it develop high early strength. Thus it is used at places
where high early strength concrete is required, such as railways

- It is used in the manufacture front of concrete sleeper for Indian Railways.

- It is used pre-stressed concrete elements.

- It is also used for high rise buildings and high strength concrete such as multi-storied
buildings.

3.16 OIL WELL CEMENT (OWC)

- It is certified by IS 8229:1986.

- This cement is used mostly in Oil Wells.

 Manufacturing of Oil -Well Cement:

It is manufactured from clinker of Portland cement and also from cement which has been
hydraulically.

Raw materials needed for production of Oil Well Cement are:

The following are the raw materials such as Limestone, Iron Ore, Coke, Iron scrap,

 Procedure:
 Where Oil Wells are drilled deeply through sedimentary rocks. There can be seen a
space between steel casing and rock formation in the oil well. The slurry used as seal off the
gaps in rock formation. Also used for to sealling the other fissures and cavities in the
sedimentary rock layer in order to prevent the escape of oil or gas from the annular space. The
cement slurry has to be pumped in such a position at such a depth, where the prevailing
temperature may be up to 175ºC and the pressure required may go up to 1300 kg/cm2. This type
of cement slurry is pumped to seal the cavities found in the oil well, hence these cement is called
Oil Well Cement110.

 Properties of Oil Well Cement:

- This kind of cement resist both high pressure and temperatures.

- The setting is slow, as it contains organic retarders prevent fast setting.

- This cement slurry is made as sufficiently as mobile which will flow to cover all cavities for
several hours and then hardened rapidly.

- This cement resist corrosive condition from Sulphur gases or from water dissolved salts.

 The best Properties of Oil-Well Cement can be Obtained by Following Ways:

- the retarders is added into ordinary portland cement and the agents used as retards are:
Starches,Cellulose products, Acids.

These agents blocks quick setting and maintain for mobile condition favouring
penetration of slurry to all fissures and cavities.

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 - Sometimes there is added some workability increasing agents to increase the mobility of
cement slurry, by adjusting the composition of compound of cement.

 Grading of Oil-Well Cement:

The following are the three grades of Oil Well Cement available:

(a) Grade -O – It is the ordinary cement and used very commonly.

(b) HSR - It has got the high level of Sulphate resistant.

(c) MSR - It has a moderate Sulphate resistant character.

Each type of the OWC grade cement is used as per the requirement for a particular range of
Sulphate environment, temperatures, pressures and depths of oil well.

 Benefit of Oil Well Cement:

It is very much in use and beneficial for the petroleum industries.
Companies manufacturing Oil Well Cement in India are:
- ACC cement ltd

- Gujarat Ambuja ltd

- India Cement Ltd.

- JK Cement ltd

- Grasim Industries ltd

- Ultra Tech. ltd

3.17 REDISET CEMENT

Reason for the Invention of Rediset Cement:

As discussed earlier, many types of admixtures were used to prepare different types of
cement to meet the growing demand for sector the sectors such as infrastructure development.

For e.g. high alumina cement, though, found to be good for early strength, but it shows
gradual decrease in strength when exposed to hot and humid conditions. This posed a big
question for the concrete industry as to how to repair the concrete roads and pavements rapidly
with out loss of time111.

In the PCA of USA, they have investigated on cement which could give high strength in
few hours without showing any such retrogression as stated in above example. Thus-

―REDISET‖ Cement was the result of investigation in USA. The Associated Cement
Company in India developed similar to that of above cement and named it as ―REDISET‖
Cement.

 Properties of “Rediset” cement:

- It allows a short handling time of with in only eight to ten minutes.

- Its strength found to be as similar as to that of OPC concrete after one day or three days.

The strength that is achieved by using the normal concrete after seven days, the same

strength can be achieved with Rediset in just three to six hours.

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 - Since, Rediset releases a lot of heat after laying, which is in-fact advantageous in winter
concreting.

- Rate of shrinkage is the fastest in this cement, but, the total shrinkage is similar to that of
OPC concrete.

- The only negative point is that sulphate resistance of Rediset is very poor.

 Applications of “REDISET” Cement:

- It is useful for repairing of patch work and emergency repairs.

- Useful for palletization of iron ore dust.

- Useful for slip formed concrete construction sectors.

- Useful to undertake construction between tides.

- Useful where the need for high early strength (three to four hours) concrete and mortar.

- Useful for quick release of forms in the pre-cast concrete products.

3.18 HIGH ALUMINA CEMENT

- It is certified under the code IS 6452:1989.

 Manufacturing of High Alumina Cement:

 - This kind of high Alumina Cement is obtained through mixing of alumina with
calcareous in proportions followed by grinding which leaves to a fine powder112.

 Procedure for making High Alumina Cement:

- The raw materials such as limestone and bauxite are included into the furnace along with
coke as fuel. The furnace is heated using with coal or other suitable materials. The fusion
readily takes place in temperature between 1550º to 1600º C. The cement is in liquid state
which is maintained in the furnace. Then the molten cement is cooled and taken for into
moulds. These casting is called Pigs. After cooling, the cement turn to the shape of a
dark fine grey compact rock, and resembles as basalt rock. The pigs are crushed when
cool powdered in about 3000 sq.cm/gm.

 Properties of High Alumina Cement:

- It is highly refractory, which is not easily controlled.

- It has low pH.

- It remains in high durability in sulfuric acid.

- The hardening takes place rapidly.

- It is somewhat less reactant than that of alumina or hydraulic lime.

- It forms into ceramic bonds at the high temperature and thus acts as bonding material
when added in refractory cartable.

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 - It possess a high resistance to chemical corrosion, hence, it is widely used in
construction of water pipes, sewage pipes, factory drains, coastal and marine
constructions and used as well in factory chimneys.

 Hydration of High Alumina Cement:

During the setting of High Alumina Cement an important reaction takes place, resulting
in the formation of –

1. As Monocalcium aluminate decahydrate (CAH10 )

2. As Dicalcium aluminate octahydrate (C2 AH8 )

3. As Alumina gel (AHn):

These aluminates are the causes for the high strength to High Alumina Cement concrete
but they are meta-stable and at the normal temperature it converts into more stable product such
as :

(a) Gibbsite and

(b) Tricalcium Alumina Hexahydrate (C3AH6) – These are more stable.

The changes that took place in composition directly reduces the strength of High Alumina
Cement concrete. With the release of water, the crystal which is like a hexagonal form changes
to cubical form resulting in to the increased porosity of concrete. These e above changes are all
depended upon the temperature, water, cement ratio and chemical environment, this change in
the chemical composition is called conversion. Various experiments suggest that the temperature
plays a dominant role in the conversion. Higher the temperature faster is the rate of conversion.
Higher the cement water ratio, greater is the rate of conversion.

3.19 HIGH STRENGTH CEMENT

3.19.1 Macro-defect-free Cement (MDF):

The innovation attempted on the high strength cement resulted in the production of
Macro-defect-free cement (MDF).

Many defects are present in conventional mixed cement pastes, due to the
entrapped air and results insufficient dispersion. Such defects tend to limit the strength of
concrete. Whereas, Macro-defect-free (MDF) contains no such defects113.

In the manufacturing process of Macro-defect-free (MDF)

One of the water-soluble polymers like- hydroxypropylmethyle cellulose or

polyacrylamide of hydrolysedpolyvinlacetate@ 4-7% is added to allow the cement to be mixed
with very small quantity of water, which Controls the particle size for evenly distribution. The
entrapped air is removed by the application of a modest pressure of 5 Mpa.

3.19.2 Densely Packed System (DPS):

After a continues research, the high strength cement resulted in the production of
a new material called Densely Packed System (DPS). It contains homogeneously
arranged ultra-fine particles.

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Manufacturing process of Densely Packed System-

- With Normal Portland cement the ultra-fine silica fume is mixed. The size of Particles of
the Portland cement should be from 0.5 to 100 and that of Silica fume varies from 0.005
to 0.5. Silica fume is added at 5 to 25 %. A compressive strength of 270 Mpa has to be
achieved with silica fume substituted paste.

3.19.3 High Early Strength Cement:

The requirement of high early strength of concrete becomes imminent. Sometimes this
kind of cement is needed for emergency repairs. This requirement has lead to the development of
rapid setting and hardening of cement which gives to give materials very high early strength.

Before 1970, there existed an uncertainties for the strength of hydrated cement paste.
The potential strength of cement paste could not be achieved due to considerable porosity after
hydration of cement. This defect led to the innovation of new approach called ―Warm Pressing‖
method to develope high strength of cement concrete114.

Warm Pressing Method: It is the method wherein the heat and pressure are applied at the
same time to the cement paste. In some cases, the strength of cement concrete was gained by
applying pressure alone. Warm pressing Portland cement and calcium aluminate cement both
have the compressive strength of 650 Mpa and tensile strength of about 68 Mpa.

For the manufacture of high early strength cement,

- The porosity which is occurring is to be removed.

- Homogeneous and very fine micro structure having a porosity as low as 1-7% are
generated.

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 - Lithium salts are used as accelerators, resulting in high early strength of cement and a
marginal decrease in the later strength.

Strength as high as- 04Mpa in 1 hour and it will be 27 Mpa in 3 hours, which goes to 49
Mpa in 1 day.

3.19.4 Magnesium Phosphate Cement (MPC):

- Magnesium Phosphate Cement has been developed by an organization which is called

the Central Road Research Institute located at New Delhi.

- Magnesium Phosphate Cement is considered to the an advanced cementing material.

- In the manufacturing of Magnesium Phosphate Cement, dead burnt magnesite (DBM)

mixed with fine aggregate phosphate115.

Process of manufacturing of Magnesium Phosphate Cement :

- To produce dead burnt magnesite, first magnesite (MgCO3) is heated at or

above 1500ºC temperature. Thereafter, dead burnt magnesite is ground to
a fineness of 300-350 m2/kg. The finely powdered dead burnt magnesite
is mixed with the following ingredients such as :

- Finely ground Mono Ammonium Phosphate.

- Finely powdered sodium tri-polyphosphate.

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 - Finely powdered di-sodium tetraborate (Borax).

- Crushed dolomite sand as a fine aggregate.

- Water.

For repair purpose the dead burnt magnesite and sand mixture is added into cold
phosphate and along with borax solution (at 12–15ºC) and a allowed for mixing for one minute.
This mixture is for air cured and is ready for opening traffic within 4-5 hours.