Cement Specifications

STANDARD METHODS OF TEST AND SPECIFICATIONS FORCEMENT, WATER & SP

Lecture by:

G. K. Tike’, Scientist E-II,& Head

Rigid Pavements Division, CRRI

What is cement? How it is manufactured? 1/26

BUILDER’S CEMENT

IS AN INORGANIC GREY COLOURED FINE POWDER CAPABLE OF REACTION WITH WATER TO PRODUCE STRENGTH GIVING COMPOUNDS, WHICH SET AND HARDEN WITHOUT ANY APPRECIABLE CHANGE WITH REGARD TO ITS PROPERTIES IN COURSE OF TIME

PORTLAND CEMENT CLINKER

IS PRODUCED BY BURNING AT ABOUT 1200 O TO 1450 O C A MIX OF - CALCIUM CARBONATE (LIMESTONE OR CHALK) AND

AN ALUMINOSILICATE(CLAY OR SHALE)

LSF = CaO

2.80 Si O2 + 1.18 Al2O3 + 0.65 Fe2O3

What is cement? How it is manufactured? 2/26

ASH FROM THE COAL INSOLUBLE RESIDUE I R;

“WHITE CEMENT CLINKER”, THE RAW MEAL IS TOTALLY IRON-FREE; IRON-FREE; GAS OR FURNACE OIL FIRED SYSTEM

C3S, C2S, C3A, C4AF ALONG WITH SOME PERICLASE IN CLINKER FORM

INTER-GRINDING GYPSUM WITH CLINKER TO NEUTRALIZE THE C3A

CaSO4.2H2O IS GYPSUM AND CaSO4. ½H2O IS PLASTER OF PARIS

COMPOSITION OF PORTLAND CEMENT3/26

OxidesGrey

Cement Clinker% %

WhiteClinker%

Factors GreyCement Clinker

WhiteClinker

Si O2 18-24 21.7 23.8 LSF % 88-102 98.4 97.2Al2 O3 4-8 5.3 5.0 LCF % - 96.2 93.8Fe2 O3 1.5-4.5 2.6 0.2 S/R 1.5-4 2.7 4.6Total CaOIncl. FreeLime

62-67 67.7 70.8 A/F 1-4 2.0 25

MgO(max. limit)

0.5-4.0 1.3 0.08 C3S % - 65.4 59.4

K2 O 0.1-1.5 0.5 0.03 C2S % - 12.9 23.5Na2 O 0.1-1.0 0.2 0.03 C3A % - 9.6 12.9S O3

(max. limit)2.0-3.0 0.7 0.06 C4AF % - 7.9 0.6

LOI(max. limit)

3.0 - -

IR(max. limit)

1.5 - -

Free Lime 0.5-1.5 1.5 2.5

COMPOSITION OF PORTLAND CEMENT 4/26

LOI = LOSS ON IGNITION (CO2 + H2O);

IR = ACID INSOLUBLE RESIDUE;

S / R = Si O2 / (Al2 O3 + Fe2 O3 );

A/ F = Al2 O3 / Fe2 O3 ;

LSF = LIME SATURATION FACTOR

LCF = LIME COMBINATION FACTOR.

BOUGE EQUATIONS 1955; WEIGHT % OF EACH OXIDE

C4AF = 3.04 Fe2 O3

C3A = 2.65 Al2 O3 – 1.69 Fe2 O3

C2S = 8.60 Si O2 + 1.08 Fe2 O3 + 5.07 Al2 O3 – 3.07 CaO

C3S = 4.07 CaO – 7.60 Si O2 – 1.43 Fe2 O3 – 6.72 Al2 O3

COMPOSITION OF PORTLAND CEMENT 5/26

33 GRADE 43 GRADE 53 GRADE LOW

ORDINARY MEDIUM HIGH HEAT

(IS : 269) (IS: 8112) (IS : 12269) ( IS: 269)

C3S 45 % 50 % 55 % 30 %

C2S 27 % 22 % 17 % 46 %

C3A 11 % 11 % 11 % 5 %

C4AF 10 % 10 % 9 % 13 %

WHAT IS UNDERSTOOD BY CHARACTERISTIC PROPERTIES OF CEMENT? 6/26

• FINENESS, (m 2 / kg)

• WATER FOR NORMAL CONSISTENCY, (%)

• INITIAL AND FINAL SETTING TIME, (min.)

• STRENGTH, (COMPRESSIVE - 3 , 7, 28 DAY) (N /mm 2 )

• DRYING SHRINKAGE, (%)

• SOUNDNESS, (PASS / FAIL)

• PERMEABILITY, ( ml / cm / sec.)

IS: 4031 – 1988 INDIAN STANDARD METHODS OF PHYSICAL TESTS FOR HYDRAULIC CEMENT

7/26

PART 1 DETERMINATION OF FINENESS BY DRY SIEVING (FIRST REVISION) FIRST REPRINT APRIL 1992

PART 2 DETERMINATION OF FINENESS BY SPECIFIC SURFACE BY AIR PERMEABILITY METHOD (FIRST REVISION) FIRST REPRINT MARCH 1992

PART 3 DETERMINATION OF SOUNDNESS (FIRST REVISION) FIRST REPRINT NOVEMBER 1991

PART 4 DETERMINATION OF CONSISTENCY OF STANDARD CEMENT PASTE (FIRST REVISION) FIRST REPRINT AUGUST 1993

PART 5 DETERMINATION OF INITIAL AND FINAL SETTING TIMES (FIRST REVISION) FIRST REPRINT NOVEMBER 1991


8/26

PART 6 DETERMINATION OF COMPRESSIVE STRENGTH OF HYDRAULIC CEMENT OTHER THAN MASONRY CEMENT (FIRST REVISION) FIRST REPRINT JUNE 1992

PART 7 DETERMINATION OF COMPRESSIVE STRENGTH OF MASONRY CEMENT (FIRST REVISION) FIRST REPRINT MARCH 1992

PART 8 DETERMINATION OF TRANSVERSE AND COMPRESSIVE STRENGTH OF PLASTIC MORTAR USING PRISM (FIRST REVISION) FIRST REPRINT JANUARY 1993

PART 9 DETERMINATION OF HEAT OF HYDRATION (FIRST REVISION) FIRST REPRINT AUGUST 1993

PART 10 DETERMINATION OF DRYING SHRINKAGE (FIRST REVISION) FIRST REPRINT AUGUST 1993


9/26

PART 11 DETERMINATION OF DENSITY (FIRST REVISION)

PART 12 DETERMINATION OF AIR CONTENT OF HYDRAULIC CEMENT MORTAR (FIRST REVISION) FIRST

REPRINT MARCH, 1992.

PART 13 MEASUREMENT OF WATER RETENTIVITY OF MASONRY CEMENT (FIRST REVISION) FIRST REPRINT SEPTEMBER 1992

PART 14 DETERMINATION OF FALSE SET (FIRST REPRINT JANUARY 1993)

PART 15 DETERMINATION OF FINENESS BY WET SIEVING (FIRST REPRINT JULY 1994)

IS:2386-1983 INDIAN STANDARD METHODS OF TEST FOR AGGREGATES FOR CONCRETE 10/26

• PART - I: PARTICLE SIZE AND SHAPE• PART - II: ESTIMATION OF DELETERIOUS MATTER• PART - III: SPECIFIC GRAVITY, DENSITY, VOIDS AND

BULKING• PART-IV: MECHANICAL PROPERTIES

• PART - V: SOUNDNESS• PART - VI: MEASURING MORTAR MAKING PROPERTIES

OF FINE AGGREGATES• PART - VII: ALKALI AGGRGATE REACTIVITY• PART - VIII: PETROGRAPHIC EXAMINATION

IS: 2386-1963 [PART-III] SPECIFIC GRAVITY, DENSITY, VOIDS, ABSORPTION AND BULKING 11/26

SPECIFIC GRAVITY= OVEN DRIED WT

[SSD WT IN AIR- SSD WT IN WATER]

APPARENT SPECIFIC GRAVITY = OVEN DRIED WT

OVEN DRIED WT - SSD WT IN WATER

WATER ABSORPTION = 100 X [SSD WT IN AIR-OVEN DRIED WT]

OVEN DRIED WT

BULK DENSITY = WT/ VOLUME IN kg / liter

VOIDS % = [SPECIFIC GRAVITY- BULK DENSITY] X 100

IS: 2386-1963 [PART-IV] MECHANICAL PROPERTIES12/26

AGGREGATE CRUSHING VALUE=

[Fr. PASSING 2.36mm] x 100

WT OF AGGREG. SAMPLE

10% FINES VALUE, LOAD REQD. TO PRODUCE 10 % FINES=

[14 x x] where x = load in tonnes, and

[y + 4] y = mean % of fines at

x- tonnes load

AGGREGATE IMPACT VALUE =

[Fr. PASSING 2.36mm] x 100

WT OF SAMPLE

AGGREGATE ABRASION VALUE [LOS ANGELES] =

[WT OF SAMPLE - WT RET. ON 1.70mm] x 100

WT OF SAMPLE

QUALITY SPECIFICATION OF WATER FOR MIXING & CURING IS: 456- 2000 Indian Standard Plain and Reinforced Concrete – Code of Practice 13/26

A)TO NEUTRALIZE 100 ML OF SAMPLE, USING PHENOLPHTHALEIN INDICATOR, SHOULD NOT REQUIRE MORE THAN 5 ML OF 0.02 NORMAL NaOH SOLUTION [DETAILS ARE AS PER IS 3025 (PART 22).]

B)TO NEUTRALIZE 100 ML OF SAMPLE, USING MIXED INDICATOR, SHOULD NOT REQUIRE MORE THAN 25 ML OF 0.02 NORMAL H2SO4 SOLUTION [DETAILS ARE AS PER IS 3025 (PART 23).]

C) PERMISSIBLE LIMITS OF SOLIDS –

SL. TESTED AS PER PERMISSIBLE LIMIT, MAX.

NO.

1. ORGANIC IS 3025 (PART 18) 200 mg / l

2. INORGANIC IS 3025 (PART 1) 3000 mg / l

3. SULPHATES (AS SO3) IS 3025 (PART 24) 400 mg / l

4. CHLORIDES (AS CL ) IS 3025 (PART 32) 2000 mg / l for concrete not containing embedded

steel and reinforced concrete work

5. SUSPENDED MATTER IS 3025 (PART 17) 2000 mg / l

IS: 4032 – 1985 INDIAN STANDARD METHOD OF CHEMICAL ANALYSIS OF HYDRAULIC CEMENT

14/26

IS 3812 : SPECIFICATION FOR FLY ASH FOR USE ASPOZZOLANA AND ADMIXTURE

Fly Ash Grade I For incorporation in cement mortar andconcrete and in lime-pozzolana mixture, and formanufacture of Portland Pozzolana cement.

Fly Ash Grade II For incorporation in cement mortar andconcrete and in lime –pozzolana mixture (may beused for PPC if IS 1489-1976 is permitting it.)

CHEMICAL REQUIREMENTS OF FLY ASH15/26

SR.NO.

CHARACTERISTIC REQUIREMENT

1 SiO2 + Al2O3 + Fe2O3 , % Min. 70.0

2 SiO2 , % Min. 35.0

3 MgO , % Max. 5.0

4 SO3 , % Max. 2.75

5 Alkalis as Na2O , % Max.* in case of reactiveaggregates, IS 4032 : 1968.

1.5

6 Loss on Ignition, % Max. 12.0

PHYSICAL REQUIREMENTS GRADE OF FLY ASH

I II

16/26

1 FINENESS- SP. SUR. IN m2/kg BYBLAINE’S PERMEABILITY METHOD, min.

320 250

2 LIME REACTIVITY – N/mm2 , min. 4.0 3.0

3 COMPRESSIVE STRENGTH AT 28 DAYS,N/mm2 , min.

NOT LESS THAN 80% OF THESTRENGTH OFCORRESPONDINGPLAIN CEMENTMORTAR CUBES

4 DRYING SHRINKAGE, % max. 0.15 0.10

5 SOUNDNESS (AUTOCLAVE), % max.EXPANSION

0.8 0.8

CHARACTERISTICS GRADE OF CEMENT 33- 43- 53- PPC-I PPC-II

FLY ASH CALCINED CLAY CHEMICAL REQUIREMENTS 17/26

1. CAO/ OXIDES RATIO NOTMORETHAN1.02 ANDNOTLESSTHAN0.66

NOTMORETHAN 1.02ANDNOT LESSTHAN 0.66

NOTMORETHAN1.02ANDNOTLESSTHAN0.80

FLY ASH (OFFINENESSMIN. 320 M2 /KG AND LIMEREACTIVITYVALUE NOTLESS THAN4.0 MPA;UNIFORMLYBLENDED ORINTERGROUND WITH OPC -IS 269: 1989;HOMOGENEITY OF MIX + 3 %)MIN. 15 %AND MAX. 35% BYWEIGHT OFOPC

CALCINEDCLAYPOZZOLANA(OF FINENESSMIN. 320 M2 / KGAND LIMEREACTIVITYVALUE NOTLESS THAN 4.0MPA;UNIFORMLYBLENDED ORINTERGROUNDWITH OPC - IS269: 1989;HOMOGENEITYOF MIX + 3 %) MIN. 15 % ANDMAX. 35 % BYWEIGHT OFOPC


FLY ASH CALCINED CLAY

CHEMICAL REQUIREMENTS: 18/26

2. ALUMINA/IRON OXIDE RATIO

NOT LESS THAN 0.66 0.66 0.66 - -

3.INSOL. RESIDUE, %

NOT MORE THAN 4.0 % 3.0 % 3.0 % X + 4.0(100-X) X + 4.0(100X)

100 100

WHERE X IS % WHERE X IS %

OF FLY ASH IN OF CAL. CLAY PPC POZZ. IN PPC

4. MgO %

NOT MORE THAN 6.0 % 6.0 % 6.0 % 6.0 % 6.0 %



CHEMICAL REQUIREMENTS: 19/26

5. TOTAL SULPHUR AS SO3 % FOR C3A 5 % OR LESS :- SO3 NOT MORE THAN 3.0 %

SO3 NOT MORE THAN 2.5 %

FOR C3A MORE THAN 5 %:-

SO3 NOT MORE THAN 3.0 %

6. TOTAL LOSS ON

IGNITION,

NOT MORE THAN 5.0 % 5.0 % 4.0 % 5.0 % 5.0 %



PHYSICAL REQUIREMENTS: 20/26

FINENESS

NOT LESS THAN, m2 / kg 225 225 225 300 300

SOUNDNESS

EXPANSION NOT MORE

THAN, mm 10 10 10 10 10

LE- CHATELIER’S :-

AUTOCLAVE: - % 0.8 0.8 0.8 0.8 0.8

IF IT FAILS THEN :-

AERATION (KEEP 75 MM

DEPTH OF LAYER AT 50 TO

80 % RH, FOR 7 DAYS).

RE-TEST FOR SOUNDNESS.

RE-TEST – NOT MORE THAN

LE- CHATELIER’S :- mm 5 5 5 5 5

AUTOCLAVE: - % 0.6 0.6 0.6 0.6 0.6


FLY ASH CALCINED CLAYPHYSICAL REQUIREMENTS: 21/26

SETTING TIME

INITIAL, NOT LESS 30 30 30 30 30

THAN, min.

FINAL, NOT MORE 600 600 600 600 600

THAN, min.

FOR FALSE SET: REMIX

AND BREAK THE FALSE

SET, RE-TEST.

COMPRESSIVE STRENGTH,

PROGRESSIVE INCREASE

IN STRENGTH, NOT LESS THAN

72+1 HR. 16 MPA 23 MPA 27 MPA 16 MPA 16 MPA



TRANSVERSE STRENGTH MUTUALLY AGREED BETWEEN PURCHASER & SUPPLIER.

(IS 4031 PT.8:1988)

DRYING SHRINKAGE

NOT MORE THAN - - - 0.15 % 0.15 %

IS 516-1959 INDIAN STANDARD METHODS OF TESTS FOR STRENGTH OF CONCRETE: COMPRESSIVE STRENGTH 22/26

SAMPLE PREPARATION• VOLUME OF CONCRETE- surplus by 10 percent

• WORKABILITY – IS 1199-1959,

• CUBE-MOULDS SIZE – 15 cm or 10 cm cube

• CYLINDERS SIZE - 15 cm dia. x 30 cm length,

• TAMPING BAR: 16 mm dia. 60 cm long bullet pointed at lower end.

• COMPACTION- 35 strokes per layer for 15 cm cubes and 25 strokes per layer for 10 cm cubes,

3-layers filling, finishing with trowel and cover.

• CURING - at 27 + 2 oC in fresh water or saturated lime solution till the time of testing.

IS 516-1959 INDIAN STANDARD METHODS OF TESTS FOR STRENGTH OF CONCRETE: COMPRESSIVE STRENGTH 23/26

CORE SPECIMEN • Height prior to capping less than 95 percent of the diameter shall be rejected,

after capping the H/D ratio should be at least one,

Correction factor for H/D ratio between 1 and 2 as per the relationship given,• CORE CAPPING – Neat cement and Sulphur capping,• EQUIVALENT CUBE STRENGTH FROM CORE STRENGTH – multiply by 5 / 4.• AGE AT TEST: 7 and 28 days, 13 weeks and 1 year.

• EQUIVALENT CUBE STRENGTH FROM BROKEN BEAM SPECIMEN

Bearing plates of thickness 6.5 to 19 mm metal plates, 10 cm square or 15 cm square as per beam specimen depth, rate of loading 140 kg / sq. cm / min, result is 5 percent greater than cube strengths.

• REPORTING – identification mark, date of test, age of specimen, curing conditions, including date of manufacture of specimen in the field, weight of the specimen, dimensions of the specimen, cross sectional area, maximum load, compressive strength and appearance of fractured faces of concrete and type of fracture.

IS 516-1959 INDIAN STANDARD METHODS OF TESTS FOR STRENGTH OF CONCRETE: FLEXURAL STRENGTH

24/26

SAMPLE PREPARATION

Coarse and fine aggregates, proportioning, weighing, mixing concrete- minimum 2 minutes in machine till concrete is uniform.

• VOLUME OF 10 percent in excess over and above the CONCRETE: requirement.

• WORKABILITY: IS 1199-1959,

• BEAM-MOULD SIZE : 15 x 15 x 70 cm beam, OR

10 x 10 x 50 cm beam

• TAMPING BAR : Weight 2 kg, 25-mm sq. ramming flat face, 40-cm long.

Casting, Curing the same way.

IS 516-1959 INDIAN STANDARD METHODS OF TESTS FOR STRENGTH OF CONCRETE: FLEXURAL STRENGTH 25/26

CALCULATION

fs = [ p x l ] / [ b x d2 ]

If ‘a’ = distance between line of fracture and the nearer support measured on the center- line of tensile side of specimen, in cm,

When ‘a’ is greater than 20 cm for 15 cm specimen, or

greater than 13.3 cm for a 10 cm specimen,

fs = [3p x a ] / [b x d2 ]

When ‘a’ is less than 20 cm but greater than 17 cm

for 15 cm specimen, or

less than 11 cm for a 10 cm specimen

Where b = measured width in cm of the specimen,

d = measured depth in cm of the specimen

l = length n cm of the span on which the beam is supported,

p = maximum load in kg applied to the specimen.

IF ‘a’ IS LESS THAN 17 CM (FOR 15-CM BEAM) OR 11 CM (FOR 10-CM BEAM)

THEN THE RESULTS SHALL BE DISCARDED.

IS 516-1959 INDIAN STANDARD METHODS OF TESTS FOR STRENGTH OF CONCRETE: MODULUS OF ELASTICITY 26/26

SIZE OF SPECIMEN: Cylinders of 15-cm dia. and 30 cm length. Or cores of

H/D ratio at least 2.

PREPARATION OF SPECIMEN: Same As above, age of testing at 28 days.

TESTING MACHINE AND EXTENSOMETERS: Two extensometers of gauge length not less than 10.2 cm and not more than half the length of the specimen

capable of measuring strains to an accuracy of 2 x 10 –6.

PROCEDURE: average Compressive strength of 3 specimens, C = 1/3 Av. C.S. nearest 5 kg/ sq. cm. Extensometers on opposite sides

parallel to axis, load applied @ 140 kg / sq. cm / min. till (C+5) kg/sq. cm Maintain this load for a minute and then gradually reduc e to 1.5 kg / sq. cm when extensometer reading is taken. Load is again applied to repeat the reading. Then the third time repeat load and reading taken. The last two readings should be in agreement to 5 percent of each other and repeat that once more till the reading difference is less than 5 percent.

CALCULATION: The stress – strain curves (straight lines) for the two-extensometer readings for the last two load-cycles are plotted. The

slopes give the average ‘E’-value expressed in kg/ sq. cm nearest to 1000 kg / sq. cm.

Cement Specifications

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