CIVIL ENGINEERING MATERIALSBAHAN KEJURUTERAAN AWAM

BFC 10502MR. MOHD KHAIRY BIN BURHANUDIN (MB-202-11)

(COORDINATOR)

DR. NOR HAZURINA BINTI OTHMANCLUSTER STRUCTURE AND MATERIAL ENGINEERING,

FACULTY OF CIVIL ENGINEERING & BUILT ENVIRONMENT,

UNIVERSITI TUN HUSSEIN ONN MALAYSIA.

SYLLABUS

1. CEMENT 1.1 Types of Cement1.2 Chemical Composition1.3 Testing of Cement1.4 Manufacturing of Cement1.5 Method of Cement Storing

2. AGGREGATES2.1 Types of Aggregates2.2 Classification of Aggregates2.3 Properties of Aggregates2.4 Grading of Aggregates

SYLLABUS3. CONCRETE

3.1 Introduction to Fresh and Hardened concrete3.2 Concrete Preparation3.3 Workability of Fresh Concrete3.4 Strength and Grade of Concrete3.5 Properties of Hardened Concrete3.6 Standard testing of Hardened Concrete

3.7 Concrete Mixture and Design 3.7.1 DOE Method for Normal Concrete3.7.2 ACI Method for Normal Concrete

4. BRICKS AND MASONRY 4.1 Bricks Classification4.2 Types of Bricks4.3 Manufacturing of Bricks4.4 Bricks Bonding and Arrangement4.5 Mortar and Plastering4.6 Standard Testing for Bricks

SYLLABUS5. TIMBER

5.1 Timber Classification.5.2 Timber Structure.5.3 Moisture, Shrinkage and Strength.5.4 Timber Defects5.5 Treatment and Curing5.6 Timber Products5.7 Wood in Construction5.8 Timber Standard Testing

6. STEEL 6.1 Steel Classification 6.2 Manufacturing of Steel6.3 Properties of Steel 6.4 Common Types of Steel and Usage in

Construction6.5 Mechanical Testing of Steel

7. OTHER CONSTRUCTION MATERIALS7.1 Bitumen7.2 Rubber7.3 Plastics7.4 Polymer7.5 Gypsum Board7.6 Glass7.7 Alloy

SYLLABUS

ASSESSMENTQUIZ – 5%ASSIGNMENT – 5%PROJECT – 20%TEST : TEST 1– 10% ( CHAPTER 1 & 2) 11/10/19

TEST 2 – 10% ( CHAPTER 3) 15/11/19LOCATION : F2 FINAL – 50% (ALL CHAPTER)

0192690137

TOTAL = 100%

ASSIGNMENT 1

• Prepare your personal detail with your photo. and

• Answer the question below:

What is cement?

What is chemical compositin in cement?

CHAPTER 1 : CEMENT

1.1. Types of Cement

1.2. Chemical Composition

1.3. Testing of Cement

1.4. Manufacturing of Cement

1.5. Method of Cement Storing

INTRODUCTION OF CEMENT

Cement is a manufactured construction material and widely used for structural constructions such as buildings, bridges, tunnels, dams, factories, pavement and etc. It is an instant glue and capable to bond mineral fragments into compact whole. There are variety type of cements can be found in the market. Each type is manufactured under certain condition depending on its special properties. However today, Portland cement is the most commonly used as mortar and

concrete in structural construction.

• Mortar: A mixture of cement, fine aggregates or sand and water to form a paste.

• Concrete: A mixture of cement, sand, coarse aggregates and water under certain ratio.

1.1 TYPES OF CEMENT

• Cement is manufactured with two basic raw ingredients called calcareous and an argillaceous material. The cement in making of concrete has the property of setting and hardening under water by virtue of chemical reaction with it and this type of cement is called hydraulic cement.

• Calcareous: The calcareous material is a calcium oxide, such as limestone, chalk, or oyster shells.

• Argillaceous: Argillaceous is a combination of silica and alumina that can be found from clay, shale, and blast furnace slag.

1.1 TYPES OF CEMENT

• Setting TimeSetting refers to the stiffening of the cement paste or the change from a plastic state to a solid state. The setting time refers to changes of the cement paste from fluid to rigid. Setting is usually described in two levels namely, initial setting and final setting.• Initial Setting:Initial setting is defined as the beginning of the noticeable

stiffening in the cement paste and it’s corresponding to the rapid rise temperature. This normally takes about 45 – 175 minutes.

• Final Setting Time: This refers to completion of setting which correspond to the peak temperature in the cement paste. The stiffening of cement paste increase as the volume of the gel increases and the stage at which this is completed, the final hardening process begins. It normally takes between 3 to 10 hours for this to happen.

• HardeningThis is referred to the gained of the strength of the cement paste. Actually during the setting time, the cement gained very little strength.

1.1 TYPES OF CEMENT

• Different concrete applications require cements with different properties. Some applications require rapid strength gain to expedite the construction and other applications require low heat hydration to control volume change and associated shrinkage cracking. Hence, each type of cement is manufactured by altering the ratios of four basic compounds namely Tricalcium Silicate, DicalciumSilicate,Tricalcium Aluminate and Tetracalcium Aluminoferitte to fit the applications.

Name of Compound Usual Abbreviation Reaction

Tricalcium Aluminate C3A Very quick

Tricalcium Silicate C3S Quick

Dicalcium Silicate C2S Slow

TetracalciumAluminoferitte

C4AF Not very important

1.1 TYPES OF CEMENT

TWO CATEGORIES OF CEMENT:1. HYDRAULIC CEMENT2. HIGH ALUMINA CEMENT

1. HYDRAULIC CEMENT:Hydraulic cement is consists of silicates and aluminates of lime. This type ofcement can be classified as;a. Natural CementNatural cements are powders obtained from certain natural rocks (clayey limestone type) which are quarried, crushed and processes. Enough heat isrequired to dry off carbonic acid gasses. Besides, it is brown in colour andsets slowly or quickly when mixed with water, depending on the amount ofclay in the limestone. The strength is low and not used for concrete work.

b. Aluminous CementThe chief ingredients of aluminous cement are calcareous and aluminiousmaterials (limestone or chalk and bauxite). These are heated to atemperature of 1400oC and the whole mass is grinded to powder form.

1.1 TYPES OF CEMENTc. Portland CementThe hardening of Portland cement is a chemical process during which heat is evolved. Modified forms of Portland based on different ratio of four main compositions are made, to suit the varying demands of different kinds of structural application.

Name Application

Normal General concrete work when the special properties ofother types are not needed. Suitable for floors, reinforced concretestructures, pavements, etc.

Moderate SulfateResistance

Protection against moderate sulfate exposure, 0.1-0.2% weight water soluble sulfate in soil or 150-1500ppm sulfate in water (sea water). Can be specified with moderate heat of hydration, making it suitable for large piers, heavy abutments, and retaining walls. The moderate heat of hydration is also beneficial when placing concrete in warm weather.

High Early of Hydration

Used for fast-tract construction when forms need to be removed as soon as possible or structure need to be put in service as soon of possible. In cold weather, reduces time required for controlled curing.

Low Heat of Hydration

Used when mass of structure, such as large dams, requires careful control of heat of hydration.

High SulfateResistance

Protection from severe sulfate exposure, 0.2-2.0% weight water soluble sulfate in soils or 1500-10,800 ppm sulfate in water.

CLASSIFICATION OF PORTLAND CEMENTS

What is cement hydration?

• Hydration is chemical reaction between cement particles and water. The features of this reaction are the change in matter, the change in energy level, and the rate of reaction.

• Example:

Tricalcium silicate + Water Calcium silicate hydrates (C-S-H) + Calcium hydroxide

C-S-H makes the hydrated cement paste strong and calcium hydroxide is susceptible to attack by sulfate and acidic water.

1.1 TYPES OF CEMENT

1.1 TYPES OF CEMENT

Ordinary Portland Cement – OPC ( BS 12 : 1971)OPC has a medium rate of hardening and is suitable for most type of work. It is the one most commonly used for structural purposes when the special properties specified for other four types of cement are not required.

ii) Rapid Hardening Portland Cement – RHPC (BS 12 : 1971)RHPC hardens rather more rapidly than OPC. It is similar in chemical composition to OPC but the proportions of the various compounds may be slightly different, and it is finely ground. Due to its finer grinding, it will increase the rate of hydration at early ages, and this leads to the increased rate of early hardening as implied by the name. This early strength is achieved by increasing C2S and C3A content of the cement and finer grinding. Since it has high heat evaluation, RHPC should not be used in large masses. With 15% of C3A, it has lower sulfate resistance. The may be limited to obtain moderate sulfate resistance or to 5% when high sulfate resistance is required.Rapid-hardening Portland cement should not be regarded as quick setting cement. The setting time specified in BS 12:1971 for RHPC is similar as specified for OPC.

1.1 TYPES OF CEMENTiii) White and Coloured Portland Cement (BS 12 : 1971)Generally used for decorative work. It is made by using China clay in place of ordinary clay to exclude impurities, especially iron oxide and limestone. Coloured cements are made by mixing pigments with Portland Cement.

iv) Low Heat Portland Cement – LHPC (BS 1370: 1974)LHPC hardens and evolves heat more slowly than OPC. It has slightly different chemical composition. It is obtained by increasing the proportion of C2S and reducing C3S and C3A. It thus hydrates more slowly and evolves heat less rapidly than OPC. The strength of LHPC is slow developed but the ultimate strength is same. However, the initial setting time is greater than OPC.

CementType

Setting Time

Initial SettingTime, minutes

(min)

Final SettingTime, minutes

(max)

OPC 30 600

RHPC 30 600

LHPC 60 600

v) Portland Blust furnace Cement - PBC (BS 146: 1973)PBC is made by grinding a mixture of OPC clinker with selected granulated blast furnace slag. The proportion of slag is limited by the British Standard to not more than 65% of the finished cement. The properties of blast furnace cement are very similar to those of OPC but it hydrates slower than those of Portland cement so thiscement evolves less heat and hardens more slowly than OPC. The resistance to sulfate is often considered to be intermediate between that of sulfate-resisting Portland cement.

vi) Sulfate-Resisting Portland Cement – SRPC (BS 4027: 1972)SRPC is specified where there is extensive exposure to sulfate. Typical applications include hydraulic structure exposed to water with high alkali content and structures subjected to seawater exposure. The surface resistance to SRPC is achieved by reducing the C3A content to a minimum since that compound is most susceptible to sulfate attack. It usually has a higher content of C4AF.Concrete made with this cement is more resistant to attack by sulfate compounds which may be found dissolved in ground water and which are present in sea water. SRPC tends to be darker in colour than OPC.

1.1 TYPES OF CEMENT

1.1 TYPES OF CEMENT

vii) High Strength Portland Cement – HSPCHSPC is produced from the same material as the case of OPC. The higher strength achieved by increasing C3S content and also by finer grinding of clinker. The initial and final setting times are the same as that of OPC. At higher water cement ratios, the HSPC has about 80% higher strength and at lower cement ratio 40% higher strength than OPC.

viii) Masonry Cement (BS 5224: 1976)For hand work such as rendering and bricklaying, mortar composed only of Portland cement and sand are not ideal. Such mortars harden too quickly, are too strong, and lack the plasticity and water retention desirable in a masonry mortar. It has been customary to overcome this difficulty by mixing lime with the cement mixtures. Masonry cement, under various brand names consists of Portland cement with a fine inert admixture and plasticizing agent.

Minimum Compressive Strength of Concrete Cube specified byBS 4550 for Portland Cement

Type of Portland Cement

Compressive Strength (N/mm2)

3 days 7 days 28 days

OPC 13 - 29

RHPC 18 - 33

PBC 8 14 22

LHPC 5 - 19

SRPC 10 - 27

1.1 TYPES OF CEMENT

2. HIGH ALUMINA CEMENT

High alumina cement is quite different both in composition and propertiesfrom Portland cement. It is comparatively slow-setting but rapid hardening,thus, produces very high early strength. As a considerable amount of heat isgenerated during the setting and hardening process, it should not be used inrich mixes or large masses. It is essential that the concrete be keptcontinuously wet for at least 24 hours from the time it begins to harden. About80% of the ultimate strength is developed at the age of 24 hours. High aluminacement has an initial setting time about 4 hours and final setting time about 5hours. The heat that generated during the hardening period has oneadvantage, as it enables the concrete to be placed at lower temperatures thanOPC.

For the same water cement ratio, the alumina cement is more workable thanPortland cement. If high alumina cement concrete is used in place wheremoisture and a high temperature present simultaneously, there will be a lossstrength whether these conditions occur early of late in the life of theconcrete.

1.1 TYPES OF CEMENT

High alumina cement concrete is more resistant than OPC to the action of sulfates, therefore suitable under sea water applications.

The raw materials are limestone or chalk and bauxite which are crushed into lumps not exceeding 100mm. The materials are heated to the fusion point at about 1600oC. The solidified material is fragmented and then ground to a fineness of 2500-3200 cm2/g. The product of very dark grey powder is passed through magnetic separators to remove metallic iron. The alumina cement is considerably more expensive.

1.1 TYPES OF CEMENT

Chemical Oxide Composition for High Alumina Cement

Alumina (Al2O3) 39%

Ferric Oxide (Fe2O3) 10%

Lime (CaO) 38%

Ferrous Oxide (FeO) 4%

Silica (SiO2) 6%

1.2 CHEMICAL COMPOSITION

Chemical Composition Limit of Portland Cement

Name of Raw Material Chemical Composition Percentage Limit

Lime CaO 60 - 67

Silica SiO2 17 - 25

Alumina Al2O3 3 - 8

Iron oxide Fe2O3 0.5 - 6

Magnesium MgO 0.1 - 4

Alkalis (Soda and or/ potash)

Na2O,K2O 0.2 – 1.3

Sulphur Trioxide SO3 1- 3

1.2 CHEMICAL COMPOSITION

The interaction of Portland cement raw materials are interacted in kiln by formingcomplex chemical compounds. Calcination in the kiln restructures the molecularcomposition by producing four main chemical compounds.

Main Compounds of Portland Cement

The minor compounds such as magnesium oxide, titanium oxide, manganeseoxide, sodium oxide, and potassium oxide are represented a few percentages byweight of cement.

Name of Compound Chemical Formula Usual Range by Weight (%)

Tricalcium Silicate 3CaO.SiO2 45 - 60

Dicalcium Silicate 2CaO.SiO2 15 - 30

Tricalcium Aluminate 3CaO.Al2O3 6 - 12

TetracalciumAluminoferitte

4CaO.Al2O3.Fe2O3 6 - 8

1.3 TESTING OF CEMENT

1.3.1 SETTING

A. Vicat Set Time ApparatusSetting time can be determined with the Vicat apparatus. The Vicat test requires sample of cement using the amount of water required for normal consistency according to a specified procedure.Procedure:The 1 mm (0.04in) diameter needle is allowed to penetrate the paste for 30 seconds and the amount of penetration is measured. The penetration process is repeated every 15 minutes until a penetration of 25 mm (1in) or less is obtained. By interpolation, the time when a penetration of 25 mm occurs is determined and recorded as the initial set time. The final set time is when the needle does not penetrate visibly into the paste.

1.3 TESTING OF CEMENT

B. Gilmore Set Time ApparatusThe Gilmore requires a normal consistency cement paste sample. A pat with a flat top is molded and the initial Gilmore needle is applied lightly to its surface. The application surface is repeated until the pat bears the force of the needle without appreciable indentation, and the elapsed time is recorded as the initial time. This process is then repeated with the final Gilmore needle and the final set time is recorded.

1.3 TESTING OF CEMENT

Soundness of the cement paste refers to its ability to retain its volume aftersetting. Expansion after setting, caused by delayed or slow hydration or reactions,could result if the cement is unsound. The autoclave expansion test is used tocheck the soundness of the cement paste. In this test, cement paste bars aresubjected to heat and high pressure, and the amount of expansion is measure.ASTM C150 limits autoclave expansion to 0.8%.

1.3.2 SOUNDNESS (LE CHATELIER TEST)

Le Chatelier Water Bath

1.3 TESTING OF CEMENT

Compressive strength of mortar is measured by preparing 50mm (2in.) cubes andsubjecting them to compression according to ASTM C109. The mortar isprepared with cement, water and standard sand (ASTM C778). Minimumcompressive strength values are specified by ASTM C150 for different cementtypes at different ages. The compressive strength of mortar cubes is proportionalto compressive strength of cylinders. However, the compressive strength of theconcrete cannot be predicted accurately from mortar cube strength, since theconcrete strength is affected by aggregate characteristics, the concrete mixingand the construction procedures.

1.3.3 COMPRESSIVE STRENGTH

1.4 MANUFACTURING OF CEMENT

Production of Portland cement deals with two basic raw ingredients namelycalcareous and argillaceous. These materials are crushed and stored in the silos. Theraw materials, in the desired proportions, are passed through grinding mill, usingeither wet or dry process. The ground material is stored until it can be sent to the kiln.

Modern dry process cement plants use a heat recovery cycle to preheat the groundmaterial, or feed stock, with the exhaust gas from the kiln. Some plants use a flashfurnace to further heat and feed stock. Both the preheater and flash furnace improvesthe energy efficiency of cement productions. In the kiln, the raw materials are meltedat temperatures 1400oC to 1650oC, changing the materials into cement clinker. Theclinker is cooled and stored. The small amount of gypsum is added to regulate thesetting time of the cement in the concrete.

The finished product may be stored and transported in either bulk or sacks. Thecement can be stored for long periods of time, provided it is kept dry.

1.4 MANUFACTURING OF CEMENT

1.5 METHOD OF CEMENT STORING

1. MOISTUREIf moisture is kept away from cement, it is found that cement willmaintain its quality for an indefinite period. Absorption of 1 to 2% ofmoisture has no appreciable effect on quality of cement. But ifmoisture absorption exceeds 5%, the cement becomes totallyuseless. Hence, when cement is to be stored for a long period, itshould be stored in air-tight containers.

2. PERIOD OF STORAGEThe lose cement may be stored indefinitely in air-tightcontainers. But it is advisable to avoid storing of cement in jutebags for a period longer than 3 months. If it is unavoidable, thecement should be tested to ascertain its properties.

3. PILESThe cement bags are stacked in piles. It is advisable to form a pile of maximum 10bags. There should be a clear distance of about 300 mm between the piles of cementbag and exterior walls of building. In between individual pile a passage of 900 mmshould be provided for easy access. Use tarpaulins or water proof paper at the topand bottom of piles, while storing cement for long period.

1.5 METHOD OF CEMENT STORING

4. REMOVAL OF CEMENTWhile removing cement bags from pile of sufficient height, then stepsshould be formed by taking out two or three bags from front piles. Cementshould be removed in order of its storage period, i.e. the rule of first in,first out should be followed.

5. STORAGE SHEDSThe walls, roof and floor of storage sheds should be of waterproof construction. A minimum number of windows shouldbe provided and they should be kept tightly shut. The floorshould be above ground. For determining the size of storageshed, it is found that 20 bags or 10 kN of cement will requireabout 1m3 of space.SHARE THIS:

CO

NC

LUSI

ON

1. What is the best storing system for cement?. Explain

2. How to speed up the strength development of concrete?. Explain.

3. What are the effects of non-potable water on concrete quality? Explain.

TUTORIAL 1