Manufacturable cement types

Manufacturable Cement types at BCL

by

Muhammad Babar Siddique

PSQCA trail

Muhammad Babar Siddique 3

Pakistan standards in 2014


PSS : 232-2008 ® Ordinary portland cement

PSS : 5313-2014® Common Cement

PSS : 5314- 2014 ® Masonary Cement

PSS : 232-2008 ®


Indian Adopted standard

•Enforced since 2008

Still applicable

•Rigid standard

PSS : 232-2008 ®Grades


33 Grade

43 Grade

53 Grade

PSS : 5313-2014 ®


European Adopted standard EN-197

• Newly Adopted in 2014

Require SRO for enforcement

• Broad / Liberal standard

PSS : 5313-2014 ®Classification basis


• STRENGTH CLASS

32.532,5R 32,5 N

42,542,5 R 42,5N

52,552,5 R 52,5 N



Mechanical and physical requirements given as characteristic values with Table-2 Table -2

Strength class

Compressive strength MPa

Initial setting time min

Soundness (expansion) mm

Early strength Standard strength 2 days 7 days 28 days

32,5 N -- ≥ 16,0 ≥ 32,5 ≥ 52,5 ≥ 75 ≤ 10

32, 5 R ≥ 10,0 -- 42,5 N ≥ 10,0 -- ≥ 42,5 ≥ 62,5 ≥ 60 42, 5 R ≥ 20,0 -- 52,5 N ≥ 20,0 -- ≥ 52,5 -- ≥ 45 52, 5 R ≥ 30,0 --



• COMPONENT CLASS

CEM-INo Additives

CEM-IIPortland-

Composite Cement

CEM-IIIBlast Furnace

Cement

CEM-IVPozolonic Cement

CEM-VComposite

Cement


Notation of the 27 products (types of common cement)

Composition [percentage by mass a)] Main constituents Minor

additio-nal constituents Clinker

K

Blast furnace slag S

Silica fume D

Pozzolans Fly ash Burnt Shale T

Limestone

Natural P

Natural calcined Q

Siliceous V

calcareous W

L

LL

Portland cement

CEM I 95-100 -- -- -- -- -- -- -- -- -- 0 TO 5

Portland-slag cement

CEM II/A-S 80 to 94 6 to 20 -- -- -- -- -- -- -- -- 0 TO 5 CEM II/B-S 65 to 79 21 to 35 -- -- -- -- -- -- -- -- 0 TO 5

Portland-silica fume cement

CEM II/A-D 90 to 94 -- 6 to 10 -- -- -- -- -- -- -- 0 TO 5

Portland-pozzolana cement

CEM II/A-P 80 to 94 -- -- 6 to 20 -- -- -- -- -- -- 0 TO 5 CEM II/B-P 65 to 79 -- -- 21 to 35 -- -- -- -- -- -- 0 TO 5 CEM II/A-Q 80 to 94 -- -- -- 6 to 20 -- -- -- -- -- 0 TO 5 CEM II/B-Q 65 to 79 -- -- -- 21 to 35 -- -- -- -- -- 0 TO 5

Portland-fly ash cement

CEM II/A-V 80 to 94 -- -- -- -- 6 to 10 -- -- -- -- 0 TO 5 CEM II/B-V 65 to 79 -- -- -- -- 21 to 35 -- -- -- -- 0 TO 5 CEM II/A-W 80 to 94 -- -- -- -- -- 6 to 10 -- -- -- 0 TO 5 CEM II/B-W 65 to 79 -- -- -- -- -- 21 to 35 -- -- -- 0 TO 5

Portland-burnt shale cement

CEM II/A-T 80 to 94 -- -- -- -- -- -- 6 to 20 -- -- 0 TO 5 CEM II/B-T 65 to 79 -- -- -- -- -- -- 21 to 35 -- -- 0 TO 5

Portland-limestone cement

CEM II/A-L 80 to 94 -- -- -- -- -- -- -- 6 to 20 -- 0 TO 5 CEM II/B-L 65 to 79 -- -- -- -- -- -- -- 21to35 -- 0 TO 5 CEM II/A-LL 80 to 94 -- -- -- -- -- -- -- -- 6 to

20 0 TO 5

CEM II/B-LL 65 to 79 -- -- -- -- -- -- -- -- 21 to 35

0 TO 5

Portland-composite cement c)

CEM II/A-M 80 to 94 < -------------------------------- 6 to 20 ---------------------------------- > 0 TO 5 CEM II/B-M 80 to 94 < -------------------------------- 21 to 35 ---------------------------------- > 0 TO 5

0 TO 5 Blastfurnace cement

CEM III/A 35 to 64 36 to 65 -- -- -- -- -- -- -- -- 0 TO 5 CEM III/B 20 to 34 66 to 80 -- -- -- -- -- -- -- -- 0 TO 5 CEM III/C 5 to 19 81 to 95 -- -- -- -- -- -- -- -- 0 TO 5

Pozzolanic cement c)

CEM IV/A 65 to 89 -- < ----------------- 6 to 20 ------------------ > -- -- -- 0 TO 5 CEM IV/B 45 to 64 -- < ----------------- 6 to 20 ------------------ > -- -- -- 0 TO 5

Composite cement c)

CEM V/A 40 to 64 18 to 30 -- < ------- 18 TO 30 ------- > -- -- -- -- 0 TO 5 CEM V/B 40 to 64 18 to 30 -- < ------- 31 TO 50 ------- > -- -- -- -- 0 TO 5

a) The values in the table refer to the sum of the main and minor additional constituents. b) The proportion of silica fume is limited to 10 % c) In Portland-composite cements CEM II/A-M and CEM II/B-M, in Pozzolanic cements CEM IV/A and CEM IV/A and CEM IV/B and in composite cement CEM V/A and CEM V/B the main constituents other than clinker shall be declared by designation of the cement (for example see clause 8).

PSS : 5313-2014 ®


Opportunities• Flexibility

27 Cement types• Vast Marketing ground

Customers needCustomers Financial standingLow Cost cementGreen industry

PSS : 5313-2014 ®Factors


Production• Additive Availability

Fly ash, Blast furnace Slag, Pozzolona, Burnt shale, silica fume

• Market DemandViable demand

• EquipmentProcess equipmentTesting equipment

• Process tuningProcess ParametersFinish Mil Parameters

PSS : 5313-2014 ® Capability Analysis


Main Type Notation of the 27 products (types of common cement)

Production Possible (Yes/NO)

If NO Limitation

If Yes Remarks

Additives Possible

Production Cost/ton.

Rs.

Cost Diff: w.r.t 43 grade

OPC from ref. price of Rs/t.4228

CEM I Portland cement

CEM I Yes 42.5 N - Nil 4663 435

42.5 R - - 4842 614

CEM II

Portland-slag cement

CEM II/A-S No Slag not available in area

- - -

CEM II/B-S

Portland-pozzolana

cement

CEM II/A-P No Pozolaona not available in area

CEM II/B-P

CEM II/A-Q

CEM II/B-Q

Portland-fly ash cement

CEM II/A-V Yes

32.5 N - 10% 4230 2 May possible that Flyash floats on cement paste if more than 4 %.

Though standard allows 20 %

CEM II/B-V

CEM II/A-W

CEM II/B-W

Portland-burnt shale cement

CEM II/A-T No Burnt Shale not available in area

CEM II/B-T

Portland-limestone

cement

CEM II/A-L Yes 32.5 N 10 % 4104 (124.00)

CEM II/B-L

CEM II/A-LL 42.5 N 7 % 4322 94 Blaine, LSF increase & Residue decrease

required CEM II/B-LL

Portland-composite cement c)

CEM II/A-M Yes 32.5 N 4% Flyash & 5 % L.S

4189 (39) Blaine increase up to 3500 cm2/gm CEM II/B-M

CEM III

Blastfurnace cement

CEM III/A No Blast furnace slag not available in area

CEM III/B

CEM III/C

CEM IV Pozzolanic cement c)

CEM IV/A No Pozolona not available in area

CEM IV/B

CEM V Composite cement c)

CEM V/A No

CEM V/B

PSS : 5314-2014 ®Masonry Cement


Properties: • Mortars used for laying bricks and blocks have special requirements for

workability, plasticity and water retention. When mixed with water and sand, masonry cement gives mortars with buttery characteristics ,which aid the masons. Masonry cement provides the fattiness and cohesiveness of a good mortar, improves its adherence to the brick or block, prevent bleeding and minimizes water loss due to absorption.

Applications : • OPC when mixed with water and sand give rise to mortar, which seemed

to be too harsh or too strong for rendering and bricklaying. Such mortars harden too quickly and lack the plasticity and water retaining qualities. They cannot take shrinkage and temperature movements in the masonry and are likely to cause cracks right through the bricks or concrete blocks. To overcome this CRACKING difficulty masonry cement is used.



European Adopted standard EN: 413 , BS-5224/95 & ASTM C-91

• Newly Adopted in 2014

Require SRO for enforcement

PSS : 5314-2014 ® Masonry CementClassification Basis


MC 5

MC 12.5MC 12.5X

MC 22.5 X

PSS : 5314-2014 ® Masonry CementClassification Basis


• Strength ClassClasses of masonry cement

Strength class Strength range at 28 daysN/mm2

Nation

With air-entraining agent

Without air-entraining agent

5 5 to 15 MC 51 Not permitted

12.5 12.5 to 32.5 MC 12.5 MC 12.5X2

22.5 22.5 to 42.5 Not permitted MC 22.5X

1)MC denotes masonry cement 2)X indicates non air-entraining.

PSS : 5314-2014 ® Masonry CementChemical & Physical properties




Composition and manufacture Masonry cements shall consists of Portland cement clinker, inorganic materials and, where appropriate, organic material, as given in table 1.

Table 1. Composition of masonry cements Class Content % (m/m) Portland

cement clinker Organic material

MC 5 ≥ 25 ≤ 1

MC 12.5 MC 12.5X MC 22.5X

≥ 40

NOTE. These masonry cement compositions permit less clinker than in the 1976 edition of this standard. The effect on strength is readily determined but the long term properties have not yet been established in the current absence of a test for durability.

Constituents shall not promote corrosion of embedded metal such as reinforcement and wall ties or impair the properties, including behaviour in fire, of the mortar made from masonry cement.

PSS : 5314-2014 ® Masonry Cement


Tests UnitsCement Addition of Limestone (%)

(Without L/S) 3 5 10 15 20 25 30 35 40

LOI % 2.31 3.75 4.45 6.57 8.96 10.85 12.44 14.87 16.79 18.93

SiO2 % 20.67 19.86 19.56 18.44 17.34 16.46 15.42 14.29 13.22 12.27

Al2O3 % 5.14 5.01 4.91 4.63 4.38 4.20 3.94 3.70 3.39 3.18

Fe2O3 % 3.59 3.48 3.36 3.19 3.00 2.82 2.74 2.49 2.27 2.06

CaO % 62.81 62.67 62.49 62.35 61.94 61.66 60.92 59.94 59.32 59.08

MgO % 2.48 2.36 2.30 2.17 2.06 2.00 1.90 1.76 1.65 1.59

SO3 % 2.40 2.42 2.43 2.46 2.52 2.49 2.39 2.61 2.60 2.66

Na2O % 0.28 0.26 0.26 0.25 0.24 0.23 0.23 0.21 0.20 0.20

K2O % 0.81 0.79 0.78 0.76 0.72 0.68 0.65 0.62 0.58 0.55

LSF % 92.24 95.60 96.88 102.47 108.09 113.31 119.43 126.34 135.32 145.05

SM 2.37 2.34 2.37 2.36 2.35 2.34 2.31 2.31 2.34 2.34

AM 1.43 1.44 1.46 1.45 1.46 1.49 1.44 1.49 1.49 1.54

F.CaO % 1.90 1.90 1.85 1.70 1.50 1.50 1.45 1.30 1.20 1.10

Blaine Cm2/gm 3260 3188 3658 3497 3406 3504 3623 3620 3689 3514

Residue(90µ) % 11.60 12.60 11.48 15.48 23.56 20.52 23.24 28.44 28.8 29.84

Consistancy % 20.40 20.00 20.00 19.50 19.50 19.30 19.30 19.10 19.10 19.10

Expansion mm 2.00 3.00 2.00 2.00 2.00 2.00 2.50 5.50 9.00 10.00

Setting Time

Initial Minutes 150 140 135 140 145 150 150 155 160 165

Final Minutes 200 190 185 180 190 190 200 210 200 200

Compressive Strength

01-day PSI 2551 2523 2580 1979 1121 835 692 549 492 263

03-Days PSI 4052 4224 4028 3523 2036 1622 1636 836 835 692

07-Days PSI 5407 5487 5305 5007 3137 2857 2565 2425 1479 1102

28-Days PSI 6850 6956 6783 6469 4381 4095 3447 2765 2136 1521

Note:- All samples are prepared in small Ball Mill at MCL using fresh MCL clinker.



Tests UnitsAddition of Limestone (%)

45 50 55 60 65 70 75

LOI % 19.27 21.22 23.03 24.94 27.98 29.85 30.25

SiO2 % 12.22 10.48 9.90 9.39 7.72 6.77 6.35

Al2O3 % 3.06 2.65 2.52 2.41 1.98 1.80 1.72

Fe2O3 % 2.33 2.02 1.82 1.60 1.19 0.95 0.80

CaO % 59.45 59.26 59.19 58.06 55.82 55.96 55.51

MgO % 1.68 1.41 1.35 1.25 1.05 0.99 0.94

SO3 % 2.42 2.48 2.50 2.45 2.47 2.48 2.54

Na2O % 0.20 0.19 0.18 0.19 0.18 0.16 0.16

K2O % 0.56 0.50 0.47 0.46 0.39 0.36 0.34

LSF % 146.81 170.27 180.19 186.72 218.76 249.91 264.30

SM 2.27 2.24 2.28 2.34 2.44 2.46 2.52

AM 1.31 1.31 1.38 1.51 1.66 1.89 2.15

F.CaO % 1.00 0.80 0.65 0.50 0.40 0.30 0.20

Blaine Cm2/gm 3557 3649 3582 3735 3941 3790 3949

Residue(90µ) % 17.60 20.72 24.24 25.28 22.8 27.04 30.08

Consistancy % 22.20 21.70 21.10 20.60 21.10 20.00 20.00

Expansion mm 8.00 12.00 13.00 15.00 14.00 14.50 13.00

Setting Time

Initial Minutes 175 180 175 180 190 200 210

Final Minutes 225 225 220 225 240 245 250

Compressive Strength01-day PSI 251 263 206 149 92 0 0

03-Days PSI 609 254 234 203 163 92 63

07-Days PSI 1007 659 559 371 292 263 206

28-Days PSI 2265 1407 912 607 549 321 263



• Marking & PackingMasonary cement

not used for structural concrete

Bag color

Printing

• URDU• ENGLISH

• White

• Red



• Opportunities• Low Cost• Market leader

• Risks• Miss use by contractors• Risks associated with illiterate population• Market Acceptability



Production• Additive Availability

Search of suitable additive (Fly ash, Blast furnace Slag, Pozzolona, Burnt shale, silica fume)

• Market DemandMarket surveys for Viable demand

• EquipmentProcess equipment

• Process tuningFinish Mil Parameters

Case StudyComposition• Clinker • Gypsum • Lime Stone


Manufacturable Cement types at BCL


Question’s, Answer’s & Discussion


Business

Manufacturable cement types