Post on 12-Apr-2017
Manufacturable Cement types at BCL
by
Muhammad Babar Siddique
PSQCA trail
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Pakistan standards in 2014
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PSS : 232-2008 ® Ordinary portland cement
PSS : 5313-2014® Common Cement
PSS : 5314- 2014 ® Masonary Cement
PSS : 232-2008 ®
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Indian Adopted standard
•Enforced since 2008
Still applicable
•Rigid standard
PSS : 232-2008 ®Grades
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33 Grade
43 Grade
53 Grade
PSS : 5313-2014 ®
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European Adopted standard EN-197
• Newly Adopted in 2014
Require SRO for enforcement
• Broad / Liberal standard
PSS : 5313-2014 ®Classification basis
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• STRENGTH CLASS
32.532,5R 32,5 N
42,542,5 R 42,5N
52,552,5 R 52,5 N
PSS : 5313-2014 ®Classification basis
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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 --
PSS : 5313-2014 ®Classification basis
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• COMPONENT CLASS
CEM-INo Additives
CEM-IIPortland-
Composite Cement
CEM-IIIBlast Furnace
Cement
CEM-IVPozolonic Cement
CEM-VComposite
Cement
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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 ®
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Opportunities• Flexibility
27 Cement types• Vast Marketing ground
Customers needCustomers Financial standingLow Cost cementGreen industry
PSS : 5313-2014 ®Factors
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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
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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
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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.
PSS : 5314-2014 ®Masonry Cement
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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
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MC 5
MC 12.5MC 12.5X
MC 22.5 X
PSS : 5314-2014 ® Masonry CementClassification Basis
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• 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
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PSS : 5314-2014 ®Masonry Cement
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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
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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.
PSS : 5314-2014 ® Masonry Cement
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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
PSS : 5314-2014 ® Masonry Cement
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• Marking & PackingMasonary cement
not used for structural concrete
Bag color
Printing
• URDU• ENGLISH
• White
• Red
PSS : 5314-2014 ® Masonry Cement
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• Opportunities• Low Cost• Market leader
• Risks• Miss use by contractors• Risks associated with illiterate population• Market Acceptability
PSS : 5314-2014 ® Masonry Cement
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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
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Manufacturable Cement types at BCL
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Question’s, Answer’s & Discussion
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