Hydraulic cement

“ Hydraulic cement is used almost exclusively as a structural material. It is an essential ingredient of concrete. Originally used chiefly for the bonding of brick and stone masonry and for foundation work, its uses have grown rapidly, especially with the introduction of reinforced concrete. ”

“ Cement is more expensive than brick. The surface to be covered should, first, be levelled, then saturated with water; after which is laid a three-inch bed of cement concrete, made of gravel, sand, and cement in proper proportions. Upon this is placed a three-fourth-inch layer of cement mortar. Ordinary American, hydraulic cement may be used for concrete, but for the three-fourth-inch layer nothing but best Portland cement should be considered. Sometimes the cement work in the cellar is done by the plasterer. Outside cement work for walks requires special skill. ”

“ Where the soil consists of a natural bed of loam, sand, or rock, the house-sewer may be of hard, salt-glazed, and cylindrical earthenware pipe, laid on a smooth bottom, free from all projections of rock, and with the soil well rammed to prevent any settling of the pipe. Each section must be wetted before applying the cement, and the space between each hub and the small end of the next section must be completely and uniformly filled with the best hydraulic cement. Care must be taken to prevent any cement being forced into the drain to become an obstruction. No tempered-up cement shall be used. ”

“ Others are sinking “driven” wells and protecting them with concrete housings. The principle of deep wells for pure water, among other things, has made gasoline engines a necessity on the farm. These engines and hydraulic rams at springs, firmly set and housed in concrete, supply an abundance of water for the concrete reservoirs or elevated, reinforced pressure tanks. From these places of storage water is distributed to float-controlled, rot-proof watering tanks and troughs of the same material. ”

“ It was not until the end of the last century that the true principles of hydraulic cement were discovered by Smeaton, who, in the construction of the Eddystone Lighthouse, made a number of experiments with the English limestones, and laid down, as a result, the principle that a limestone yielding from fifteen to twenty-five per cent of residue when dissolved in hydrochloric acid will set under water. ”

“ The beds of sewers, therefore, should be made of good flat stones, or, which is still better, of hydraulic cement, when it can be procured, because the water finds its way between the joints of the stones; while, if the cement is properly used, it forms along the whole channel one homogeneous mass perfectly water-tight. Besides we take care to give to the bed of a drain a section slightly concave, joining its walls without angles; for water takes advantage of angles to effect its work of destruction. Angles, moreover, are not easily cleared out when subterranean channels have to be cleansed. ”

“ An hydraulic cement may also be made which will serve for the manufacture of architectural ornaments, by making a paste of pulverised chalk, with a solution of the silicate of potash. The said liquor of flints likewise gives chalk and plaster a stony hardness, by merely soaking them in it after they are cut or moulded to a proper shape. On exposure to the air they get progressively indurated. Superficial hardness may be readily procured by washing over the surface of chalk, &c., with liquor of flints, by means of a brush. ”

“ Added to block concrete, in the proportion of 1/4 to 1/2 the cement used, it will be found to make the blocks lighter in color, denser, and decidedly less permeable by water.
Cement.—Portland cement is the only hydraulic material to be seriously considered by the blockmaker. Natural and slag cements and hydraulic lime are useful for work which remains constantly wet, but greatly inferior in strength and durability when exposed to dry air. A further advantage of Portland cement is the promptness with which it hardens and develops its full strength ”

“ Some piers in the Rosetta Barrage were therefore chosen for a similar experiment, but this time liquid Portland cement was used instead of clay, and the results were entirely satisfactory. Few discoveries have been of more signal service than the invention of Portland cement. It is not too much to say that it has revolutionized hydraulic engineering by the facilities it affords for constructing solid works in water. ”

“ It has been shown that the best hydraulic lime, or volcanic puzzuolana and lime, if properly ground while slaking, and otherwise treated in the best-known manner, as well as some of the so-called natural (calcareous) cements, will yield results certainly not inferior to those obtained from Portland cement. The only objection that can in any case be urged against most of the natural products is that a longer time is required for induration ”

“ This was made by first laying down six inches of well-prepared concrete, consisting of pounded granite, brick-dust, and gravel cemented together by hydraulic mortar, then overlaid with pure cement, and after this coated with an inch thick of asphalt. Around the whole building was an open drain, about two feet inside of the pillars, and built like the floor, and carefully graded to the outfall. The walls, pillars, and drains were coated with coal tar, and here and there daily renewed to ensure deodorization. ”

“ In English practice hydraulic lime is slaked by the user. Seeing that regular and perfect slaking is more easily attained when working systematically on a large scale and by storing the material for a long period, the French method is the better and more rational. The product may then be regarded as a cement of the Portland class mixed with slaked lime. When gauged with water and made into a mortar it sets slowly, but ultimately becomes almost as strong as Portland cement. Its slow setting is an advantage for some purposes, e.g. ”

“ The best lime is that procured from boulders, which when mixed in the proportion of one part lime to two parts of soorkee, or pounded brick, forms an excellent mortar for hydraulic works. Kunkur lime, as a rule, is simply mixed with sand. When lime is burnt with oopla, care must be used in sifting and separating it from the ashes of the burnt fuel, otherwise, of course, its strength will be greatly impaired. Artificial cements have scarcely hitherto been made or used in India. You will find a valuable paper on the relative cost of the manufacture and importation of Portland cement, in No. ”

“ Some builders like wet concrete and some like dry concrete. It should be noticed, however, that wet concrete is cheaper because it requires little or no tamping. Wet concrete, however, should be spaded, that is, a spade forced down into the mixture, particularly against the forms, so that particles of air caught between the stones may escape, and so that there may be no pockets between the stones into which the liquid cement mixture does not penetrate. It is generally considered that about fifteen per cent of the volume of concrete is the necessary volume of water for the mixture. ”

“ Where can better concrete be found than that which has set under water? A certain definite amount of water is necessary and sufficient to hydrate the cement; less than that amount will be detrimental, while an excess can do no harm, provided, as before mentioned, that it does not wash the mortar from the stone. Again, dry concrete is apt to be very porous, which in certain positions is a very grave objection to it—this, not only from the fact of its porosity, but from the liability to disintegration from water freezing in the crevices. ”

“ Under such circumstances the membrane treatment used in addition to a properly proportioned concrete, while the most expensive method of waterproofing, probably will give the most reliable results. This treatment consists of layers of burlap or tar paper cemented to the surface and together with tar or asphalt. Where the membrane is subject to injury it is sometimes protected by a coating of cement mortar or brick backing.
First-class workmanship and special attention to details are required to secure water-tightness. The essential requisite is that the voids be filled. ”

“ The lift from the bottom of the car is excessive, and as pointed out previously, shoveling stone or gravel by digging into it from the top is a difficult task.
The delivery of the concrete into the forms was accomplished by chute where possible, otherwise by wheelbarrows or cranes, and in one case by belt conveyor. In the last instance the mixer car was equipped with a Drake continuous mixer and was set in front. Behind it came three or four gondola cars of sand and stone, and at the rear end a box car of cement. All material was wheeled on side runways to two charging hoppers over the mixer. ”

“ Workability is an important quality; in some respects it will have to be obtained at the expense of strength. Increasing the amount of mixing water increases the workability of the mixtures, with a resulting decrease in strength which may have to be accepted or else overcome by increasing the cement in the mix.
180An excess of water is often used unnecessarily through ignorance of the injurious results. A high proportion of coarse aggregate, up to a certain limit, will give concrete of high strength, but the mixture will be harsh-working and not easy to place. ”

“ Fresh concrete will riot bond readily to concrete that has hardened and a seam may be formed that will permit water to trickle through. When bonding fresh concrete to that which has been in place for a short time it is usually sufficient to roughen the hardened surface with a pick or by other means so as to expose the gravel or stone, and to clean off all loose particles. The hardened concrete should be soaked with water, the excess water removed, and the surface then given a coat of grout (a mixture of cement and water) of the consistency of cream just before the new concrete is deposited. ”

“ The principal causes of scaling or crumbling surfaces are improper mixing, drying out before the cement has thoroughly hardened and the use of bad materials.
Cement needs water not only when mixed, but after being placed and tamped, and until it has entirely hardened. If concrete is not kept continually wet until hard, it is weakened, and the surface of such a walk scales or becomes soft and chalky. ”

“ It is obvious in the case of a reservoir embankment or a slope alternately submerged and unsubmerged, that an exposed clay puddle covering cannot be used, as heat or the sun’s rays will cause it to crack, although if constantly wet it would succeed. A puddled clay covering with a broken stone bed placed upon it to receive dry or mortar-set stone pitching has been frequently adopted; a simple cement concrete facing about 6 to 12 inches in thickness, depending upon the depth of the water and the nature of the soil, or in conjunction with an asphalt coating of ordinary thickness. ”

“ At times a lean mixture, 1 cement, 3 sand, 5 gravel, might be advantageously adopted. Where gravel or broken stone is not used, the proportion of cement to sand should be as 1 to 4. A fat mixture has greater tensile strength than a lean mixture, but resistance to compression depends upon a thorough filling of voids. A lean mixture thoroughly worked, proves more satisfactory than a fat mixture with hasty and indifferent handling. With any mixture success is attained only by completely coating every grain of sand with cement, and every piece of stone or gravel with the sand-cement mortar. ”

“ Spread out the mixture of sand and gravel as much as the board will readily permit, add enough water to wet the gravel and sand thoroughly, spread the cement evenly in a thin layer over the sand and gravel, and turn over, as described previously, at least three times, adding the rest of the water necessary to get the required consistency while the materials are being turned. It requires some experience to work up a natural mixture of bank sand and gravel, and if at all doubtful about the concrete made from it, first screen the sand from the gravel, and then mix in the regular way. ”

“ It can be transported on a belt conveyor, elevated by bucket conveyer, mixed with sand and cement and delivered to the work all with very little manual labor when the installation of a very efficient plant is justified by the magnitude of the job. Large rubble stones cannot be handled so cheaply or with so great rapidity as crushed stone; the work may be so expensive, due to repeated handlings, as to offset the cost of crushing as well as the extra cost of cement in plain concrete. ”

“ The ideal mixture is one in which all the spaces or voids between the grains of sand are filled with the cement and all the voids in the gravel are filled with the cement-sand mortar. This perfection is seldom attained, because the voids in each lot of gravel and sand vary slightly, and in order to be absolutely safe a little more sand and cement than will just fill the voids are used.
The strongest concrete is not required in every structure, and, in many instances, the cost of it would be unwarranted. ”

“ Safety in this respect calls for a much greater degree of hardness than would be needed to bear the weight of the building. Again, strength and hardness, with a given proportion of cement, depend greatly on the character of the other materials used; blocks made of cement and sand, 1 to 3, will not be so strong or so impermeable to water as those made from a good mixed sand and gravel, 1 to 5. On the whole, it is doubtful whether blocks of satisfactory quality can be made, by hand mixing and tamping, under ordinary factory conditions, from a poorer mixture than 1 to 5. ”