CEMENT

CEMENT:
1. Introduction
2. Ingredients
3. Manufacturing
4. Types.
 CEMENT
Functions of Cement Ingredients: The main
features cement ingredients are given below:
Ingredient Percentage in cement
Lime 60-65
Silica 17-25
Alumina 3-8
Magnesia 1-3
Iron oxide 0.5-6
Calcium Sulfate 0.1-0.5
Sulfur Trioxide 1-3
Alkaline 0-1
Lime:
• Lime is calcium oxide or calcium hydroxide.
• The presence of lime in a sufficient quantity is
required to form silicates and aluminates of
calcium.
• Deficiency in lime reduces the strength of the
property to the cement.
• Deficiency in lime causes the cement to set
quickly.
• Excess lime makes cement unsound.
• The excessive presence of lime causes the
cement to expand and disintegrate.
Silica:
• Silicon dioxide is known as silica, chemical
formula SiO2.
• A sufficient quantity of silica should be present in
cement to dicalcium and tricalcium silicate.
• Silica imparts strength to cement.
• Silica usually presents to the extent of about 30
percent cement.
Alumina:
• Alumina is Aluminium oxide. The chemical formula is
Al2O3.
• Alumina imparts quick setting property to the cement.
• Clinkering temperature is lowered by the presence of
the requisite quantity of alumina.
• Excess alumina weakens the cement.

Magnesia:
• Magnesium Oxide. The chemical formula is MgO.
Magnesia should not be present more than 2% in
cement.
• Excess magnesia will reduce the strength of the cement.
Iron oxide:
• Chemical formula is Fe2O3. Iron oxide imparts color to
cement.
• It acts as a flux.
• At a very high temperature, it imparts into the chemical
reaction with calcium and aluminum to form tricalcium
alumino-ferrite.
• Tricalcium alumino-ferrite imparts hardness and strength
to cement.

Calcium Sulfate:
• Chemical formula is CaSO4 This is present in cement in
the form of gypsum(CaSO4.2H2O)
• It slows down or retards the setting action of cement.
Sulfur Trioxide:
• Chemical formula is SO3 It should not be present
for more than 2%.
• Excess Sulfur Trioxide causes the cement to
unsound.
Alkaline:
• It should not be present more than 1%.
• Excess Alkaline matter causes efflorescence.
Manufacturing of Cement By Dry and Wet Process
In the manufacturing of cement, the following three
important and distinct operations occur:
• Mixing of Raw materials.
• Burning
• Grinding
The process, by which cement is manufactured, depends
upon the technique adopted in the mixing of raw
materials. Therefore, on the basis of mixing the raw
materials, the processes may be classified as:-
• WET PROCESS
• DRY PROCESS
• Out of this wet process is generally used.
The Raw material, which is used for manufacturing
of cement, contains the following materials:
• CALCAREOUS (i.e. chalk consists of limestone.)
• ARGILLACEOUS (i.e. clay consists of silicates of
alumina.)
WET PROCESS
• When the raw materials are soft, then the wet
process is preferable to be used.
• The cement is manufactured by the following
procedure:-
Mixing of Raw Materials:
• In the wet process, there are two raw materials e. calcareous
and argillaceous. Initially, Calcareous materials are crushed
using crushers and argillaceous material is washed With
water in the container.
• After washing the lime stones are stored in silos similarly
after washing the clay is stored in basins.
• The crushed materials from different silos and basins are
drawn in correct proportions in a channel called wet grinding
mills. Both the materials are intimately mixed in the
presence of water and to form a fine thin paste known as
slurry
• Slurry is then stored in another silo may be called as slurry
silo where it is constantly stirred. The composition of raw
materials is checked again and, if required, corrected by
adding clay or chalk materials as desires.
Burning: In this operation, the slurry is directly fed into a long inclined steel
cylinder called a Rotary kiln. In this kiln there are 3 different zones shown in
fig. below
Cement Manufacturing Process Flow Chart
• (i) Drying Zones: In the wet process, the drying zone is comparatively
larger than the dry process. It is because the raw material in slurry form
is directly fed into the kiln which has more amount of water. As shown
in the figure it is the upper portion of the kiln. In this zone, water is
evaporated at a temperature of 100-400°C.
• (ii) Formations of modules: As the slurry gradually descends in the kiln,
the carbon dioxide from the slurry evaporates and small lumps formed
which may be called modules.
• (iii) Burning Zone:- The modules enter this zone where temperatures are
kept about 1400-1500° C. The modules are converted into dark
greenish balls and the product obtained in the kiln, known as clinker, is
of varying size 5 to 20 mm. The clinkers are very hot when coming out of
this zone.
• (iv) Cooling of Clinkers:- rotary kiln is used to cool down the clinkers
up to about 90°C.
Grinding:
• The cooled clinkers are finely ground in ball mills
or tube mills.
• Also, the gypsum is added during grinding about 2-
4%. The gypsum acts as a retarder i.e. it increases
the initial setting time of cement.
Storage and Packing:
• As cement comes out from grinding mills, it is
collected in a hopper and taken in bucket elevator
for storage in silos.
• The cement from silos is packed by machines in
bags. Each bag of cement contains 50 kg or 0.035
m3 of cement.
DRY PROCESS
When the available raw materials are quite hard, then this process
is used.
• Mixing of Raw Materials: The raw materials i.e. argillaceous
and calcareous materials undergo the following stages:-
• Crushing: The raw materials, first of all, are broken into
crushers into small fragments that vary in size.
• Drying: The crushed materials are dried by heating at a
sufficiently high temperature. It may be done in drying kilns.
• Reduction of size: The drying materials are then ground by
using ball mills and tube mills to reduce the size of materials to
find powder.
• Mixing in correct proportion: The finely dried materials are
mixed in exact proportions. The mixing may be done either
mechanically or by pneumatic methods ([Link] under
pressure).
Burning and Grinding:
• These operations are the same as for the wet
process. Except for the mixing of raw materials.
• In the dry process, the raw materials mixed, fined,
and then fed into kiln whereas, in the wet process,
the raw materials are crushed separately and then
directly mixed in correct proportion in the
presence of water to make a fine thin paste known
as Slurry.
Types of Cement
There are different types of cement as classified as follows :-
1. Ordinary Portland Cements
a. 33 Grade
b. 43 Grade
c. 53 Grade
2. Rapid Hardening Cement
3. Extra Rapid Hardening Cement
4. Low Heat Portland Cement
5. Portland Slag Cements
6. Portland Pozzolana cement
7. Sulphate Resisting Portland Cement
8. White Portland Cement
9. Coloured Portland Cement
10. Hydrophobic Cement
11. High Alumina Cement
12. Super Sulphated Cement
13. Special Cement
a. Masonry Cement
b. Air Entraining Cement
c. Expansive Cement
d. Oil Well Cement
1. Ordinary Portland Cement ( OPC )
 Also known as setting cement.
 It is the basic Portland cements and manufactures
in large quantities than all other cements.
 It is presently available in three different grades
viz. C33, C43 and C53.
 The numbers 33, 43 and 53 correspond to the 28
days compressive strength of cement as obtain
from standard tests on cement -sand mortar
specimens.
 It uses in general concrete construction.
2. Rapid Hardening Cement ( RHC )
 It is finer than ordinary Portland cements.
 It contains more C3S and less C2S than OPC.
 The one day strength of this is equal to the 3 days
strength of OPC with the same water cement
ratio.
 The main advantage of rapid hardening cement is
that shuttering may be removed much earlier, thus
saving considerable time and expenses.
 RHC is also used for road work where it is
imperative to open the road traffic with the
minimum delay.
3. Extra Rapid Hardening Cement ( ERHC )
 It is obtained by mixing calcium chloride with RHC.
 Addition of CaCl2 imparts quick setting properties in
extra RHC.
 The acceleration of setting, hardening and evolution of
heat in the early period of hydration makes this cement
very suitable for concreting in cold weathers.
 The 1 or 2 day strength of extra RHC is 25% more than
that of RHC.
 The gain of strength disappears with age and 90 days
strength of extra RHC and RHC are nearly the same.
 Use of extra RHC prohibits in prestressed concrete
construction.
4. Low Heat Portland Cement
 It is a Portland cement which is obtained by reducing more rapidly
hydrating compounds like C3S and C3A and increasing C2S.
 The heat of hydration of low -heat cement shall be as follows :-
 7 days – not more than 65 calories per gm
 28 days – not more than 75 calories per gm
 Since, the rate of gain of strength of this cements is slow, hence
adequate percaution should be taken in this use such as with regard
to removal of formwork, etc.
 LHC uses in massive construction works like abutments, retaining
walls, dams, etc. where the rate at which the heat can be lost at the
surface is lower than at which the heat is initially generated.
 It has low rate of gain of strength, but the ultimate is practically the
same as that of OPC.
5. Portland Slag Cement ( PSC )
 Portland Slag Cement (PSC) is a type of cement that is made by
combining Portland cement clinker, granulated blast furnace slag,
and gypsum. The slag is a byproduct of the iron and steel industry,
and it is ground into a fine powder before being added to the other
ingredients. The mixture is then ground into a fine powder, and it
is ready to be used to make concrete.
 The heat of hydration of portland blast furnace slag cements is
lower than that of OPC. So, this cement can use for mass
concreting but is unsuitable for cold weather.
 It has fairly high sulphate resistance, rendering it suitable for use
in environments exposed to sulphates.
 It uses for all purpose for which ordinary portland cement uses.
 Because of its low heat evolution, it can use in mass concrete
structure such as dams, foundations and bridge abutments.
6. Portland Pozzolana Cement ( PPC )
 It can produce either by grinding together portland cement clinker
and pozzolana with the addition of gypsum or by blending
uniformly portland cement and fine pozzolana.
 PPC produces less heat of hydration and offers great resistance to
the attack of impurities in water than OPC.
 PPC is particularly useful in marine and hydration constructions,
and other mass concrete structures.
 The disadvantage of using PPC is that the reduction in alkalinity
reduces the resistance to corrosion of steel reinforcement.
 This cement has higher resistance to chemical agencies and to sea
water because of absence of lime.
 It evolves less heat and its initial strength is less but final strength
is equal to OPC.
 It has lower rate of development of strength than OPC.