CEMENT

What is Cement ?
Cement is a binder.

Asubstance that sets and hardens independently, and can bind

other materials together

Afinely ground, grayish color powder.

Commonly known as: Portland cement

 Binding materials

o Lime

o Cement

o Mud
 Evolution of Cement
STAGE 1 : materials used before invention of cement

Clay (calcium silicate)

Calcined Gypsum mortar (calcium sulphate dihidrate)

Mixture of lime (CaCo3)

sand
and water
STAGE 2 : Invention of Pozzolanic cement

Romans were the 1ST ones who developed a cement by mixing

of slaked lime with pozzolana, a volcanic ash from
MountVesuvius.

This cement was called as ‘ Pozzolanic cement ‘ and was

capable of hardening under water.
STAGE 3 : Invention of Portland cement

Joseph Aspdin, a mason produced a material by firing finely

ground clay and limestone until the clay was calcined.

He named it as ‘ Portland cement’ in 1824

STAGE 4 : Development of Portland cement

In 1845, Isaac Johnson made the first modern Portland

Cement by firing a mixture of chalk and clay at much higher
temperatures
STAGE 5 : Invention of different types of Cement

As cement industry went on developing, many different types

of cement with different chemical properties were started
to be manufactured for variety of uses.
 Cement production

Ingredients of cement

o Calcium ( Lime )
o Silicon ( Sand)
o Aluminum (clay)
o Iron
o Sulphate (optional)
Raw Constituents of Cement
➢ Limestone ( CaCO3 ) = Lime
It is present in amount of 70 to 75% of total composition.
Excess of limestone slowdowns the setting process of cement

➢ Mixture ofAlumina (Al2O3) &Silica (SiO2) = Clay

Clay is present in the proportion of 20 to 25% of total composition.
Excess clay can cause cement to set down quickly..

➢ Iron Oxide, Magnesia, Alkalies,etc.

These ingredients are present in very small quantities and are used to control special
chemical properties of cement.
Composition of Cement
 The constituents of cement are present in form of compounds.
Portland cement is made of following main 4 compounds

✓ Tri-Calcium Silicate ( C3S )

✓ Di-Calcium Silicate ( C2S )

✓ Tri-CalciumAluminate ( C3A)

✓ Tetra-Calcium Alumino ferrite ( C4AF )

Small amounts of un-combined lime and magnesia also are present, along
with alkalis and minor amounts of other elements.
 Manufcturing of Cement

1. Blasting and extraction of raw material.

2. Crushing in small pieces
3. Raw Grinding
4. Burning (formation of clinker)
5. Final grinding with addetives
6. Packaging
Manufacturing process

Step 1 :

All the raw materials are extracted from the

quarry and broken down into smaller pieces.

Step 2 :

those broken pieces of raw material along with

some additional ingredients are put in the
blender and blended together
Step 3 :

The blended raw material (called the 'raw feed' or

'kiln feed' )is then crushed and fed into a rotary
kiln where it reaches a temperature of about
1400 C to 1500 C.

Step 4 :

The material formed in the kiln,

described as 'clinker‘ (typically composed
of rounded nodules between 1mm and 25mm
across.) is then passed directly to the
cement mill where it is ground to a fine
powder.
Asmall amount of Gypsum is also added during grinding to control the
setting properties of cement.
 THE CEMENT MANUFACTURING PROCESS
quarry

dumper
loader

Quarry face

1. BLASTING 2. TRANSPORT

storage at
crushing
the plant
conveyor

3. CRUSHING & TRANSPORTATION

1.BLASTING : The raw materials that are used to manufacture cement (mainly limestone and clay) are blasted
from the quarry.
2.TRANSPORT : The raw materials are loaded into a dumper.

3.CRUSHING AND TRANSPORTATION : The raw materials, after crushing, are

transported to the plant by conveyor. The plant stores the materials before they are Next
homogenized.
 THE CEMENT MANUFACTURING PROCESS
Raw grinding and burning

storage at Raw mill

the plant
conveyor Raw mix

1. RAW GRINDING
preheating

kiln

cooling

clinker

2. BURNING

1.RAW GRINDING : The raw materials are very finely ground in order to produce the raw mix.
2.BURNING : The raw mix is preheated before it goes into the kiln, which is heated by a flame that can
be as hot as 2000 °C. The raw mix burns at 1500 °C producing clinker which, when it leaves the kiln, is
rapidly cooled with air fans. So, the raw mix is burnt to produce clinker : the basic material needed to
make cement.
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 THE CEMENT MANUFACTURING PROCESS
Grinding, storage, packing, dispatch

Gypsum and the secondary additives are added

to the clinker.
clinker
storage Finish grinding

1. GRINDING
silos

dispatch

bags

2. STORAGE, PACKING, DISPATCH

1.GRINDING : The clinker and the gypsum are very finely ground giving a “pure cement”. Other secondary
additives and cementitious materials can also be added to make a blended cement.

2.STORAGE, PACKING, DISPATCH :The cement is stored in silos before being dispatched either in
bulk or in bags to its final destination.
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Some leading cement manufacturers

o Lafarge o J K Laxhmi

o Binani o ESSROC

o ACC o Prism

o Birla o Ultratech

o Ambuja o Jaypee
Use of cement

Bridges

Buildings Roads
Dam Canal

Sculpture
Why Cement ?

➢ High compressive Strength

➢ Flexible & mouldable

➢ Easily available

➢ Easy to handle and use

➢ Good Binder

➢ Almost any kind of structure or finishing can be obtained

Ronchamp chapel -- Le Corbusier
Cement use in Various forms
▪ 1. Concrete
A proportioned mixture of cement, sand, aggregate and water.

Sub types

o PCC ( plain cement concrete)

o RCC ( reinforced cement concrete)

Most commonly used form of cement.

 2. Plain Cement Concrete
Concrete used without any reinforcement is called PCC.

Generally used in

Plinth
Foundation bed
Bed block etc.

Thickness of PCC layer may vary

depending on the use and
proportion
Plain Cement Concrete
3. Reinforced Cement Concrete (RCC)
Concrete when reinforced with steel, is called as Reinforced Cement
Concrete. (RCC)
➢ Imparts Tensile and compressive
strength to structure.

➢ Good for going high rise.

➢ Reduces ground solid space,

( compared to load bearing structures) ➢ Gives freedom ofform
giving more usable area.

➢ Non reactive. So can be used

any where in any conditions
Lotus Temple -- Delhi
▪ 4. Mortar
A proportioned mixture of cement, sand and water.

Used as a binder for constructionmaterials.

▪ 5. Cement Bricks

Bricks made from cement and fly ash

 Disadvantages of the use ofcement
➢ Large emission of Carbon Dioxide, increasing Global warming

➢Unlike Lime, Cement does not have a very long life and its strength
starts decreasing after a certainpoint
➢Non-Reusable.
Properties of Portland Cement
✓ Fineness : It refers to the particle size of cement and affects the rate
of hydration which is responsible for the rate of strength gain.
Approximate size of particles is less than 45 microns up to even
15 microns.

✓ Soundness : It refers to the ability of hardened cement paste to retain

its volume after setting.

✓ Consistency : It refers to the ability of cement paste to flow.

It is measured using vicat's apparatus. It
depends on the water - cement ratio.
✓ SettingTime : Cement has two setting times.

Initial setting time is the time elapsed from the instance of adding water
to the cement until the time the paste stops behaving like a fluid.
It is normally 45 minutes for OPC.

Final setting time is the time required by the cement paste to reach
certain state of hardness to sustain load
It is normally 10-12 hours for OPC.
✓ Compressive strength :
Strength of cement mortar varies according to time. It is generally reported
as 3 days, 7 days and 28 days strength.

✓ Heat of hydration :
The heat generated during the reaction of cement and water is known as
heat of hydration.
Factors affecting heat of hydration are C3A (Tri calcium aluminates),
C3S (Tri calcium aluminates),Water cement ratio, fineness of cement
and curing temperature.

Conduction calorimeters is used to test heat of hydration.

✓ Bulk density : It is the ratio of total mass to the volume of cement.

Bulk density ranges from

830 kg/cu.mt. To1600 kg/cu.mt.

✓ Loss on Ignition: The weight of cement lost after it being heated is called
as the loss on ignition. Loss more than 3% indicates pre
hydration .
 Steps involved in structure
formation

✓ Mixing : Mixing of concrete and water to form a slurry

✓ Placing : Pouring the slurry into the formwork

✓ Hydration / Setting : Hydration means Reaction with water.

The hydration of Portland cement is the chemical reaction

between grains of cement and water to form the hydration product, cement gel
which can be laid down only in water-filled space
 ✓ Curing
Curing can be defined as a procedure for insuring the hydration of the
Portland cement in newly-placed concrete.

It generally implies control of moisture loss and sometimes of

temperature.

Following are the results of concrete

▪ Increase concrete strength
▪- Increase concrete abrasion resistance
▪- Lessen the chance of concrete scaling
▪- Lessen the chance of surface dusting
▪- Lessen the chance of concrete cracking
Water Curing
 TYPES OF CEMENTS

➢ Ordinary Portland Cement ➢ Air Entraining cement

➢ Rapid Hardening Cement ➢ Coloured cement

➢ Sulphate Resisting Cement ➢ Hydrophobic cement

➢ Quick setting Cement ➢ Masonry cement

➢ Super Sulphated Cement ➢ Rediset cement

➢ Low Heat Cement ➢ High alumina cement

➢ Portland Pozollana Cement ➢ High early strength cement

 TYPES OF PORTLAND CEMENTS
Five types of Portland cement are standardized in the United States by the
AmericanSociety for Testing and Materials(ASTM)

✓ Type 1 : Ordinary

✓ Type 2 : Modified ( Quick setting cement)

✓ Type 3 : High Early strength

✓ Type 4 : Low heat

✓ Type 5 : Sulphate Resistant

✓ Ordinary Cement
• Ordinary Portland cement (OPC) is the most important type of cement.

• The OPC is classified into three grades, namely 33 grade, 43 grade and
53 grade depending upon the strength of the cement at 28 days when tested
as per IS 4031-1988.

(If the 28 daysstrength is not lessthan33N/mm2,

it is called 33 gradecement, if the strength is not lessthan 43N/mm2, it is called
43 gradecement, and if the strength is not lessthan 53 N/mm2, it iscalled
53 grade cement).

• Most commonly used cement.

• Eg:- normal buildings, sidewalks etc.

✓ Quick setting Cement / Medium sulphate resistant

• This cement as the name indicates sets very early.

• The early setting property is brought out by reducing the gypsum content
at the time of clinker grinding.
• This cement is required to be mixed, placed and compacted very early.
• It is used mostly in under water construction where pumping is involved.
Use of quick setting cement in such conditions reduces the pumping time
and makes it economical.
• Quick setting cement may also find its use in some typical grouting operations.
• Moderate sulphate resistance.
• Moderate heat of hydration
✓ High Early Strength. ( Rapid Hardening Cement )

▪ As the name indicates it develops strength rapidly.

▪ Rapid hardening cement develops strength at a higher rate whereas

Quick setting-cement sets quickly.

▪ Rapid hardening cement develops at the age of three days the same strength,
as that is expected of ordinary Portland cement at seven days.

▪ The rapid rate of development of strength is attributed to the higher fineness

of grinding and higher C3S and lower C2S content.

▪ The higher fineness of cement particles expose greater surface area for action
of water and also higher proportion of C3S results in quicker hydration.
.
Uses of Rapid hardening cement:

▪ In pre-fabricated concrete construction.

▪ Where formwork is required to be removed early for reuse.

▪ Road repair works.

▪ In cold weather concrete where the rapid rate of

development of strength reduces the vulnerability of
concrete to the frost damage.
✓ Low heat cement
• It is well known that hydration of cement produces large quantity of heat
during hydration.

• Formation of cracks in large body of concrete due to heat of hydration has

focused the attention of the concrete technologists to produce a kind of
cement which produces less heat or the same amount of heat, at a low rate
during the hydration process.

• Alow-heat evolution is achieved by reducing the contents of C3S and C3A

which are the compounds evolving the maximum heat of hydration and
increasing C2S.

• Areduction of temperature retards the chemical action of hardening and so

further restrict the rate of evolution of heat.

• It is used in mass concrete construction, such as dams, where temperature rise

by the heat of hydration can become excessively large.
✓ Sulphate Resistant Cement

▪ Ordinary Portland cement is susceptible to the attack of sulphates, where

during setting sulphate reacts with the calcium and aluminium
from cement to form other compounds.

▪ The expansion of these other compounds in hardened cement results in crack

formation in concrete structures.

▪ Toavoid this, the use of cement with low C3Acontent is found to be effective.
Such cement with low C3A and comparatively low C4AF content is known as
Sulphate Resisting Cement.
Uses of Sulphate resisting cement:

• Concrete to be used in marine condition.

• Concrete to be used in foundation and basement, where soil is infested

with sulphates.

• Concrete used for fabrication of pipes which are likely to be buried in

marshy region or sulphate bearing soils.

• Concrete to be used in the construction of sewage treatment works.

There are some more types of cements commonly available and used.

✓ Coloured cement
▪ Coloured cements are made by grinding 5 to 10 percent of suitable
pigments with white or ordinary gray Portland cement
▪ Used for Aesthetic purpose.

✓ Air Entraining Cement

▪ Air-entraining cements are made by the addition on grinding of a small amount,
about 0.05 percent, of an organic agent that causes the entrainment of very fine
air bubbles in a concrete
▪ This increases the resistance of the concrete to freeze-thaw damage in cold climates.
There are some more types of cements commonly available and used.

✓ Low-Alkali cement
▪ Low-alkali cements are Portland cements with a total content of
alkalis not above 0.6 percent.

✓ Oil WellCement
▪ Oil-well cements are used for cementing work in the drilling of oil wells where
they are subject to high temperatures and pressures.

▪ They usually consist of Portland or Pozzolanic cement with special organic

retarders to prevent the cement from setting too quickly.
✓ Portland Blast furnace slag cement

▪ The granulated slag made by the rapid chilling of suitable molten slags
from blast furnaces forms the basis of another group of constructional cements.

▪ Amixture of Portland cement and granulated slag, containing up to 65

percent slag, is known as blast furnace / slag cement.

▪ Properties of these slag cements are broadly similar to those of Portland cement,
but they have a lower lime content and a higher silica and alumina content.

▪ Those with the higher slag content have an increased resistance to chemical attack.