Cement As A Building Material
Cement As A Building Material
BUILDING MATERIAL
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INTRODUCTION
• CEMENT:
A cement is a binder, a substance used
for construction that sets, hardens, and adheres
to other materials to bind them together. Cement
is seldom used on its own, but rather to bind
sand and gravel (aggregate) together. Cement
mixed with fine aggregate produces mortar for
masonry, or with sand and gravel,
produces concrete. Cement used in construction
are usually inorganic, often lime or calcium
silicate based, and can be characterized as
either hydraulic or non-hydraulic, depending
on the ability of the cement to set in the presence
of water (see hydraulic and non-hydraulic lime
plaster).
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• Non-hydraulic cement: does not set in wet conditions
or under water. Rather, it sets as it dries and reacts
with carbon dioxide in the air. It is resistant to attack by
chemicals after setting.
• Hydraulic cements: (e.g., Portland cement) set and
become adhesive due to a chemical reaction between
the dry ingredients and water. The chemical reaction
results in mineral hydrates that are not very water-
soluble and so are quite durable in water and safe from
chemical attack. This allows setting in wet conditions
or under water and further protects the hardened
material from chemical attack. The chemical process
for hydraulic cement found by ancient Romans
used volcanic ash (pozzolana) with added lime
(calcium oxide).
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• The word "cement" can be traced back to
the Roman term opus caementicium, used to describe
masonry resembling modern concrete that was made
from crushed rock with burnt lime as binder.The
volcanic ash and pulverized brick supplements that
were added to the burnt lime, to obtain a hydraulic
binder, were later referred to
as cementum, cimentum, cäment, and cement. In
modern times, organic polymers are sometimes used
as cements in concrete.
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History of Cement
The cementitious properties of lime in mortars
and concrete have been known since early
historic times. The Romans used lime
concretes and developed pozzolanic cements
of lime and certain volcanic earths.
Lime mortars and concretes continued to be
used in the middle Ages.
1824, Joseph Aspdin from Leeds city -
England, produced a powder made from the
calcined mixture of limestone and clay.
He called it "Portland Cement", because when
it hardened it produced a material similar to
stones from the quarries near Portland Island
in UK.
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Although the method of making cement has been improved,
the basic process has remained same.
Cement production in Turkey was first started in Darıca
Cement Factory in 1913 with a production capacity of
20,000 ton/year.
Today the annual cement production in Turkey is more than
25 million tons from more than 50 cement factories all over
the country.
In North Cyprus, there is 1 cement factory (BEM--Boğaz
Endüstri Madencilik Ltd.). Rest of cement comes from
other countries (i.e. Turkey, Lebanon, Egypt, Syria).
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THE CEMENT MANUFACTURING
PROCESS
loader
dumper
1. BLASTING 2. TRANSPORT
storage at
crushing
the plant
conveyor
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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
homogenized.
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storage at Raw mill
the plant
conveyor Raw mix
1. RAW GRINDING
preheating
kiln
cooling
clinker
2. BURNING
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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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clinker
storage Finish grinding
1. GRINDING
silos
dispatch
bags
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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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CHEMICAL COMPOSITION OF
CEMENT
LIME(Cao) :63%
SILICA(SiO2) :22%
ALUMINA(Al203) :06%
IRON OXIDE(Fe2O3) :03%
GYPSUM(CaSO4.2H2O) :01 –4%
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TYPES OF CEMENT
1. ORDINARY PORTLAND CEMENT.
2. RAPID HARDENING CEMENT.
3. EXTRA RAPID HARDENING CEMENT.
4. SULPHATE RESISTING CEMENT.
5. QUICK SETTING CEMENT.
6. LOW HEAT CEMENT.
7. PORTLAND POZZOLANA CEMENT.
8. PORTLAND SLAG CEMENT.
9. HIGH ALUMINA CEMENT.
10. AIR ENTRAINING CEMENT.
11. SUPERSULPHATED CEMENT.
12. MASONRY CEMENT.
13. EXPANSIVE CEMENT.
14. COLORED CEMENT.
15. WHITE CEMENT. JNNCE 15
(1) ORDINARY PORTLAND
CEMENT:
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Chemical Composition of O.P.Cement:
O.P.C has the following approximate chemical
composition:
The major constituents are:
1.Lime (Cao) 60 – 63%.
2.Silica (SiO2) 17 – 25%.
3.Alumina (Al2O3) 03 – 08%.
4.Iron Oxide (Fe2O3) 0.5 – 06%.
5.Magnesia (MgO) 1.5 – 03%.
6.Sulphur Tri Oxide (SO3) 01 – 02%.
7.Gypsum 01 – 04%.
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(2)RAPID HARDENING CEMENT:
• Also known as early gain in strength of cement. This
cement contains more %tage of C3S and less %tage of
C2S,high proportion of C3S will impact quicker
hydration.
• The high strength at early stage is due to fine grinding,
as fineness of cement will expose greater surface area
for the action of water.
• The strength obtained by this cement in 03 days is same
as obtained by O.P.C in 7 days.
• Initial and final setting times are same as O.P.C .ie.
30mins and 10hrs.
• Greater lime content than O.P.C.
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(3)EXTRA RAPID HARDENING
CEMENT:
• It is obtained by intergrinding CaCl2 with rapid
hardening cement.
• Addition of CaCl2 should not exceed 2% by
weight of the rapid hardening cement.
• Concrete made by using this cement should be
transported, placed, compacted & finished
within about 20 minutes.
• Strength is higher than 25% than that of rapid
hardening cement at 1 or 2 days.
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(4)SULPHATE RESISTING
CEMENT:
• It is modified form of O.P.C and is specially
manufactured to resist the sulphates.
• This cement contains a low %tage of C3A and
high %tage of C3S.
• This cement requires longer period of curing.
• It develops strength slowly, but ultimately it is
as strong as O.P.C.
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(5)QUICK SETTING CEMENT:
• This cement is manufactured by adding small
%tage of aluminium sulphate (Al2SO4) which
accelerates the setting action.
• Gypsum content is reduced.
• Sets faster than O.P.C.
• Initial setting time is 5 minutes. Final setting
time is 30 minutes.
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(6)LOW HEAT CEMENT:
• Low percentage of tri-calcium aluminates (C3A) and
silicate (C3S) and high %tage of di-calcium silicate
(C2S) to keep heat generation low.
• Very slow rate of developing strength as rate of C3S
content is low.
• Heat evolved @ 7 days – 66 cal/g and 28 days – 75
cal/g.
• Initial set time – 1 hr, final set time – 10 hrs.
• Better resistance to chemical attack than O.P.C.
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(7)PORTLAND POZZOLANA
CEMENT:
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(8)PORTLAND SLAG CEMENT:
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(10)AIR ENTRAINING CEMENT:
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(12)MASONRY CEMENT:
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(13)EXPANSIVE CEMENT:
• The main difference in this cement is the incre ase
in volume that occurs when it settles.
• Used to neutralize shrinkage of concrete made from
ordinary cement so as to eliminate cracks. A small
percentage of this cement with concrete will not let
it crack. It is specially desirable for hydraulic
structures.
• In repair work, it is essential that the new concrete
should be tight fitting in the old concrete This can
be done by using this cement.
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(14)COLORED CEMENT:
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(15)WHITE CEMENT:
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MAJOR CEMENT
MANUFACTURERS IN INDIA
1.ACC Limited.
2.Aditi Industries.
3.Zuari cement Ltd.
4.Ambuja Cement Ltd.
5.Anjani Portland Cement Ltd.
6.Asian Concretes Cement Ltd.
7.Bagalkot Cement & Inds.Ltd.
8.Bharti Cement Corpn. Pvt. Ltd.
9.Bhavya Cement Ltd.
10.Binani Cement Ltd.
11.Birla Corporation Ltd.
12.Cement Corporation of India Ltd.
13.Century Textiles and Industries Ltd.
14.Chalukiya Cements.
15.Chettinad Cement Corporation Private Limited.
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16.Creative Housewares Pvt. Ltd.
17.Dalmia Cement (Bharat) Ltd.
18.Deccan Cement Ltd.
19.Emami Cement Ltd.
20.Goldstone Cements Ltd.
21.Green Valliey Industries Limited.
22.Gujarat Sidhee Cement Ltd.
23.H K Cement Industries Private Limited.
24.HeidelbergCement India Ltd.
25.Hemadri Cement Ltd.
26.Hemawati Cement Industries.
27.India Cements Ltd.
28.J & K Cement Corporation.
29.J.K. Cement Ltd.
30.J.S.W. Cement Ltd.
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31.Jagdamba Industries Limited.
32.Jaiprakash Associates Ltd.
33.Jammu & Kashmir Cements Ltd.
34.Janta Cement Industries.
35.Jay Shree Kripa Cement Pvt. Ltd.
36.Jindal Shakti Cement.
37.JK Lakshmi Cement Ltd.
38.K. J. S. Cement Ltd.
39.K.C.P. Ltd.
40.Kakatiya Cement & Sugar Industries Ltd.
41.Kalyanpur Cements Ltd.
42.Kamdhenu Cement Ltd.
43.Kesoram Cement.
44.M/S. VIJAY CEMENTS.
45.Madras Cements Ltd.
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46.Malabar Cements Ltd.
47.Mancherial Cement Ltd.
48.Mangalam Cement Ltd.
49.Mawmluh Cherra Cements Ltd.
50.Meghalaya Cements Ltd.
51.MPL Cement And Sponge Private Ltd.
52.My Home Industries Private Limited.
53.Nuvoco Vistas Corp. Ltd.
54.OCL India Ltd.
55.Orient Cement.
56.Panyam Cement & Mineral Industries Ltd.
57.Parasakti Cement Ltd.
58.Penna Cement Industries Ltd.
59.Prism Johnson Ltd.
60.Purbanchal Cement Ltd.
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61.R.V.R Exports And Imports.
62.Rain Cements Ltd.
63.Reliance Cement Company Private Limited.
64.RNB Cements (P) Ltd.
65.S.A.L. Steel Limited.
66.Sagar Cement Ltd.
67.Sanghi Industries Ltd.
68.Saurashtra Cement Ltd.
69.Shiva Industries.
70.Shivalik Cement Industries.
71.Shree Cement Ltd.
72.Shree Digvijay Cement Co. Ltd.
73.Shree Jagjothi Cement Ltd.
74.Shri Keshav Cements and Infra Ltd.
75.Shri Lakshmi Industries.
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76.Shri Ram Industries.
77.Shriram Cement Works.
78.Sree Jayajothi Cements Pvt.Ltd.
79.Srikalahasthi pipes limited.
80.Star Cement Limited.
81.Sunrise Cement Industries.
82.SVS Cement Products.
83.Tamil Nadu Cements Corpn. Ltd.
84.Tatachemicals Ltd.
85.UltraTech Cement Ltd.
86.Uma Cement Industries.
87.Vadraj Cement Ltd.
88.Viket Sagar Cement.
89.Wonder Cement Ltd.
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NAME SETTING COST AREA OF DISCOUNT NAME OF
OF THE TIME COVERAGE PER BAG THE SHOP
CEMENT
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NAME OF SETTING COST AREA OF DISCOUNT NAME OF
THE CEMENT COVERAGE PER BAG THE SHOP
CEMENT
ACC 330/- 5-10%.
SURAKSHA
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NAME OF SETTING COST AREA OF DISCOUNT NAME OF THE
THE TIME COVERAGE PER BAG SHOP
CEMENT
MAHA 43 300/- 5-10%
GRADE
MAHA 290/- 5-10%
PPC
BIRLA 340/- 5-10%
SHAKTHI
43 GRADE
MOOKAMBHIKA
BIRLA 330/- 5-10% ENTERPRISES,
SHAKTHI SHIMOGA.
PPC
BIRLA 350/- 5-10%
SHAKTHI
53 GRADE
KARTHIK 280/- 5-10%
PPC
MYCEM 280/- 5-10%
PPC
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NAME OF SETTING COST AREA OF DISCOUNT NAME OF
THE TIME COVERAGE PER BAG THE SHOP
CEMENT
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ADVANTAGES AND
DISADVANTAGES OF CEMENT
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