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Cement As A Building Material

Cement is a binder used in construction that sets and binds other materials like sand and gravel to form concrete or mortar. There are two main types of cement - hydraulic cement like Portland cement that sets when mixed with water, and non-hydraulic cement that sets when dry. The cement manufacturing process involves quarrying raw materials like limestone and clay, crushing and grinding them into a powder, burning the powder to form clinker, and finely grinding the clinker with gypsum to produce cement. There are many types of cement used in construction with different properties, such as ordinary Portland cement, rapid hardening cement, and sulfate resisting cement.

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0% found this document useful (0 votes)
390 views44 pages

Cement As A Building Material

Cement is a binder used in construction that sets and binds other materials like sand and gravel to form concrete or mortar. There are two main types of cement - hydraulic cement like Portland cement that sets when mixed with water, and non-hydraulic cement that sets when dry. The cement manufacturing process involves quarrying raw materials like limestone and clay, crushing and grinding them into a powder, burning the powder to form clinker, and finely grinding the clinker with gypsum to produce cement. There are many types of cement used in construction with different properties, such as ordinary Portland cement, rapid hardening cement, and sulfate resisting cement.

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You are on page 1/ 44

CEMENT AS A

BUILDING MATERIAL

JNNCE 1
JNNCE 2
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).

JNNCE 3
• 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).

JNNCE 4
• 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.

JNNCE 5
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.
JNNCE 6
 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).

JNNCE 7
THE CEMENT MANUFACTURING
PROCESS
loader
dumper

1. BLASTING 2. TRANSPORT

storage at
crushing
the plant
conveyor

3. CRUSHING & TRANSPORTATION

JNNCE 8
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.
JNNCE 9
storage at Raw mill
the plant
conveyor Raw mix

1. RAW GRINDING
preheating

kiln

cooling

clinker

2. BURNING

J NNCE 10
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.

JNNCE 11
clinker
storage Finish grinding

1. GRINDING
silos

dispatch
bags

2. STORAGE, PACKING, DISPATCH

JNNCE 12
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.

JNNCE 13
CHEMICAL COMPOSITION OF
CEMENT
 LIME(Cao) :63%
 SILICA(SiO2) :22%
 ALUMINA(Al203) :06%
 IRON OXIDE(Fe2O3) :03%
 GYPSUM(CaSO4.2H2O) :01 –4%

JNNCE 14
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:

 It is called Portland cement because on


hardening(setting)its color resembles to rocks
near Portland in England. It was first of all
introduced in 1824 by Joseph Asp din,
England.
 It is one of the most important type of
cement which is classified into three
grades,namely 33 grade, 43 grade and 53
grade.

JNNCE 16
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%.

JNNCE 17
(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.

JNNCE 18
(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.
JNNCE 19
(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.

JNNCE 20
(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.

JNNCE 21
(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.

JNNCE 22
(7)PORTLAND POZZOLANA
CEMENT:

• OPC clinker and Pozzolana (Calcined Clay,


Surkhi and Fly ash) ground together. Which
produces less heat of hydration and offers
great resistance to attacks of Sulphates.
• Used in marine works and mass concreting.
• Ultimate strength is more than OPC.
• Low shrinkage on drying.

JNNCE 23
(8)PORTLAND SLAG CEMENT:

• Produced by mixing Portland cement


clinker, gypsum and granulated blast
furnace slag which shall not exceed 65%.
• Blackish grey in color.
• Lesser heat of hydration.
• Suitable for marine works, mass concreting.
• Offers good resistance to the attack of
sulphate.
JNNCE 24
(9)HIGH ALUMINA CEMENT:

• It is different from OPC.


• Characterised by its dark color, high heat of
hydration and resistance to chemical attack.
• Initial setting time of 4 hrs and final setting
time of 5 hrs.
• Raw materials used are limestone and
bauxite.

JNNCE 25
(10)AIR ENTRAINING CEMENT:

• OPC with small quantity of air entraining


materials (oils, fats, fatty acids) ground
together.
• Air is entrained in the form of tiny air
bubbles which enhance workability and
reduces segregation and bleeding.
• It increases sulphate water resistance of
concrete.
JNNCE 26
(11)SUPERSULPHATED CEMENT:

• Ground blast furnace slag + OPC + CaSO4.


• Heat of hydration which is considerably
lower.
• It is also resistance to Sulphate attacks.
• Used in a)Marine Structures, b)Mass
concrete works.

JNNCE 27
(12)MASONRY CEMENT:

• Unlike ordinary cement, it is more plastic.


• Made by mixing hydrated lime, crushed
stone, granulated slag or highly colloidal
clays are mixed with it.
• Addition of above mentioned materials
reduces the strength of cement.

JNNCE 28
(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.

JNNCE 29
(14)COLORED CEMENT:

• Suitable pigments used to impart desired


color.
• Pigments used should be durable under
light, sun or weather.

JNNCE 30
(15)WHITE CEMENT:

• OPC with pure white color produced with


white chalk or clay free from iron oxide.
• As iron oxide gives the grey color to
cement, it is therefore necessary for white
cement to keep the content of iron oxide as
low as possible.
• Instead of coal, oil fuel is used for burning.

JNNCE 31
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.

JNNCE 32
 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.

JNNCE 33
 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.

JNNCE 34
 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.

JNNCE 35
 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.

JNNCE 36
 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.
JNNCE 37
NAME SETTING COST AREA OF DISCOUNT NAME OF
OF THE TIME COVERAGE PER BAG THE SHOP
CEMENT

ULTRATE 5 hrs. 330/- 5-10%


CH RENUKA
TRADERS,
MYCEM 8 hrs. 280/- 5-10% SHIMOGA.

ZUARI 330/- 5-10%

RAMCO 330/- 5-10%

PRIYA 310/- 5-10% SURYA


TRADERS,
SHIMOGA.
KARTHIK 10 hrs. 300/- 5-10%

J.K 320/- 5-10%

JNNCE 38
NAME OF SETTING COST AREA OF DISCOUNT NAME OF
THE CEMENT COVERAGE PER BAG THE SHOP
CEMENT
ACC 330/- 5-10%.
SURAKSHA

ACC 350/- 5-10%.


CONCRETE
PLUS
ACC OPC 360/- 5-10%.
SHRI NIDHI
ENTERPRISES,
ULTRATEC 320/- 5-10%.
SHIMOGA.
H PPC

ULTRATEC 330/- 5-10%.


H 43
GRADE
ZUARI 320/- 5-10%.
43 GRADE

JNNCE 39
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
JNNCE 40
NAME OF SETTING COST AREA OF DISCOUNT NAME OF
THE TIME COVERAGE PER BAG THE SHOP
CEMENT

ULTRATEC 340/- 5-10%


H PPC
ULTRATEC 360/- 5-10%
H OPC
ULTRATEC 320/- 5-10%
H 43 VIJAY
GRADE TRADERS,
SHIMOGA.
PRIYA PPC 280/- 5-10%

ACC PPC 340/- 5-10%

ACC OPC 360/- 5-10%

RAMCO 43 310/- 5-10%


GRADE
JNNCE 41
NAME OF SETTING COST AREA OF DISCOUNT NAME OF
THE TIME COVERAGE PER BAG THE SHOP
CEMENT
CORAMAND 320/- 5-10%
AL KING PPC
DRUVA
CORAMAND 330/- 5-10% TRADERS,
AL KING SHIMOGA.
OPC
CORAMAND 335/- 5-10%
AL KING 53
GRADE
ACC F2R 345/- 5-10% PRAMOD

ACC STAR 360/- 5-10%

ACC 360/- 5-10%


COASTAL
ACC GOLD 285-399/- 5-10%

JNNCE 42
ADVANTAGES AND
DISADVANTAGES OF CEMENT

• CEMENT IS VERY STRONG

43
44

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