CONCRETE TECHNOLOGY

PREPARED BY:- PROF. ANUJ

CHANDIWALA

CEMENT MANUFACTURING PROCESS

What is cement?
History
Overview of the cement manufacturing process
Brief overview of kiln operations.

PORTLAND CEMENT
Limestone + shale/clay + heat = clinker + CKD + exit gas
Material temperatures exceed 2700 F
Pulverized clinker + gypsum = Portland cement
Cement is powder so fine that one pound contains 150 billion grains

 Basic chemical components of Portland cement:

Calcium (Ca)
Silicon (Si)
Aluminum (Al)
Iron (Fe)
Typical Raw Materials:
Limestone (CACO3)
Sand (SiO2)
Iron ore/ mill scale (Fe2O3)

PORTLAND CEMENT
Calcareous component

Argillaceous Component

Lime stone

Clay

Marly lime stone

Shale

Chalk

Calcareous marl

Coral limestone

Marl

Marble

Marly clay

Lime- sand

Tuff, ash

Shell deposits

Phyllite, slate

Lime sludge

glass

PORTLAND CEMENT

HISTORY OF PORTLAND CEMENT

First cements produced by early Greeks and Romans from volcanic ash mixed with
slaked lime
This art was lost during the middle ages Portland cement developed in England by
Bricklayer joseph Aspdin in early 1800s
Called Portland because concrete made with it
Resembled natural stone from the isle of Portland

 First rotary kiln designed to produce Portland Cement patented in 1885 by

Frederick Ransome
First economical U.S. Kilns developed by Atlas Cement company in 1895
Thomas A. Edison first developed long kilns (150 Feet compared to 60 to 80
feet).

TYPES OF CEMENT PROCESSES

Wet process
Dry process - 74% of cement produced
Preheater/ Precalciner process

EVOLUTION OF THE CEMENT PROCESS

Wet process easiest to control chemistry & better for moist raw materials.
Wet process high fuel requirements - fuel needed to evaporate 30+% slurry water
Dry process kilns less fuel requirements
Preheater/ Precalciners further enhance fuel efficiency & allow for high production
rates

THE WET CEMENT KILN

The kiln is a continuous stream process vessel in Which feed and fuel are held in
dynamic balance.
5 distinct process functions are performed in the kiln:
Dry Preheat Calcine Sinter Cool

DRY PROCESS PREHEATER/ PRECALCINER

SYSTEM

STEPS IN THE MANUFACTURE OF PORTLAND

CEMENT

STEPS IN THE MANUFACTURE OF PORTLAND

CEMENT

 Proportioning of feed stock.

Size reduction to < 125.
Control of moisture.
Blending to reduce standard deviation.
Uniform delivery rate of feed to the kiln

STEPS IN THE MANUFACTURE OF PORTLAND

CEMENT

CEMENT KILNS
High temperature
Long residence time
Natural alkaline Environment
CKD is only by-product of the
process
Thermal stability

KILN PROCESS CONTROL

Critical parameters: fuel, feed, Kiln speed, gas flow
Kiln temperatures - burning zone
Kiln stability
Chemistry
Instrumentation

THE WET CEMENT KILN

Critical parameters: fuel, feed, kiln speed, gas flow Kiln temperatures.

KILN FUELS

A typical wet kiln burns about 400# of fuel to make a ton of clinker (5.0
mmBtu/ton of clinker) Fuels can be any combustible hydrocarbon such as:
Coal, coke, natural gas, used motor oil, wood, tires, Cellulose others.

 MANUFACTURING OF CEMENT

COMPOSITION OF CONCRETE

CEMENT
The mixture of cement and water is called paste.
The function of paste is to bund sand aggregate particles by the chemical process of
hydration. It also fills the void between sand and aggregate particles.
The strength of concrete depends upon the properties of cement, sand and
aggregates.

AGGREGATE
The aggregates occupy about 75% of the volume of concrete and here their influence on various
properties of concrete is considerable.
Properties of aggregates greatly affect the properties of concrete such as workability, strength,
durability and economy.
To know more about the concrete it is very essential to know about the aggregate.
It is cheaper then cement and impart greater volume stability and durability to concrete.
It is used primarily for the purpose of providing bulk to the concrete.
To increase the density of concrete the aggregate is frequently used in two or more sizes.

WATER
It has been estimated that for C3S and C2S compounds, on an average 23% of water by
weight of cement is required for chemical reaction.
This 23% of water chemically combines with cement and therefore, it is called bound
Water.
A certain quality of water is imbibed within gel- pores. This water is known as gel water.

ADMIXTURE
Admixture is defined as a material other than the basic ingredients of concrete cement,
aggregates and water, added to the concrete mix immediately before or during mixing to
modify some properties of concrete in the fresh or hardened state.
They should not adversely affect any property of concrete.
Admixture are no substitute for good concreting practice.
The use of admixtures like accelerators, retarders, air- entraining agents, pozzolanic
materials, water proofing admixtures etc. is being practiced by Indian construction industry
since long back.
It is generally added in a relatively small quantity ranging from 0.005 to 2% by weight of
cement.

AIR

The air voids in the mass of concrete can be classified in two groups.
Entrapped air
Entrained air

Entrapped air

Entrained air

It is the voids present in the concrete due It is the intentionally incorporated minute
to insufficient compaction.

spherical bubbles.

The size of voids may range from 10 to The size of air bubbles may range from 5 to 80
1000 microns or more.

microns.

The voids are not uniformally distributed The air bubble are uniformally distributed
throughout the concrete mass

throughout the mass of concrete.

STRENGTH MECHANISM
When water is added to cement, ingredients of cement react chemically with water and
form various complicated chemical compounds. The chemical reaction that take place
between cement and water is referred as hydration of cement.
Anhydrous cement does not bind fine and coarse aggregate. It acquires adhesive
property only when mixed with water.
The hydration of cement may happen in two ways. The one is through solution
mechanism, in which the cement compounds dissolve in water to produce a super
saturated solution from which different hydrated products get precipitated. The second
theory is that water attack cement compounds in the solid state converting them into
hydrated products.

CURRENT PRACTICE AND FUTURE TRENDS

Concrete is a versatile material possessing good compressive strength. But is suffers from
many drawbacks like low tensile strength, permeability to liquids, of reinforcement,
susceptibility to chemical attack and low durability.
Modifications have been made from time to time to overcome the deficiencies of cement
concrete. The recent developments in the materials and construction technology have led to
significant changes resulting in improved performance, wider and more economical use.
Improvement in mechanical properties like compressive strength, tensile strength, impact
resistance etc.
Improvement in durability in terms of increased chemical and freeze than resistance.
Improvement in impermeability, thermal insulation, abrasion, skid resistance etc.

READY MIXED CONCRETE

A concrete whose constituents are weight-batched at a central batching plant, mixed
either at the plant itself or in truck mixers, and then transported to the construction site
and delivered in a condition ready to use, is known as ready mixed concrete (RMC).
This technique is very useful in congested sites or at diverse work places and saves the
consumer from the botheration of procurement, storage and handling of concrete
materials.
The use of RMC is also advantages when only small quantity of concrete are required
or when concrete is placed only at intervals.