Name 205

Shipbuilding Materials and Metallurgy

Present No:14
Prof. Dr. Md. Abdul Gafur
PP&PDC, BCSIR and Adjunct Faculty, MIST

CEMENT
 Ceramic raw materials are joined using a binder
Cement that does not require firing on sintering in a
process called cementation. of sodium
silicate, the introduction of CO2 gas acts as
a catalyst to dehydrate the sodium silicate
solution into a glassy material:
xNa2O +ySiO2.H2O + CO2  glass
Figure shows silica sand grains used to
produce molds for metal casting. The
liquid sodium silicate coats the sand
Figure grains and provides bridges between
A micrograph of silica sand grains
bonded the sand grains. Introduction of the
with sodium silicate through the CO2 converts the bridges to a solid,
cementation mechanism (X60).
joining the sand grains.
 Cement
• Fine alumina powder
dispersions catalyzed with
phosphoric acid produce an
aluminum phosphate cement
Al2O3 + 2H3PO4  2AlPO4 +
3H2O
• When alumina particles are
bonded with the aluminum
phosphate cement,
refractories capable of
operating at temperatures as
high as 1650°C are produced.
• Plaster of paris, or gypsum, is
another material that is
hardened by a cementation
reaction:
• CaSO4.1/2 H2O + 3/2H2O
CaSO4. 2H2O
• When the liquid slurry reacts,
interlocking solid crystals of gypsum
(CaSO4. 2H2O) grow with very small
pores between the crystals.
• Larger amounts of water in the
original slurry provide more porosity
and decrease the strength of the final
plaster.
• One of the important uses of this
material is for construction of walls in
buildings.
• The most common and important of
the cementation reactions occurs in
Portland cement, which is used to
produce concrete
 Portland Cement
• Cements are classified as hydraulic and
nonhydraulic.
• Hydraulic cements set and harden under water.
Nonhydraulic cements (e.g., lime, CaO) cannot
harden under water and require air for
hardening.
• Portland cement is the most widely used and
manufactured construction material.
• It was patented by Joseph Aspdin in 1824 and is
named as such after the limestone cliffs on the
Island of Portland in England.
 Portland Cement
• Hydraulic cement is made from calcium silicates with an
approximate composition of CaO (60 to 65%), SiO2 (20 to
25%), and iron oxide and alumina (7 to 12%).
• The cement binder, which is very fine in size, is composed of
various ratios of 3 SiO2.Al2O3 (S3A), 2CaO.SiO2 (C2S)
,3CaO.SiO2 (C3S), 4CaO.A2O3.Fe2O3 (C4AF) and other
minerals.
• In the cement terminology, CaO, SiO2, Al2O3, and Fe2O3 are
often indicated as C, S, A, and F, respectively. Thus, C3S means
3CaO-SiO2.
• When water is added to the cement, a hydration reaction
occurs, producing a solid gel that bonds the aggregate
particles.
Types of Cements
 Reaction with water
• 2C3S+6H 3Ch+C3S2H3 (tobomorite gel)
• 2C2S+4H Ch+C3S2H3 (tobomorite gel)
• C3A+10H+CSH2 C3ACSH12 aluminino monosulpahte hydrate
Calcimum

• C3A+12H+Ch C3AChH12 tetracalcium alumininate hydrate

• C4AF+10H+ChC6AFH12 calcium alumininate hydrate

• Concrete is an aggregate composites – is a combination

of sand and gravel (aggreate) bounded by cement with
water. Cement is the matrix. Modern concrete uses
the portland cement named for the Island of
Portland where a local local limestone closely
resembles to the synthetic product.
Pozzolana, also spelled pozzuolana, or pozzolan,
hydraulic cement discovered by the Romans and
still used in some countries, made by grinding
pozzolana (a type of slag that may be either
natural—i.e., volcanic—or artificial, from a blast
furnace) with powdered hydrated lime.
Roman engineers used two parts by weight of
pozzolana mixed with one part of lime to give
strength to mortar and concrete in bridges and
other masonry and brickwork.
During the 3rd century BC, the Romans used
pozzolana instead of sand in concrete and
mortared rubblework, giving extraordinary
strength.
Used with an aggregate of broken tuff, travertine,
brick, or marble, the material contributed to the
evolution of new architectural forms in such
monumental constructions as the Pantheon and
the Baths of Caracalla at Rome.
Pozzolana was first found at Puteoli
(modern Pozzuoli), near Naples, where
there are still extensive beds, and also
around Rome.
Natural pozzolana is composed mainly of a
fine, chocolate-red volcanic earth. An
artificial pozzolana has been developed
that combines a fly ash and water-
quenched boiler slag.
 Brick  banned

• End