Cement: Chemical Composition of

Cement is the mixture of cement is:

calcareous, siliceous, argillaceous
Lime 63%
Silica 22%
and other substances. Cement is Alumina 06%
used as a binding material in Iron oxide 03%
mortar, concrete, etc.
Gypsum 01 to 04%

(a) Dry process:

MANUFACTURING OF CEMENT: In this process calcareous material such as lime
stone (calcium carbonate) and argillaceous
(1) Mixing and crushing of raw material such as clay are ground separately to
fine powder in the absence of water and then are
materials a. Dry process
mixed together in the desired proportions. Water
b. Wet process
is then added to it for getting thick paste and
then its cakes are formed, dried and burnt in
(2) Burning kilns. This process is usually used when raw
(3) Grinding materials are very strong and hard.
In this process, the raw materials are changed to

powdered form in the absence of water.

(b) Wet process:

In this process, the raw materials are changed to
powdered form in the presence of water. (b) Wet Process: Continued------
In this process, raw materials are pulverized by using a
Ball mill, which is a rotary steel cylinder with hardened This process is generally used when raw
steel balls. When the mill rotates, steel balls pulverize
materials are soft because complete mixing
the raw materials which form slurry (liquid mixture). The
slurry is then passed into storage tanks, where correct is not possible unless water is added.
proportioning is done. Proper composition of raw Actually the purpose of both processes is to
materials can be ensured by using wet process than dry
process. Corrected slurry is then fed into rotary kiln for
change the raw materials to fine powder.
burning.

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(2) Burning:
Corrected slurry is feed to rotary kiln, which
is a 150-500 feet long, 8-16 feet in diameter
and temperature arrangement is up to 1500-
1650 degree C.At this temperature slurry
losses moisture and forms into small lumps,
after that changes to clinkers. Clinkers are
cooled in another inclined tube similar to kiln
but of lesser length.
TYPES OF CEMENT:
1. Ordinary Portland Cement
2. Sulphate Resisting Cement
3. Rapid Hardening Cement (or)
High Early Strength cement
4. Quick Setting Cement
5. Low Heat Cement
6. High Alumina Cement
7. Air Entraining Cement
8. White Cement
(3) Grinding:
Now the final process is applied which is
grinding of clinker, it is first cooled down to
atmospheric temperature. Grinding of clinker
is done in large tube mills. After
proper grinding gypsum (Calcium
sulphate Ca SO4) in the ratio of 01-04
% is added for controlling the setting
time of cement. Finally, fine ground
cement is stored in storage tanks
from where it is drawn for packing.
(1) ORDINARY PORTLAND CEMENT: It is
the variety of artificial cement. It is called
Portland cement because on hardening
(setting) its colour resembles to rocks
near Portland in England. It was first of all
introduced in 1824 by Joseph Asp din, a
bricklayer of Leeds, England.
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Functions of Cement
Manufacturing
Constituents
(ii) Silica (SiO2): The quantity of
silica enough to form di-calcium
silicate (C2SiO2) and tri-calcium
silicate in the manufacturing of
cement. Silica gives strength to
the cement. Silica in excess
causes the cement to set slowly
(iv) Iron Oxide (Fe2O3):
Iron oxide gives colour
to the cement.
(i) Lime (CaO):
Lime forms nearly two-third (2/3) of the
cement. Therefore sufficient quantity of the
lime must be in the raw materials for the
manufacturing of cement. Its proportion has
an important effect on the cement.
Sufficient quantity of lime forms di-
calcium silicate (C2SiO2) and tri-calcium
silicate in the manufacturing of cement.
Lime in excess, causes the cement to
expand and disintegrate.
(iii) Alumina (Al2O3): Alumina
supports to set the cement. It
also lowers clinkering
temperature. Alumina excess,
reduces the strength of the
cement.
(v) Magnesia (MgO):
It also helps in giving colour to the
cement. Magnesium in excess
makes the cement unsound.
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(vi) Calcium Sulphate (or) Gypsum (Ca
SO4) :
At the final stage of
manufacturing, gypsum is added
to increase the setting of cement.
(3) RAPID HARDENING CEMENT:
The chemistry of rapid-hardening hydraulic cement, which differs from
portland cement, is composed primarily of hydraulic tetracalcium
trialuminate sulphate (CSA) and dicalcium silicate (C2S). C2S is the
most durable compound found in portland cement. The CSA compound,
often referred to as calcium sulfoaluminate, hydrates to form ettringite-a
strong needle-like crystal that develops quickly to give rapid-hardening
hydraulic cement its high performance. Another significant aspect of
this product's chemistry is the absence of tricalcium aluminate (C3A),
which makes a cement susceptible to sulfate attack. Because rapid-
hardening hydraulic cement has little or no C3A, it is very durable in
sulfate environments.One type of this cement is manufactured by
adding calcium chloride (CaCl2) to the O.P.C in small proportions.
Calcium chloride (CaCl2) should not be more than 02%. When this type
of cement is used, shuttering material can be removed earlier.
(5) LOW HEAT CEMENT:
In this cement the heat of hydration is
reduced by tri calcium aluminate (C3A )
content. It contains less %age of lime than
ordinary port land cement. It is used for
mass concrete works such as dams etc.
(2) SULPHATE RESISTING CEMENT: It is modified form of
O.P.C and is specially manufactured to resist the
sulphates. In certain regions/areas where water and soil
may have alkaline contents and O.P.C is liable to
disintegrate, because of unfavourable chemical reaction
between cement and water, S.R.C is used. This cement
contains a low %age of (tricalcium aluminate) C3A not
more than 05%. This cement requires longer period of
curing. This cement is used for hydraulic structures in
alkaline water and for canal and water courses lining. It
develops strength slowly, but ultimately it is as strong as
O.P.C.
(4) QUICK SETTING CEMENT: When
concrete is to be laid under water,
quick setting cement is to used. This
cement is manufactured by adding
small %age of aluminum sulphate
(Al2SO4) which accelerates the setting
action. The setting action of such
cement starts with in 05 minutes after
addition of water and it becomes
stone hard in less than half an hour.
(6)
HIGH ALUMINA CEMENT:
This cement contains high aluminate %age
usually between 35-55%. It gains strength
very rapidly with in 24 hours. It is also used
for construction of dams and other heavy
structures. It has resistance to sulphates
and action of frost also.
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(7) AIR ENTRAINING CEMENT: (8) WHITE CEMENT:
This type of cement was first of all developed in U.S.A to
produce such concrete which would have resistance to This cement is called snowcrete. As iron
weathering actions and particularly to the action of frost. It oxide gives the grey colour to cement, it
is found that entrainment of air or gas bubbles while
applying cement, increases resistance to frost action. Air
is therefore necessary for white cement
entraining cement is produced by grinding minute air to keep the content of iron oxide as low
entraining materials with clinker or the materials are also as possible. Lime stone and china clay
added separately while making concrete. Entrainment of
air also improves workability and durability. It is free from iron oxide are suitable for its
recommended that air contents should be 03-04 % by manufacturing. This cement is costlier
volume.
than O.P.C. It is mainly used for
Natural resins, fats, oils are used as air
architectural finishing in the buildings.
entraining agents.

TO CHECK THE QUALITY OF

CEMENT IN THE FILED:
1.Colour greenish grey.
2.One feels cool by thrusting one’s
hand in the cement bag.
3.It is smooth when rubbed in
between fingers.
4.A handful of cement thrown in a

bucket of water should float.