Geologi Mineral Industri

Geology and Benefication of

Cement Materials
Dr.-rer.nat. I Wayan WARMADA
Laboratorium Bahan Galian,
Departemen Teknik Geologi
warmada@ugm.ac.id
 Introduction
 Cement was invented in 1824 in England by Mr. Joseph
Aspidin. Manufacturing first started in England in 1824
and in india in 1904
 Cement is a fine-grained compound that turns into a solid
when mixed with water. It is a mixture of limestone, clay,
silica, and gypsum
 The term. “Cement” to an average user means only
“Portland Cement”. Portland cement is manufactured by
calcining a mixture of limestone and clay or shale.
 Cement is the most commonly used construction material.
Introduction
 Introduction
 There are different
varieties of cement
based on different
compositions ac-
cording to specific
end uses, that is
Ordinary Portland
Cement, Portland
Pozolona Cement,
Portland blasta
Furnace Slag
Cement, White
Cement and etc. Cement Works No 2 by Eric Revilious 1934
Introduction
 Varieties and Characteristics
 Ordinary portland cement
Popularly known as grey cement, has
95% clinker and 5% of Gypsum and
other materials. It accounts for 70%
of the total consumption. White
cement is a variation of OPC and is
used for decorative purpose like
rendering of walls, flooring etc. It
contains a very low proportion of
iron oxide. Ordinary Portland
Cement is the most commonly used
cement for a wide range of
applications.
 Varieties and Characteristics
 Portland pozzolona cement
Portland pozzolana cement is
ordinary portland cement blended
with pozzolonic material (power-
station fly ash, burnt clays, ash from
burnt plant material or siliceous
earths). PPC has 80% clinker, 15%
pozolona and 5% gypsum and
account for 18% of the total cement
consumption. it is cheaply
manufactured because it uses fly
ash/burnt clay/coal waste as the
main ingredient.
 Varieties and Characteristics
 Portland blast furnace slag cement
Portland blast-furnace slag cement
contains up to 70% of finely ground,
granulated blast-furnace slag, a
nonmetallic product consisting
essentially of silicates and alumino-
silicates of calcium. Slag brings with
it the advantage of the energy
invested in the slag making. Grinding
slag for cement replacement takes
only 25% of the energy needed to
manufacture portland cement.
 Mineralogical Compositions
 Portland cement
 Mineralogical Compositions
 Portland cement
Ternary and quaternary cement blends are those
mixtures containing two or three supplementary
cementing materials, such as various kinds of fly ash,
grounded slag and silica fume (SF), in addition to
Portland cement.
 Chemical Compositions
 Portland cement
 Other Cements
 White cement
 Sulphate resistant cement
 Oil well cement
 Masonry cement
 High alumina cement
 Etc.
 Material Compositions
 Supplementary Cementitious Materials (SCM)
 SCM: Fly Ash
 Chemical composition of fly ashes include SiO2, Al2O3, and
CaO, Fe2O3, MgO, TiO2, SO3, Na2O, and K2O, and LOI.
Amongst these SiO2 and Al2O3 together make up about 45–
80% of the total ash.
 Benefits of Using Fly Ash in Cement/Concrete
(1) Reduced Bleeding and Segregation
(2) Improved Workability
(3) Reduced Heat of Hydration
(4) Higher Ultimate Strength
(5) Reduced Permeability
(6) Increased Resistance to Sulfate Attack
(7) Improved Resistance to Corrosion
(8) Increased Resistance to Alkali-Silica Reactivity (ASR)
 SCM: Fly Ash
 The concentrations of important minerals found in fly ashes
bituminous coal;
SCM: Silica Fume
 Silica fume has a very high content of amorphous
silicon dioxide and consists of very fine spherical
particles. Silica fume generally contains more than
90% SiO2. Small amounts of iron, magnesium, and
alkali oxides are also found.
SCM: Silica Fume
 Advantages of using silica fume
 High early compressive strength
 High tensile,flexural strength, and modulus of elasticity
 Very low permeability to chloride and water intrusion
 Enhanced durability
 Increased toughness
 Increased abrasion resistance on decks, floors, overlays
and marine structures
 Superior resistance to chemical attack from chlorides,
acids, nitrates and sulfates and life-cycle cost
efficiencies.
 Higher bond strength
 High electrical resistivity and low permeability
SCM: GGBS
 Ground granulated blast furnace slag (GGBS)
 Blast furnace slag is a non-metallic product,
consisting essentially of silicates and alumino-
silicates of calcium and other bases. Slag is made
up of both glassy and crystalline phases. The glassy
nature is responsible for its cementitious properties.
In GGBS, glass content is between 85 and 90%.
GGBS comprises mainly of CaO, SiO2, Al2O3,
MgO. It has the same main chemical constituents as
ordinary Portland cement, but in different
proportions.
SCM: GGBS
 Advantages of using GGBS
 Improved workability, compaction characteristics and
surface finish
 Increased pumpability and strength.
 Enhanced durability and architectural appearance
 Reduced permeability, reduction in maintenance and repair
costs.
 High resistance to chloride penetration, sulfate attack, and
ASR
 Low heat of hydration.
 Suppresses efflorescence
 Enhancement of the life cycle of concrete structures.
 Slashes lifetime construction costs.
 Production of GGBS involves virtually zero CO 2 emissions,
and no emissions of SO2 and NOx
SCM: Metakaolin (MK)
 Metakaolin (MK)
 Metakaolin (MK) is a pozzolanic material. It is a
dehydroxylated form of the clay mineral kaolinite.
It is obtained by calcination of kaolinitic clay at a
temperature between 500°C and 800°C.
SCM: Metakaolin (MK)
 Advantages of using metakaolin
 Enhanced workability
 Increased compressive strength, tensile and flexural
strengths
 Increased durability
 Reduced permeability
 Increased resistance to chemical attack
 Reduction in alkali–silica reactivity (ASR)
 Reduced shrinkage due to particle packing
 Reduced potential for efflorescence
SCM: Rise Husk Ash (RHA)
 Rise husk ash (RHA)
 Rice husk constitutes about 20% of the weight of
rice. It contains about 50% cellulose, 25–30%
lignin, and 15–20% of silica.
 Rice husk ash (RHA) is generated by burning rice
husk. On burning, cellulose and lignin are removed
leaving behind silica ash. The ash so produced is
pulverized or ground to required fineness and
mixed with cement to produce blended cement
SCM: Rise Husk Ash (RHA)
 Advantages of using RHA
 Rice-husk ash is a very fine pozzolanic material. The
utilization of rice husk ash as a pozzolanic material
in cement and concrete provides several
advantages such as: Improved strength, enhanced
durability properties, reduced materials costs due
to cement savings, and environmental benefits
related to the disposal of waste materials and to
reduced carbon dioxide emissions.
Genesis of Industrial Cements
 Cement history
The Assyrians and Babylonians used clay as the
bonding substance or cement. The Egyptians used lime
and gypsum cement. In 1756, British engineer, John
Smeaton made the first modern concrete (hydraulic
cement) by adding pebbles as a coarse aggregate
and mixing powered brick into the cement. In 1824,
English inventor, Joseph Aspdin invented Portland
Cement, which has remained the dominant cement
used in concrete production.
Cement Manufacturing Process
Cement Manufacturing Process

The basic minerals used to make cement (limestone)

Cement Manufacturing Process

The basic minerals used to make cement (shale)

Cement Manufacturing Process

The basic minerals used to make cement (gypsum)

Cement Manufacturing Process
Cement Manufacturing Process

Most important technologies for clinker (cement) production (John 2020)

Usage/Utilization of Cements
Cement is used for construction activities like:
 Hydro projects e.g Owen falls dam
 Roads and bridges
 Buildings
 Concrete application; concrete is prepared and
fabricated in all sorts of conceivable shapes and
structural systems in realms of infrastructure,
habitation, transportation, work and play e.g
suspended slabs, beans, columns, water retaining
structures.
Cement Demand
Global Cement Production
SNI – Standar Nasional Indonesia

No. Type SNI Number

1 Portland Cement SNI 15 2049 2004

2 Masonry Cement SNI 15 3758 2004
3 White Portland Cement SNI 15 0129 2004
White Portland Pozzolan
4 SNI 15 0302 2004
Cement (PPC)
Portland Composite
5 SNI 15 7064 2004
Cement (PCC)
6 Mixed Portland Cement SNI 15 3500 2004
Source: Irawan (2013)
ASTM C150/C150M – 12
ASTM 150 classify portland cement into 5 classes:
 Type I – For use when the special properties specified
for any other type are not required
 Type II – For general use, more especially when
moderate sulfate resistance ore moderate heat of
hydration is desired
 Type III – For use when high early strength is desired
 Type IV – For use when a low heat of hydration is
desired
 Type V – For use when high sulfate resistance is
desired.
Further Readings
 Brandt, A.M. (2009) Cement-based composites:
materials, mechanical properties, and performance.
2nd Edition, Routledge, New York, 536p
 Greenspec® (2019) Cement: Materials and
manufacturing process. URL:
https://www.greenspec.co.uk/building-design/cement
-materials-and-manufacturing-process/
 Irawan, R.R. (2013) Semen Portland di Indonesia untuk
Aplikasi Beton Kinerja Tinggi. Pusat Penelitian dan
Pengembangan Jalan dan Jembatan BPP-KemenPU.
 Khan, M, I & Siddique, R. (2011). Supplementary
Cementing Materials, Springer-Verlag Berlin
Heidelberg, 302p
Thank you …