Estate

Construction, Cons
, Construction Material
& Real
R.Theory for Ex: 1
Draughtsman Civil Materials
Cement hne nel covave a Cct
pach al ccmcnt

Objectives: At the end of this lesson you shall be abie o

define cement
state the Im
properties of cement helghdf:y
-

explain uses of cement my

nt-OndinuTy

(OPC
used eime
compare cement and lime ma
state
manufacturing of cement
Cxplain the flow diagram of the wet process of cement manurau
describe types of cement mcnudeed red i2tneihoci O 5,
state cement water e m ont
proofer
state Admixtures
explain test for cement CUving temp 27c
Introduction
cement is the most
important material in building 5 Easilyworkable.
construction. This is obtained by
and clay. Cement may be
heating a mixture ot lime 6 Good moisture-resistant.
prescribed as a material with
adhesive and cohesive properties which must be capable
of bonding mineral Uses of cement:
fragments intoa compact whole. Cement
may be classified as: (i) Natural Cement, (i) Artificial 1 Cement mortar for masonry works,
Cement. plaster, poi
etc.
Definition 2 Concrete for laying floors, roofs and constructingi
Material obtained by burming mixture of calcareous and beams, weather sheds, stairs, pillars, etc.
argillaceous Materials with a small quantity of gypsum at
3 Construction of important
avery high temperature and pulverizzed into very fine powder, engineering structuress
known as Cement. as, bridges, culverts, dams, tunnels, storage reser
light houses, docks, etc.
Properties of cement
4 Construction of water tanks, wells, tennis courfs,
Good cement possésses the following properties: tanks, lamp posts, roads, telephone cabins, er
1 Provides strength to masonry 5 Making joints for drains, pipes, etc.
2 Stiffens or hardens early. 6 Manufacture of
precast pipes, piles, garden
artistically design urns, flower pots, etc., O
3 Possesses good plasticity. fencing posts, etc.
4 An excellent building material.
7Preparation of foundations, watertight filoors, ou
etc.
Comparison between cement and lime
S.No. Aspects Cement
Lime
ColouIr Onin
 FLOW DIAGRAM OF DRY PROCESS:- (fig.1and fig.2)
emic
in non
|Argillaceous materials
Calcareous Materials
din

Cushing Crushing

Fine grinding in ball mill &

tube mill Fine grinding in ball mill

Storage Hoppers
Storage

Wet grinding (Ball mills)

Doy zone - woles evepords Fire-coal
nehon
Smell vmp cqleof Raw slury
Co evpoackej-|esming nodoley 14n Vertiel
Crushing& grinding mdls br

Elevators
(Ball mills) Maden lekh
Busning zone1400c - 15S00 c day poe
>oUmcion o clioler Lime slurry
Come out with Corrections silos F Pulverized coal
Clay slury
000 150o'c SiZe
3-20mM

Rotary kilns
Gandingin battmitb
widh adertion at3-4%Gypu
Smllsoteay Kiln in oppok divechon Clinker
to cool down hot clin kes B u s n i n g z o n a

Oulpo Lemp abov q5 C

Calcinchon zone

Gypsum Elvators(Clinker storage)

gmilis) Evpordhon

Gypsum hopper Clinker grinding (Cement grinding milis) |

sinding in bell milh with. Roteoykiln

Elevator (cement silos)
addition of 3-4% aypiom 250 30Ocm Dia
0 120m long

Paching in Jote/Gomy beg | Weighing. packing and despatch in 25 to I in 30 qadierb|

50 ks/e 3 3pn
o 0 35m omed of steal bbes
8 relsatay lined in
66 CCMRE-D'man Civil -R.Theory for Ex -1.2.08 imside susta te
 The burning is
carried out in a rotary kilin as bucket elevator for storage in silos. The cement from
Burning:

1. Arotary klin is formed of steel tubes. Its silos is fed to the packer machines. Most of the modern
in fig
S h o w n

varies form
250 to
cm 300cm. Its length varies piants have electric packing plant having provision plan to
djaam ti20m. It is laid at a gradien of about 1 in 25 to account for the weights of empty bags of different types
roan The klin is supported at intervals by columns of and to ensure a 50kg net weight of cement bag within
conor concrete. The refractory lining is provided on +200g limit.Each bag of cement contains 50kg or about
the inside surface or rotary klin. it is so arranged that the 0.035m of cement. These bags are automatically
klin rotates ataboutone to threerevolutions per minute
aboutits longitudinal axis.
discharged from the packer to the conveyoyur belts to
Tpm different loading area. They are carefully stored in a dry
place Fig 1 shows the flow diagram of buring and grinding
The coected slumy Is Injected at the upper end of klin. operations.
Fig 1 shows the rotary klin for the wet process. The hot
ames are forced through the lower end of kiln.
gases orflam
The portion ofthe kiln near its upper end is known as dry
zone andinthis zone, the water of slurrythereis evaporated. From storage tanks Coal dust
slurry gradualy descends, is rise in
Asthe in the next sectin of kiln, the carbon
temperatrue and
dioxide from slury is evaporated. The small lumps, known
are formed at this These nodules
as nodules, stage.
thengradually roll down passing through zones of risinhg Rotary kiln
temperatrue and ultimately reach to the buming zone,
where temperature is about 1400°Cto 1500°C. In burning cthteepmly
zone, the calcined product is formed and nodules are
Gonverted into small hard dark greenishblue balls which Formation of clinkers
clinkers.
are known
as

Inthe modem technology.of dry process, the coal brought

from the coalfields is pulverised in verticalcoal milland it
is stored in silos. ltis pumped with required quantity of air Gypsum Coolers
throughthe bumers. The preheated raw Materials roll down
the kiln and get heated to such an extent that the carbon
dioxide is driven off with combusion gases. The material
is then heated to temperature of nearly 1400 Cto 1500C
when t getsfused together. The fused product is known In cement mil
Grinding of clinkers in ball
as clinkers or raw cement. doT modean
mills and tube Mills
pleny
The size of clinkers varies from 3mmto 20mm and they Contoin dl sire chsom
are very hot when they come out of buring zone of kiln. bal
The clinkertemperatureat theoutlet ofkilnis nearly 1000°C
to1500°Cwhen it gets fused together. The fused product
isknown as clinkers orrawcement, Storageinsilos
The size ofclinkers varies from 3mmto 20mm adn they
kiln.
arevery hot when they come out of buring zone of
The cinker temperature at the outlet of kin is nearly 1000°C.
the Weighing and packing in bags
Arotary kiln of small size is provided to coolas down
shown in
hot clinkers. It is laid in opposite direction
Fig 1 and the cooled clinkers havingtemperature of about
95C are collected in containers of suitable sizes.

therotary kilo
Grinding: The clinkers as obtianed fromDuring Distribution
tube mills. grinding
arefinely groundinballmillsand of is added
small
ahe quantity about 3 to 4 percent gypsum
gypsum controls the initial setting time of cement. Flow diagram of burning and grinding operations
9ypsum is not added,the cement would set as soon as of cement
acts as a retarder and it
eier is added. The gypsum cement. It thus pemits cement Packing of cement: The packing of cement is mostly
of
eays the setting action tobe placed in
o De mixed with the aggregate and done in ourcountry in conventional jute or gunny bags.
containers as
position. These bags have proved to be satifactory
their shape and size make them convenient to handle. If
outin
ne grinding ofclinkers in modern plants is.carriedballs the properly handled, they may make three to five trips
Cement mill which contains chromium steel of
andgrind the form the factory to the cement users. However the main
nous sizes.These balls.rollwithin themill
and taken in the drawbacks of such type of packing are as follows:
UXTure which is collected in a hopper
CCMRE-D'man Civil -R.Theory for Ex -1.2.08 67
 At every point of For dry process the heat required per kg of clinke
handling some portion of cement
contained in jute bag is wasted. produced is less.

Even after emptying the cement bag, small quantity of
cement remains in the bag and it is thus not possible to
take advantage of the full contents of the ba9.
Such type of packing leads to the air polluti
The handling ofjute bags proves harmful to the healthy of
labourer also as he inhales a considerable amount of
cement partides during the transport of such bags.
The quality of cement is affected due to entry of moisture
from the atmosphere.
The blending of dry powders has now perfected and
the wet process which requires much higher
consumption of powercan be replaced with confidence
The application of moden technology has madethe
production of cement by dry process more economica
and of superior quality.
Both the processesinvolve the following steps:
Collection of raw materials.

Dry process this is usually employed where the raw Crushing, grindingand mixing of rawmaterials.
materials are hard such as cement rock orblastfurnace
slag. adopted in mostofthe cement industries, due to- Burning
Grinding ofclinker.(Fig92)
Fig 1 Cnce naped
CHIMNEY
vTnecl ttorn
CEMENT SLURRY TANK
PreTe- 250c

EVAPARATION
ZONE
-CLINKERING ZONE- CLINKENING
ZONE
Cenbel-C«lcin «b TOne

ovlput> Clinkers i
ROTRACTORY LINING POWDERED

TO CHMNEY

HOTAR

SUPPORT

coOLAR
ROTARY KILN

Ball mill (Fig 2)

TYPES OF CEMENT
i
Fig 2
Cement is specified by its grade (compressive strength of
1:3cement mortars as cubes of 50 cm2 areas (7.06 cm
OUTLET CASING in28 days for defining.strength) thus, Grade-33 cement
CURVER STEEL
(C-33) means cement withstandard mortar cube strength
WEERING PLATE of33 N/ mm2 in 28 days. Only the grade of the cementis
SEVE marked on the bags of 50 kg.,)
The following are the IS specifications:
HARDENEDD
STEEL BALLS
1.Ordinary Portland cement (OPC) in 3 grades,
(a) Grade 33 IS: 269-1989 designated as C-33.
(b) Grade 43- IS: 269-1989 designated as C-43,
CUTER IUNNEL
(c)Grade53-IS: 269-1989 designated as C-53
2. Portland pozzolana cement (PPC) (a mixture of OPC
BALL MILL
and Pazznlanal