CT2641 - Construction Materials

CEMENT
Assignment 4

Faculty:
Prof. Bhargav Tewar
T.A: By:
Shivam Soni Jay Patel - UCT20064
 OUTLINE:
1. Description and history of the material
2. Manufacturing process
3. Applications in construction
4. Different qualities or grades of the materials and its properties
5. Cost of all qualities of the material.
6. Major source of the material
7. Top manufacturers of the material
8. Advantages and disadvantages of the material
9. Sustainability of the material
10. How do you rate the material
DESCRIPTION:
What is Cement?
● A cement is a binder, a substance used for construction that
sets, hardens, and adheres to other materials to bind them
together.
● Concrete is the most widely used material in existence and is
behind only water as the planet's most-consumed resource.
Application of Cement:
Different types of cement
● Cement mixed with fine aggregate produces mortar for
masonry, or with sand and gravel, produces concrete.
● Mixtures of soil and portland cement are used as a base for
roads.
● Cement also is used in the manufacture of bricks, tiles, shingles,
pipes, beams, railroad ties, and various extruded products.

Cement Ingredient
HISTORY:
● The beginning of hydraulic cement returns to old Greece and
Rome.
● The materials utilized were lime and a volcanic debris that
gradually responded with it within the sight of water to frame a
hard mass.
● This framed the establishing material of the Roman mortars and
cements of over 2,000 years prior and of resulting development
work in Western Europe.
● Volcanic debris mined close to what is currently the city of
Pozzuoli, Italy, was especially plentiful in fundamental
aluminosilicate minerals, bringing about the exemplary
pozzolana concrete of the Roman period.
● The creation of portland cement ordinarily is credited to Joseph Joseph Aspdin
Aspdin of Leeds, Yorkshire, England, who in 1824 took out a
patent for a material that was delivered from an engineered
combination of limestone and clay.
● He referred to the item as "portland cement" in light of a liked
similarity of the material, when set, to portland stone, a
limestone utilized for working in England.
MANUFACTURING:
There are four stages in the manufacture of cement:
1. Crushing and Grinding
2. Blending the Materials
3. Burning
4. Grinding
● The three processes of manufacture are known as the wet, dry, and semi dry processes and are so termed
when the raw materials are ground wet and fed to the kiln as a slurry, ground dry and fed as a dry powder,
or ground dry and then moistened to form nodules that are fed to the kiln.

Process of Cement Manufacturing Flow diagram of manufacturing process

MANUFACTURING:
1. Crushing and Grinding
● Soft materials first crushed, that too in two stages. This
Grinding can be done in a wet or dry state, that depends
on the process which is in use. However, for grinding in the
dry state the raw materials are needed to be dried in
cylindrical rotary dryers.
● Soft materials are needed to be broken down through
vigorous stirring with the water in wash mills, producing a
fine slurry, which is later passed through the screens for
removal of oversize particles.
Cement Crushing & Grinding Plant

2. Blending the Materials

● The next step involved after crushing and grinding is
blending the crushed raw materials. Initially, an
approximation of the chemical composition required for a
specific cement is obtained through selective quarrying
and with control of the raw material fed in the process to
the crushing and grinding plant.
● In the dry process mixing of the materials in the silos is
carried out by agitation and vigorous circulation which
include compressed air.
Cement Blending Plant
MANUFACTURING:
3. Burning
● Bottle kilns ate the traditional types of kilns followed by
chamber kilns and then continuous shaft kilns were
invented. The shaft kiln is used in many countries in
modern days but the dominant means of burning is the
rotary kiln.
● When the raw material fed to the kiln at the upper end, it
slowly moves down the kiln at the firing, end.
● The fuel used for firing is pulverized coal, oil, or natural
gas. Cement burning kiln parts
● The temperature at the firing end could be as equal as in
the range of 1,350 to 1,550 °C or 2,460 to 2,820 °F,
depending on the type of raw material is being burned.
● The burned product comes out from the kiln in the form
of small nodules of clinker.
● These clinkers are then passed into coolers for cooling.
● The colled clinker depending on its properties can be
immediately ground to cement or stored in stockpiles for
further use.

Cement burning kiln

MANUFACTURING:
4. Grinding
● The clinker and gypsum are ground to form a fine
powder in mills similar to those used before for grinding
the raw materials brought directly to mills.
● Material properly grinned are passed further while the
improperly grinned are again taken to grinding.
● Sometimes it is required to add a small amount of
grinding aid to feed material.
● Finished cement is stored in bags & packages for
distribution. Cement grinding diagram

Cement grinding mill

APPLICATION IN CONSTRUCTION:
According to the Cement Manufacturers Association, India is the
second-largest Cement Industry in the world by consuming 8% of the
global cement installed capacity.

There are application of cement:

● It is used in mortar for plastering, masonry work, pointing, etc.
● It is used for making joints for drains and pipes.
● It is used for water tightness of structure.
● It is used in concrete for laying floors, roofs and constructing lintels,
Cement used in Mortar
beams, stairs, pillars etc.
● It is used where a hard surface is required for the protection of
exposed surfaces of structures against the destructive agents of the
weather and certain organic or inorganic chemicals.
● It is used for precast pipes manufacturing, piles, fencing posts etc.
● It is used in the construction of important engineering structures
such as bridges, culverts, dams, tunnels, lighthouses etc.
● It is used in the preparation of foundations, watertight floors,
footpaths etc.
● It is employed for the construction of wells, water tanks, tennis
courts, lamp posts, telephone cabins, roads etc. Cement used in Concrete
TYPES OF CEMENT:
These are the majorly used type of cement:
1. Ordinary Portland Cement (OPC)
2. Portland Pozzolana Cement (PPC)
3. Portland Slag Cement (PSC)

Less popular types of cement available in market:

1. Rapid Hardening Cement
2. Extra Rapid Hardening Cement
3. Quick Setting Cement
4. Low Heat Cement
5. Sulphate Resisting Cement
6. High Alumina Cement
7. White Cement Different types of cement available in market
8. Coloured Cement
9. Air Entraining Cement
10. Hydrophobic Cement
11. Masonry Cement
12. Expansive Cement
13. Oil Well Cement
TYPES OF CEMENT:
1. Ordinary Portland Cement (OPC)
● OPC means Ordinary Portland Cement is a fully
automated and dry manufacturing process. It is
available in two different grades-OPC-43 & OPC-53.
a. OPC-43: This type of cement is used for plain
concrete work and plastering works.
b. OPC-53: This type of cement is used for the
structural purposes as in reinforced cement
concrete.
2. PPC Grade Cement OPC- 53 OPC- 43
● PPC means Portland Pozzolana Cement is a fully
automated and dry manufacturing process and
also contains gypsum and pozzolanic materials.
Used for dams & bridges where strong resistivity is
required. It also offers the best surface finish.
3. PSC Grade Cement
● PSC means Portland Slag Cement is manufactured
by inter-grinding in Portland cement clinker. This
cement has replaced partially Ordinary Portland
Cement and has many environmental and
economic benefits. PSC grade cement PPC grade cement
TOP MANUFACTURERS IN INDIA:
1. UltraTech Cement Ltd
2. Ambuja Cements Ltd
3. ACC Ltd
4. Shree Cement Ltd
5. Dalmia Bharat Ltd
6. Birla Corporation Limited
7. India Cements Ltd
8. The Ramco Cements Limited
Ultratech cement logo Ambuja cement logo
9. Orient Cement Ltd
10. Heidelberg Cement India Ltd

ACC cement logo Shree cement logo

COST:
Cement Brand Grade Price (Rs.)

Ultratech Cement 43 Grade OPC Rs. 307

KPC Cement PPC cement Rs. 350

Ultratech Cement 53 Grade OPC Rs. 410

Maha Cement PSC Rs. 320

Cetcoat cement White Cement Rs. 900

Ultratech cement bag

Kamal Cement Oil Well Cement Rs. 290

Sarvottam Eliminates High Alumina Cement Rs. 1250

High Performance
ACC cement Rs. 530
Cement

ACC cement Hydrophobic Cement Rs. 490

Sulphate Resisting
Kamal Cement Rs. 305
Cement

Ambuja cement bag

MAJOR SOURCE:
Madhya Pradesh is the largest cement producer in India and hold 23 cement plants in the state.
Followed by the Andhra Pradesh which holds 19 plants, Rajasthan with 15 plants and Gujarat with 12 plants.

1. Madhya Pradesh
● Major Centre: Katni, Jamul, Satna, Durg, Maihar, Neemach
2. Andhra Pradesh
● Major Centre: Vijayawada, Karimnagar, Cementnagar, Krishna, Adilabad
3. Rajasthan
● Major Centre: Hopur, Chittorgarh, Udaipur
4. Karnataka
● Major Centre: Bhadravati
5. Gujarat
● Major Centre: Porbandar
ADVANTAGES & DISADVANTAGES:
Advantages Of Cement: Disadvantages of Cement:
● Cement is a magnificent development material ● Cement can't be utilized for large scope
that is utilized for its high binding strength. development works since it has higher heat
● You can observe general use cement in for all hydration than concrete.
intents and purposes in each building work. ● The sturdiness of cement is low.
● Cement is explicitly utilized in structural elements ● Cement is less strong than concrete and inclined
where high strength is expected at an early to breaking. It is additionally challenging to fix,
timeframe. consequently making it unsatisfactory for regions
● There are 5 sorts of cement going from general that are powerless to development.
use type I to higher strength type II and III as well
as Portland cement.
● Each kind of cement you require can
undoubtedly be found in DIY and tool shops at
reasonable costs.
SUSTAINABILITY:
● It is estimated that around 4–8 percent of the
world’s carbon dioxide (CO2) emissions come
from the manufacture of cement, making it a
major contributor to global warming.
● Some of the solutions to these greenhouse gas
emissions are common to other sectors, such as
increasing the energy efficiency of cement
plants, replacing fossil fuels with renewable
energy, and capturing and storing the CO2 that
is emitted. Pollution produced by cement plant

● In addition, given that a significant portion of

the emissions are an intrinsic part of the
production of clinker, novel cements and
alternate formulations that reduce the need for
clinker are an important area of focus.
RATING:
● Cement is the key ingredient in the manufacture of mortar and concrete because of its high binding
strength.
● It has a lot of applications and uses in the construction industry.
● In spite of all these advantages of cement, cement is a large contributor to global warming.
● Its manufacture causes a lot of pollution and is thus a major contributor of global warming.
● It also causes a lot of water consumption in its manufacturing process and is a large source of water
consumer in the world.
● Since, cement is not sustainable, i have rated it 6 out of 10.
REFERENCES:
● https://www.heidelbergcement.com/en/cement
● https://www.hanson.my/en/types-cement-construction-industry
● https://www.investoxpert.com/blog/top-7-types-of-cement-used-in-indian-construction
● https://indiancompanies.in/top-10-companies-in-cement-industry-in-india/
● https://www.britannica.com/technology/cement-building-material/The-major-cements-composition-and-
properties
● https://www.jagranjosh.com/general-knowledge/geographical-distribution-of-cement-industry-in-india-154
9272487-1#:~:text=Cement%20Industry%20is%20mainly%20based,materials%20are%20limestone%20and%20
coal.
● https://civiltoday.com/civil-engineering-materials/cement/46-uses-of-cement#:~:text=1%20It%20is%20used
%20in%20mortar%20for%20plastering%2C,tennis%20courts%2C%20lamp%20posts%2C%20telephone%20cabi
ns%2C%20roads%20etc.
● https://www.buildersmart.in/blogs/types-of-cement-and-their-uses-in-construction
THANK YOU :)