INTRODUCTION » The name cement refer to the material manufacture from limestone and clay and made available in powder form. Popular as Building material. Material with adhesive and cohesive properties. + To bind the fine and corse aggregate together. Common variety of cement is known as the Portland cement. » India is the fifth largest producer of cement in the world. Rajasthan is the second largest producer of cement in india after Andra Pradesh.CEMENT INDUSTRY IN INDIA » 183 large cement plants and MOre _ sormarketing, tne country is aivided into te regions and atew companies than 360 mini cement plants Comins eens ets » 330 million tonnes a year installed capacity » 97% of the installed capacity is accounted for by large producers, around 40 in number oe * 21 top companies control 90% of the marketCOMPOSITION OF ORDINARY CEMENT Lime Silica Alumina Calcium sulphate Iron oxide Magnesia Sulphur Alkalies 62% - 67% 17% - 25% 3% - 8% 3% - 4% 3% - 4% 0.1% - 3% 1% - 3% 0.2% - 1% Soundness and strength of cement Strength to the cement Quick setting property Increase the initial setting time. Colour, Hardness and strength Hardness and colour Making sound cement Harmful, carried away by flue gases.PORTLAND CEMENT » Made by mixing substances containing Calcium carbonate such as Limstone/chalk. And by mixing substances containing Silica, Aluminia and Tron oxide such as clay. Raw material is then heated and made CLINKER. Clinker is then grounded to powder. Why it is called Portland cement ? Joseph Aspedin, an english mason who patented the product named it Portland because it produced a concrete that resembled the colour natural limestone that quarried on the isle of Portland, peninsula of english channel.HYDERATION OF CEMENT » It is a process of chemical reaction between cement and water. » It results first in setting (the concrete becomes solid) and then hardening (increase of strength and stiffness) * Heat is liberated during Hyderation process. » Thus, during the Hardening process, the concrete is being continually warmed by internal heat generated * The more rapid the rate of hardening the more susceptible is a concrete to shrinkage. » The amount of water required to hydrate cement is about 25%. » Water/cement ratio is between 0.4 to 0.6SETTING OF CEMENT » When cement is mixed with sufficient water, within one and two hours after the mixing, the sticky paste losses its fluldity, within a few hours after mixing noticable stiffness commences. » Setting can be divided into two stages : 1. Initial Set 2. Final set » Initial set - When the paste begin to stiffen. » Final set - Beginning to harden and able to sustain some loads.MANUFACTURING OF CEMENT » Three distinct operations are involved in the manufacturing of ordinary cement MIXING OF RAW MATERIAL BURNING GRINDING 1. MIXING OF RAW MATERIALS : Raw materials such as limestone and clay are mixed either by DRY PROCESS or by WET PROCESS Calor Material ‘agilloceous Matti Limestone Clog | £ — Craig Crosing £ £ Fine Grinding in Ball Mie moe nd Tube Mil ‘ond Tube Mill = z Strge Storage ‘Maing Correct Proprtion ¥ ‘Storage Tank for Row Mix Flow diagram of dry process» The raw materials are first reduced in the size of | 2. BURNING Soe eS Oa orocese * Carried out in a rotary kiln, diameter varies * Wet process ( Old technology ), cement industry from 2.5 m to 3 mand length varies from 90m underwent a number of changes. to 120m. * In case of mixing of raw material in wet process Laid at a gradient of 30 deg from horizontal a SLURRY is formed. plane. + 1-2 revolutions per minute about its sear) longitudinal axis. Working from Sage Tank el | pene = Storage in Base | pp Surry net Sa | ay a a aa mae fy etry | = x Grinding Mill iain + Clk aie Flow diagram of wet process Rotary kiln for wet process trage Tonks3. GRINDING * Clinkers as obtained from rotary kiln are finely ground in ball mills and tube mills * GYPSUM is added about 3-4% during grinding. hom Sige Tae [=m] ; Lp seaome ul aon Tb ae z Sion Son z Weng od Pahig i Bape z ric fw dope ee at gaat — BALL MILLS AND TUBE MILLS + Used to carry out grinding of raw materials or mixture or clinkers. * The ball mills are used to have preliminary grinding and the tube mills are used to carry out final grinding. ott | awe eeInside a (stationary!) cement mill. The part- ground clinker and steel grinding media are clearly visible. (Picture courtesy Castle Cement).TYPES OF CEMENT In addition to ordinary cement, following are the other important types of cement: » Acid resistant cement * Pozzolana cement Blast furnace cement * Quick setting cement Coloured cement * Rapid hardening cement Expanding cement Sulphate resisting cement High Alumina cement » White cement. Hydrophobic cement Air entraining cement » Low heat cement» Acid resistance cement - Used for of chemical industry. It is not water-resistant and it fails when attacked by water. By adding 0.5% of linseed oil resistance water is increased. Seuacue » Blast furnace cement The as obtained from blast furnace is Sas apace sat used. The slag is a waste product in the manufacturing process of and it contains the basic elements of cement, namely 60-65% of slag is ground with CLINKER. It requires longer curing period. Not suitable for use in dry arid zones.» Coloured cement The cement of desired colour may be obtained by intimately mixing mineral pigments with ordinary cement or white cement. ron Oxide G Mineral pigment ,, if % increases Hat2ed: ” sissy strength decreases. Used as finishing of s etc » Expanding cement This type of cement is produced by an expanding medium like and a stabilising agent to the ordinary cement. Hence this cement expands whereas cements shrink. The exeancipe) cement is used for construction oi» High Alumina cement - Is specified that total alumina content should not be less than Withstand Used in workshops, refractories where high temperature is involved, Ist- and Fs.t Evolve great heat. » Hydrophobic cement This type of cement contains admixtures which Admixtures like acidol, naptheline forms a Use of hydrophobic cement considerably increases the water resistance of an concrete.» Pozzolana cement Pozzolana is a volcanic powder. This type of is used to prepare mass concrete of lean mix and marine structures, It is also used in sewage works and for laying concrete under water. » Low heat cement The considerable heat is produced during the setting of cement. In order to reduce the amount heat, this type of cement is used! Decrease tri- calcium aluminate about 5% and increase ¢ri- calcium silicate about 46%. Used in mass construction works. » Quick setting cement This cement is produced by adding a small percentage of s/uminium sujohate-and by finely grinding the cement This type of cement is used to lay concrete under static’ water or running water. I.s.t- 5 minutes and F.s.t — 30 minutes Used in under water construction, rainy and cold wheather conditions. Air entraining cement Itis produced by adding indigenous air entraining agents such as resins glues, sodium salts of Sujohates etc during the grinding of clinker. This, type of cement is specially suited to improve the workability with smaller water cement ratio and to improve frost resistance of concrete.Rapid hardening cement The initial and final setting times of this cement are same as those of ordinary cement, But it attains high strength in early days. It Contains high percentage of tricalcium silcate Used when foam work is to be removed early. Less curing. Sulphate resisting cement In this cement, it results in the increase in resis power against sulphates. Used for structures which are likely to be damaged by severe alkaline conditions such as canal linings, culverts, chemical industries et ing ~ White cement Prepared from such raw materials which are fee from colouring oxides 6 fon, manganese or chromium. For burhing of this cement, the co! Used instead of coal leis white in colour and is used Lal for lcor finish, plaster work, ornament work, etc |USES OF CEMENT Some of the numerous functions of cement are given below ~ * Itis 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 /aying floors, roots and constructing lintels, beams, stairs, pillars etc. + Itis used where 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.used for precast pipes manufacturing, piles, fencing posts etc. » Its used in the construction of important engineering structures such as bridges, culverts, dams, tunnels, light houses etc. + It is used in the preparation of foundations, water tight floors, footpaths etc. + It is employed for the construction of wells, water tanks, tennis courts, lamp posts, telephone cabins, roads etcTEST OF CEMENT AT CONSTRUCTION SITE The following are the quality tests on cement at construction site: * Colour test * Presence of lumps + Adulteration test + Temperature test + Float tests * Strength test * Setting test + Date of packing » Colour Test of Cement The color of the cement should be uniform. It should be grey colour with alight greenish shade + Presence of Lumps The cement should be free from any hard lumps, Such lumps are formed by the absorption of moisture from the atmosphere. Any bag of cement containing such lumps should be rejected » Cement Adulteration Test The cement should feel smooth when touched or rubbed in between fingers. If itis felt rough, it indicates adulteration with sand,Temperature Test of Cement If hand is inserted in a bag, of cement or heap of cement, it should feel cool and not warm, Float Test Ifa small quantity of cement is thrown in a bucket of water, the particles should float for some time before it sinks. Setting Test » A thick paste of cement with water is made on a piece of glass plate and itis keot under water for 24 hours. should set and not crac Strength of Cement Test * A block of cement 25 mm_x25 mm and 200 mm long is prepared and it is immersed for days in water. Itis then placed on supports 15cm apart and it is loaded with a weight of about 34 kg. The block should not show signs of failure. Date of Packing: * Strength of cement reduces with time, so itis important to check the manufacturing date of the cement.VARIOUS LAB TEST ON CEMENT Tests to be conducted to judge the quality of cement. 1 Fineness 2. Soundness 3. Consistency 4. Compressive strength 5. Tensile strength FINENESS TEST This testis carried out to check proper grinaing of coment. In seve test the cement weighing {00gmis taken and it is continuously passed for 18 min through standard BIS sieve no. 9) Boas Fier reeea mee weet re ret Different sieve sizes, IS sieve,2. SOUNDNESS TEST 3. CONSISTENCY TEST + The purpose of this testis to detect the presence of. The basic aim is to find out the water content uncombined lime in cement. Sound A eee required to produce a cement paste of standard * Soundness of cement is determined by Le- ae Fer eRe Tevas Toate rad ‘method as per IS: 4031 (Part 3) — 2 cman iad Meer * Soundness of cement is the property of + Apparatus = Vicat apparatus) hardened cement paste undergoing large + Initial Setting time and normal consistency change in volume after setting without determination. delayed destructive expansion. ~ The expansion of cement should not exceed 10mm ¢ Vicat apparatus Le-Chatelier apparatus.4. COMPRESSIVE STRENGTH + To determine the compressive strength. + The compressive strength at the end of 3 days should not be less than 115 kg/cm sq and at the end of 7 days should not be less than 175 kg/cm sq. Cee uaa) Compression testing machine 5, TENSILE STRENGTH +» Test was formerly used to have an indirect indication of compressive strength of cement. * Ultimate tensile stress = failing load / 6.45 » The tensile stress at the end of 3 days should not be less than 20 kg/em2 or 2 N/mmz2 and that at the end of 7 days should not be less than 25 kg/em2 or 2.50 N/mm2. Applying tensife strength Standa?d Briquette BaquettelmoudPROPERTIES OF GOOD CEMENT * Provides strength to masonry. + Stiffens or hardens early. + Possesses good plasticity. * An excellent building material. * Easily workable, * Good moisture-resistant.THANKS FOR THE PATIENCE