CEMENT

Under the guidance of

Dr. Bahurudeensir

Ajinkya Ingale

RITWIK CHAUHAN

2015H130062P

2015H130055P

O VERVIEW
INTRODUCTION
HISTORY OF CEMENT
PRODUCTION OF CEMENT
CEMENT AND ITS COMPOSITION
HYDRATION
HEAT OF HYDRATION
MISCELLANEOUS

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W hat is Cem ent?

Cement can be defined as any substance

Definition
C150:
which can by
joinASTM
or unite
two or more pieces of
some
substance
together
to form aby
unit
A other
hydraulic
cement
produced
mass
SOURCE: Technology of Portland and blended cementspulverizing
clinkers
consisting
H.N.Banaerjea
essentially of hydraulic calcium
Acementis abinder, a substance that sets
silicates,
and
a
small
amount
of
one
or
and hardens and can bind other materials
more formsSOURCE:www.wikipedia.org
of calcium sulfate as an
together
interground addition
A powder of alumina, silica, lime, iron oxide,

and magnesium oxide burned together in a

kiln and finely pulverized and used as an
ingredient
of mortar and concrete
SOURCE: http://www.merriam-webster.com/dictionary/cement

CEMENT

Hydrated products are

resistant to water

Hydrated products are

not resistant to water

Applications ofCem ent

Mortar for plastering,masonry work,

pointing, etc.
Water tightness of structure, Making
joints for drains and pipes.
In concrete for laying floors, roofs and
constructing lintels, beams, stairs, pillars
etc.
For precast pipes manufacturing, piles,
fencing posts etc.
Construction of important engineering
structures such as bridges,

SOURCE:https://www.google.co.in/search?q=cement+production

PRODUCTION

Data in thousand metric tons

SOURCE: http://minerals.usgs.gov/minerals/pubs/commodity/cement/cemenmcs07.pdf

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H ISTO RY
3000 BC - Egyptian Pyramids

(Mud + Straw + Gypsum + Lime)

300 BC - 476 AD-Roman Architecture

(Close to Modern Cement + Animal Products)

1756- Hydraulic lime was first developed

(John Smeaton erected theEddystone lighthouseoff

the coast of Plymouth, Devon, England)
1824-Portland Cement Invented

(Joseph Aspadin synthetic mixture of limestone

and clay)

H ISTO RY
1836-Strength Testing (Germany)

(Tensile and Compressive Strength Test of

concrete)
1845 First Modern Prototype of Portland
Cement
(Isaac Johnson- Chalk + Clay @ 14000 C
-15000C)
1889- Alvord Lake Bridge, San
Francisco, CA
1891- Concrete Street, Ohio
1903-The Ingalls Building, Ohio
SOURCE: http://www.concretenetwork.com/concrete-history/

PRODUCTION
OF
CEMENT

Raw M aterials N ecessary for Portland

Cem ent M anufacture M ust Provide the
Follow ing

Calcium
Silica
Alumina
Iron

SOURCE:
https://uqu.edu.sa/files2/tiny_mce/plugins/filemanager/files/4250117/1-

Cem ent M anufacturing

Processes
Wet Process

(mostly used now-a-days)

Dry Process
(almost updated)

THE CEMENT
MANUFACTURING PROCESS

1. Quarry
2.Grinding
3.Burning
4.Grinding,
5.Storage,
6.Packing,
7.Dispatch

MANUFACTURING STEPS
1) Raw materials are crushed, screemed & stockpiled.
2) Raw materials are mixed with definite proportions to

obtain raw mix. They are mixed either dry (dry

mixing) or by water (wet mixing).
3) Prepared raw mix is fed into the rotary kiln.
4) As the materials pass through the kiln their temperature
is rised upto 1300-1600 C. The process of heating is
named as burning. The output is known as clinker
which is 0.15-5 cm in diameter.
5) Clinker is cooled & stored.
6) Clinker is ground with gypsum (3-6%) to adjust setting
time.
7) Packing & marketing.

THE CEMENT MANUFACTURING PROCESS

quarry
dumper
loader

Quarry face
1. BLASTING

2. TRANSPORT

crushing
conveyor

storage at
the
plant

3. CRUSHING & TRANSPORTATION

1.BLASTING : The raw materials that are used to manufacture cement (mainly limestone
and clay) are blasted from the quarry
2.Transport: The raw materials are loaded into a dumper
3.Crushing and Transportation : The raw materials after crushing, they are homogenized, and
transported to the plant by conveyor. The plant stores the materials

THE CEMENT MANUFACTURING PROCESS

Raw grinding and burning

storage at
the
plant

preheating

Raw mill
conveyor

Raw mix

1. RAW GRINDING

kiln
cooling
clinker
2. BURNING

1.RAW GRINDING : The raw materials are very finely ground in order to produce the raw mix.
2.BURNING : The raw mix is preheated before it goes into the kiln, which is heated by a flame that
can be as hot as 2000 C. The raw mix burns at 1500 C producing clinker which, when it leaves the
kiln, is rapidly cooled with air fans. So, the raw mix is burnt to produce clinker : the basic material
needed to make cement.

THE CEMENT MANUFACTURING PROCESS

Grinding, storage, packing, dispatch
Gypsum and the secondary additives are added
to the clinker.
clinker
storage

Finish grinding

1. GRINDING

silos

dispatch
bags

2. STORAGE, PACKING, DISPATCH

1.GRINDING : The clinker and the gypsum are very finely ground giving a pure cement.
Other secondary additives and cementitious materials can also be added to make a blended
cement.
2.STORAGE, PACKING, DISPATCH :The cement is stored in silos before being dispatched either
in bulk or in bags to its final destination.

Quarry

1. Stone is first reduced to 125 mm (5 in.)

size, then to 20 mm (3/4 in.), and stored.

Raw
mill
4 materials
225tph limestone
88%,
sandstone 5%,
kaolin/clay 5%,
mill scale 2%

2. Raw materials are ground to powder and blended.

Or 2. Raw materials are ground, mixed with water to form

slurry, and blended.

Kiln

3. Burning changes raw mix chemically into cement clinker.

4. Clinker is ground with gypsum into portland

cement and shipped.

Reactions in Kiln

REACTIONS IN THE KILN

~100C free water evaporates.

~150-350C loosely bound water is lost from clay.

~350-650Cdecomposition of claySiO2&Al2O3

~600Cdecomposition of MgCO3MgO&CO2 (evaporates)

~900Cdecomposition of CaCO3CaO&CO2 (evaporates)

~1250-1280Cliquid formation & start of compound formation.

~1280Cclinkering begins.

~1400-1500Cclinkering

~100Cclinker leaves the kiln & falls into a cooler.

Sometimes the burning process of raw materials is performed in two stages:

Clinker + G ypsum = Portland Cem ent

Clinker
Formed by burning calcium

and siliceous raw materials

in a kiln.
Size: About 20 mm (34
in.) in diameter.

Gypsum
A source of sulfate, is

PCA

interground with portland

clinker to form portland
cement.
It helps control setting,
drying shrinkage
properties, and strength
development.

Intergrinding with gypsum

Final step in cement manufacture
Gypsum added as a set regulator
(absence flash set)
Strict control on temperature required
Done in ball mills; vertical roller presses are
now used for better efficiency
Cement of required fineness produced

For m ore about cem ent

m anufacturing process .
https://www.youtube.com/watch?v=n

-Pr1KTVSXo
https://www.youtube.com/watch?v
=bAKBX2VoMn0
https://www.youtube.com/watch?v
=0EH9AAAoO2M

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O xide Com position ofP.C.

Oxide

Approx.
Amount (%)

Common Name

Abbreviation

CaO

Lime

60-65

SiO2

Silica

17-25

Al2O3

Alumina

3-8

Fe2O3

Iron-oxide

0.5-6

MgO

Magnesia

0.5-4

Na2O

Soda

K2 O

Potassa

SO3

Sulfuric
Anhydride

0.5-1.3
1-2

BASIC PRO PERTIES IN TERM S O F OXID E

Sr.
No
.

Oxide

Properties

1.

Lime(CaO)

Strength-giving properties, increases

setting time

2.

Silica(SiO2)

Higher setting time, Higher strength

3.

Alumina(Al2O3)

Decreases setting time, Reacts quickly

with water

4.

Iron Oxide(Fe2O3) Acts as Catalyst and helps burning

temperature

5.

Magnesia (MgO)

Affects Colour and Hardness of cement

6.

Sulphur
Trioxide(SO3)

Increases setting time, causes

unsoundness

7.

Alkalis

If present in excess, they may react

with aggregate, cause efflorescence

CEMENT COMPOSITION

Bogue Com pound Com position

Name
Tri Calcium
Silicate
10%
Di Calcium
Silicate

Chemical
5% Formula

Abbreviati
ons

Alternate
Name

3CaO.SiO2

C3S

C3S
Allite
C2S
C3A
Bellite
C4AF
Gypsum

10%

Tri Calcium
Aluminate
25%
Tetra Calcium
Alumino
Ferrite

2CaO.SiO2
3CaO.Al2O3
4CaO.Al2O3.Fe2O
3

50%

C2S
C3A

Cellite

C4AF

Brownmillerite

SOURCE:http://matse1.matse.illinois.edu/concrete/prin.html

BASIC PRO PERTIES IN

CO M PO U N D S
Sr.
No.

Compounds

Properties

1.

Calcium
silicates(C3S,C2S)

Strength, controls setting time

2.

Tricalcium
Aluminate (C3A)

Reacts faster with water

3.

Tetracalcium
Alumino
Ferrite(C4AF)

Hydrates rapidly, individual

contribution to the strength is
insignificant

Bogues Com pound Com position

C3S =4.07(CaO)-7.6(SiO2)- 6.72(Al2O3)1.43(Fe2O3 ) 2.85(SO3 )
C2S= 2.87 (SiO2) - 0.75( 3Cao. SiO2)
C3A= 2.65(Al2O3) 1.69 (Fe2O3 )
C4AF = 3.04 (Fe2O3 )

HYDRATION PROCESS

H ydration:
It is the reaction (series of chemical

reactions) of cement with water to

form the binding material. In other
words, in the presence of water, the
silicates (C3S and C2S) and
aluminates (C3A and C4AF) form
products of hydration which in time
produce a firm and hard mass the
hydrated cement paste.
SOURCE: http://uotechnology.edu.iq/dep-building/LECTURE

Characteristics of H ydration ofthe

Cem ent Com pounds
Chemical

Reaction
Rate

Amount
liberated

Strength

Heat
Liberation

C3S

Moderate

Moderate

High

High

C2S

Slow

Low

Low

Low

Low initially,
Higher later

Very High

C3A

Fast

Very High

C4AF

Moderate

Moderate

Low

SOURCE:http://elearning.vtu.ac.in/16/ENotes

Moderate

SOURCE: http://www.slideshare.net/rizwansamor/hydration-of-

Cem ent hydration process

SOURCE: Mindess and

MICROSTRUCTURE OF CEMENT PASTE

SOURCE:http://elearning.vtu.ac.in/16/ENotes

C -S -H G EL M O D EL

Young et al., 1998

C -S -H G EL M O D EL

C -S -H G EL M O D EL

M IC R O S TR U C TU R E O F
C A LC IU M
SEttringite
U LFO A LU M IN ATES
Monosulfoalumina
te

AFt (first): Prismatic needles

AFm (later): Plane hexagonal crystals
low surface area 2 m2/g
Volume 15-20%

Mehta and Monteiro; Mindess and Young

M IC R O S TR U C TU R E O F
H Y D R ATED C EM EN T PA S TE
C-S-H:
Agglomerations of C-S-H
particles of 1-100 nm.
H:
Hexagonal crystals of
calcium hydroxide,
monosulfoaluminate and
calcium aluminohydrate
of about 1 m.
C:
Capillary pores and voids
of 10 nm to 1 m.

Mehta and Monteiro

M IC R O S TR U C TU R E O F
C A LC IU M H Y D R O X ID E O R
P O R TLA N D ITE

Large hexagonal crystals

Low surface area (0.5 m2/g)
Low Van der Waals forces
Volume 20-25%
Mehta and Monteiro

M O R P H O LO G Y O F H Y D R ATIO N
P R O D U C TS IN 7 D AY S
Large crystals of
calcium hydroxide
Platelets of
monosulfoalumina
te
Cement particle
coated with C-SH, which is
surrounded by
ettringite needles

Young et al., 1998

A M O U N T O F H Y D R ATIO N
P R O D U C TS FO R M ED

PCA, Young et al.

EV O LU TIO N A N D
V O LU M ES O F H Y D R ATIO N
P R O D U C TS
PCA: Kosmatka (2005)

TH E FA C TO R S A FFEC TIN G
TH E K IN ETIC S O F
1.Composition of cement
H Y D R ATIO N
2.The amount and form of gypsum in the cement:
3.Fineness of cement
4.w/c of mix
5.Curing conditions
6.Hydration temperature
7.Presence of chemical admixtures: For example, set
controllers, and plasticizers.

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H EAT O F H YD RATIO N
It is the quantity of heat (in joules) per gram

of un-hydrated cement evolved upon

complete hydration at a given temperature.

The heat of hydration can be determined by

ASTM C 186 or by a conduction calorimeter.

The temperature at which hydration occurs

greatly affects the rate of heat development.

Fineness of cement also affects the rate of

heat development but not the total amount

of heat librated

R ATE O F H EAT
EV O LU TIO N D U R IN G
H Y D R ATIO N

Stage I:

Rapid evolution of heat, lasts about 15 minutes (C 3A and

some C3S reaction).
Stage II:
Dormant period, lasts until initial set occurs in 2 to 4 hours
Stage III:
Rapid reaction of C3S during the acceleration period, with
the peak being reached at about 8-10 hours, much after final
set at 4-8 hours and hardening has begun

Mindess & Young

Heat of Hydration of Pure

Compounds
HEAT OF
HYDRATIO
N
(cal/gm)
C3S

120

C2S

62

C3A

207

C4AF

100

The am ount ofheat

liberated is aff
ected by
the fractions ofthe
com pounds ofthe
cem ent.
H eat of
H ydration(cal/gr)= 120*
(% C 3S)+ 62*(% C 2S)
+ 207*(% C 3A)
+ 100*(C 4AF)

H EAT O F H Y D R ATIO N
Cement hydration is an EXOTHERMIC reaction

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SOURCE: Building Materials- M L Gambhir, Neha Jamwal

PH YSICAL TESTS O N CEM EN T

FINENESS

K
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