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What is Cement &

How it is produced
 “CEMENT”

cement is a binder, a substance used in construction that

sets and hardens and can bind other materials together. The
most important ways of using cement are in the production of
mortar in masonry, and in concrete, which is a combination of
cement and aggregate to form a strong building material.
 WHAT ARE THE CONSTITUENTS OF
CEMENT ( CCN)
A)Tricalcium silicate (C3S): Hydrates and hardens rapidly and is
largely responsible for initial set and early strength.

B) Dicalcium silicate (C2S): Hydrates and hardens slowly and is

largely responsible for strength increases beyond one week.

C) Tricalcium aluminates (C3A): Hydrates and hardens the

quickest. It liberates a large amount of heat almost
immediately and contributes somewhat to early strength.
Gypsum is added to Ordinary Portland cement to retard C3A
hydration. Without gypsum, C3A hydration would cause
ordinary Portland cement to set almost immediately after
adding water.
CONTINUED ……

D) Tetracalcium aluminoferrite (C4AF): Hydrates rapidly but

contributes very little to strength. Most ordinary Portland
cement colour effects are due to C4AF.

E) Pozzolanic material: Such volcanic ash, shale and certain

type of clay i:e as fly ash in India , which is a by product
of coal ashes from power plants.
 TYPES OF CEMENT

OPC PPC
 OPC
• The name Ordinary Portland cement was given
by Joseph Aspin in 1824 due to its similarity
in color & its quality when it hardens like
Portland stone . Portland stone is white grey
limestone in inland of Portland.
• The chief chemical composition of ordinary
Portland cement are calcium, Silica , Alumina ,
Iron
 PPC

Portland Pozzolana Cement also commonly known as

PPC cement. The percentage of pozzolanic material
used in the preparation should be between 10 to
30. If the percentage is exceeded, the strength
of cement is reduced.
Some of the pozzolanic materials used are volcanic
ash, shales and certain type of clays. But in our
country (In India) Fly ash is the main constituent
used in preparation of cement. And moreover, this
type of cement is used more than 80% for
construction purposes.
 Advantages
PCC
•Higher durability of concrete structure
due to less permeability of water.
•More resistance towards the attack of
alkalis, sulphates, chlorides, chemicals.
•Better work ability.
•Low heat of hydration.
•Due to high fineness, PPC has better
cohesion with aggregates and makes
more dense concreteness.
•Comparative lower Water-Cement ratio
provides an added advantage for the
further increase of compressive
strength of the concrete.
•Better surface finish.
OPC
• Produces highly durable and
sound concrete due to very
low percentage of alkalis,
chlorides, magnesia and free
lime in its composition.
• Almost negligible chloride
content results in restraining
corrosion of concrete
structure in hostile
environments.
• Significant saving in cement
consumption while making
concrete of grades M15,
M20, M25, M35 and pre-cast
segments due to high
strength.
 HOW CEMENT IS
PRODUCED

Pozzolanic materials ( FLY ASH USED IN PPC)

OPC (C3S+C2S+C3A
OPC (C3S+C2S+C3A+
+C4AF+FLY ASH
C4AF )
FLOW CHART OF CEMENT IS PRODUCED
 STEP 1
Limestone excavated from
Mines is transported through
Dumpers and fed to crushers
wherein it is reduced from
above 850 mm to 80 mm size.
 STEP 2
Environmental friendly
Conveyor belts transport
the limestone from the
Crusher to the Plant Site
 STEP 3
Scientifically designed
Stackers provide for stacking
of the limestone received
from the mines in circular /
longitudinal stock piles. Use of
Reclaimers ensure consistency
in quality
 STEP 4
State of the Art Vertical
Roller Mill grinds
Limestone feed   to
powdered form called Raw
Meal
 STEP 5
Most advanced Coal Mill
pulverizes the coal to be
injected into Kiln for
burning of Raw Meal.
 STEP 6
Rotary Kiln provides for
Clinkerisation where in Raw
Meal fed from VRM is first
burnt to melting (1400 C) &
then cooled to 100 - 120 C
by means of coolers
immediately outside the Kiln
to produce Clinker.
 STEP 7
Close Circuit Cement Mill ensures high quality
grinding of clinker, gypsum and pozzolana to yield
best possible uniformity of the cement particles.
 STEP 8
Centralised Control
Room monitoring the
manufacturing
process through
computers.
 STEP 9
Consistency and accuracy in the
packing of bags by electronic
packing machines.  Packing Plant is
equipped with computer controlled
electronic packers, which ensure
that cement bags are packed and
sealed to 50 kg of cement each
accurately.  Manual check is also
carried out at random to monitor
computer accuracy and introduce
correction as applicable.
 STEP 10
Loading of bags in the
wagon/trucks is carried
out automatically by
means of wagon / truck
loading machines,
equipped with Electronic
Loading Counters which
accurately keep count of
the Number of bags being
loaded.