AN AUTONOMUS INSTITUTE OF GOVT. OF MAHARASHTRA

IN PURSUIT OF GLOBAL COMPETITIVENESSIN PURSUIT OF GLOBAL COMPETITIVENESS

CEMENT

Created BY:- Nikhil Pakwanne

CEMENTCEMENTCement is a Building material obtained by Cement is a Building material obtained by burning and crushing of powder form , burning and crushing of powder form , homogeneous and well proportioned homogeneous and well proportioned

mixture of lime (calcareous) and clay mixture of lime (calcareous) and clay (argillaceous material).(argillaceous material).

Chemicals and material Chemicals and material

Tri-calcium silicate (Ca)Tri-calcium silicate (Ca) Di-calcium silicateDi-calcium silicate Tri-calcium aluminateTri-calcium aluminate Tetra-calcium alumino ferriteTetra-calcium alumino ferriteOther ChemicalsOther Chemicals Lime Lime SilicaSilica AluminaAlumina Iron oxideIron oxide MagnesiaMagnesia Soda and PotashSoda and Potash Sulphur tri-oxideSulphur tri-oxide Free limeFree lime

Manufacturing process of cement

Manufacturing of cementManufacturing of cement There are 3 steps of manufacturing There are 3 steps of manufacturing

of cementof cement1)1) Mixing of raw materialsMixing of raw materials2)2) BurningBurning3)3) GrindingGrinding

1) Mixing of raw Material :-1) Mixing of raw Material :- clay and limestone are taken in clay and limestone are taken in

appropriate proportion and mixed in appropriate proportion and mixed in dry and wet condition.dry and wet condition.

2) Burning:-2) Burning:- mixed material is heated about 1400 mixed material is heated about 1400

– 1600 Degree celcius and cooled by – 1600 Degree celcius and cooled by passing through coolers.passing through coolers.

3) Grinding:-3) Grinding:- so material obtained (clinker) is so material obtained (clinker) is

ground in mill and 2 % to 4 % ground in mill and 2 % to 4 % gypsum is added to control the gypsum is added to control the setting time of cementsetting time of cement

Types of CementTypes of Cement

1)Ordinary Portland cement1)Ordinary Portland cement2)Portland Pozzolana Cement2)Portland Pozzolana Cement3)Sulphate Resisting Cement3)Sulphate Resisting Cement4)Coloured Cement 4)Coloured Cement 5)Rediset Cement5)Rediset Cement6)Very high strength cement6)Very high strength cement7)Rapid Hardening Cement7)Rapid Hardening Cement8) Portland Slag Cement 8) Portland Slag Cement 9)Masonry Cement 9)Masonry Cement 10)Oil Well Cement10)Oil Well Cement

Ordinary Portland CementOrdinary Portland Cement (is 269:1989)(is 269:1989)

Although there are many types of Cement , about 80 -90% Although there are many types of Cement , about 80 -90% of total production is of Ordinary Portland Cement (OPC) of total production is of Ordinary Portland Cement (OPC) only. only.

OPC is classified in three types of grades depending upon OPC is classified in three types of grades depending upon strength of cement as strength of cement as

1)33 Grade 1)33 Grade 2)43 Grade 2)43 Grade 3)53 Grade 3)53 Grade

Faster rate of development of strengthFaster rate of development of strength Offers 10-20 % savings in cement consumptionOffers 10-20 % savings in cement consumption 33 grade cement is almost out of the market33 grade cement is almost out of the market The manufacture of OPC is decreasing in view of popularity The manufacture of OPC is decreasing in view of popularity

of blended cement on account of lower energy of blended cement on account of lower energy consumption, environmental pollution.consumption, environmental pollution.

Portland Pozzolana CementPortland Pozzolana Cement It is manufactured by intergrinding of OPC clinker It is manufactured by intergrinding of OPC clinker

with 10-25% of pozzolanic materialwith 10-25% of pozzolanic material PPC produces heat of hydration and offer greater PPC produces heat of hydration and offer greater

resistance to the attack of aggressive water than resistance to the attack of aggressive water than OPC.OPC.

PPC can generally be used where OPC is usablePPC can generally be used where OPC is usable rate of development of strength unto 7 daysrate of development of strength unto 7 daysSuitabilitySuitability It is economicalIt is economical It offers durability charecteristics in marine & It offers durability charecteristics in marine &

hydraulic structureshydraulic structures Strength of PPC is higher than OPC Strength of PPC is higher than OPC

Coloured cementColoured cement ( ( is 8042-1989is 8042-1989))

For manufacturing of this cement ,white or For manufacturing of this cement ,white or grey portland cement is used as basegrey portland cement is used as base

Use of white cement is costly while using Use of white cement is costly while using grey portland cement only red & brown grey portland cement only red & brown cement can be producedcement can be produced

Consists of PPC with 5-10% of pigmentConsists of PPC with 5-10% of pigment For manufacture of white portland cement For manufacture of white portland cement

required limestone is only available required limestone is only available around Jodhpur(Rajasthan)around Jodhpur(Rajasthan)

White cement is ground finer than grey White cement is ground finer than grey cementcement

Rapid Hardening CementRapid Hardening Cement ( (is 8041-1990is 8041-1990))

This cement develops higher rate of This cement develops higher rate of development of strengthdevelopment of strength

SuitabilitySuitability

-Road repair works-Road repair works

-In pre-fabricated concrete -In pre-fabricated concrete construction construction

-In cold weather concrete-In cold weather concrete

Storage of cementStorage of cement

Water proof Water proof mesonry walls mesonry walls should be provided.should be provided.

Leak proof roof with Leak proof roof with water proof cover water proof cover should be provided.should be provided.

Ground should be Ground should be drained away to drained away to prevent from rain prevent from rain water water

Storage of cement bagsStorage of cement bags

Bags should not be Bags should not be allowed to directly rest allowed to directly rest on the walls.on the walls.

Not more than 15 Not more than 15 bags be piled over the bags be piled over the other.other.

If cement is to be If cement is to be stored in mansoon or stored in mansoon or for long period piles for long period piles should be covered by should be covered by polythene sheet.polythene sheet.

Field Tests for cementField Tests for cement

Cement should be of uniform color.Cement should be of uniform color. When small sample of cement is When small sample of cement is

rubbed between fingers ,it should rubbed between fingers ,it should feel smooth and cool.feel smooth and cool.

There should no lumps in the There should no lumps in the cement.cement.

Laboratory tests of cementLaboratory tests of cement1)Fineness :-1)Fineness :- This test is varified by using I.S. sieve No.9.This test is varified by using I.S. sieve No.9. -now gentle sieving is done for fifteen minutes.-now gentle sieving is done for fifteen minutes. -The residue left is measured this should not be -The residue left is measured this should not be

exceed 10 % by weight of the sample of the exceed 10 % by weight of the sample of the cement.cement.

2)Consistency:-2)Consistency:- This is a test sonducted to estimate quantity This is a test sonducted to estimate quantity of water to be mixed with cement.of water to be mixed with cement.3) Soundness of cement ;-3) Soundness of cement ;- Due to excess of lime in the cement expansion of Due to excess of lime in the cement expansion of

cement occurs, that should be minimized. cement occurs, that should be minimized.

4)Setting time :-4)Setting time :-

The object of this test The object of this test is to make distinction is to make distinction between normal between normal setting time and final setting time and final setting time. This test setting time. This test can be conducted by can be conducted by using Vicat using Vicat apparatus.apparatus.

ReferencesReferences

S.Ramamrutham ,S.Ramamrutham ,Basics of civil Basics of civil Engineering,Dhanpat rai publishing Engineering,Dhanpat rai publishing company,New Delhi.company,New Delhi.

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