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Cement is a substance which is applied to the surface of solid bodies to make them adhere firmly or more specifically a
powdered substance which is made plastic with water is used in a soft and pasty stage. On hardening or drying it binds
together with bricks, stones, etc., in construction. Portland cement is a calcined material comprising lime and silicates,
which is mixed with sand and stone and upon hydration forms a plastic material which then sets and hardens to a rock
like material called concrete.
Portland cement is manufactured in a series of process. Limestone (Calcium Carbonate) and other material containing
appropriate proportions of Calcium, silicon, aluminium and iron oxides are crushed and milled to a fine flour like stuff
called “Raw Meal“. This is preheated in a pre heater or in A rotary kiln to dis-associate calcium carbonate to active calcium
oxide with The evolution of carbon dioxide and then to react calcium oxides with Other component in a Rotary Kiln to form
calcium silicates and aluminates Which partially fuse at material burning temp up to 1400 oC. The Reaction Product leave
the kiln as a dark grayish nodules called “ Clinker “ The Clinker is finally inter ground with a small proportion of Gypsum to
control The rate of hydration and the fine product is cement.
This refers to rigidity of the cement paste which can occur within 5-10 minutes of mixing with water and is referred to as
irreversible rigidity. This is caused by the formation of aluminate hydrate due to high content of
C3A and / or a small amount of easily soluble calcium sulphate. Cement produced with this behavior is unsuitable to use.
What is Impermeability?
Impermeability plays a primary role on the durability of concrete, which in turn depends on the water cement ratio. In the
air entrained concrete, minute air bubbles are trapped inside, which improves the workability of the mix and also function
as minute safety values by providing room for the free water in hardened concrete to escape.
Quality of Cement
The quality of cement is judged by its performance in combination with water as a binder in a material and it includes
properties like setting behavior, strength development, heat development, volume stability and durability. It is very
essential to ensure that the contribution to these properties of the cement is kept at a certain level and with variations as
small as possible to meet the demand expressed in the standard specifications and to comply with the wishes and needs
of the market.
These factors are associated with the characteristics of the materials being used for the cement viz. Clinker, Gypsum and
Additives, and how they are altered during grinding and storage.
Note: Of the above SO3, K2O, Na2O, MgO and Cl components are undesirable for the cement process and should be
as minimum as possible. As a consequence, Dolomitic Limestone is not desirable.
Note: Of the above SO3, K2O, Na2O, MgO and Cl components are undesirable for the cement process and should
be as minimum as possible.
Designation BauxiteType BauxiteType BauxiteType Pyrite Hematite Umber Iron Sand Sand
I II III Ash Slag Stone
SiO2 % 4.3 3.3 3.1 7.8 11.0 32.1 21.5 94.7 80.2
Al2O3 % 56.0 56.6 57.6 1.0 3.1 4.3 8.8 2.9 8.37
Fe2O3 % 22.1 9.4 15.8 84.3 77.7 37.5 57.6 0.24 3.26
Note: Of the above SO3, K2O, Na2O, MgO and Cl components are undesirable for the cement process and should
be as minimum as possible.
In the Cement Manufacturing Process, the selected raw material components are blended, proportioned and finely ground
to a powder form called as Raw Meal, which often have a fineness of 14 – 16 % residue on 90-micron sieve. This material
is heated in stages and finally in a rotary Kiln at about 1400 oC. In the Kiln, after the completion of chemical reactions, a
sintered mass is produced which is called as Clinker. This semi-finished product is again proportioned with Gypsum and
then ground to a powder, which is called as Cement.
The following chemical reactions and phase transformations take place at different temperature ranges.
< 100 Drying and elimination of free water from raw H2O ( Liq) » H2O ( Gas)
material components
100 – 400 Elimination of combined water or physically
absorbed water.
400 – 750 Decomposition of clay minerals with the Al4(OH)8Si4O10 » 2(Al2O3.2SiO2) + 4 H2O
formation of metakaolinite. Removal of structural
H2O.
600 – 1000 Dissociation of limestone and formation of CaCO3» CaO + CO23CaO+2SiO2+Al2O3» 2(CaO.SiO2) +
intermediate products CS and CA CaO.Al2O3
800 –1300 Binding of lime by CS and CA with the formation CaO.SiO2+CaO » 2CaO.SiO2 2CaO+CaO+Al2O3»
of C2S, C3A and C4AF.Formation of belite and 3CaO.Al2O33CaO+CaO+Al2O3+Fe2O3» 4CaO.Al2O3.Fe2O3
liquid phases such as aluminate and ferrite melt
Common Control factors and their influence on the property of Clinker and Cement
100 ( C + 1.5M) /
2.8 S + 1.8
A+0.65 F when M
> 2.0
Legend: Alite: Tricalcium Silicate (3CaO.SiO 2) Belite: Dicalcium Silicate (2CaO.SiO2) C – CaO Calcium Oxide; A – Al2O3
Aluminium Oxide; F – Fe2O3 Ferric Oxide; S – SiO2 Silicon Di Oxide
Mn2O3 % Nd 0.64
P2O5 % Nd 1.52
Cl % Nd 0.16
F% Nd 0.35
Based on the availability of different types of raw material components, a composite Raw Mix design is made (Raw Meal)
which should have the following resultant chemical composition. With this composition high quality Type I OPC - Clinker
can be manufactured, which will have the composition as mentioned in the table below.