Cement

Cement that consists of Calcareous (limestone)

and Argillaceous material (Clay) i.e. produced by
calcinations reaction. Mostly used as cement
mortar/Cement concrete.
0% Cement Composition
6% 1% 1%

CaO
SiO2
23%
Al2O3
Fe2O3
69% MgO
Alkalies
Manufacturing Process
 Wet Process Dry Process

Water + Clay + Limestone Crushed Limestone + Clay

Grinding Mill – Raw meal

Wet Grinding mills to form slurry (30-35%)

Mixed with Compressed air

Fed in to Rotary Kiln

Granulator – 12% water to pellets

Formation of Clinker
Conversion into Clinker in Rotary Kiln

Powdered in ball mill with 2-5% of Gypsm

Powdered in ball mill with 2-5% of Gypsm

Cement Siols Cement Silos

Heat of Hydration

Bogue’s Compounds
• Tricalcium Silicate - 3CaO.SiO2 - C3S
• Dicalcium Silicate - 2CaO.SiO2 - C2S
• Tricalcium Aluminate - 3CaO. Al2O3 - C3 A
• Tetracalcium Aluminoferrite - 4CaO Al2O3 Fe2O3 - C4AF

• C3S - Large Heat of hydration, Early Strength

• C2S - Less Heat of Hydration, Later Strength
• C3 A - Flash Set
Heat of Hydration

Bogue’s Compounds
 Water Requirement
• Two parts, For formation of Hydrated
Compounds, i.e bound water
• Another gel pores
• 23% + 15% by weight of cement

• Transition Zone
 Types of Cement
• OPC(Ordinary Portland Cement)
• Rapid Hardening Cement
• Low Heat Cement
• PPC (Portland Pozzolana Cement)
• White Cement
• High Alumina Cement
• Sulphate resisting cement
 Opc Rapid Hardeninng
Cement

• Classified in to 3 grades • High C3S

• High Earlier Strength

• 33, 43, 53 grade
• Used in road repair work,
• Represent the 28th day
Cold Climatic Countries
strength 33 N/mm2
 Low Heat Cement Sulphate resisting
Cement

• Low C3S and C3A • Sulphate attack in

marine environment
• High C2S
• Ca(OH)2 and C3A
• Low heat of hydration
• Low C3 A content
• 7 days strength > 16 MPa
 PPC White Cement

• Same as OPC but usage of

• Mixing of Pozzolanic material
high quality limestone (96%)
such as calcined clay/flyash
• Whiteness measured in
• Calcium hydroxide converted
Hunters scale, 90%
in to C-S-H gel

• 15 to 35% to clinker

• Less heat of hydration

• Reduces the leaching of

calcium hydroxide useful in
hydraulic structure
 Testing of Cement
• Fineness test
• Setting time
• Strength
• Soundness
• Heat of hydration
• Chemical Composition
 Fineness Test
• Sieve test – 100g of Cement sieve through 90micron
sieve for 15 mins, residue<10%

• Air permeability meter – measurement of surface

area, i.e cm2/g , usually 2250 cm2 /Kg
 Standard Consistency test
• The water content in which
the needle (10mm dia, 50 mm
lenghth) will make a
penetration of 35mm

• Initial setting time (30 mins)

• Final Setting Time , about 10

hr

vicat’s apparatus
 Strength Test
• Take 1:3 (555g of cement,
185g of fine aggregate)

• Add water

• 7.06 cm cube

• Test in compression
testing machine (min 3
units)
 Soundness test
• The Cement shouldn't exhibit
appreciable expansion

• Lime/Mg/Calcium sulphate

• Free lime – Lechatlier test

• Free lime, Mg – Autoclave

• Calcium Sulphate –Chemical

analysis

• <0.8% or 10mm
 Heat of hydration
• Exothermic reaction
• 120cal/g
• For Low heat cement
• Vacuum flask / adiabatic
calorimeter
• <75 cal/g for low heat
cement
 Chemical Composition (Plant Control Measures - Clinker)

• Lime saturation factor

• Silica Ratio
• Alumina Ratio