Chemical Composition of

Cement: cement is:

Cement is the mixture of Lime 63%
calcareous, siliceous, argillaceous Silica 22%
and other substances. Cement is Alumina 06%
used as a binding material in Iron oxide 03%
mortar, concrete, etc. Gypsum 01 to 04%

(a) Dry process:

MANUFACTURING OF CEMENT: In this process calcareous material such as lime
stone (calcium carbonate) and argillaceous
(1) Mixing and crushing of raw materials material such as clay are ground separately to fine
powder in the absence of water and then are mixed
a. Dry process
together in the desired proportions. Water is then
b. Wet process added to it for getting thick paste and then its cakes
are formed, dried and burnt in kilns. This process
(2) Burning is usually used when raw materials are very strong
(3) Grinding and hard.
In this process, the raw materials are changed to
powdered form in the absence of water.

(b) Wet process:

In this process, the raw materials are changed to
powdered form in the presence of water. (b) Wet Process: Continued------
In this process, raw materials are pulverized by using
a Ball mill, which is a rotary steel cylinder with This process is generally used when raw
hardened steel balls. When the mill rotates, steel
balls pulverize the raw materials which form slurry
materials are soft because complete mixing
(liquid mixture). The slurry is then passed into is not possible unless water is added.
storage tanks, where correct proportioning is done. Actually the purpose of both processes is to
Proper composition of raw materials can be ensured
change the raw materials to fine powder.
by using wet process than dry process. Corrected
slurry is then fed into rotary kiln for burning.

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(2) Burning:
Corrected slurry is feed to rotary kiln, which
is a 150-500 feet long, 8-16 feet in diameter
and temperature arrangement is up to 1500-
1650 degree C.At this temperature slurry
losses moisture and forms into small lumps,
after that changes to clinkers. Clinkers are
cooled in another inclined tube similar to kiln
but of lesser length.
(3) Grinding:
Now the final process is applied which is
grinding of clinker, it is first cooled down to
atmospheric temperature. Grinding of clinker
is done in large tube mills. After proper
grinding gypsum (Calcium sulphate Ca SO4)
in the ratio of 01-04 % is added for
controlling the setting time of cement.
Finally, fine ground cement is stored in
storage tanks from where it is drawn for
packing.

TYPES OF CEMENT:
1. Ordinary Portland Cement
2. Sulphate Resisting Cement (1) ORDINARY PORTLAND CEMENT:
3. Rapid Hardening Cement (or) High It is the variety of artificial cement. It is
Early Strength cement called Portland cement because on
4. Quick Setting Cement hardening (setting) its colour resembles to
5. Low Heat Cement rocks near Portland in England. It was first
6. High Alumina Cement of all introduced in 1824 by Joseph Asp din,
7. Air Entraining Cement a bricklayer of Leeds, England.
8. White Cement

Chemical Composition of O.P.Cement: Continued-------

Chemical Composition of O.P.Cement: The auxiliary constituents are:

O.P.C has the following approximate chemical 1. Iron oxide (Fe2O3) 0.5- 06%
composition:
2. Magnesia (MgO) 1.5- 03%
The major constituents are:
1. Lime (CaO) 60- 63% 3. Sulphur Tri Oxide (SO3) 01- 02%
2. Silica (SiO2) 17- 25% 4. Gypsum 01 to 04%
3. Alumina (Al2O3) 03- 08%

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Functions of Cement
Manufacturing
Constituents
(ii) Silica (SiO2):
The quantity of silica should be
enough to form di-calcium
silicate (C2SiO2) and tri-calcium
silicate in the manufacturing of
cement. Silica gives strength to
the cement. Silica in excess
causes the cement to set slowly.
(iv) Iron Oxide (Fe2O3):
Iron oxide gives colour to the
cement.
(i) Lime (CaO):
Lime forms nearly two-third (2/3) of the
cement. Therefore sufficient quantity of the
lime must be in the raw materials for the
manufacturing of cement. Its proportion has
an important effect on the cement. Sufficient
quantity of lime forms di-calcium silicate
(C2SiO2) and tri-calcium silicate in the
manufacturing of cement.
Lime in excess, causes the cement to expand
and disintegrate.
(iii) Alumina (Al2O3):
Alumina supports to set quickly to
the cement. It also lowers the
clinkering temperature. Alumina in
excess, reduces the strength of the
cement.
(v) Magnesia (MgO):
It also helps in giving colour to the cement.
Magnesium in excess makes the cement
unsound.
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(vi) Calcium Sulphate (or) Gypsum (Ca
SO4) :
At the final stage of manufacturing,
gypsum is added to increase the setting of
cement.
(3) RAPID HARDENING CEMENT:
The chemistry of rapid-hardening hydraulic cement, which differs
from portland cement, is composed primarily of hydraulic
tetracalcium trialuminate sulphate (CSA) and dicalcium silicate
(C2S). C2S is the most durable compound found in portland
cement. The CSA compound, often referred to as calcium
sulfoaluminate, hydrates to form ettringite-a strong needle-like
crystal that develops quickly to give rapid-hardening hydraulic
cement its high performance. Another significant aspect of this
product's chemistry is the absence of tricalcium aluminate (C3A),
which makes a cement susceptible to sulfate attack. Because rapid-
hardening hydraulic cement has little or no C3A, it is very durable
in sulfate environments.One type of this cement is manufactured by
adding calcium chloride (CaCl2) to the O.P.C in small proportions.
Calcium chloride (CaCl2) should not be more than 02%. When this
type of cement is used, shuttering material can be removed earlier.
(5) LOW HEAT CEMENT:
In this cement the heat of hydration is
reduced by tri calcium aluminate (C3A )
content. It contains less %age of lime than
ordinary port land cement. It is used for
mass concrete works such as dams etc.
(2) SULPHATE RESISTING CEMENT:
It is modified form of O.P.C and is specially
manufactured to resist the sulphates. In certain
regions/areas where water and soil may have alkaline
contents and O.P.C is liable to disintegrate, because of
unfavourable chemical reaction between cement and
water, S.R.C is used. This cement contains a low %age
of (tricalcium aluminate) C3A not more than 05%.
This cement requires longer period of curing. This
cement is used for hydraulic structures in alkaline water
and for canal and water courses lining. It develops
strength slowly, but ultimately it is as strong as O.P.C.
(4) QUICK SETTING CEMENT:
When concrete is to be laid under water,
quick setting cement is to used. This cement
is manufactured by adding small %age of
aluminum sulphate (Al2SO4) which
accelerates the setting action. The setting
action of such cement starts with in 05
minutes after addition of water and it
becomes stone hard in less than half an
hour.
(6) HIGH ALUMINA CEMENT:
This cement contains high aluminate %age
usually between 35-55%. It gains strength
very rapidly with in 24 hours. It is also
used for construction of dams and other
heavy structures. It has resistance to
sulphates and action of frost also.
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 (7) AIR ENTRAINING CEMENT:
This type of cement was first of all developed in U.S.A
to produce such concrete which would have resistance
to weathering actions and particularly to the action of
frost. It is found that entrainment of air or gas bubbles
while applying cement, increases resistance to frost
action. Air entraining cement is produced by grinding
minute air entraining materials with clinker or the
materials are also added separately while making
concrete. Entrainment of air also improves workability
and durability. It is recommended that air contents
should be 03-04 % by volume.
Natural resins, fats, oils are used as air entraining
agents.
TO CHECK THE QUALITY OF
CEMENT IN THE FILED:
1.Colour greenish grey.
2.One feels cool by thrusting one’s hand in
the cement bag.
3.It is smooth when rubbed in between
fingers.
4.A handful of cement thrown in a bucket of
water should float.
(1) Fineness Test:
Finer cements react quicker with water and
develop early strength, though the ultimate
strength is not affected. However finer cements
increase the shrinkage and cracking of concrete.
The fineness is tested by:
By Sieve analysis:
Break with hands any lumps present in 100 grams
of cement placed in IS sieve No.9 and sieve it by
gentle motion of the wrist for 15 minutes
continuously. The residue when weighed should
not exceed 10 percent by weight of the cement
sample.
(8) WHITE CEMENT:
This cement is called snowcrete. As iron
oxide gives the grey colour to cement, it is
therefore necessary for white cement to keep
the content of iron oxide as low as possible.
Lime stone and china clay free from iron
oxide are suitable for its manufacturing. This
cement is costlier than O.P.C. It is mainly
used for architectural finishing in the
buildings.
QUALITY TESTS OF CEMENT:
(1) Fineness Test,
(2) Consistency test / setting time test
(3) Setting Time Test
(4) Compressive strength test
(2) Consistency Test /Setting Time Test :
This test is performed to determine the quantity
of water required to produce a cement paste of
standard or normal consistency.
Standard consistency of cement paste may be
defined as the consistency which permits the
Vicate’s plunger (10 mm, 40 to 50 mm in length)
to penetrate to a point 5 mm to 7 mm from the
bottom ( or 35 mm to 33 mm from top) of Vicat
mould. When the cement paste is tested within
the gauging time ( 3 to 5 minutes) after the
cement is thoroughly mixed with water.
Vicat apparatus is used for performing this test.
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(3) Setting Time Test:
In cement hardening process, two instants are
very important, i.e. initial setting and final
setting.
Final Setting Time:
The process elapsing between the time
when water is added to the cement and
the time at which a needle used for
testing final setting upon applying gently
to the surface of the test block, makes an
impression thereon, while the attachment
of the needle fails to do so, is known as
final Setting Time of Cement.
Initial Setting Time:
The process elapsing between the time
when water is added to the cement and
the time at which the needle ( 1 mm
square or 1.13 mm dia., 50 mm in
length) fails to pierce the test block ( 80
mm dia. and 40 mm high) by about 5
mm, is known as Initial Setting Time of
Cement.
(4) Compressive Strength test of Cement:
This test is very important. In this test, three moulds
of (face area 50 cm2) are prepared and cured under
standard temperature conditions and each cube
tested by placing it between movable jaws of the
compressive strength testing machine. The rate of
increasing load is zero in the beginning and varies at
350 kg/cm2 per minute. The load at which the cube
gets fractured divided by the cross sectional area of
the cube, is the compressive strength of the cube.
The average of the compressive strengths of three
cubes is the required compressive strength of the
cement sample.