SNPIT&RC,

UMRAKH

M. E. [CONSTRUCTION
ENGINEERING &
MANAGEMENT]
YEAR I (SEMESTER II)
ADVANCED CIVIL ENGINEERING
MATERIALS(2721401)

CEMENT
PREPARED BY : PATEL TARUN
(140490714006)
PATEL JATIN
(140490714014)

GUJARAT
TECHNOLOGIC
AL UNIVERSITY

DEFINITION
Cements

are

materials

that

exhibit

characteristic

properties of setting and hardening when mixed to a paste

with water. This makes them join rigid masses into
coherent structures. It is powdery bonding material having
adhesive and cohesive properties.

Chemically it is a finely ground mixture of calcium

silicates and aluminates which set to a hard mass when

treated with water. These are called as Hydraulic Cements
(Portland Cement) and those setting in air are Non
Hydraulic cements (Ordinary Lime).

HISTORY

Lime and clay have been used as cementing material on

constructions through many centuries.

Romans are commonly given the credit for the

development of hydraulic cement, the most significant

incorporation of the Romans was the use of pozzolanlime cement by mixing volcanic ash from the Mt.
Vesuvius with lime.
Best know surviving example is the Pantheon in Rome

In 1824 Joseph Aspdin from England invented the

Portland cement

CLASSIFICATION OF CEMENT
Natural Cement: Obtained by calcinations and pulverizing natural

cement rock of argillaceous and clay with limestone. It does not have
sufficient strength and is cheap and quick setting & have hydraulic
properties.
Pozzolana Cement: Volcanic ash containing silicates of calcium, iron

and aluminum when mixed with lime and heated produces this cement.
Slag Cement: Mixture of blast furnace slag (Ca and Al Silicates) and

hydrated lime. Sometimes accelerators like clay, salt, caustic soda are
added to hasten hardening process.
Portland Cement: It consists of compounds of lime, silica, alumina and

iron. When mixed with water it forms a paste which binds the rock, sand
and gravel to form concrete.

TYPES OF CEMENT:
1)

Ordinary Portland Cement

2)

Sulphate Resisting Cement

3)

Rapid Hardening Cement (or) High Early Strength cement

4)

Quick Setting Cement

5)

Low Heat Cement

6)

High Alumina Cement

7)

Air Entraining Cement

8)

White Cement

GRADES OF PORTLAND CEMENT

33 grade General Construction like plastering, finishing

works etc, where strength is not required.

43 grade Useful for structural works, precast items etc,

Strength development is faster than 33 grade.

53 gradeUsed for multi-storey buildings, precast pre-stressed

items, bridges, tall structures etc. Develops very fast strength
and speeds up construction.

PORTLAND CEMENT COMPOSITION

Lime (CaO)

60-66%

Excess reduces strength and make

cement disintegrate and in less
amount reduces strength and makes
it quick setting.

Silica (SiO2)

17-25%

Provides strength to cement

Alumina (Al2O3)

3-8%

Helps in quick setting

Calcium Sulphate
(Gypsum)
Iron Oxide

Enhances initial setting of cement

2-6%

Gives color, Strength and hardness.

Sulphur trioxide 1-3%

(SO3)

Provides soundness

Alkali
Oxides 0.5(Na2O and K2O)
1.5%

in
excess
efflorescent

Magnesium
Oxide (MgO)

1-5%

makes

cement

RAW MATERIALS

Calcareous Materials : Supplies Lime to cement

Lime Stone (65-80% CaCO3), Marl, Chalk, Shale, Calcite, Alkali waste. It should
contain less than 3.3% of MgO and 3-4% of SiO2, Fe2O3, and AlO2 combined.

Argillaceous Materials : Supplies Silica, Alumina and Iron Oxide. Clay, Marl,
Shale, Blast Furnace Slag, sand etc. Here Silica provides strength, Alumina imparts
quick setting, iron provides color, strength and hardness.

Gypsum: increases setting time.

Powdered Coal and Fuel Oil: For generating required temperatures.

MANUFACTURE OF PORTLAND CEMENT

Crushing

Mixing (Wet Process)

Mixing (Dry Process)

Grinding (Ball Mill and Tube Mill)

Storage of Ground Materials

Burning

Drying Zone

Calcinations Zone

Clinkering Zone

Grinding

Retarder

Dispersing Agent

Water Proofing

Packaging

CRUSHING

This is the first step in the manufacture of

Portland Cement.

Jaw crushers of various sizes are employed for

the crushing purpose.

Raw materials are crushed by crushers till the

size of the raw material reduces to of an inch.

It is than send for either Wet process or Dry

process. Wet process is universally employed.

MIXING PROCESS
Wet process

Calcareous materials are crushed, powdered and stored in bins.

Argillaceous materials is mixed with water and washed. This removes any
adhering organic impurities.

Powdered Calcareous and Washed Argillaceous materials are mixed in proper

proportions to get a slurry.

Chemical composition is analyzed and corrected if necessary by addition of the

deficient materials.

This slurry is then fed into the rotary kiln.

Dry process

Hard raw materials like cement rock or blast furnace slag are first
crushed to 50mm pieces in ball mill, then dried and stored.

Crushing is done by gyratory crushers and drying is done by rotary

driers.

Separate powdered ingredients are mixed in required proportions to

get the raw mix which is then fed to rotary kilns.

STORAGE OF GROUND MATERIALS

The ground materials containing 30 40% of water is stored

in separate tanks equipped with agitators.

This step is followed by process of burning

BURNING

Slurry is burnt in rotary kiln where actual chemical changes takes place.
Kiln is long steel cylinder 30-40 meter in length, 2-4 meter in diameter, lined by refractory
bricks. It is inclined at gradient of 0.5-0.75 inch and can be rotated at the desired speed.
The material is introduced in the kiln from the upper end as the kiln rotates material passes
slowly towards the lower end.
Kiln is heated by burning pulverized coal or oil and temperature is maintained at about
1400-1500C. At clinkering temperature actual chemical reactions takes place

GRINDING
Grinding can be done in two stages
Ball Mill

Consists of cast iron drum containing iron and

steel balls of different sizes. The principle used in
ball mills impact and shear produced by large no.
of tumbling and rolling balls.
Tube Mill

Ball mill grinding is followed by tube mill

grinding. Tube mill is conical at the discharge end
with separate inlet and outlet.

Slower is the feeding speed finer is the product

coming out of the tube mill.

Clinkers are finally grinded in ball mill and tube mill to a fine powder. Additives added are as
follows.

Retarder:
Gypsum or Plaster of Paris acts as retarder to prevent quick setting. After initial setting
gypsum retards the dissolution of tricalcium aluminates by forming tricalcium
sulphoaluminate.
Dispersing Agent:
Sodium salts and polymers of condensed naphthalene or sulphonic acid are added to prevent
the formation of lumps and cakes in the cement.
Water proofing agents are also added.

PACKAGING
The ground powder is packed
by automatic machines in a
bag.

This is then dispatched to the

markets where it is sold.

QUALITY TESTS OF CEMENT:

(1) Fineness Test,
(2) Consistency test / setting time test
(3) Setting Time Test
(4) Compressive strength test

(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.

(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 Vacates 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 Vacate mould.
When the cement paste is tested within the gauging time ( 3 to 5 minutes) after the
cement is thoroughly mixed with water.
Vacate apparatus is used for performing this test.

(3) Setting Time Test:

In cement hardening process, two instants are very important, i.e. initial
setting and final setting.
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.

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.

(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.

CHARACTERISTICS OF CEMENT

When water is added to initiate dry mixtures of cement and sand,

hydration of cement starts and it will binds sand particles as well as
the surrounding surfaces of masonry and concrete.

The proportion of cement and sand will decide the strength of

mortar.

A richer mix than 1:3 proportion is prone to shrinkage.

Solid surface are provided by well proportioned mortar.

A leaner mix is not able of closing the voids in sand.

COMMON APPLICATIONS OF CEMENT

Building (floors, beams, columns, roofing, piles, bricks, mortar, panels,

plaster).

Transport (roads, pathways, crossings, bridges, sleepers, viaducts, tunnels,

stabilization, runways, parking).

Water (pipes, culverts, kerbing, drains, canals, weirs, dams, tanks, pools).

Civil (piers, docks, retaining walls, silos, warehousing, poles, pylons,

fencing).

Agriculture (buildings, processing, housing, feedlots, irrigation).

ADVANTAGES AND DISADVANTAGES

Advantages:

Cement is very strong.

It can create large structures quickly.

It conforms to different shapes (arcs and circles, etc).

It has high thermal mass (moderates temperature).

Disadvantages:

Cement is subjected to cracking.

It is very difficult to provide idoneous curing conditions.

It is not ideal for situation when settlement is expected.

THANK YOU