CemNet Training - Course TCM01 Module 1 - Session 1

Cement Manufacturing
Technology
1. Fundamental requirements of cement in application.
1.1. Cement performance.

Cement Technology Training 1.1 Major Applications

Cement Technology 1.1 Cement Performance

Cement is a hydraulic material which binds the sand and aggregates

used in mortars and concrete in building applications.
Hydraulic materials undergo chemical reactions when mixed
with water.
When cement is mixed with water to form a paste these chemical
reactions cause the paste to first stiffen and then set into a solid
mass.
This stiffening and setting is caused
by the growth of hydroxide crystals,
which are the product of the reactions
between the cement minerals and
water.

Cement Technology Training 1.1 Major Applications

Cement Technology 1.1 Cement Performance

Cement is a hydraulic material which binds the sand and aggregates

used in mortars and concrete in building applications.
Hydraulic materials undergo chemical reactions when mixed
with water.
When cement is mixed with water to form a paste these chemical
reactions cause the paste to first stiffen and then set into a solid
mass.
These hydraulic reactions continue
for many hours, days, weeks and
months beyond the initial setting of
the cement, increasing the strength
of the mortar or concrete made from
the cement.
Cement Technology Training 1.1 Major Applications

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 CemNet Training - Course TCM01 Module 1 - Session 1

Cement Technology 1.1 Cement Performance

Cement is only one component in the mortars and concrete used in

building applications. (Albeit the most important one).
Cement is never used in
isolation, but is always used
as the binder with sand,
aggregates and water.

The properties of the sand,

aggregate and water are
important contributors to the
performance of mortar or
concrete made with the
cement.

Cement Technology Training 1.1 Major Applications

Cement Technology 1.1 Cement Performance

Cement is only one component in the mortars and concrete used in

building applications. (Albeit the most important one).
However, as the cement is the
binder and therefore the most
important component, the
properties of the cement are the
most important in determining
mortar or concrete performance.

This fact that cement is an intermediate product forming only

one component of final mortar or concrete product places
fundamental requirements on the manufacture of cement.

Cement Technology Training 1.1 Major Applications

Cement Technology 1.1 Cement Performance

Cement is only one component in the mortars and concrete used in

building applications.
A cement manufacturing company does not have control over
the use of their cements in the production and placing of mortars
and concretes.
Indeed, a cement manufacturing company usually does not know
in which applications their cement will be used, or the
combination of other components that will be used in the mortar
or concrete.
This means that the cement produced must be a commodity
product with consistent properties which are suited to its use in
many mortar and concrete applications.

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 CemNet Training - Course TCM01 Module 1 - Session 1

Cement Technology 1.1 Cement Performance

The cement produced must be a commodity product with consistent

properties suited to its use in many building applications.
This explains the efforts which cement manufacturing
companies devote to homogenisation and control throughout the
cement manufacturing process.
For the concrete producing customers of a cement company the
consistency of cement properties, and lack of variability in these
properties, is the most important quality characteristic.

Cement Technology Training 1.1 Major Applications

Cement Technology 1.1 Cement Performance

The cement produced must be a commodity product with consistent

properties suited to its use in many building applications.
A concrete producer is responsible for demonstrating that the
mixes they use will produce hardened concretes which conform
with the requirements of the architect or concrete specifier.
To do this they must apply quality assurance
procedures to each component of their
concrete mixes.
Their field sampling and subsequent
concrete testing must demonstrate this
conformance.

Cement Technology Training 1.1 Major Applications

Cement Technology 1.1 Cement Performance

The cement produced must be a commodity product with consistent

properties suited to its use in many building applications.
A concrete producer is responsible for demonstrating that the
mixes they use will produce hardened concretes which conform
with the requirements of the architect or concrete specifier.
Increases in the variation of their field
sampling and testing mean that they must
introduce additional testing to re-establish
conformance.
This increases their costs and quickly leads
to complaints regarding the quality
(variability) of the cement used in the
concrete mix.
Cement Technology Training 1.1 Major Applications

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 CemNet Training - Course TCM01 Module 1 - Session 1

Cement Technology 1.1 Cement Performance

The cement produced must be a commodity product with consistent

properties suited to its use in many building applications.
A concrete producer is responsible for demonstrating that the
mixes they use will produce hardened concretes which conform
with the requirements of the architect or concrete specifier.
Additional field sampling and testing are not the only source of
increased costs.
Concrete mix design requires that a safety margin of +2 standard
deviations in strength performance above specification must be
used to determine the cement content of the concrete.
Higher variability means higher standard deviation in concrete
strength and therefore higher cement content and cost.
Cement Technology Training 1.1 Major Applications

Cement Technology 1.1 Cement Performance

After variability the next most important quality parameter is the

compressive strength of the concrete produced with the cement.
The cement hydraulic reactions
continue for many hours, days,
weeks and months beyond the initial
setting of the cement, increasing the
strength of the mortar or concrete
made from the cement.

Cement Technology Training 1.1 Major Applications

Cement Technology 1.1 Cement Performance

After variability the next most important quality parameter is the

compressive strength of the concrete produced with the cement.
Compression
Must emphasise that concrete and
mortar are capable of developing
significant strength in compression.

Concrete pile

Concrete and mortar have very Flexure

poor flexural strength.

Hence the need to use reinforcement in applications where

loads vary and flexural strains are imparted to the concrete.
Cement Technology Training 1.1 Major Applications

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 CemNet Training - Course TCM01 Module 1 - Session 1

Cement Technology 1.1 Cement Performance

After variability the next most important quality parameter is the

compressive strength of the concrete produced with the cement.

After the initial setting

period of a few hours
Compressive
the compressive
Strength
strength increases
rapidly.
As time proceeds the
rate of strength growth
reduces..
1 3 7 28
Days but does not end.
Cement Technology Training 1.1 Major Applications

Cement Technology 1.1 Cement Performance

After variability the next most important quality parameter is the

compressive strength of the concrete produced with the cement.
Different concrete applications demand different strength
growth characteristics from the cement.

Flooring screeds require high early

strength to allow finishing within the
working day.

Cement Technology Training 1.1 Major Applications

Cement Technology 1.1 Cement Performance

After variability the next most important quality parameter is the

compressive strength of the concrete produced with the cement.
Different concrete applications demand different strength
growth characteristics from the cement.

Flooring screeds require high early

strength to allow finishing within the
working day.
Precast concrete manufacture also
requires high early strength to allow early
demoulding and the reduce warehouse
space required for curing.

Cement Technology Training 1.1 Major Applications

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 CemNet Training - Course TCM01 Module 1 - Session 1

Cement Technology 1.1 Cement Performance

After variability the next most important quality parameter is the

compressive strength of the concrete produced with the cement.

28-day strength remains

the most important
specification for general
concrete applications.
This means that a cement company encounters pressure
from their concrete customers for high early and late
strength characteristics so that the cement is suitable for all
applications.

Cement Technology Training 1.1 Major Applications

Cement Technology 1.1 Cement Performance

Workability is just as important as the strength, because the two

characteristics are effectively linked.
The wet concrete must be
sufficiently fluid to be placed in a
mould and around reinforcement.

Cement Technology Training 1.1 Major Applications

Cement Technology 1.1 Cement Performance

Workability is just as important as the strength, because the two

characteristics are effectively linked.
The wet concrete must be
sufficiently fluid to be placed in a
mould and around reinforcement.

Cement Technology Training 1.1 Major Applications

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 CemNet Training - Course TCM01 Module 1 - Session 1

Cement Technology 1.1 Cement Performance

Workability is just as important as the strength, because the two

characteristics are effectively linked.
Workability is measured
in the field by the slump
test.

The slump cone is filled

with the concrete, and
then lifted.
The slump of the cone of
concrete is measured to
assess the workability.

Cement Technology Training 1.1 Major Applications

Cement Technology 1.1 Cement Performance

Workability is just as important as the strength, because the two

characteristics are effectively linked.
Workability is determined by the
characteristics of the cement and the
water content of the concrete.

Poor workability can be corrected by

more water addition
.but strength falls.
Hence the effective link between
workability and strength.

Cement Technology Training 1.1 Major Applications

Cement Technology 1.1 Cement Performance

Workability is just as important as the strength, because the two

characteristics are effectively linked.
Where concrete must be pumped the workability becomes a
particularly important consideration.

Cement Technology Training 1.1 Major Applications

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 CemNet Training - Course TCM01 Module 1 - Session 1

Cement Technology 1.1 Cement Performance

Setting time of the cement and the wet concrete is also important.
In cold climates rapid set will be
required to allow finishing during
the working day.
In hot climates slower setting will be
required to allow the concrete to be
placed.
Control of the setting time is
therefore the most important
consideration.

Cement Technology Training 1.1 Major Applications

Cement Technology 1.1 Cement Performance

Durability is a critical consideration in applications where the

environment could attack and destroy the concrete.

In foundations where sulphates and

acid ground waters could attack the
concrete.

Cement Technology Training 1.1 Major Applications

Cement Technology 1.1 Cement Performance

Durability is a critical consideration in applications where the

environment could attack and destroy the concrete.
In foundations where sulphates and
acid ground waters could attack the
concrete.
In structures exposed to seawater
attack.

Cement Technology Training 1.1 Major Applications

This document is for the sole use of students enrolled on course TCM01 and cannot be reprinted, reproduced or distributed without prior written consent from Tradeship Publications Ltd 2005
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 CemNet Training - Course TCM01 Module 1 - Session 1

Cement Technology 1.1 Cement Performance

In massive concrete structures low heat generation during hydration

is important to prevent cracking of the concrete.

Dams.
Consistency of colour can be an important consideration in
concrete buildings and structures.

Cement Technology Training 1.1 Major Applications

Cement Technology 1.1 Cement Performance

In massive concrete structures low heat generation during hydration

is important to prevent cracking of the concrete.

Dams.
Consistency of colour can be an important consideration in
concrete buildings and structures.

In special applications special properties may be required.

Oil well cementing.

Cement Technology Training 1.1 Major Applications

Cement Technology 1.1 Cement Performance

In massive concrete structures low heat generation during hydration

is important to prevent cracking of the concrete.
Dams.
Consistency of colour can be an important consideration in
concrete buildings and structures.

In special applications special properties may be required.

Oil well cementing.

Refractory structures.

Cement Technology Training 1.1 Major Applications

This document is for the sole use of students enrolled on course TCM01 and cannot be reprinted, reproduced or distributed without prior written consent from Tradeship Publications Ltd 2005
http://training.CemNet.com 9
 CemNet Training - Course TCM01 Module 1 - Session 1

Cement Technology 1.1 Cement Performance

In massive concrete structures low heat generation during hydration

is important to prevent cracking of the concrete.

Dams.
Consistency of colour can be an important consideration in
concrete buildings and structures.

In special applications special properties may be required.

Oil well cementing.

Refractory structures.

Abrasion resistant surfaces.

Cement Technology Training 1.1 Major Applications

Cement Technology 1.1 Cement Performance

This then is what is required of the cement product:

High early and late (28-day) strength.
Good workability characteristics.
Controlled setting, matched to local climatic conditions.
Reliable durability in the long term.
Consistent colour.
These are not a pick & mix wish list...
...the concrete customers will want all these.

Cement Technology Training 1.1 Major Applications

Cement Technology 1.1 Cement Performance

This then is what is required of the cement product:

High early and late (28-day) strength.
Good workability characteristics.
Controlled setting, matched to local climatic conditions.
Reliable durability in the long term.
Consistent colour.
And most importantly.
Minimal variation in these characteristics.
In the remaining modules of this course we will learn not only how
to manufacture cement, but also how to control and influence these
characteristics.
Cement Technology Training 1.1 Major Applications

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 CemNet Training - Course TCM01 Module 1 - Session 1

Cement Technology 1.1 Cement Performance

We will see the type and composition of raw materials which must
be found and exploited.
How those raw materials must be processed.

Cement process diagrams from ABB advertisments.

.up to and through the cement kiln to produce

cement clinker.
And finally converted in cement in the finish milling.
Cement Technology Training 1.1 Major Applications

Cement Technology 1.1 Cement Performance

The concrete producer wants a commodity cement and will then add
supplementary cementitious materials and admixtures to control the
concrete properties for particular applications.
The cement producer would like to take greater control over the
applications of their cements and tailor them to particular
applications.

In this way they can take greater control over the added-value
of their product, and command higher prices and generate higher
profits.
This simmering conflict in the concrete supply chain continues
to demand greater sophistication in cement manufacture.

Cement Technology Training 1.1 Major Applications

Cement Technology 1.1 Cement Performance

The concrete producer wants a commodity cement and will then add
supplementary cementitious materials and admixtures to control the
concrete properties for particular applications.

The cement producer would like to take greater control over the
applications of their cements and tailor them to particular
applications.

This demand for greater sophistication in cement manufacture is

a primary reason to follow this training course.

Cement Technology Training 1.1 Major Applications

This document is for the sole use of students enrolled on course TCM01 and cannot be reprinted, reproduced or distributed without prior written consent from Tradeship Publications Ltd 2005
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 CemNet Training - Course TCM01 Module 1 - Session 1

Cement Manufacturing
Technology
1. Fundamental requirements of cement in application.
1.1. Cement performance.
I now suggest that we conduct an exercise to explore the strength
characteristics, strength growth and variability of the cement
being produced by the course participants.
Concrete pictures from Concrete Solutions.

Cement Technology Training 1.1 Major Applications

Cement Manufacturing
Technology
1. Fundamental requirements of cement in application.
1.1. Cement performance.
As a first step please send me an e-mail, mcc@whitehopleman.com,
telling me the typical 1, 2, 3, 7 and 28-day strength of the cement
you produce, and the units in which the strength is measured.
Concrete pictures from Concrete Solutions.

Cement Technology Training 1.1 Major Applications

Cement Manufacturing
Technology
1. Fundamental requirements of cement in application.
1.1. Cement performance.
For those participants who are not cement manufacturers please
try to send the typical strengths from one of your cement
manufacturing customers.
Concrete pictures from Concrete Solutions.

Cement Technology Training 1.1 Major Applications

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 CemNet Training - Course TCM01 Module 1 - Session 1

Cement Manufacturing
Technology
1. Fundamental requirements of cement in application.
1.1. Cement performance.
Rest assured that no strength data from any cement manufacturer
will be revealed we guarantee confidentiality of the
information provided in these training course exercises.
Concrete pictures from Concrete Solutions.

Cement Technology Training 1.1 Major Applications

Cement Manufacturing
Technology
1. Fundamental requirements of cement in application.
1.1. Cement performance.
When I receive the e-mails I will send back an Excel spreadsheet
which will allow us to explore strength growth and variability.

Concrete pictures from Concrete Solutions.

Cement Technology Training 1.1 Major Applications

This document is for the sole use of students enrolled on course TCM01 and cannot be reprinted, reproduced or distributed without prior written consent from Tradeship Publications Ltd 2005
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