WHAT IS CEMENT ?

Definition: Cement is a crystalline compound of calcium silicates and aluminates and other compounds having hydraulic properties (Macfadyen, 2006).

In the most general sense of the word, a cement is a binder, a substance which sets and hardens independently, and can bind other materials together.
Cements that are used for construction fall into two main categories based on cement properties, hydraulic or non-hydraulic.

USES

Main use of cement is the production of mortar and concretethe bonding of natural or artificial aggregates to form a strong building material which is durable in the face of normal environmental effects Modern uses Building (floors, beams, columns, roofing, piles, bricks, mortar, panels, plaster) Transport (roads, pathways, crossings, bridges, viaducts, tunnels, parking, etc.) Water (pipes, drains, canals, dams, tanks, pools, etc.) Civil (piers, docks, retaining walls, silos, warehousing, poles, pylons, fencing) Agriculture (buildings, processing, housing, irrigation)

TYPES OF CEMENT

Hydraulic cement
An inorganic material or a mixture of inorganic materials that sets and develops strength by chemical reaction with water by formation of hydrates and is capable of doing so under water.

Non-hydraulic cement
Non-hydraulic cement is cement which cannot harden while in contact with water, as opposed to hydraulic cement which can. Non-hydraulic cements are created using materials such as non-hydraulic lime and gypsum plasters, and oxychloride, which has liquid properties. After nonhydraulic cement is utilized in construction, it must be kept dry in order to gain strength and hold the structure. When non-hydraulic cement is used in mortars, those mortars can set only by drying out, and therefore gain strength very slowly. Due to the difficulties associated with waiting long periods for setting and drying, non-hydraulic cement is rarely utilized in modern times.

HISTORY
Lime and clay have been used as cementing material on constructions through many centuries. The word "cement" traces to the Romans, who used the term "opus caementicium" to describe masonry which resembled concrete and was made from crushed rock with burnt lime as binder. Romans are commonly given the credit for the development of hydraulic cement, the most significant incorporation of the Romans was the use of pozzolan-lime cement by mixing volcanic ash from the Mt. Vesuvius with lime. Best know surviving example is the Pantheon in Rome

CLASSIFICATION OF CEMENT

Natural Cement: Obtained by calcinating 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.

PORTLAND CEMENT

In addition to the two main forms of cement which exist, hydraulic and non-hydraulic, there are also several types of hydraulic cements that can be made and used in construction. The main form of cement used in construction worldwide today is the hydraulic cement called Portland cement. Portland cement is a type of hydraulic cement made by heating a limestone and clay mixture in a kiln and pulverizing the materials. It is a fine, grey or white powder that is made by grinding Portland cement clinker, a limited amount of calcium sulfate which controls the set time, with other minor constituents. Portland cement is the most common type of cement in general usage in many parts of the world. The cement is used as the basic ingredient of concrete, mortar, stucco and most non specialty grout. Invented in the 19th century, Portland cement has become the staple form of cement produced and used worldwide. All references to cement worldwide refer to Portland cement, as it constitutes virtually all cement produced.

COMPOSITION OF CEMENT
Lime (CaO) 60-66% Excess reduces strength and make cement disintegrate and in less amount reduces strength and makes it quick setting. Provides strength to cement Helps in quick setting Enhances cement initial setting of

Silica (SiO2) Alumina (Al2O3) Calcium Sulphate (Gypsum)

17-25% 3-8%

Iron Oxide

2-6%

Gives color, hardness.

Strength

and

Sulphur trioxide 1-3% (SO3) Alkali Oxides 0.5(Na2O and K2O) 1.5% Magnesium Oxide (MgO) 1-5%

Provides soundness in excess efflorescent 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.

MANUFACTURING PROCESS

Crushing Mixing (Wet Process) Mixing (Dry Process) Grinding (Ball Mill and Tube Mill) Storage of Ground Materials Burning Drying Zone Calcination 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 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 klin.

MIXING 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 klins.

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 mill s 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.

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 klin where actual chemical changes takes place. Klin 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 klin from the upper end as the klin rotates material passes slowly towards the lower end. Klin is heated by burning pulverized coal or oil and temperature is maintained at about 1400-1500C. At clinkering temperature actual chemical reactions takes

BURNING

BURNING ZONE

A. DRYING ZONE The upper part of the klin is known as drying zone. The temperature is about 200-500C. Most of the water gets evaporated from the slurry by means of hot gases.

B. CALCINATING ZONE This the middle zone of the klin with temperature around 1000C. Organic matter burns away and CaCO3 decomposes to quick lime and CO2 escapes out. The material forms small lumps called as nodules.

BURNING ZONE (CONTD.)

C. CLINKERING ZONE This is lowest portion of Klin with a temperature of about 14001600C. Lime and clay nodules melts with chemical fusion and gives calcium aluminates and silicates. These silicates and aluminates then fuse together to form small hard stones called Clinkers which than fall down from lower end of the Klin.

CaCO3 CaO + CO2 2CaO + SiO2 Ca2SiO4 3CaO + SiO2 Ca3SiO5 3CaO + Al2O3 Ca3Al2O6 4CaO + Al2O3+Fe2O3 Ca4Al2Fe2O10

Calcium Oxide Dicalcium Silicate Tricalcium Silicate Tricalcium Aluminate Tetracalcium Aluminoferrite

COMPOSITION OF CLINKERS
Clinkers are cooled under controlled condition to produce a definite degree of crystallization. Clinker Constitution Ca2SiO4 Dicalcium Silicate Gypsum (3.5%) Other Ca3SiO5 Tricalcium Silicate (1.5%) Ca3Al2O6 Tricalcium Aluminate Ca4Al2Fe2O10 Tetracalcium Aluminoferrite Tetracalcium Aluminoferrite (8%) MgO Magnesia

Cao

When burning is incomplete

Tricalcium Aluminate (12%) Tricalcium Silicate (50%)

Dicalcium Silicate (25%)

GRINDING
Clinkers are finally grinded in ball mill and tube mill to a fine powder. Additives added are as follows. Retarder Gypsum CaSO4.2H2O or Plaster of Paris CaSO4.H2O acts as retarder to prevent quick setting. After initial setting gypsum retards the dissolution of tricalcium aluminate by forming tricalcium sulphoaluminate (3CaO.Al2O3.xCaSO4.7H2O). Dispersing Agent Sodium salts and polymers of condensed napthlene 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 50kg bag.

This is then dispatched to the markets where it is sold for constructions of cities.

CHEMISTRY OF SETTING
Cement forms paste like mass with water resulting in hydration of compounds of cement. This mass then becomes stiff and hard. This change of fluid to solid is known as setting of cement. setting action continues for long time on addition of water complicated chemical compounds are formed a) tricalcium aluminate (3Cao. Al2o3) : formed whithin 24 hrs

b) tetra-calcium alumino-ferrite(4Cao.Al2o3.Fe2o3): formed within 24 hrs

c) Tricalcium silicate(3Cao.Sio2): formed within one week and impart strength in early period
d) Dicalcium silicate(2Cao.Sio2): formed slowly and impart progressive strength

CHEMISTRY OF HARDENING
During hardening the solid cement material begins to gain strength. It depends upon the chemical combination of cement and water. Hardening starts with great speed but finally its speed reduces. The hardening of concrete stops and it is dried out. The hydration reactions are exothermic Hydrated cement dissociates on heating by destroying the bond which held the mass together.

 during initial period of hardening the gain in strength of dicalcium silicate is small

after 28 days hydration of tricalcium silicate is completed and hydration of dicalcium silicate begins on large scale
if high strength concrete is required in short time then high content of tricalcium silicate is used if high strength concrete is required at later stage then high content of dicalcium silicate is used tricalcium aluminate is used in quick hardening portland cement to speed up the process of hardening

REACTION INVOLVED
2Ca3OSiO4 + 6H2O 3CaO.2SiO2.3H2O + development in the first few days. 3Ca(OH)2

This is a relatively fast reaction, causing setting and strength

2Ca2SiO4 + 4H2O 3CaO.2SiO2.3H2O + Ca(OH)2 This reaction is relatively slow, and is mainly responsible for strength growth after one week.

Tricalcium aluminate hydration is controlled by the added calcium sulfate, which immediately goes into solution when water is added. Firstly, ettringite is rapidly formed, causing a slowing of the hydration (see tricalcium aluminate):

Ca3(AlO3)2 + 3CaSO4 + 32H2O Ca6(AlO3)2(SO4)3.32H2O

The ettringite subsequently reacts slowly with further tricalcium aluminate to form "monosulfate" . Ca6(AlO3)2(SO4)3.32H2O + Ca3(AlO3)2 + 4H2O 3Ca4(AlO3)2(SO4).12H2O

This reaction is complete after 1-2 days. The calcium aluminoferrite reacts slowly due to precipitation of hydrated iron oxide: 2Ca2AlFeO5 + CaSO4 + 16H2O Ca4(AlO3)2(SO4).12H2O + Ca(OH)2 + 2Fe(OH)3

The pH-value of the pore solution reaches comparably high values and is of importance for most of the hydration reactions.

SETTING TIME
on adding water to cement, the paste formed remain plastic for short period during which it can be moulded as per the requirements. This initial period of hardening of cement is called the setting time of cement.

setting time depends on various factors like temperature, type of cement, chemical admixtures,water-cement ratio etc.
in winter the setting time of cement is longer due to low temperature setting time=k\temp

Two stages of settting are: i) Initial set: Occurs when the paste begins to stiffen considerably

ii) Final set: Occurs when the cement has hardened to the point at which it can sustain some load.

These particular times are just random points used to characterize cement, they do not have any fundamental chemical significance

Determining setting time of cement

Test Method Set Type Initial Vicat Final 375 minutes Time Specification 45 minutes

Initial Gillmore

60 minutes

final

600 minutes

These datas are for ordinary cement

The Vicat needle test is more common and tends to give shorter times than the Gillmore needle test.

RAPID HARDENING PORTLAND CEMENT

Rapid Hardening Portland Cement (RHPC) is a type of cement that is used for special purposes when a faster rate of early high strength is required produced by fusion of limestone and shale at extremely high temperatures followed by addition of gypsum Its hardening and setting time is very low used at the places where quick repairs are required like bridges, airfield and highway pavements

 The raw materials required for the manufacture of rapid hardening cement are:
i) Limestone : chief ingredient and it provides strength

ii) Shale: formation of calcium silicate iii) Gypsum: to increase workability iv) Coke: used as a fuel to provide high fusion temperature

The major companies producing Rapid Hardening Portland Cement in India are:

i) Acc cement ii) India cement ltd. iii) Gujarat ambuja cement iv) Jk cement v) Grasim industries

MARKET STUDY

What is OPC Cement? OPC means Ordinary Portland Cement which contains mixture of Portland clinker and Gypsum ground to a very fine powder. What is PPC Cement? PPC means Portland Pozzolana Cement. It is manufactured by blending a mixture of Ordinary Portland cement and Pozzolana materials such as Fly Ash, in proportions not less than 15% and not more than 35% by weight of cement. The fineness of PPC will be greater than OPC. Difference between OPC and PPC Cement Addition of Pozzolanic material such as fly ash in the cement manufacture by 15% to 35% is the only difference between OPC and PPC. Duration of curing for OPC and PPC Duration for curing is same for both OPC and PPC. But the water cement ratio may be slightly varied. As the cement is attaining full

MARKET STUDY

What are the setting time for OPC and PPC? Same for both OPC and PPC. i.e. initial setting time 30 minutes and final setting time 600 Minutes. (10 hours) Preferable constructions by OPC and PPC OPC: OPC is categorized as 33 Grade, 43 Grade and 53 Grade. It is preferably used in Defence Services, Railway Sleeper making and in lean concrete structures. PPC: PPC is having better resistance to Sulphate attack and hence it is preferably used in Sea Shore, Dam constructions and in the earth work concreting to neutralize corrosion effect of soil and water under the earth's crest. Due to higher fineness, mostly it is used in plastering work for smooth finishing.

GRADES OF CEMENT AVAILABLE

Ordinary Portland cement (opc)

Opc is available in 2 grades (i) 53 grade

There is no grade 4 ppc cement

(ii) 43 grade

Ppc1.Nowadays it is used 4 each and every purposes.eg: bridge, buildings construction, road construction, etc 2. Setting time- slow 3. Its strength increases day by day. Therefore there is no complaint about ppc cement. 4. durability more than opc. Opc1.It is used 4 building superstructure, dam, road furniture, panels, beam, Commercial Buildings, Industrial Constructions, Multi-storied complexes, Cement concrete, roads, Heavy Duty Floors etc. 2. Setting time faster than ppc 3. Its strength does not increases day by day. What it attend at 28 day, remains the same throughout.. 4. durability not more than ppc.

RATES
The rate of all the standard cements available is approximately same. The rate of Opc and ppc is the same. The cost of one bag of cement is Rs 275. dealer ------------------retailer------------------consumer Rs 232 +12.50% tax = Rs. 262