CONSTRUCTION

MATERIAL
CE 103

Prepared by Muhammad Adil 19 CE Sec B

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 CEMENT
A cement is a binder, a substance used for construction that sets, hardens, and adheres to other
materials to bind them together. Cement mixed with fine aggregate produces mortar for masonry,
or with sand and gravel, produces concrete.
BASIC COMPONENTS OF CEMENT
• There are Two Major Components Used in Cement.
• I Argillaceous Materials: Argillaceous Materials are Compounds of silica, alumina and oxides
of iron. Clay and shale are common argillaceous material used as cement ingredient in the
process of manufacturing cement.
• II Calcareous Materials: Calcareous Materials are compounds of calcium and magnesium.
Lime stones are common calcareous material used in manufacturing cement.

COMPONENTS OF CEMENT
Components Percent % Range
i) Lime (Cao)……..62 62-67
ii) Silica (Sio2)……..22 17-25
iii) Alumina (Al2O3)…..5 3-8
iv) Calcium Sulphate (Caso4)……4 3-4
v) Iron Oxide (Fe2O3)……3 3-4
vi) Magnesia (Mg o)……2 1-3
vii) Sulphur (S)……1 1-3
viii) Alkalies 1 0.2-1
Total 100

MANUFACTURING PROCESS OF CEMENT

1) MIXING 4) STORAGE
OF RAW 2) BURNING 3) GRINDING AND
MATERIAL PACKAGING

1) MIXING OF RAW MATERIAL

The mixing procedure of the manufacture of cement is done in 2 methods
Dry process
Wet process
a) Dry Process:- The both calcareous and argillaceous raw materials are firstly crushed in the
gyratory crushers to get 2-5cm size pieces separately. The crushed materials are again grinded to get
fine particles into ball or tube mill. Each finely grinded material is stored in hopper after screening.
Now these powdered minerals are mixed in required proportion to get dry raw mix which is then
stored in silos and kept ready to be sent into rotary kiln. Now the raw materials are mixed in
specific proportions so that the average composition of the final product is maintained properly.

Prepared by Muhammad Adil 19 CE Sec B

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 FLOW DIAGRAM OF DRY PROCESS

• b) Wet Process
• The raw materials are firstly crushed and made into powdered form and stored in silos. The clay
is then washed in washing mills to remove adhering organic matters found in clay.
• The powdered limestone , water and washed clay are sent to flow in the channels and transfer to
grinding mills where they are completely mixed and the paste is formed, i.e., known as slurry.
• The grinding process can be done in ball or tube mill or even both. Then the slurry is led into
collecting basin where composition can be adjusted. The slurry contains around 38-40% water
that is stored in storage tanks and kept ready for the rotary kiln.

FLOW DIAGRAM OF WET PROCESS

Prepared by Muhammad Adil 19 CE Sec B

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 2) BURNING OF RAW MATERIALS
The burning process is carried out in the rotary kiln while the raw materials are rotated at 1-2rpm
at its longitudinal axis. The rotary kiln is made up of steel tubes having the diameter of 2.5-3.0
meter and the length differs from 90-120meter. The inner side of the kiln is lined with refractory
bricks.
As the kiln position is inclined and it rotates slowly, the material charged from upper end moves
towards lower end at the speed of 15m/hr. In the upper part, water or moisture in the material is
evaporated at 400oC temp, so this process is known as Drying Zone. The central part i.e.
calcination zone, the temperature is around 10000C, where decomposition of lime stone takes
place. The lower part (clinkering zone) have temperature in between 1500-17000C where lime
and clay are reacts to yielding calcium aluminates and calcium silicates. This aluminates and
silicates of calcium fuse to gather to form small and hard stones are known as clinkers.
The size of the clinker is varies from 5-10mm.The lower part i.e. clinkering zone has the
temperature around 1500-1700C. In the region lime and clay reacts to yield calcium aluminates
and calcium silicates. This products of aluminates and silicates of calcium fuses together to form
hard and small stones known as clinkers. The size of the small and hard clinkers varies from 5 to
10mm. The clinker coming from the burning zone are very hot. To bring down the temperature of
clinkers, air is admitted in counter current direction at the base of the rotary kiln. The cooled
clinkers are collected in small trolleys.

3) GRINDING OF CLINKERS
The cooled clinkers are received from the cooling pans and sent into mills. The clinkers
are grinded finely into powder in ball mill or tube mill. Powdered gypsum is added
around 2-3% as retarding agent during final grinding. The final obtained product is
cement that does not settle quickly when comes in contact with water.
After the initial setting time of the cement, the cement becomes stiff and the gypsum
retards the dissolution of tri-calcium aluminates by forming tricalcium sulfoaluminate
which is insoluble and prevents too early further reactions of setting and hardening.

4) STORAGE AND PACKAGING

The grinded cement is stored in silos, from which it is marketed either in container
load or 50kg bags

Prepared by Muhammad Adil 19 CE Sec B

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TYPES OF CEMENT AS PER ASTM STANDARD
According to ASTM Standard cement is described as :
Portland Cement ASTM C150
Blended Cement ASTM C595
ASTM C150 Standard Specification for Portland Cement covers the following cement
types:
Type I (Ordinary Portland cement):Used for general construction work when the
special properties of the other types are not required. • Normally used for reinforced
concrete buildings, bridges, pavements and sidewalks when the soil conditions are
normal, for concrete masonry units, and for all uses where the concrete is not
subjected to special sulfate haazard, heat of hydration is not objectionable, where
freezing- thawing is not expected.
Type II (Modified Portland Cement): • It has better resistance to the action of
sulfates than normal (ordinary) Portland cement and used where sulfate concentrations
in groundwater are higher than normal but not very severe. • Generates heat at a
slower rate than OPC and is used in certain concrete mass work like retaining walls. •
Reduced temperature rise is beneficial for hot weather concrete, too
Type III: (High Early Strength Cement)• Used where high early strengths are
required at early periods, usually a week or less. • It is particularly usefull where it is
required to remove forms as soon as possible or when the structure must be brought
into service quickly. • High-early strength makes it possible to reduce the period of
Total 43protection for concrete during cold weather.
Type IV (Low Heat Portland Cement):• It is used where the amount and rate of heat
generation must be minimized. Strength is also developed at a slower rate. It is
intended for use in massive concrete structures such as dams.
Type V (Sulfate Resistant Portland Cement):• It is used in structures subject to
sulfate attack, chemical plants, etc. It is also resistant to the action of sea water.
Type IA, IIA and IIIA :These are type I, II or III cement in which air-entraining agent
is inter-ground where air entrainment in concrete is desired.
ASTM C 595 Standard Specification for Blended Hydraulic Cement : It covers
blended hydraulic cements for both general and special applications, using slag or
pozzolana, or both, with Portland cement or Portland cement clinker or slag with lime.
Type IP: This consist of an intimate and uniform blend of Portland Cement (or
Portland Blast Furnace Slag Cement) and fine pozzolana in which the pozzolana
content is between 15 and 40 per cent of the weight of the total cement.
Type IS: Portland blast-furnace slag cement
Type IT: Ternary blended cement

Prepared by Muhammad Adil 19 CE Sec B

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 CHEMICAL COMPOUND IN CEMENT
CEMENT C3S C2S C3A C4AF CSH2se

I 59 15 16 8 2.9

II 46 29 6 12 2.8

III 60 12 12 8 3.9

IV 30 46 5 13 2.9

V 43 36 4-5 12 2.7

Tricalcium silicate, C3S:-

This compound hydrates and hardens rapidly. It is largely responsible for
Portland cement’s initial set and early strength gain.
Dicalcium silicate, C2S:-
C2S hydrates and hardens slowly. It is largely responsible for strength gain
after one week.
Tricalcium aluminate, C3A:-
It liberates a lot of heat during the early stages of hydration, but has little
strength contribution. Gypsum slows down the hydration rate of C3A.
Cement low in C3A is sulfate resistant.
Ferrite, C4AF:-
This is a fluxing agent which reduces the melting temperature of the
raw materials in the kiln (from 3,000o F to 2,600o F). It hydrates
rapidly, but does not contribute much to strength of the cement paste.
Gypsum CSH2:-
Gypsum is a mineral and is hydrated calcium sulfate in chemical form.
Gypsum plays a very important role in controlling the rate of
hardening of the cement. During the cement manufacturing process,
upon the cooling of clinker, a small amount of gypsum is introduced
during the final grinding process.Gypsum is added to control the
“setting of cement”..

Prepared by Muhammad Adil 19 CE Sec B

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PROPERTIES OF CEMENT

Prepared by Muhammad Adil 19 CE Sec B

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