Full information on Cement as a material

1. Submitted by:
Sneha
Sonika
Kavita
Abhiniti
Navdha
Sonali
Anurag
Suchar

2. Table of Contents
 Introduction
 Raw materials of cement
 Manufacturing of cement
 Characteristics of cement
 Types of cement and their Properties
 Grades of cement
 Function of cement
◦ Setting
◦ Ratio of mixture
 Storage of cement
 Tests
 Uses of cement
 Conclusion

3. Introduction
 Cement is a building material
for binding bricks, stones or
aggregates.
 Used for making mortar or
concrete.
 Cements natural and artificial.
 Natural cement-burning and
crushing of stones and lime.
 Artificial cement-burning at
high temperature and gypsum
is added.

4.  Lime- excess will decrease the strength.
Deficiency will make it set quickly.
 Silica- higher silica increases the strength but
setting time is prolonged.
 Alumina- results in quick setting. Excess alumina
weakens cement.
 Iron oxide- for hardness and strength.
 Magnesia- hardness and colour.

5. Raw material
ingredient range approximate
lime 60-65% 63
Silica 17-25% 21
Alumina 4-8% 6
Iron oxide 1-6% 3
Magnesia 1-3% 1.5
Calcium sulphate 3-5% 4
Sulphur 1-3% 1
Alkalies 0.2-1% 0.5

6. Manufacturing Of Cement
 Mixing of raw material(wet or dry)
 Burning
 Grinding

7.  Wet process- when raw materials are soft.
 Raw materials are mixed and crushed, stored in silos.
 Crushed material from different silos are drawn in
appropriate proportion in a channel called wet grinding
mill.
 Mixed with water called slurry. Stored in slurry silo.
 Slurry fed in rotary kiln passing through 3 zones-dry
zone, burning zone and cooling zone.

8.  Grinding- cooled
clinkers are ground
and gypsum is
added.
 As cement comes
out of grinding mill
it is collected in
hopper for storage
in silos.
c
li
n
k
e
r

9.  Dry process-available raw material is hard.
 Mixing of raw materials undergo crushing, drying,
reduction in size, mixing in correct proportion.

11. KILN

12. THE CEMENT MANUFACTURING PROCESS
1. BLASTING : The raw materials that are used to manufacture cement (mainly limestone and clay) are blasted
from the quarry.
Quarry face
1. BLASTING 2. TRANSPORT
3. CRUSHING AND TRANSPORTATION : The raw materials, after crushing, are
transported to the plant by conveyor. The plant stores the materials before they are
homogenized.
quarry
3. CRUSHING & TRANSPORTATION
2. TRANSPORT : The raw materials are loaded into a dumper.
crushing
conveyor
dumper
storage at
the plant
loader

13. 1. RAW GRINDING : The raw materials are very finely ground in order to produce the raw mix.
1. RAW GRINDING
Raw grinding and burning
2. BURNING
2. BURNING : The raw mix is preheated before it goes into the kiln, which is heated by a flame that can
be as hot as 2000 °C. The raw mix burns at 1500 °C producing clinker which, when it leaves the kiln, is
rapidly cooled with air fans. So, the raw mix is burnt to produce clinker : the basic material needed to
make cement.
conveyor
Raw mix
kiln
cooling
preheating
clinker
storage at
the plant
Raw mill

14. THE CEMENT MANUFACTURING PROCESS
1.GRINDING : The clinker and the gypsum are very finely ground giving a “pure cement”. Other secondary
additives and cementitious materials can also be added to make a blended cement.
1. GRINDING
Grinding, storage, packing, dispatch
2. STORAGE, PACKING, DISPATCH
2. STORAGE, PACKING, DISPATCH :The cement is stored in silos before being dispatched either in
bulk or in bags to its final destination.
clinker
storage
Gypsum and the secondary additives are added
to the clinker.
silos
dispatch
bags
Finish grinding

15. Characteristics
 Strength- atleast 175kg/cm2
 Fineness
 Colour
 Resistant to moisture.
 Setting time

16. Types of Cement
 Ordinary portland cement
 Rapid hardening cement
 High alumina cement
 Blast furnace slag cement
 Super sulphated cement
 Low heat cement
 Air entraining cement
 Quick setting cement
 Coloured cement
 White cement
 Acid resistance cement
 Hydrophobic cement

17.  Ordinary portland cement
◦ Most commonly used cement
◦ Moderate strength
◦ Less heat of hydration but does not cause any
defect.
◦ Mainly used in pavements and buildings.
◦ Normal setting time.(initial setting 30mins, final
setting 8hrs, hardening in 3days)
 Rapid hardening cement
◦ hardens in 1 day.
◦ Stronger than OPC
◦ light weight, extra fine
◦ Mainly used in highways, under water structures
and in cold weather areas.

18.  High alumina cement
◦ Long setting time(initial setting time
3-5hrs)
◦ Very high compressive strength
◦ High resistance to sulphate
◦ Used in sea water construction.
◦ High heat of hydration
◦ Highly resistant to corrosion and
temp.
◦ Very expensive, unsuitable for
massive construction.
◦ Extra care required.

19.  Blast furnace slag cement
◦ Low heat of hydration
◦ Not suitable for dry acid zones
◦ Less strength than other cement, need longer
curing period.
◦ cheap
 Quick setting cement
◦ Higher aluminium sulphate content.
◦ Sets in 5mins and final setting 30mins.
◦ Extra care required, hardens very quickly
◦ Used in running water

20.  Coloured cement
◦ Can get colours by
adding mineral
pigments.
◦ Green(chromium
oxide), blue(cobalt),
red, brown, yellow(iron
oxides)
◦ Used for decorations.

21.  White cement
◦ Raw material- pure
white chalk(lime stone)
◦ Free from iron oxide
and manganese oxide.
◦ Dries quickly.
◦ Used for plastering or
ornamental flooring or
marking.

22. Grades of Cement
 Before 1987 only one grade of cement. After 1987
higher grades were introduced.
 Grades signifies the strength of cement after 28
days.
 Grade 33- attains 33N/mm2 in 28days, when the
mortar of cement and sand is 1:3. initial setting time
30mins and final setting time maximum 10hrs.
 Grade 43- attains 43N/mm2 in 28 days
 Grade 53- attains 53N/mm2 in 28 days.

23. Grade 53
 3 day strength 27 N/mm2. 7 day strength 37 N/mm2.
28 day strength 53N/mm2.
 Used in making strong structures-bridges, highways,
high rise buildings, concrete roads, precast
pavement blocks and tile blocks.
 Fast hydration, high heat generation. Hence
requires more care.

24. Grade 43
 3 day strength 23N/mm2. 7 day strength 33N/mm2.
28 day strength 43N/mm2.
 Used in making medium structures, precast blocks,
plastering, flooring, asbestos products(sheets,
pipes), RCC.
 Medium hydration.
 Nowadays it is used maximum.

25. Grade 33
 3 day strength 16N/mm2. 7 day strength 22N/mm2.
28 day strength 33N/mm2.
 Used in making general construction work, mass
concrete, plain plastering, precast blocks,
plastering, flooring.
Nowadays it is used less with more availability of
grade 43.

26. Setting of Cement
 Setting-when water is mixed
with cement, the action of
changing from flux to solid
state.
 During the next stage of
hydration, paste gains
strength and starts
hardening.
 Initial setting time period- is
the time required when the
cement paste looses its
plasticity. For OPC- 30mins
 Final setting time period- is
the time required to achieve
hardness. For OPC – 10hrs

27. Storage Guidelines
 Away from moisture.
 Storage period should be short.
If long, should be stored in steel
drums
 Avoid jute bags
 More frequent delivery of
smaller lots
 Damp proof sheds
 Bags should be stacked in piles.
Not more than 10bags in a pile.
 Cover with tarpaulin
 Ensure FIFO.

28. Tests
 For fineness
◦ Sieve test
◦ Surface area test
 For normal consistency –
to determine the setting
time
 For soundness

29. Application of Cement
 Cement as mortar
◦ For laying or binding
masonry units (bricks , stones
,etc)
◦ For pointing the masonry
joints
◦ For plastering the surface to
protect from weather.
◦ For decorative finish
◦ For filler material in ferro
cement construction.
◦ For damp proof course
below the ground level.
◦ Water proofing, crack
repairs and structures.

30.  Cement as concrete
◦ For manufacturing solid
and hollow concrete
blocks.
◦ For laying subfloors and
floors
◦ For RCC constructions
(slab, beam, column,
stairs, footings, etc)

31. CEMENT
A CATEGORY
ULTRATECH
CEMENT
ACC CEMENT
SHREERAM
CEMENT
LAFARGE
CEMENT
B
CATEGOREY
J.K SUPER
CEMENT
J.P CEMENT
BIRLA UTTAM
FREE
CEMENT
C CATEGORY
BIRLA
CHETAK
ROCK
STRONG
CEMENT
BINANI
CIMENT
RS.28
0
RS.30
0
RS.26
5
RS.28
0
RS.26
0-255
RS.27
0
CATEGORIES AND
PRICES OF CEMENT

32. TYPES OF CEMENT
GREY CEMENT
P.P.C (PORTLAND
PAZZOLANA
CEMENT)
O.P.C
(ORDINARY
PAZZOLANACEMENT)
GRADE 43
GRADE 53 GRADE 33
WHITE CEMENT
IT HAS MORE AMMOUNT OF GYPSUM
IRON OXIDE IS 1%
USED ONLY FOR DECORATIVE WORK
FLAG CEMENT
MASONARY CEMENT
TYPES OF CEMENT

33. www.youtube.com/watch?v=NUN9cTAIFdE

34. REFFERENCES
LAFARGE CEMENT
JK SUPER CEMENT CONSULTANTS
WIKIPEDIA

35. THANK YOU

36. FINENESS
So we need to determine the fineness of cement by dry sieving as per IS: 4031 (Part 1)
– 1996.The principle of this is that we determine the proportion of cement whose grain
size is larger then specified mesh size.
The apparatus used are 90µm IS Sieve, Balance capable of weighing 10g to the
nearest 10mg, A nylon or pure bristle brush, preferably with 25 to 40mm, bristle, for
cleaning the sieve.
Sieve shown in pic below is not the actual 90µm seive.Its just for reference.
Procedure to determine fineness of cement
i) Weigh approximately 10g of cement to the nearest 0.01g and place it on the sieve.
ii) Agitate the sieve by swirling, planetary and linear movements, until no more fine
material passes through it.
iii) Weigh the residue and express its mass as a percentage R1,of the quantity first
placed on the sieve to the nearest 0.1 percent.
iv) Gently brush all the fine material off the base of the sieve.
v) Repeat the whole procedure using a fresh 10g sample to obtain R2. Then calculate R
as the mean of R1 and R2 as a percentage, expressed to the nearest 0.1 percent.
When the results differ by more than 1 percent absolute, carry out a third sieving and
calculate the mean of the three values.
Reporting of Results
Report the value of R, to the nearest 0.1 percent, as the residue on the 90µm sieve.