CEMENT

INTRODUCTION

Natural Cement is obtained by burning and crushing the stones containing clay, carbonate of lime
and some amount of carbonate of magnesia.
The natural Cement is brown in colour and it is known as the Roman Cement. It sets very quickly
after addition of water. It is not so strong as artificial Cement and hence it has limited use in
practice.
It was in the 18th century that the Portland Cement was invented.
The common variety of artificial Cement is known as the normal setting Cement or ordinary
Cement.
This Cement was invented by a mason Joseph Aspdin of Leeds in England in 1824. He took out a
patent for this Cement and called it Portland Cement because it had resemblance in its colour after
setting, to a variety of sandstone which is found in abundance in Portland in England.
PROPERTIES OF CEMENT
Following are the important properties of a good cement which primarily depends upon its chemical
composition, thoroughness of burning and finess of grinding.
It gives strength to the masonry.
It is an excellent binding material.
It is easily workable.
It offers good resistance to the moisture.
It stiffens or hardens easily.
FIELD TEST FOR CEMENT:
Following four field tests may be carried out to ascertain roughly the quality of cement:
1) Colour
2) Physical properties
3) Presence of lumps.
4) Strength.

1)Colour:

The colour of Cement should be uniform. It should be typical Cement colour ie. grey colour with light

2) PHYSICAL PROPERTIES:
The Cement should feel smooth when thouched or rubbed in between fingers.If it is felt rough, it indicates
adulteration with sand.
If hand is inserted in a heap or bag of cement, it should feel cool and not warm.
If a small quantity of Cement is thrown in a bucket of water, it should it sink and not float on the surface.
If Cement contains too much of pounded clay and silt as an adulterant, the paste will give an earthy smell.
3)PRESENCE OF LUMPS:
The Cement should be free from any hard lumps. Such lumps are formed by the absorption of moisture
from the atmosphere. Any bag of Cement containing such lumps should be rejected.
4) STRENGTH:
Small blocks of mortar are made of size 75mm x 25mm x 12mm. The proportion of cement and sand may
be 1:6. The blocks are immersed in water for a period of 3 days. If Cement is of sound quality, such blocks
will not be broken easily and it will be difficult of convert then into powder form.
MANUFACTURE OF CEMENT:
The manufacture of Cement involves 3 distinct operations :
1) Mixing of raw materials
2) Burning
3) Grinding
1) MIXING OF RAW MATERIALS:
The raw materials such as lime stone or chalk, shale or clay are thoroughly mixed. The mixing of raw
materials can be done in two ways:-

MIXING OF RAW MATERIALS

I
Wet Process

I
Dry Process

WET PROCESS:
In the earlier days ie, from 1913 to 1960, the wet process was popular for the manufacture of cement.
The techniques of intimate mixing of raw materials were not available then. Later, with the
development of the technique of dry mixing of powdered materials using compressed air, the dry
process gained momentum.
The dry process requires much less fuel as the materials are already in a dry state, whereas, in the wet
process the slurry contains 35% to 50% water. To dry the slurry, more fuel is required.

In the wet process, the Calcareous materials such as limestone are crushed and stored in silos or storage
tanks. The argillaceous material such as clay is thoroughly mixed with water in a wash mill. The washed
clay is then stored in basins.
The crushed limestone from the silos and wet clay from basins are mixed together in a wet grinding mill to
make slurry. At this stage, the chemical composition of the slurry is tested and adjusted as necessary.
The corrected slurry is stored in storage tanks and kept ready to serve as feed for a rotary kiln.

II) DRY PROCESS:

The boulders of limestone upto 1.2m size are transported in huge dumpers and dumped into the
hoppers of the crusher. The limestone is now crushed to 75mm. The crushed limestone is moved from
the crusher by a series of conveyers for stacking. The argillaceous material is also crushed and stacked
like the limestone. The crushed materials are checked and any material found short, is added
separately. The materials are then ground to the desired degree of fineness. The material is again
checked and corrected for its right composition and mixed by means of compressed air.

The blended material is further sieved and fed into a rotating disc called granulator. A small quantity of
water, about 12% by weight, is added to make the blended material (meal) into pallets. This is done to
permit air flow for exchange of heat for further chemical reactions and conversion of the same into
clinkers in the rotary kiln.

BURNING:

Burning is carried out in a rotary kiln.

The rotary kiln rotates at about 1-3 revolutions per minute, about its longitudinal axis. It is laid at a
gradient of about 1 in 25 to 1 in 30.

fig.

The corrected slurry is injected at the upper end of the kiln and hot gases or flames are forced through the
lower end. The portion of the kiln near its upper end is known as the dry zone. In this zone the water of
the slurry is evaporated. As the slurry gradually descends, there is an increase in the temperature and in
the next section of the kiln , carbon-di-oxide from the slurry is evaporated. This leads to the formation of
small lumps known as nodules. These nodules then gradually roll down to the burning zone, where the
temperature is about 1400 c to 1500 c. In the burning zone, the nodules are calcinated and formation of
small, hard dark greenish-blue balls known as clinkers take place.
In the dry process, coal brought from coal fields is pulverised in vertical coal mill and is stored in silo. It is
pumped with required
quantity of air through the burners. The pre-heated raw-materials roll down the kiln and get heated to
such an extent that carbon-di
Oxide is expelled along with other combustible gases. The material is Then heated to a temperature of
1400 c to 1500 c. and the formation Of clinkers take place. The size of the clinkers varies from 3mm to 20
mm. The temperature of the clinkers coming out of the burning zone Of the kiln is as high as 1000 c. a
rotary kiln of small size is provided to Cool down the hot clinkers. Cooled clinkers, having temperatures of
About 95 c, are collected in containers of suitable sizes.
III) GRINDING:
The clinkers, as obtained form the rotary kiln, are ground to the Required degree of fineness in a ball mill
or a tube mill. During
Grinding a small quantity of gypsum (about 3% to 4% ) is added.
Gypsum controls the initial setting time of cement. If gypsum is not added, the cement would set as soon
as water is added to it. Thus, gypsum acts as a retarder and delays the initial setting time of cement.
VARIETIES OF CEMENT:
In addition to ordinary cement, the following are the other varieties of cement:
1) ACID RESISTANT CEMENT:
An acid-resistant cement is composed of acid-resistant aggregates such quartz, sodium silicate or
soluble glass, etc.
The acid-resistant is used for acid-resistant and heat-resistant coatings of installations of chemical
industry. It is not water-resistant and it fails when attacked by water.
BLAST FURNACE CEMENT:
For this cement, the slag, as obtained from blast furnace, is used. The slag is a waste product in the
manufacturing process of pig-iron and it contains the basic elements of cement, namely alumina, lime and
silica.
It proves to be economical as slag, which is a waste product, is used in its manufacture.

COLOURED CEMENT:
The cement of desired colour may be obtained by intimately mixing mineral pigments with ordinary
cement. The amount of colouring material may vary from 5 to 10 %. If this % exceeds 10%, the strength
of cement is affected. The coloured cement are widely used for finishing of floors, external surfaces,
artificial marble, window sill slabs, stair treads, etc.
EXPANDING CEMENT:
This
type cement.
of cement
is produced
by adding
expanding
medium
like for
sulpho-aluminate
and a stabilizing
Ordinary
Hence
this expands.
The an
expanding
cement
is used
repairing the damaged
surfaces.
agent to the
HIGH ALUMINA CEMENT:
It is specified that total alumina content should not be less than 32%.
Some of the advantages of this cement are:
i) initial setting time of this cement is more than 3 1/2 hours. The final setting time is 6-8 hours. It
therefore allows more time for mixing and placing operations.
Ii) it can stand high temperatures.
Iii) it evolves great heat during setting. It is therefore not affected by forst.
Iv) it resists the action of acids in a better way.
V) it sets quickly and attains higher ultimate strength in a short period.
ITS DISADVANTAGES ARE:
i) Extreme care has to be taken to see that it does not come in contact with even traces of lime or ordinary
cement.
Ii) it cannot be used in mass construction as it evolves great Heat .
Iii) it is costly.
HYDROPHOBIC CEMENT:
When hydrophobic cement is used, the fine pores in concrete are uniformly distributed and thus frost
resistance and water resistance of such concrete are considerably increased.
LOW HEAT CEMENT:
Considerable heat is produced during the setting action of cement . In order to reduce the amount of heat,
this type of Cement is used. The initial setting time of is about one hour and the final setting time is about
ten hours. It is mainly used for mass concrete work.
POZZOLANA CEMENT:
The Pozzolana is a volcanic powder. It is found in Italy. The percentage of Pozzolana material should be
between 10% to 30%.

ADVANTAGES:
i)It attains compressive strength with age.
Ii)It evolves less heat during setting.
Iii) it imparts higher degree of water tightness.
Iv) it is cheap
V) it possesses higher tensile strength.
FOLLOWING ARE THE DISADVANTAGES:
i) it possesses less resistance to the erosion and weathering action.
This cement is used to prepare mass concrete of lean mix. It is also used in sewage works.
QUICK SETTING CEMENT:
The setting action of cement starts within 5 minutes of adding
Of water and it becomes hard like stone in less than 30 minutes or so.
Extreme care has to be taken when this cement is used as mixing and placing of concrete are to be
completed in a very short period. This cement is used to lay concrete under static or running water.
RAPID HARDENING CEMENT:
The initial and final setting times of this cement are the same as those of ordinary cement. But it
attains high strength in early days.
This cement is slightly costlier than ordinary cement, but it offers the following advantages:
i) As it sets rapidly, the construction work may be carried out speedily.
Ii) the formwork of concrete can be removed earlier and it can therefore be used frequently.
Iii) it is light in weight.
Iv) it is not damaged easily.
V) it obtains strength in a short period.
Vi) this cement requires short period of curing.
Vii) the use of this cement allows higher permissible stresses in the design. It therefore results in
economic design.
SULPHATE RESISTING CEMENT:
This cement is used for structures which are likely to be damaged by severe alkaline conditions such
as canal linings, culverts, etc.

WHITE CEMENT:
This is just a variety of ordinary cement and it is prepared form such raw materials which are
practically free from coloring oxides.
It is white in colour and it is used for floor finish, plaster work, or ornamental work, etc. it is more
costly than ordinary cement. It is quick drying, possesses high strength and has superior aesthetic
value. It can be used in swimming pools where it replaces the use of glazed tiles with coloured shades
usable under water, for moulding sculptures and statues, for painting garden furniture, etc. it is also
used for pre-cast concrete blocks, and also for fixing marble and glazed tiles.
COMPOSITION OF ORDINARY CEMENT:
The ordinary cement contains:
i) lime 62%
Ii) Silica 22 %
Iii) Alumina 5%
Iv) Calcium sulphate 4%
V) Iron oxide 3%
Vi) Magnesia 2%
Vii) sulphur 1%
Viii) Alkalies 1%
USES OF CEMENT:
Following are the uses of cement:
i) Cement mortar for masonry work, plaster, pointing, etc.
Ii) Concrete for laying floors, roofs and constructing lintels, beams, weather shades, stairs, pillars, etc.
Iii) Construction of important engineering structures such as bridges, dams, tunnels, storage
reservoirs, light houses, etc.
Iv) Construction of water tanks, tennis courts, septic tanks, roads, etc.
V) Making joints for drain pipes etc.
Vi) Manufacture of pre-cast pipes, piles, flower pots, garden seats, etc.
Vii) preparation of foundations, floors, foot-paths, etc.
PACKING OF CEMENT:
The conventional jute or gunny bags used for the packing of cement is replaced by plastic bags.
If properly handled, they (jute bags), may may make 3 to 5 trips from the factory to the cement users.
However, the main drawbacks of such types of packing are as follows;

i) At every point of handling some portion of cement contained in jute bags is wasted.
Even after emptying the cement bags, small quantity of cement remains in the bags and it is thus not possible to take
advantage of the full contents of the bag.
Such type of packing leads to air pollution.
The handling of jute bags proves harmful to the health of labourers, as he inhales a considerable amount of cement particles
during the loading and unloading of such bags.
The quality of cement is affected due to entry of moisture from the atmosphere.
The modern use of plastic bags are more suitable for protecting the cement from the moisture.
1kg, 2kg, 5kg, and 10kg bags are also available in the market. 50 kg is also available.
STORAGE OF CEMENT:
Cement should be stored carefully, otherwise it may absorb moisture form the atmosphere and may become useless for the
structural work. Following precautions should be taken for the storage of cement:
i) Moisture: If moisture is kept away from cement, it is found that cement will maintain its quality for indefinite period.and
absorption of 1 or 2 % of moisture has no appreciable effect on quality of cement. But if moisture absorption exceeds 5%,
the cement becomes totally useless. Hence, when cement is to be stored for a long period, it should be stored in air-tight
Containers.
PERIOD OF STORAGE:
It is advisable to avoid storing of cement in jute bags for a period longer than 3 months. If it is unavoidable, the cement
should be tested to ascertain its properties.
PILES: The cement bags are stacked in piles. It is economical to form a pile of 10 bags of cement. A distance of about 300
mm should be kept between the piles of cement bags and exterior walls of the building. The passages of width of about 900
mm shhould be provided between the piles. For long storage, the top and bottom of piles should be covered with tarpaulins
or Water-proof paper.
REMOVAL OF CEMENT:
It is advisable to remove cement in order of its storage period ie cement which is stored previously, should be taken out first.
In other words, the rule of first in first out should be followed.
STORAGE SHEDS:
For storing cement for a sufficiently long period, the storage sheds of special design should be constructed. The walls, roof,
and floors of such sheds should be water-proof construction. Few small windows should be provided and they should be
tightly shut. For determining the size of storage shed, it is found that 20 bags of cement will require about 1 m cube of
space. Cement should not be stored for a longer period.