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    Cement 150423063701 Conversion Gate02

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    Muhammad kalimullah

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    © All Rights Reserved
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    Cement 150423063701 Conversion Gate02

    Uploaded by

    Muhammad kalimullah
    6 views30 pages

    Copyright

    © © All Rights Reserved

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    PDF, TXT or read online from Scribd

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    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    6 views30 pages

    Cement 150423063701 Conversion Gate02

    Uploaded by

    Muhammad kalimullah

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
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    Presented by:

    Sneha
    Himani
    Naveen
    Amit
    Table of Contents
     Introduction
     History
     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
    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.
    History
     1756-John Smeaton (England) created hydraulic
    lime from lime stone.
     1796- John Parker(England) created an improved
    version. Birth of natural cement industry.
     1824-portland cement was invented by Joseph
    Aspedin. It resembled the colour of sand stone
    found in Portland, U.K .
     1904-First cement factory in Tamil Nadu, India.
    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
     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 colour hardness and strength.
     Magnesia- hardness and colour.
    Manufacturing Of Cement
     Mixing of raw material(wet or dry)
     Burning
     Grinding
     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.
     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
     Dry process-available raw material is hard.
     Mixing of raw materials undergo crushing, drying,
    reduction in size, mixing in correct proportion.
    THE CEMENT MANUFACTURING PROCESS
    quarry

    dumper
    loader

    Quarry face

    1. BLASTING 2. TRANSPORT

    storage at
    crushing
    the plant
    conveyor

    3. CRUSHING & TRANSPORTATION

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

    storage at Raw mill


    the plant
    conveyor Raw mix

    1. RAW GRINDING
    preheating

    kiln

    cooling

    clinker

    2. BURNING

    1. RAW GRINDING : The raw materials are very finely ground in order to produce the raw mix.
    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.
    Back Next
    THE CEMENT MANUFACTURING PROCESS
    Grinding, storage, packing, dispatch

    Gypsum and the secondary additives are added


    to the clinker.
    clinker
    storage Finish grinding

    1. GRINDING
    silos

    dispatch

    bags

    2. STORAGE, PACKING, DISPATCH

    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.

    2. STORAGE, PACKING, DISPATCH :The cement is stored in silos before being dispatched either in
    bulk or in bags to its final destination.
    Back Home page
    Characteristics
     Strength- atleast 175kg/cm2
     Fineness
     Soundness
     Presence of lumps
     Colour
     Resistant to moisture.
     Setting time
    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
     Whit cement
     Acid resistance cemet
     Hydrophobic cement
     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.
     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.
     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
     Coloured cement
    ◦ Can get colours by adding
    mineral pigments.

    ◦ Green(chromium
    oxide),blue(cobalt),red,
    brown, yellow(iron oxides)
    ◦ Used for decorations.
     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.
    Grades of Cement
     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.


    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
    Abram’s Law
    water to cement ratio
     Strength of fully
    compacted concrete is
    inversely proportional to
    water cement ratio.
     In practice, around 40%
    water is used.
     Practically, if we use less
    water the mixture becomes
    very stiff and difficult to
    handle.
    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 taurpaulin
     Ensure FIFO.
    Tests
     For fineness
    ◦ Sieve test
    ◦ Surface area test
     For normal consistency –
    to determine the setting
    time
     For soundness
    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.
     Cement as concrete
    ◦ For manufacturing solid
    and hollow concrete
    blocks.
    ◦ For laying subfloors and
    floors
    ◦ For RCC
    constructions(slab,
    beam, column, stairs,
    footings, etc)
    Recap
     Introduction
     History
     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
     Thank you

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