Cement is a binding agent that sets and hardens after mixing with water. Romans first developed hydraulic cement by mixing volcanic ash with lime. Portland cement, the most common type today, was invented in 1824 and consists of calcium silicates and other compounds. It is produced through a process of grinding raw materials like limestone and clay, heating the mixture in a kiln to form clinker, then grinding the clinker with gypsum. The clinker compounds hydrate and harden when mixed with water. Cement is primarily used to bind sand, gravel and water into concrete for construction applications.

1. CEMENT

2. INTRODUCTION
Definition: “Cement is a crystalline compound of
calcium silicates and other calcium compounds
having hydraulic properties.
or
Material with adhesive and cohesive properties
Any material that binds or unites - essentially like glue

3. History
Lime and clay have been used as
cementing material on constructions
through many centuries.
Romans are commonly given the credit
for the development of hydraulic cement,
the most significant incorporation of the
Roman’s 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
In 1824 Joseph Aspdin from England
invented the Portland cement
(http://www.holcim.com/NZ/EN/id/71772/mod/gnm20/page/editorial.htm)
(http://pubs.usgs.gov/of/2005/1152/2005-1152.pdf)
http://www.artchive.com/artchive/r/roman/roman_pantheon.jpg

4. FUNCTION OF CEMENT
 To bind the sand and coarse aggregate
together
 To fill voids in between sand and coarse
aggregate particle
 To form a compact mass

5. Types of Cement
 2 types of cement normally used in
building industry are as follows:
a) Hydraulic Cement
b) Nonhydraulic Cement

6. Hydraulic Cement
Hydraulic Cement sets and hardens by action of
water. Such as Portland Cement
In other words it means that hydraulic
cement are:
“ Any cements that turns into a solid product
in the presence of water (as well as air)
resulting in a material that does not
disintegrate in water.”

7. Most common Hydraulic Cement is Portland Cement

8. Nonhydraulic Cement
 Any cement that does not require water to
transform it into a solid product.
 2 common Nonhydraulic Cement are
a) Lime
- derived from limestone / chalk
b) Gypsum

9. Cements are considered hydraulic because of their ability to set and harden
under or with excess water through the hydration of the cement’s chemical
compounds or minerals
There are two types:
Those that activate with the addition of water
And pozzolanic that develop hydraulic properties when the interact
with hydrated lime Ca(OH)2
Pozzolanic: any siliceous material that develops hydraulic cementitious properties when
interacted with hydrated lime.
HYDRAULIC CEMENTS:
Hydraulic lime: Only used in specialized mortars. Made from calcination of clay-
rich limestones.
Natural cements: Misleadingly called Roman. It is made from argillaceous
limestones or interbedded limestone and clay or shale, with few raw materials.
Because they were found to be inferior to portland, most plants switched.
)
Types of Cement

10. Portland cement: Artificial cement. Made by the mixing clinker with gypsum
in a 95:5 ratio.
Portland-limestone cements: Large amounts (6% to 35%) of ground
limestone have been added as a filler to a portland cement base.
Blended cements: Mix of portland cement with one or more SCM
(supplementary cemetitious materials) like pozzolanic additives.
Pozzolan-lime cements: Original Roman cements. Only a small quantity is
manufactured in the U.S. Mix of pozzolans with lime.
Masonry cements: Portland cement where other materials have been added
primarily to impart plasticity.
Aluminous cements: Limestones and bauxite are the main raw materials.
Used for refractory applications (such as cementing furnace bricks) and certain
applications where rapid hardening is required. It is more expensive than portland.
There is only one producing facility in the U.S.
).

11. PORTLAND CEMENT
 Chemical composition of Portland Cement:
a) Tricalcium Silicate (50%)
b) Dicalcium Silicate (25%)
c) Tricalcium Aluminates (10%)
d) Tetra calcium Aluminoferrite (10%)
e) Gypsum (5%)

12. FUNCTION :TRICALCIUM
SILICATE
 Hardens rapidly and largely responsible for
initial set & early strength
 The increase in percentage of this compound
will cause the early strength of Portland
Cement to be higher.
 A bigger percentage of this compound will
produces higher heat of hydration and
accounts for faster gain in strength.

13. FUNCTION :DICALCIUM
SILICATE
 Hardens slowly
 It effects on strength increases occurs at
ages
beyond one week .
 Responsible for long term strength

14. FUNCTION :TRICALCIUM
ALUMINATE
 Contributes to strength development in the
first few days because it is the first compound
to hydrate .
 It turns out higher heat of hydration and
contributes to faster gain in strength.
 But it results in poor sulfate resitance and
increases the volumetric shrinkage upon drying.

15.  Cements with low Tricalcium Aluminates
contents usually generate less heat, develop
higher strengths and show greater
resistance to sulfate attacks.
 It has high heat generation and reactive
with soils and water containing moderate
to high sulfate concentrations so it’s least
desirable.

16. MANUFACTURING OF
PORTLAND CEMENT
 The 3 primary constituents of the raw
materials used in the manufacture of
Portland Cement are:
a) Lime
b) Silica
c) Alumina
 Lime is derived from limestone or chalk
 Silica & Alumina from clay, shale or bauxite

17. There are 2 chief aspects of the
manufacturing process:
First
To produce a finely divided mixture of raw materials –
chalk / limestone and clay / shale.
Second
To heat this mixture to produce chemical composition
There 2 main process that can be used in manufacturing of
Portland Cement that is
i) wet process ii) dry process

18. WET PROCESS
 Raw materials are homogenized by crushing,
grinding and blending so that approximately 80% of the
raw material pass a No.200 sieve.
 The mix will be turned into form of slurry by adding 30 -
40% of water.
 It is then heated to about 2750ºF (1510ºC) in
horizontal revolving kilns (76-153m length and 3.6-4.8m
in diameter.
 Natural gas, petroluem or coal are used for
burning. High fuel requirement may make it
uneconomical compared to dry process.

19. DRY PROCESS
 Raw materials are homogenized by crushing,
grinding and blending so that approximately
80% of the raw material pass a No.200 sieve.
 Mixture is fed into kiln & burned in a dry state
 This process provides considerable savings in
fuel consumption and water usage but the
process is dustier compared to wet process
that is more efficient than grinding.

20.  In the kiln, water from the raw material is
driven off and limestone is decomposed into
lime and Carbon Dioxide.
limestone lime + Carbon Dioxide
 In the burning zone, portion of the kiln, silica
and alumina from the clay undergo a solid
state chemical reaction with lime to produce
calcium aluminate.
silica & alumina + lime calcium aluminate
DRY PROCES & WET PROCESS

21.  The rotation and shape of kiln allow the
blend to flow down the kiln, submitting it to
gradually increasing temperature.
 As the material moves through hotter regions
in the kiln, calcium silicates are formed
 These products, that are black or greenish
black in color are in the form of small
pellets, called cement clinkers
 Cement clinkers are hard, irregular and ball
shaped particles about 18mm in diameter.

22. CEMENT CLINKERS

23.  The cement clinkers are cooled to about
150ºF (51ºC) and stored in clinker silos.
 When needed, clinker are mixed with 2-5%
gypsum to retard the setting time of cement
when it is mixed with water.
 Then, it is grounded to a fine powder and
then the cement is stored in storage bins or
cement silos or bagged.
 Cement bags should be stored on pallets in
a dry place.

24. KILN

25. GEOLOGY (RAW MATERIALS)
The fundamental chemical compounds to produce cement clinker are:
Lime (CaO)
Silica (SiO2)
Alumina (Al2O3)
Iron Oxide (Fe2O3)
(
Fly ash: by-product of burning finely grounded coal either for industrial application or in
the production of electricity
Raw materials used in the production of clinker cement

26. Clinker compounds in Type I portland cement

27. Sedimentary deposits of marine origin (limestone)
Marble (metamorphosed limestone)
Chalk
Marl
Coral
Aragonite
Oyster and clam shells
Travertine
Tuff
LIMESTONES
Originate from the biological deposition of shells and skeletons of plants and animals.
Massive beds accumulated over millions of years.
In the cement industry limestone includes calcium carbonate and magnesium carbonate.
Most industrial quality limestones is of biological origin.
The ideal cement rock 77 to 78% CaCO3, 14% SiO2, 2.5% Al2O3, and 1.75% FeO3.
Limestone with lower content of CaCO3 and higher content of alkalis and magnesia
requires blending with high grade limestone
SOURCES OF CaCO3

28. Argillaceous mineral resources:
Clay and shale for alumina and silica
Iron ore for iron
Other natural sources of silica are and alumina are:
Loess, silt, sandstone, volcanic ash, diaspore, diatomite, bauxite
Shales, mudstones, and sandstones are typically interbedded with the
limestone and were deposited as the inland waters and oceans covered the
land masses. Clays are typically younger surface deposits
SOURCES OF ARGILLACEOUS MINERALS
(

29. Limestone deposits are mainly extracted by bench mining
in which holes are charged with ammonium nitrate and
fuel oil explosive and blasted
The rock is excavated with front end loaders (10 m3
capacity) and loaded into 70 to 90 tons haul trucks and
then transported to the primary crusher
Marl and chalk normally do not require blasting.
A trend is to use in pit moveable primary crushers and
belt conveyors to transport the rock to a fixed secondary
crusher, thereby reducing the number of trucks and
haulage distance
Underground mining of limestones is not typical, in the
U.S one plant obtains its limestone from underground
operation, using room and pillar mining method.
Clay and shale normally extracted using front end loaders
and loaded into haul trucks.
When they occur as overburden the clays and shales not
used are stored and often reused for reclamation in the
mined out areas of the quarry
MINING METHODS

30. PROCESSING

31. (Macfadyen, 2006)

32. Uses
Main use is in the fabrication of concrete and mortars
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)
USES
(http://pubs.usgs.gov/of/2005/1152/2005-1152.pdf)
(http://www.holcim.com/NZ/EN/id/71772/mod/gnm20/page/editorial.
html)
(http://en.wikipedia.org/wiki/Mortar_%28masonry%29)
http://www.wpclipart.com/working/construction/concrete_block.png
http://irandaily.ir/1383/2116/html/005991.jpg

33. SUBSTITUTES
It competes in the construction industry with concrete substitutes:
Alumina
Asphalt
Clay brick
Fiberglass
Glass
Steel
Stone Wood
Some materials like fly ash and ground granulated furnace slugs have
good hydraulic properties and are being used as partial substitutes for
Portland cement in some concrete applications