The document provides an overview of cement, highlighting its composition, manufacturing processes, types, and applications, emphasizing Portland cement as the most common variety. It details hydration, setting stages, and quality tests for cement, along with a description of various types such as acid-resistant, blast furnace, and white cement, among others. Additionally, it outlines the numerous functions of cement in construction and describes essential properties that characterize good-quality cement.

1. CEMENT
By - Ar. Priyanka Gurjar

2. INTRODUCTION
• The name cement refer to the material manufacture from limestone and clay and
made available in powder form.
• Popular as Building material.
• Material with adhesive and cohesive properties.
• To bind the fine and corse aggregate together.
• Common variety of cement is known as the Portland cement.
• India is the fifth largest producer of cement in the world.
• Rajasthan is the second largest producer of cement in india after Andra Pradesh.

3. • 183 large cement plants and more
than 360 mini cement plants
• 330 million tonnes a year installed
capacity
• 97% of the installed capacity is
accounted for by large producers,
around 40 in number
• 21 top companies control 90% of
the market
CEMENT INDUSTRY IN INDIA

4. COMPOSITION OF ORDINARY CEMENT
Ingredient Percentage Property
Lime 62% - 67% Soundness and
strength
of cement
Silica 17% - 25% Strength to the cement
Alumina 3% - 8% Quick setting property
Calcium sulphate 3% - 4% Increase the initial
setting time.
Iron oxide 3% - 4% Colour, Hardness and
strength
Magnesia 0.1% - 3% Hardness and colour
Sulphur 1% - 3% Making sound cement
Alkalies 0.2% - 1% Harmful, carried away
by flue gases.

5. PORTLAND CEMENT
• Made by mixing substances
containing Calcium carbonate
such as Limstone/chalk.
• And by mixing substances
containing Silica, Aluminia and
Iron oxide such as clay.
• Raw material is then heated and
made CLINKER.
• Clinker is then grounded to
powder.
Why it is called Portland cement ?
- Joseph Aspedin, an english mason
who patented the product named it
Portland because it produced a
concrete that resembled the colour
natural limestone that quarried on
the isle of Portland, peninsula of
english channel.

6. HYDERATION OF CEMENT
• It is a process of chemical reaction between cement and water.
• It results first in setting (the concrete becomes solid) and then hardening (increase of
strength and stiffness)
• Heat is liberated during Hyderation process.
• Thus, during the Hardening process, the concrete is being continually warmed by
internal heat generated.
• The more rapid the rate of hardening the more susceptible is a concrete to shrinkage.
• The amount of water required to hydrate cement is about 25%.
• Water/cement ratio is between 0.4 to 0.6

7. SETTING OF CEMENT
• When cement is mixed with sufficient water, within one and two hours after
the mixing, the sticky paste losses its fluIdity, within a few hours after mixing
noticable stiffness commences.
• Setting can be divided into two stages :
1. Initial Set
2. Final set
• Initial set – When the paste begin to stiffen.
• Final set – Beginning to harden and able to sustain some loads.

8. • Three distinct operations are involved
in the manufacturing of ordinary
cement
1. MIXING OF RAW MATERIAL
2. BURNING
3. GRINDING
1. MIXING OF RAW MATERIALS :
Raw materials such as limestone and
clay are mixed either by DRY PROCESS
or by WET PROCESS
MANUFACTURING OF CEMENT

9. • The raw materials are first reduced in the size of
about 25 mm in crushers in dry process.
• Wet process ( Old technology ), cement industry
underwent a number of changes.
• In case of mixing of raw material in wet process
a SLURRY is formed.
2. BURNING
• Carried out in a rotary kiln, diameter varies
from 2.5 m to 3 m and length varies from 90m
to 120m.
• Laid at a gradient of 30 deg from horizontal
plane.
• 1- 2 revolutions per minute about its
longitudinal axis.
• Temperature is about 1400°C – 1700°C.

10. 3. GRINDING
• Clinkers as obtained from rotary kiln are finely
ground in ball mills and tube mills
• GYPSUM is added about 3-4% during grinding.
BALL MILLS AND TUBE MILLS
• Used to carry out grinding of raw materials or
mixture or clinkers.
• The ball mills are used to have preliminary
grinding and the tube mills are used to carry
out final grinding.

12. TYPES OF CEMENT
In addition to ordinary cement, following are the other important types of cement:
• Acid resistant cement
• Blast furnace cement
• Coloured cement
• Expanding cement
• High Alumina cement
• Hydrophobic cement
• Low heat cement
• Pozzolana cement
• Quick setting cement
• Rapid hardening cement
• Sulphate resisting cement
• White cement.
• Air entraining cement

13. • Acid resistance cement -
Used for acid-resistance and heat
resistance coatings of installations of
chemical industry. It is not water-resistant
and it fails when attacked by water.
By adding 0.5% of linseed oil resistance
water is increased.
• Blast furnace 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.
60-65% of slag is ground with CLINKER.
It requires longer curing period.
Not suitable for use in dry arid zones.
acid resistant cement

14. • Coloured cement
The cement of desired colour may be
obtained by intimately mixing mineral
pigments with ordinary cement or white
cement.
Mineral pigment 5-10%, if % increases
strength decreases.
Used as finishing of floors, external
surfaces etc.
• Expanding cement
This type of cement is produced by
an expanding medium like sulpho-
aluminate and a stabilising agent to the
ordinary cement.
Hence this cement expands whereas
cements shrink.
The expanding cement is used for
construction of water retaining structures
and also for repairing the damaged
concrete surfaces.
damaged concrete surfaces

15. • High Alumina cement -
Is specified that total alumina content should not
be less than 32%.
Withstand high temperature.
Used in workshops, refractories where high
temperature is involved.
I.s.t – 3 hours and F.s.t – 5 hours.
Evolve great heat.
• Hydrophobic cement
This type of cement contains admixtures which
decreases the wetting ability of cement grains.
Admixtures like acidol, naptheline forms a thin
film layer over the cement grains.
Use of hydrophobic cement considerably
increases the water resistance of an concrete.
High alumina
cement
Water resistance towards concreteHydrophobic cement

16. • Pozzolana cement
Pozzolana is a volcanic powder. This type of
is used to prepare mass concrete of lean mix and
marine structures. It is also used in sewage works
and for laying concrete under water.
• Low heat cement
The considerable heat is produced during the
setting of cement. In order to reduce the amount
heat, this type of cement is used.
Decrease tri- calcium aluminate about 5% and
increase tri- calcium silicate about 46%.
Used in mass construction works.
• Quick setting cement
This cement is produced by adding a small
percentage of aluminium sulphate and by finely
grinding the cement
This type of cement is used to lay concrete under
static water or running water.
I.s.t – 5 minutes and F.s.t – 30 minutes
Used in under water construction, rainy and cold
wheather conditions.
• Air entraining cement
It is produced by adding indigenous air entraining
agents such as resins, glues, sodium salts of
Sulphates etc during the grinding of clinker. This
type of cement is specially suited to improve the
workability with smaller water cement ratio and to
improve frost resistance of concrete.

17. • Rapid hardening cement
The initial and final setting times of this cement are
same as those of ordinary cement. But it attains high
strength in early days. It contains high percentage of
tricalcium silicate.
Used when foam work is to be removed early.
Less curing.
• Sulphate resisting cement
In this cement, it results in the increase in resisting
power against sulphates.
Used for structures which are likely to be damaged by
severe alkaline conditions such as canal linings,
culverts, chemical industries etc.
• White cement
Prepared from such raw materials which are
free from colouring oxides of iron, manganese or
chromium. For burning of this cement, the oil fuel is
used instead of coal. It is white in colour and is used
for floor finish, plaster work, ornament work, etc.
White cement
canal linings culverts

18. USES OF CEMENT
Some of the numerous functions of cement are given below –
• It is used in mortar for plastering, masonry work, pointing, etc.
• It is used for making joints for drains and pipes.
• It is used for water tightness of structure.
• It is used in concrete for laying floors, roofs and constructing lintels, beams, stairs, pillars etc.
• It is used where hard surface is required for the protection of exposed surfaces of structures
against the destructive agents of the weather and certain organic or inorganic chemicals.

19. • used for precast pipes manufacturing, piles, fencing posts etc.
• It is used in the construction of important engineering structures such as bridges,
culverts, dams, tunnels, light houses etc.
• It is used in the preparation of foundations, water tight floors, footpaths etc.
• It is employed for the construction of wells, water tanks, tennis courts, lamp posts, telephone
cabins, roads etc

20. The following are the quality tests on
cement at construction site:
• Colour test
• Presence of lumps
• Adulteration test
• Temperature test
• Float tests
• Strength test
• Setting test
• Date of packing
TEST OF CEMENT AT CONSTRUCTION SITE
• Colour Test of Cement
The color of the cement should be uniform. It
should be grey colour with a light greenish
shade.
• 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.
• Cement Adulteration Test
The cement should feel smooth when
touched or rubbed in between fingers. If it is
felt rough, it indicates adulteration with sand.

21. Temperature Test of Cement
• If hand is inserted in a bag of cement or
heap of cement, it should feel cool and not
warm.
Float Test
• If a small quantity of cement is thrown in a
bucket of water, the particles should float for
some time before it sinks.
Setting Test
• A thick paste of cement with water is made
on a piece of glass plate and it is kept under
water for 24 hours. It should set and not
crack.
Strength of Cement Test
• A block of cement 25 mm ×25 mm and 200
mm long is prepared and it is immersed for
days in water. It is then placed on supports
15cm apart and it is loaded with a weight of
about 34 kg. The block should not show
signs of failure.
Date of Packing:
• Strength of cement reduces with time, so
it is important to check the
manufacturing date of the cement.

22. Tests to be conducted to judge the quality of
cement.
1. Fineness
2. Soundness
3. Consistency
4. Compressive strength
5. Tensile strength
1. FINENESS TEST
This test is carried out to check proper grinding of
cement.
In sieve test the cement weighing 100gm is taken and it
is continuously passed for 15 min through standard BIS
sieve no. 9.
The residue is then weighed and this weight should not
be more than 10% of original weight.
Different sieve sizes, IS sieve.
VARIOUS LAB TEST ON CEMENT

23. 2. SOUNDNESS TEST
• The purpose of this test is to detect the presence of
uncombined lime in cement.
• Soundness of cement is determined by Le-
Chatelier method as per IS: 4031 (Part 3) –
1988.
• Soundness of cement is the property of
hardened cement paste undergoing large
change in volume after setting without
delayed destructive expansion.
• The expansion of cement should not exceed 10mm
Le-Chatelier apparatus.
3. CONSISTENCY TEST
• The basic aim is to find out the water content
required to produce a cement paste of standard
consistency as specified by the IS: 4031 (Part 4) –
1988.
• Apparatus – Vicat apparatus .
• Initial Setting time and normal consistency
determination.
Vicat apparatus

24. 4. COMPRESSIVE STRENGTH
• To determine the compressive strength.
• The compressive strength at the end of 3 days
should not be less than 115 kg/cm sq and at the
end of 7 days should not be less than 175 kg/cm sq.
5. TENSILE STRENGTH
• Test was formerly used to have an indirect
indication of compressive strength of cement.
• Ultimate tensile stress = failing load / 6.45
• The tensile stress at the end of 3 days should not be
less than 20 kg/cm2 or 2 N/mm2 and that at the
end of 7 days should not be less than 25 kg/cm2 or
2.50 N/mm2.
Cement cubes
Compression testing machine Briquette mould
Applying tensile strength
Standard Briquette

25. • Provides strength to masonry.
• Stiffens or hardens early.
• Possesses good plasticity.
• An excellent building material.
• Easily workable.
• Good moisture-resistant.
PROPERTIES OF GOOD CEMENT

26. THANKS FOR THE PATIENCE