The document provides a comprehensive overview of cement, including its raw materials, manufacturing processes, characteristics, types, and uses. Key details include the steps in cement production from raw material preparation to grinding and packaging, as well as the various types of cement and their specific properties and applications. It also discusses grades of cement, their strengths, and appropriate storage guidelines.

1. CEMENT
mmbc - ii
Ar. Sunil Kumar
Ar. Praneetha Jagdale

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.
• Calcium sulfate is mainly from gypsum
and has an effect of slowing down the
solidification speed.

6. 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

7. Manufacturing Of Cement
• Mixing of raw material(wet or dry)
• Burning
• Grinding

8. • Raw Material Preparation - Extraction Raw materials like limestone, clay, and
shale are extracted from quarries.
• Crushing: The raw materials are crushed into smaller pieces to facilitate grinding.
• Mixing: The raw materials are mixed with water to form a slurry with about 30-
40% water content.
• Grinding: The slurry is finely ground in a ball mill to form a homogenous
mixture.
• Blending: The slurry is stored in blending tanks and continuously stirred to
ensure uniformity.
• Preheating: The slurry is preheated in a series of cyclones to remove moisture
and begin the chemical reactions.
• Kiln Feeding: The preheated slurry is fed into a rotary kiln.
• Calcination: In the rotary kiln, the slurry is heated to about 1450°C, where it
undergoes calcination. Calcium carbonate decomposes into calcium oxide and
carbon dioxide.
• Clinkering: The temperature in the kiln increases further, leading to the
formation of clinker nodules (small, hard, spherical nodules of various
compounds).

9. clinker
• Cooling: The hot clinker is cooled in a clinker
cooler.
• Grinding: The cooled clinker is ground together
with a small amount of gypsum to produce
Portland cement.
• Storage and Packaging: The final cement
product is stored in silos before being packed and
distributed.
cement
https://www.youtube.com/watch?v=YjTl4Jp1TB0

10. • Dry process-Mixing of raw materials
undergo crushing, drying, reduction in
size, mixing in correct proportion.

12. • The dry process of cement manufacturing involves the following steps:
• Raw Material Preparation: Raw materials (limestone, clay, and other
components) are mined and transported to the cement plant.
• Crushing: The raw materials are crushed into smaller sizes using crushers.
• Mixing and Pre-homogenization: The crushed materials are mixed and
stored in silos to achieve a uniform chemical composition.
• Drying and Grinding: The raw materials are dried and ground into a fine
powder in a raw mill.
• Homogenization: The powdered raw materials are homogenized in blending
silos to ensure a consistent mix.
• Preheating: The homogenized raw meal is preheated in a series of cyclones to
begin the chemical reactions and remove moisture.
• Pre-calcination: In the pre-calciner, the material is further heated, and
calcination begins, transforming calcium carbonate into calcium oxide and
releasing CO2.
• Kiln Feeding: The preheated and pre-calcined raw meal is fed into a rotary
kiln.
• Calcination and Clinkering: Inside the rotary kiln, the material is heated to
about 1450°C, where it undergoes complete calcination and forms clinker
nodules through chemical reactions.
• Cooling: The hot clinker is cooled rapidly in a clinker cooler to stabilize its
structure and make it easier to handle.
• Grinding: The cooled clinker is ground with a small amount of gypsum in a
cement mill to produce cement.
• Storage and Packaging: The finished cement is stored in silos and then
packed in bags or transported in bulk for distribution.

13. KILN
1.Length:
1. Modern rotary kilns are generally between 60 to 200
meters long.
2.Diameter:
1. The diameter of cement kilns usually ranges from 3 to 6
meters.
3.Production Capacity:
1. The capacity of cement kilns can vary, typically ranging
from 500 to 10,000 tons per day.

14. Characteristics
Fineness: The fineness of cement particles affects
the rate of hydration and strength development.
Finer cement reacts faster with water.
Setting Time: Cement should have a specific
initial and final setting time. Initial setting time
should be enough for mixing, transporting, and
placing. Final setting time is the time taken to
completely harden.
Soundness: Soundness ensures that the cement
does not undergo excessive expansion after
setting, which could lead to cracking.
Strength: Cement should develop sufficient
strength in compression, tension, and flexure. The
compressive strength of cement is most
commonly measured.

15. Characteristics
Consistency: Refers to the ability of cement paste
to flow. Standard consistency is determined using a
Vicat apparatus.
Durability: Cement should contribute to the
durability of concrete, resisting chemical attacks,
weathering, and wear over time.
Workability: Cement should impart good
workability to the concrete or mortar, making it
easy to mix, place, and finish.
Alkali Content: Lower alkali content in cement
reduces the risk of expansion and cracking.
Color: Uniformity in color is essential for aesthetic
purposes in architectural concrete.

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
• 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
• 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. • Colored cement
• Can get colors 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, 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 slurry 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

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 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
RETAIL
PRICE
WHOLESALE
PRICE
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. THANK YOU