Cement is produced by heating limestone and clay in a kiln to form clinker, which is then ground with gypsum. There are two main types: hydraulic cement hardens when mixed with water due to a chemical reaction, while non-hydraulic cement hardens through carbonation. The Romans used early forms of concrete and cement in structures like the Colosseum. Modern cement production involves mining raw materials, grinding and heating them to form clinker, and then grinding the clinker to produce cement powder. Cement is used primarily in concrete and mortar for construction of buildings, roads, bridges and other infrastructure.

1. CEMENT

2.  INTRODUCTION



Cement is a binder,a substance that sets and
hardends independenly,and can bind other
materials together.
Cement is a bonding agent obtained by buring a
mixture of limestone and clay together to form
clinker,then pulverizing the clinker with gypsum.
Cements used in construction can be
characterized as being either hydraulic or nonhydraulic.

3. 

Hydraulic cements (e.g., Portland cement)
harden because of hydration, a chemical
reaction between the anhydrous cement
powder and water. Thus, they can harden
underwater or when constantly exposed to wet
weather. The chemical reaction results in
hydrates that are not very water-soluble and
so are quite durable in water.
Non-hydraulic cements do not harden
underwater; for example, slaked limes harden
by reaction with atmospheric carbon dioxide.

4.  HISTORY



The word cement has come from the roman word
‘opus caementicium’
1824-Portland Cement Invented
Joseph Aspdin,a british stonemason,invented
portland cement way back in 1824.With this
invention,Aspdin laid the foundation of today’s
cement industry.

5.  3000
BC-Egyptian Pyramids
 The Egyptians were
using early forms of
concrete over 5000
years ago to build
pyramids. They mixed
mud and straw to
form bricks and used
gypsum and lime to
make mortars.

6.  300 BC - 476 AD,Roman Architecture

The ancient Romans
used a material that is
remarkably close to
modern cement to build
many of their
architectural marvels,
such as the Colosseum,
and the Pantheon. The
Romans also used
animal products in their
cement as an early form
of admixtures.

7.  CHEMISTRY

Cement is hydraulic material which develops
strength when it reacts with water.
 It is inorganic material which consists of oxides of
calcium,silicon,iron,aluminum.
 Non-hydraulic cement such as slaked limes
(calcium hydroxide mixed with water), harden due
to the reaction of carbonation in presence of the
carbon dioxide naturally present in the air. Calcium
oxide is produced by lime calcination at
temperatures above 825 °C (1,517 °F) for about
10 hours at atmospheric pressure:
 CaCO3 → CaO + CO2

8. 
The calcium oxide is then spent mixing it to water
to make slaked lime:
 CaO + H2O → Ca(OH)2
 Once the water in excess from the slaked lime is
completely evaporated (this process is technically
called setting), the carbonation starts:
 Ca(OH)2 + CO2 → CaCO3 + H2O
 This reaction takes a significant amount of time
because the partial pressure of carbon dioxide in
the air is small. The reaction of carbonation
requires the air be in contact with the dry cement,
hence, for this reason the slaked lime is a nonhydraulic cement and cannot be used under water.

9. 
Conversely, the chemistry ruling the action of the
hydraulic cement is the hydration. Hydraulic
cements (such as the Portland cement) are made
of a mixture of silicates and oxides, the four main
components being:
1. Belite (2CaO·SiO2);
2. Alite (3CaO·SiO2);
3. Celite (3CaO·Al2O3);
4. Brownmillerite (4CaO·Al2O3·Fe2O3).

10.  CO2 EMISSIONS

The amount of CO2 emitted by the cement
industry is nearly 900 kg of CO2 for every 1000 kg
of cement produced. In the European union the
specific energy consumption for the production of
cement clinker has been reduced by
approximately 30% since the 1970s. This
reduction in primary energy requirements is
equivalent to approximately 11 million tonnes of
coal per year with corresponding benefits in
reduction of CO2 emissions.

11.  MANUFACTURING OF CEMENT

Mixing and Crushing of raw materials

Wet process
Semi dry process
Dry process



Burning
 Grinding

12. 1. Wet process
•
In this process the kiln feed enters the kiln in the
form of a slurry with a moisture content of 30-40%.

Advantage with this process:
1.
2.

1.
Uniform quality product can be produced.
Dust emission can be reduced.
Disadvantages with this process
Fuel and power consumptions are very high.

13. 2. Semi dry process:
•
In this process all raw materials are ground in dry
state and the resultant powder is pelletized into
small nodules by means of 10-15% of water
addition,then nodules are fed into kiln.

Advantage with this process:
1.

1.
Fuel consumption is lower than the consumption
of fuel in wet process.
Disadvantage with this process:
Fuel consumption is higher than the consumption
of fuel in dry process.

14. 3. Dry process:
•
In this process all raw materials are ground in dry
state and the resultant powder is fed into kiln in
powder form.

Advantage with this process:
1.
2.
3.
Fuel consumption is lower than the consumption
of fuel in wet and semi dry process.
Throughput of kilm is higher than the throughput
of wet and semi dry process kiln.
Unit cost of product can be reduced.

15.  CEMENT RAW MATERIALS

In manufacture cement five types of raw
materials are required:
1. Calcareous raw materials
2. Argillaceous raw materials
3. Siliceous raw materials
4. Ferrous raw materials
5. Gypsum raw materials

16. 1.Calcareous raw materials:
•
1.
2.
3.
4.
Calcareous raw materials contributing mainly
calcium carbonate.
Limestone
Chalk
Marbles
Seashells

17. 2. Argillaceous raw materials:
•
1.
2.
3.
4.
Argillaceous raw material is used as supply source
of silica,alumina and iron.
Shale
Clay
Bauxite
Soil

18. 3. Ferrous raw materials:
As argillaceous materials can’t supply of sufficient
Fe2O3,Ferrous raw material is used.
1. Iron ore (>60% Fe2O3)
2. Laterite (High grade >45%,low grade <45%)
3. Copper slag (Around 50% Fe2O3)
4. Furnace dust
•

19. 4. Siliceous raw material:
•
In case where orgillaceous raw material supplying
insufficient Sio2 component,siliceous raw
materials is used:
1. Silica sand (>85% silica)
2. Clay stone (>70%silica)
3. Granite (>85% silica)

20. 5. Gypsum
1.
2.
3.

1.
2.
3.
Natural Gypsum (It is available in nature)
Synthetic or Chemical Gypsum (It is a by-product
in chemical/fertilizer industry)
Marine Gypsum (It is available in sea shores)
Gypsum is available in the mature in three
forms:
Gypsum di-hydrate (CaSo4.2H2O)
Gypsum hemi-hydrate (CaSo4.1/2H2O)
Gypsum anhydrite ( CaSo4.O.H2O)

21.  TYPES

1.
2.
3.
4.
5.
As per ASTM there are 8 types of cement
and they are:
Type – I&IA*
Type – II&IIA*
Type – III&IIIA*
Type – IV*
Type – V*

22. 
What is ASTM ?
•
ASTM means American Society for testing and
materials
It is an international organization which has been
in operation for over a century
The organization is specialized in developing
standard for various materials
•
•

23. 
1.
2.

1.
2.
3.
4.
What are the various cement ?
Portland cement
Blended cement
Portland cement:
Ordinary Portland Cement
Portland White Cement
Portland Oil Well Cement
Portland High Alumina Cement

24. 
•
Blended cement:
Blended cements are produced by intimately and
uniformly intergriding or blending portland cement
and two or more types of fine materials such as:
1. Ground granulated blast furnace slag (It is a by
product in steel industry)
2. Fly ash (By product in thermal power plants)
3. Silica fume (By product in ferrosilicon alloys)
4. Volcanic ash (Volcanic eruption)
5. Calcined clay (Burnt clag)
6. Limestone (Naturally available)

25. 
1.
2.
3.
Examples for Blended cements
Portland blast furnace slag
Portland fly ash cement
Portland masonry cement

26.  APPLICATIONS OF CEMENT

Type -1

Types -1 is a general purpose of portland cement
suitable for all uses where the special properties of
other types are not required.It can be used for ……
pavements,sidewalks,reinforced concrete
buildings,bridges,railway structures,tk
s,reservoirs,culverts,sewers,water pipes.


27. 
Type -II

Type -II portland cement is used where precoution
against moderate sulfate attack is important.it can
be used for…..
Drainage structures,large piers,heavy retain walls.


28. 
Type -III

Type -III is a high early strength portland cement
that provides high strength at an early period
usually a week or less.
It is used when forms to be removed as soon as
possible or when the structure must be put into
service quickly.


29. 
Type -IV

Type-IV is a low heat of hydration cement for use
where the rate and amount of heat generated
must be minimized.
It is intended for use in massive concrete
structures,such as large dams.


30. 
Type -V

Type V portland cement is a sulfate resisting
cement.it is used only in concrete exposed to
sever sulfate action.
C3a content,generally 5% or less,is requires when
high sulfate resistance is needed.


31. 
APPLICATION OF AIR ENTRAINING
PORTLAND CEMENTS
•
Type IA,IIA,IIIA.
•
Small quantities of air entraining materials such
as,organic substances are inter ground with the
clinker.The purpose of entraining materials
addition are:
To resist freeze thraw action (Air entraining
materials create and well distribute the tiny air
bubbles in concrete).The air bubbles provide
space for freezing water to expand without
damaging the concrete.
1.

32.  USES OF CEMENT

Production of concrete
 Construction purpose
•
•
•
•

Building (Floors,beams,columns,roofing)
Transport (Roads,pathwayes,crossing,bridge)
Water (Pipes,drains,canals)
Agriculture (Irrigation,housing)
The most important uses of cement are as
an ingredient in the production of mortar in
masonry, and of concrete, a combination of
cement and an aggregate to form a strong
building material that is durable in the face
of normal environ mental effects.