TESTS ON CEMENT:

Following four field tests may be carried out to ascertain roughly the quality of
cement .

1) Colour

2) Physical Properties

3) Presence of Lumps

1) Colour : The colour of the cement should be uniform. It should be typical cement
colour i.e., grey colour with light greenish shade . This is not always a reliable test.
But it gives an indication of excess lime or clay and the degree of burning.

2) Physical Properties: The cement should feel smooth when touched or rubbed
with fingers. If it is felt rough, it indicates adulteration with sand. If hand is inserted in
a bag or heap of cement, it should feel cool and not warm.

If small quantity of cement is thrown in a bucket of water, it should sink and should
not float on water surface.

3) 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 bags of
cement contains such lumps should be rejected.

LABORATORY TESTS FOR CEMENT:

1) Fineness

2) Soundness test

3) Consistency test

4) Setting Time test

5) Compressive styrength test

1) Fineness of Cement : Fineness of cement is measured by sieving cement on

standard sieve . The proportion of cement of which the cement particle sizes are
greater than 90 micron is determined.

Fineness of cement is property of cement that indicate particle size of cement and
specific surface area of particles of cement per unit mass.

Importance/ Effect of Fineness of Cement: Fineness of cement affects hydration rate

and hence the rate of strength gain. The smaller the particle size , the greater the
surface area to volume ratio, and thus, the more area available for water –cement
interaction per unit volume. Therefore finer cement reacts faster with water and the
the rate of development of strength and corresponding heat of hydration is high.

APPARARUS REQUIRED:

As per IS : 4031 (PART-1)-1996. The cement of good quality should have less than
10% of weight of cement particles larger than 90 (micron) .

The following apparatus is used for this test :

1) Sieve with Pan

2) Sieve with Lids

3) Sieve shaking Machine

4) Weighing Balance

PROCEDURE:

1) Take a 100gm sample of cement (W1).

2) Pour this 100gm sample on 90 micron IS Sieve and close it with the lid .

3) Place it on the sieve shaking machine and sieve it for 5 minutes . We can also
simply sieve it for 15 minutes by hand.

4) Next, the weight of the residue retained on 90 micron sieve is measured and
noted as W2.

5) Then calculate the percentage of weight of cement retained on sieve .

6) Repeat the above experiment with three different samples of cement and average
the values for accurate results % of fineness of cement . =W2/W1*100.

Max value of fineness should not exceed 10%

The value of our experiment comes out 10%

2) Soundness Test : The ability of cement to retain its volume after it gets
hardened is known as Soundness of cement . That means the cement should be at
minimum volume change after gets hardened .

The purpose this tests is to detect the amount of uncombined lime in the cement.

Thus the test conducted to identify the excess amount of lime present in the cement
is known as the Soundness Tests of Cement.
SIGNIFICANCE OF SOUNDNESS TEST: We know that cement is macro-product
which consists of 8 micro-ingredients like lime , silica, alumina , magnesia , iron
oxide, calcium-sulphate, etc. Each has its own set of props and characterstics to
make a perfect cement. As we can see lime is the main product which contributes
70% of its total composition. Deficiency of lime makes the cement set quicker and
affects the property of cement. Meanwhile , the excess of lime makes the cement.
Unsound. It means it causes the cement expands more quicker after it gets
hardened. It means it causes the cement expands. More or after it gets hardened
that is why we are testing soundness of cement.

This test ensures that the cement were not go any subsequent expansions due to
excess amount of lime present in it.

PROCEDURE:

1) The cement paste is prepared. (sample taken=200gm of cement ) with the amount
of water equal to .78 times the water reqd. for consistency test.

2) Mix the paste well using trowel. And now place the lightly oiled le-chatlier mould
on the glass panel.

3) Fill the mould with the prepared paste.

4) Now place another glass plate on the top and put weight on it. Submerge the
whole assembly into water pot at room temp. and keep it undisturbed for 24 hours.

5) Now remove the whole assembly and measure the distance between the mould
edges. Note it as L1.

6) Submerge the mould again into the water and bring it to the boiling point and cool
down to room temp. (Boiling of water is kept for 24 hours)

7) Now again measure the mould edges distance as L2.

Soundness of cement = L1-L2.

This value must not be exceed 10mm for OPC and PPC.

3) Consistency test of cement: A minimum amount of water required to initiate

the chemical reaction between water and cement to form a paste is known as
Consistency of cement.

STANDARD CONSISTENCY: It is that cement consistency which will allow the vicat
plunger to penetrate to 5-7mm point from the bottom of the vicat mould is known as
Standard consistency.
APPARTUS USED FOR THE EXPERIMENT: The vicat apparatus is used for
conducting the standard consistency test. The vicat apparatus consists of a frame
having a moveable rod with a cap at one end at other end. Any one of the following
equipment which is interchangeable.

1) Needle for determining the initial setting time.

2) Needle for determining final setting time.
3) Plunger for determining the std. consistency

The plunger use for standard consistency test has diameter =10mm.

Vicat Mould: Diameter of Vicat mould 60 mm or 80 mm and height =40mm.

PROCEDURE:

1) Take 400gms of cement.

2) Assuming that consisting for OPC would be 30% , take water = 120 grams by
wt.
3) Mix water with cement to make a uniform paste.
4) Now fill the vicat mould with the cement paste and compact it well after filling
the mould.
5) Now place the mould at the vicat apparatus.
6) Now release the plunger and allow it to penetrate through the paste.
7) After removing wait for few seconds (say 5 to 6) sec. and then note down the
the reading on the vicat measuring scale. If the penetration of the plunger is
between 5 to 7mm from the bottom, the water added is correct.
8) If the penetration is not proper, the process is repeated with different
percentages of water.

The tests results desired should be 5-7 mm penetration of the vicat plunger
from the bottom of the mould.

4) Setting time test of cement: When cement is mixed with water, it is stiff
and a sticky paste is formed. The cement paste remains plastic for short period.
As the time period, the plasticity gradually disappears and the paste changes into
a solid mass. The phenomenon by virtue of which the cement paste changes
from plastic state to solid state is known as setting of cement and the time taken
to reach this stage is known as setting time.

This setting time divided into two parts:-

Initial Setting Time

Final Setting Time

INITIAL SETTING TIME:-

The time at which the water is added to the cement to the time at which paste starts
losing its plasticity. Initial setting time is the time taken by the cement paste to stiffen
enough that needle of Vicat apparatus penetrates by 5-7 mm from the bottom of the
mould.

FINAL SETTING TIME:-

Final setting time of the cement is the time elapsed b/w the moment at which the
water is added to the cement to the time at which the paste completely loses its
plasticity.

APPARTUS:-

Vicat apparatus is used which was same except the bottom cross section of needle
used is 1mm × 1mm, Unlike the vicat plunger of dia 10mm .

PROCEDURE:-

FOR INITIAL SETTING TIME:-

1) Prepare a paste of 300 grams of cement with 0.85 times the water required to give
a paste of standard consistency IS : 4031 Part 1988.

2) This paste is filled in a mould. The square needle of cross section 1mm *1mm is
attached to a moving rod of vicat appartus.

3) The needle is quickly released and it is allowed to penetrate the cement paste. At
such a water content where the penetration of needle is b/w 5 to 7mm from the
bottom of the mould will give the initial setting time. The initial setting time is the time
interval b/w the addition of water to a cement and the stage when the needle ceases
to penetrate completely. This time should be about 30 minutes for OPC.

FOR FINAL SETTING TIME:-

1) The cement paste as prepared as above and it is filled in a vicat mould.

2) The needle that was used above is replaced with annular collar and the similar
procedure as followed.

3) The final setting time was not reached as the penetration of the needle with
annular collars was not reached at a depth of 33 to 35mm from top of the mould or 5
to 7mm from bottom.

Permissible Limits :-

For initial setting time (AS PER IS CODE : 4031 (PART 4) 1988.The minimum time
should be about 30 minutes for both OPC and PPC.
FOR FINAL SETTING TIME ( AS PER IS CODE : 4031 (PART 50 1988. The
maximum value of Final setting Time should be 10 hours.

5) Compressive Strength test of cement:- The compressive strength of

hardened cement is the most important of all properties. Strength tests is not made
on neat cement paste because of difficulties of excessive shrinkage and subsequent
cracking of neat cement.

APPARTUS :-

1) Standard Sand

2) Vibration Machine

3) Cube Mould

4) Compression Testing Machine

5) Balance

6) Graduated Glass Standards

PROCEDURE:-

1) Preparations of tests specimens – clean appliance shall be used for mixing, the
temp. of the water and that of the test room at the time of above operations are
being performed shall be 27(+/-) 2 degree Celsius. Potable distilled water is used in
preparing cubes.

2) The material for each cube should be mixed separately and the quantity of
cement, std. sand and water shall be as follows:-

Cement 200gm and std. sand 600gm.

Water (P/4)+3.0) percent of combined mass of cement and sand , where P is the %
of water reqd. to produce a paste of standard consistency determined in IS :4031
PART 4 1988.

3) Place on non porous plate, mixture of cement and std. sand. Mix it dry with at
trowel for one minute and then with water until the mixture of uniform colour. The
time of mixing shall in any event not be less than 3 minutes. And the time taken to
obtain uniform colour exceed 4minutes. The mixture is rejected and is repeated with
fresh quantity of cement, sand and water.

4) Treat the interior faces of the mould with a thin coating of mould oil.

5) Place the assembled mould on the table of the vibration machine and hold it firmly
in position by means of suitable clamp. Attach a hopper of suitable size and shape
securely at the top of the mould to facilitate filling and this hopper of shall not be
removed until the completion of the vibration period.

6) The period of vibration shall be two minutes at the specified speed of 12000(+/-)
400 vibration per minute.

7) At the end of vibration, remove the mould together with the base plate from the
machine and finish the top surface of the cube in the mould by smoothing the
surface with the blade of a trowel.

8) Keep the filled moulds in a moist closest or moist room for 24(+/-) hour after
completion of vibration. At the end of that period, remove them from the moulds and
immediately submerge in clean fresh water and keep there until taken out just prior
to breaking.

9) The water in which the cubes are submerged shall be renewed every 7 days and
shall be maintained at room temperature.

10) Test three cubes for compressive strength for each period of curing mentioned
under the relevant specifications( i.e; 3 days , 7 days, 28 days ).
SITE LOCATION FOR CEMENT FACTORY:-
The location of cement factory should be decided carefully. Some of the important
guiding factors are to be paid attention to while making selection for site of proposed
cement factory:-

1) Availability of labour:- The site should be such that it is easy to get the required
labour easily and economically.

2) Market for Product:- The site should be at a reasonable distance from the market
so that the cost of transport is also less and there less chances of cement getting
harmed during transportation.

3) Power and Fuel:- There should be proper facilities of electricity and easy
availability of fuel at a reasonable cost.

4) Raw Materials:- These should be available easily and continuously around the
area of site under construction. In J&K there are bright chances for the cement
industries to flourish as there is easy availability of the raw materials such as
limestone which is present in abundance in Kashmir. Satyam cements brought their
raw materials from Srinagar and Anantnag and some other districts such as Doda
etc. Thus the feasibility of establishment of the new factories is high in this area .

5) Transport Facililties:- The site for the cement factory should be such that transport
facilities are available for raw materials and finish products.

6) Climate:- The site should be located in such an area where climatic conditions are
normal throughout the year and extreme conditions not occur.
INDUSTRIAL TRAINING REPORT

DONE BY

ARUN KUMAR

ROLL NO :- 16001009014

AT

M/S SATYAM CEMENTS

MFG. OF CEMENT & CLINKER

NEW INDUSTRIAL AREA , AREA RAKH JALPHAR- KATHUA (J&K)

SUBMITTED TO

DEPARTMENT OF CIVIL ENGINEERING

DEENBANDHU CHHOTU RAM UNIVERSITY OF

SCIENCE AND TECHNOLOGY