Cementing materials

• A cementing materials is a semi-finished product that is

processed at construction sites in making concrete mixes.
There are various ways of processing binders and quality
of the binders used. For example, the use of alumina
cement in winter is hampered by the fact that only cold
ingredients must be used in the concrete mixture.
– Common lime and carbonate of lime
– Gypsum binders
– Gypsum cementing materials
– Magnesium binders
– Magnesium cementing materials
– Hydraulic lime
– Lean hydraulic lime
– Lime pozzaolanic and lime slag cementing materials
 Raw Materials for the Manufacture of
Cement
• The essential raw materials for the manufacture of
cement are limestone and clay which are supply all the
four principle ingredients such as CaO, 𝐹𝑒2 𝑂3 , 𝐴𝑙2 𝑂3 ,
and 𝑆𝑖𝑂2 .
• CaO and 𝐹𝑒2 𝑂3 are obtained from limestone and 𝑆𝑖𝑂2
and 𝐴𝑙2 𝑂3 are from clay.
• Thus the raw materials include:
– Calcareous materials such as limestone, calcium carbonate
sludge, marl, chalk and alkali waste which contains
precipitated 𝐶𝑎𝐶𝑂3 . Calcareous materials supply lime and
they contain 3-4% 𝑆𝑖𝑂2 , 𝐹𝑒2 𝑂3 and 𝐴𝑙2 𝑂3 and less than
3.3% MgO.
– Siliceous or Argillaceous materials which supply 𝑆𝑖𝑂2 ,
𝐹𝑒2 𝑂3 and 𝐴𝑙2 𝑂3 . These include clay, blast furnace slag,
siliceous stones, shale etc.
What is the Effect of Free Lime (CaO)
on Cement
• If excess of free lime is present in cement then it
is left uncombined which cracks during setting.
• If free lime is less than required the resulting
cement is weak in strength and it is very difficult
to work by this cement due to its rapid setting.
 What is the function of 𝑆𝑖𝑂2 , 𝐴𝑙2 𝑂3 and 𝐹𝑒2 𝑂3 in
cement?/Why we use 𝑆𝑖𝑂2 , 𝐴𝑙2 𝑂3 and 𝐹𝑒2 𝑂3 for good
quality of cement
• 𝑆𝑖𝑂2
– The strength of concrete depends on silica.
– It promotes the moisture resistance of the cement to accelerate hardening of
cement under 𝐻2 O to increase the resistance of the concrete to dissolve 𝐶𝑂2
corrosion.
– If excess of 𝑆𝑖𝑂2 present in cement, the hardening process becomes slow.
• 𝐴𝑙2 𝑂3
– It increases the rate of settling but excess 𝐴𝑙2 𝑂3 weakness the strength of
cement.
• 𝐹𝑒2 𝑂3
– About 1400°C needed in rotary kilns for cement manufacture, but if
𝐹𝑒2 𝑂3 is mixed in cement, the temp is reduced.
– It gives colour, strength and hardness of cement.
– If excess of 𝐹𝑒2 𝑂3 is present, the cement becomes black in colour.
– If it is present in small amount, the cement becomes white in colour.
 Manufacture Process of Portland
Cement
• Two methods for the manufacture of portland cement
– Dry process
• Calcareous material (Limestone)
• Argillaceous material (Clay)
– Wet process
• Chemical reaction
𝐹𝑖𝑛𝑎𝑙𝑦 𝑝𝑜𝑤𝑑𝑒𝑟𝑒𝑑
Calcareous materials + Argillaceous materials ( ) → Clinker
1400°𝐶
2−3% 𝑔𝑦𝑝𝑠𝑢𝑚
( ) → Cement
𝑝𝑜𝑤𝑒𝑟𝑒𝑑

• Application or uses:
– Cement is one of the most important building materials now a day
and used in the construction of roads, buildings, dams, bridges etc.
– It is used in the form of a paste with sand and water.
 Manufacture Process of Portland
Cement (Cont..)
Calcareous materials Argillaceous materials

Crushing Crushing

Drying Drying
Mixing

2-5%
Automatic Scale gypsum
Automatic Scale
added

Portland
Pulverising Rotary Kiln Clinker Grinding
Cement

Fig: Flow sheet for manufacturing portland cement

Manufacture Process of Portland Cement
(Cont..)
• Process description:
– In dry process, at first the calcareous materials and argillaceous materials are
separately crushed and ground in suitable machine and then dried. Crushing is
done in gyratory crushers and drying is done by rotary driers.
– These are then mixed in proper portions, pulverised in ball mills and finally
homogenised, i.e made slighty uniform by means of a compressed air mixing
arrangement. The resulting mass is known as raw meal.
– The raw meal is now introduced into the hopper provided on the upper part of a
rotary kiln. In rotary kiln the raw meal is heated about 1400°C to 1600°C temp,
which is the maximum temp of the kiln. At this temp, the mixture is partly fused
and the chemical reaction takes place.
• 𝐶𝑎𝐶𝑂3 → 𝐶𝑎𝑂 + 𝐶𝑂2
• 2CaO + 𝑆𝑖𝑂2 → 2𝐶𝑎𝑂. 𝑆𝑖𝑂2
• 3CaO + 𝑆𝑖𝑂2 → 3CaO. 𝑆𝑖𝑂2
• 3CaO + 𝐴𝑙2 𝑂3 → 3𝐶𝑎𝑂. 𝐴𝑙2 𝑂3
• 4CaO + 𝐹𝑒2 𝑂3 + 𝐴𝑙2 𝑂3 → 4𝐶𝑎𝑂. 𝐴𝑙2 𝑂3 . 𝐹𝑒2 𝑂3
– The resulting greenish black or grey coloured mass is called clinker. These are
allowed to enter a revolving tube known as rotary cooler where clinkers are
cooled down. Generally 2-3% gypsum is also added to the clinker and finally
ground to an exceedingly fine powder in grinding machine. Finally the cement
is filled in air tight bags to exclude moisture.