\FACULTY NAME: NIKHIL SOMAN

INTRODUCTION
▪ Cement was invented by Joseph Aspidin in the year 1824.
▪ 1st cement factory in India was established in the year 1904 – South
Indian Cement Ltd.(Chennai)
▪ 1st cement factory in Kerala was established in the year 1946 –
Travancore Cement Ltd. (Kottayam)
▪ Properties of Ordinary Portland Cement (OPC):
Density : 1440 kg/mᵌ
Specific gravity : 3 to 3.15
1 mᵌ of cement = 29 bags
50 kg cement = 35 liter = 1.23 ft ᵌ
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 INGREDIENTS OF OPC
# Constituent Content (%) Impart
Excess cause
1 Lime 62 – 67 Binding property unsoundness
2 Silica 17 – 25 Strength Excess
increase
3 Alumina 3–8 Flux; accelerate setting
setting time
4 Gypsum 3–4 Retard setting
5 Iron oxide 3–4 Colour and hardness
6 Magnesia 2–3 Colour and hardness Excess cause
7 Sulphur 1–2 Soundness unsoundness
8 Alkali oxide Not > 1 -
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 HYDRATION OF CEMENT
▪ Exothermic reaction - Order of formation of hydration compounds
(product of hydration / order of heat liberation)–C3A>C4AF > C3S > C2S
▪ Bogue’s Compounds
1. Tri-Calcium Aluminate (C3A) – Celite – 11% - formed within 24
hours helps quick setting and evolves high heat of hydration.
2. Tetra-Calcium Alumino Ferrate (C4AF)- Felite – 9% - formed
within 24 hr.
3. Tri- Calcium Silicate (C3S) – Alite – 54 % - formed within 1 week –
provide early strength
4. Di-Calcium Silicate (C2S) – Belite -16% - progressive strength gain
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 MANUFACTURING OF CEMENT
Manufacturing process
Wet Process Dry Process
CM AM CM AM
Wash Mixed in Ball & tube mill
Mixed together
Stored Stored
Stored in silos
in silos in basin

Kiln
Mixing in channel
Slurry
CM – Calcareous material
5 Kiln AM – Argillaceous material
 MANUFACTURING OF CEMENT
• The stored material is fed into ROTARY KILN
Kiln Temp – 1200 to 1400 degree Celcius
Diameter – 2.5 to 3 m
Length – 90 to 120 m
Slope – 1 in 24
RPM – 3
Fuel – Coal (Except for white cement - use oil fuels)
End product – Clinkers – powdered in Ball & Tube mill

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 TEST ON CEMENT – FIELD TEST
• Sample should be collected from 12 different bags (or heaps)
• Uniform gray color with a slight greenish shade.
• Cement should be free from lumps.
• If the hand is plunged into a bag of cement, it should be cool inside the
cement bag.
• When cement is touched or rubbed in between fingers, it should give a
smooth feeling.
• If a small quantity of cement is thrown into the water, it should float some

7 time before finally sinking.

 TEST ON CEMENT – LAB TEST
1. Fineness test
a. Sieve analysis (IS Sieve No. 9, 90 micron)
100 g cement used
% retained should not be greater than 10%.
b. Blane’s air permeability test
Fineness measured in terms of Specific Surface Area (SSA)
Grade SSA (cm2/g)
33 > 2250
43 > 3400
8 53 Much > 3400
 TEST ON CEMENT – LAB TEST
2. Compressive strength test
Cement mortar in mix 1:3 & W/C – 0.4
Cube of size – 7.06 x 7.06 x 7.06 cm (50 sq. cm surface area on each
face)
Curing & testing carried out for 7th ,14th , 28th days
3rd day strength > 11.5 N/sq. mm
For
7th day strength > 17.5 N/sq. mm OPC

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 TEST ON CEMENT – LAB TEST
3. Tensile test
▪ Briquette apparatus used
▪ 600 g cement & W/C – 0.08
▪ 12 Nos. of briquette testedf or 3rd and 7th day
▪ Tensile strength = Failure load / 6.45 sq. cm.
3rd day TS > 2 N/sq. mm.
7th day TS > 2.5 N/ sq. mm.

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 TEST ON CEMENT – LAB TEST
4. Soundness test
▪ Le- Chatelier apparatus used
▪ Conducted to check presence of free lime which causes expansion.
▪ Gap between arms < 10 mm

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 TEST ON CEMENT – LAB TEST
5. Consistency test
▪ 300g cement
▪ Vicat apparatus + Plunger of 1 sq. cm. area
▪ Depth of penetration – 33 to 35 mm from top
( 5 to 7 mm from the bottom) – Std. Consistency
▪ Mould height 40 mm

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 TEST ON CEMENT – LAB TEST
6. Initial & Final Setting Time
Initial Setting Time Final Setting Time
Needle (1 sq. mm. or 1 mm) Needle with annular collar

Depth of penetration – 33 to 35 mm Till the needle cannot make an

from top impression.
W/C – 0.85 time Std. Consistency

Time which start lose plasticity from

Time to lose plasticity completely
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time of addition of water
 TEST ON CEMENT – LAB TEST
6. Initial &Final Setting time test (Continue…)
Gauge time – time between addition of water to filling of mould (3.75
Min to 4.25 Min)
7. Chemical composition test
Lime saturation factor
= % Lime
% Iron oxide + % Alumina + % Magnesia
LSF > 0.65

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Loss due to ignition < 5%