PORTLAND CEM Portland cement is a fine powder which is produced by heating limestone and clay minerals in a kiln and forms clinker. The clinker is grinded to fine powder with addition of small amount of other materials. It is the most commonly used types of cement in the world. It is used as basic ingredients of concrete, mortar.) stucco-ete, It is named as Portland cement because of its similarity to Portland stone which was found on the Isle of Portland in Dorset, England. It is invented by the Joseph Aspdin in 1824.|But the credit for the invention of the modern-Portland cement goes to his son William_ Aspdin in 48405. The Portland cement consists of 4 basic chemical compounds in the table below: | Prema ranted Prrmheyy PrGlciuy Slade} 260 - SiQz Hyalemy SMirbe} 2 Cq0- S*O> oo & ao Co a 1- ORDINARY PORTLAND CEMENT (TYPE I This type of cement use in constructions when there is no exposure (o sulfates in the soil or groundwater. The chemical composition requirements are 0;Magus Ga + Percentage‘gf MgO 5% (max.) 2h + Fineness not lé¥sthan 2250 em2/g 4 * C3S limits ( 42 - 67 )% + C2S limits (8-31 )% * C3A limits (5-14)% + C4AF limits (6 — 12 )% 2. MODIFIED PORTLAND CEMENT (TYPE Ii ) In some application, a very low early strength may be a disadvantage, and for this reason a modified cement was developed (60% low heat Portland cement and 40% ordinary Portland cement) this cement has a higher rate of heat development than that of low heat Portland cement, and a rate of gain of strength similar to that of ordinary Portland cement. This cement is recommended for structures where a moderately low heat generation is desirable or where moderate sulfate attack may occur. 3. RAPID HARDENING PORTLAND CEMENT ( TYPE Ill ) This type develops strength more rapidly than ordinary Portland cement. The initial strength is higher, but they equalize at 2-3 months .Setting time for this type is similar to that of ordinary Portland cement .The rate of strength gain occur due to increase of C3S compound, and due to finer grinding of the cement clinker Rate of heat evolution is higher than in ordinary Portland cement due to the increase in C3S and C34, and due to its higher fineness. Chemical composition and soundness requirements are similar to that of ordinary Portland cement. Uses a) The uses of this cement is indicated where a rapid strength development is desired (to develop high early strength, i.e.( its 3 days strength equal that of 7 days ordinary Portland cement). b) For construction at low temperatures, to prevent the frost damage of the capillary water. VIF (Oogqruction® ©) This type of cement does not use at mass concrete CO" vy) Its 4. LOW HEAT porTLAND yee composition Contains less 5 Percentage of C2g in i i ore ihng ’ ary Portla PRoprtring omparison with ordinary 1 i price and delay the heat of hydration as lower carly strength compared ‘wifi’ ordinary cement, 3) Its fineness ii Snot less than 3200 cm2/ USES came ‘tis used in mass concrete constructions: the rise of tempe”t se Mebumcemaucrete dueltol prasression iniktat of hydration 681 1 ous cracks. So it is important to limit the rate of heat evolule” 3A percentage, nd cement portland ure Seri in this type of construction, by using the low heat cement. 3. SULFATE- RESISTING CEMENT TYPE V) This type '§ similar to ordinary Portland cement but it contains Lower percentage of C3A and C4AF which considers as the most Is by sulfates and higher percentage of silicates affected as ordinary Portland cement. For this type of in comparison yi cement C2S represents a high proportion of the silicates, CTAF is _form- more resistance to sulfate than C3A: because _a layer w which surround. _the-free-C3A-teadingto_reduce its affect_by sulphates-— Properties * Low early strength. * Its resulted heat of hydration is little higher than that resulted from low heat cement. * Its cost is higher than ordinary Portland cement — because of the special requirements of material composition, including addition of iron powder to the raw materials. 2ho bloD Blast FURNACE CEM TYPE * omnent “onsists of an intimate mixture of Portlan¢ Slag — ; 4 nulated blast furnace slag, 5 iron Chemically fac Product in the manufacture of Pit 199 IS & mixture of 42% time, 30% silic™ ides D Peni and 1% alkalis, that is, the same © pms AP Portland cement but not in the same Be is : um percentag, A use in this type of Cem Gnd EE rcaca nig ge cn Standard ASTM C595 to be between 25-65%, PROPERTIES _ _, SOPERTIES. Ats e: 8th is lower than that of ordi Strength is equal at late ages (about 2 months). - The requir, are similar. heir y cement, but f ¢Ments for fineness and setting time and soundness those of ordinary Cement. ~ The workability is higher than that of ordinary cement. ~ Heat of hydration is lower that of ordinary cement. ~ Its sulfate resistance is high, Uses ~ Mass concrete ~ It is possible to be use in constructions subjected to sea water (marine constructions). - May not be use in cold weather concreting. MANUFACTURE PROCESS OF CEMENT 1, Mixing of raw material fal otThe maj, jor are Calan Sie Materials used in the manufacture of cement av different tory,’ Hon and Aluminum. These minerals ar¢ ¥S° ws rm mDer the avenge i ~ ‘Table sho’ a raw maieriale Availability of the minerals. TaD! for facture ne Portland cement manuf a Argillaccous Materials Aluminum Iron Ma Clay [Clay ay, ra i Sang — Sha [tron ore Aregoniig >] — Seed Fy as —| — Mill scale m Aluminum ore refuse | Shale p. Blast fumace and argillaceous raw materials are firstly | the gyratory crushers to get 2-5em size pieces ly. The crushed materials are again grinded to get sine 0 ball or tube mill. Each finely grinded material is in hopper after screening,the average composition of the final product is maintained Calcareous Argillaceous materials materials | bot is 2 Jaw Jaw [crusher] Crusher 1 Bin Bin Mixing Pulverizing [Rotary AI" ype Kiln Portland Clinker Cemei Grinder properly. Fig: Manufacture of Cement by Dry Process b) Wet Process The raw materials are firstly crushed and made into powdered form and stored in silos. The clay is then washed in washing mills to remove adhering organic matters found in clay. The powdered limestone and water washed clay are sent to flow in the channels and transfer to grinding mills where they are completely mixed and the paste is formed, i.e., known as slurry. The-grinding— precess-can_be-done_in_ball or tube-milt or-even_both. Then the slurry is led into collecting basin where composition can be adjusted. The slurry contains around 38-40% water that is stored § og {¢in storage tanks and kept ready Calcareous Argillaceous for the rotary kiln. ufacture of Cement by Wet Process parison of dry process and wet process of Cement _ Wet process Any type of raw material High con sumptionTime of process Lesser Higher Quality Inferior Superior quality quality Cost of production High Low Overall cost Costly Cheaper Physical state Raw mix liqui (solid) Slurry (liquid) 2. Burning of Raw Materials The burning process is carried out in the rotary kiln while {aw materials are rotated at 1-2rpm at its longitudinal axisj Thi n ini : eel tubes having the-diameter of 2/5- jffers from 90-120meter. The inner side iln isfined with refractory brigKs. The kiln is Sappyted on ithe €olumy of masonry or concreté and rested oral fr Bearing i radient of 1'in 25te1 in 30,/ slurry of wet process is he raw mix of dry process injected into the kiln from the upper end. The kiln is heated with the help of powdered coal or oil or hot gases from the lower end of the kiln so that the long hot flames is produced. As the kiln position is inclined and it rotates slowly, the material charged from upper end moves towards lower end at the speed of 15m/hr. In the upper part, water or moisture in the material is evaporated at 4000C temp, so this process is known as Drying Zone. The central part i.e. calcination zone, the temperature is around 5 rf 10CaC03= Cad +C92 The low eee | , lower part (clinkering at h Es 1500-17000C where lime Vo yeaa in between aluminates and calej aud clay ar 0 yielding, calcium on alcium silicates. This aluminates and silicates of ‘ (0 gather to form small and hard stones are-known as clinkers, Phe size of the-clinker-is-varies trom S-tonmr. The ‘ inkering zone has the temperature 500- 7 7 ie} calcium —Time=and_ clay_reacts—to—y1e! fmuminates and he and calciuny silicates. 7 is products of al et 0 I] an — 2CaO + SiO2 = Ca2Si04 (declaim silicate (C2S)) 3CaO + Si02 = Ca3Si05 (tricalcium silicate (C3S)) 3CaO + AI203 = Ca3AI206 (dicalcium aluminate (C2A)) 4CaO + AI203 + Fe203 = Ca4AI2Fe2010 (tetracalcium aluminoferrite(C4AF)) The clinker coming from the burning zone are very hot. To bring down the temperature of clinkers, air is admitted in counter current direction at the base of the rotary kiln, The cooled clinkers are collected in small trolleys. 3. Grinding of Clinkers The cooled clinkers are received from the cooling pans and sent into mills. The clinkers are grinded finely into powder in ball mill or tube mill. Powdered gypsum is added around 2-3% as G r~eawlaAretarding a; : is ‘inal grinding. The btained produc! is cement eee I grinding. The final obtained product wate does not settle quickly when comes in contact with r . _ C ‘er the initial setting time of the cement, the cement rs es stiff and the gypsum retards the dissolution 0! tri- Ge cium aluminates by forming tricalcium sulfoaluminate which is insoluble and prevents too early further reactions of setting and hardening. 3Ca0.AI203 + xCaSO4.7H20 = 3Ca0.A1203.xCaS04-720 4, Storage and packaging from which it is marketed The grinded cement is stored in silos, either in container load or 50kg bags-