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It is the time required to change the stage of cement paste from fluid to a rigid One.
False set is used to describe the premature stiffening of the cement paste which some time
occurs within 10-15 minutes of mixing with water which is caused by dehydration of Gypsum
dehydrated due to high temp. during cement grinding process. However the plasticity of the
paste is regained on remixing.
This refers to rigidity of the cement paste which some time occur Within 5-10 Minutes of
mixing with water and is referred To as Irreversible rigidity. This is caused by the formation of
aluminate hydrate due to high content of C3A and or a too small amount of easily soluble
calcium sulphate. Cement Produced with this behavior is unsuitable to use.
When cement is mixed with water, the chemical reaction between the calcium Silicates in
cement with water producing gel like calcium silicates hydrate and Calcium hydroxide is called
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“ Hydration of cement paste “ This hydration Reaction is an exothermic reaction which means
heat is liberated. This is called heat of hydration in cement paste. The quantity of heat
liberated in quite Appreciable and due consideration to be taken while making mass concrete
construction. During cooling of the concrete after hydration reaction, cracks can develop due
to thermal gradients if enough design consideration are not taken care.
The term ‘drying shrinkage’ can be defined as the decrease in length of the cement test
specimen, where the decrease is caused by any factor other than externally applied forces
under stated environmental conditions. The terms includes the net effect of a variety of
phenomena, including hydration of the cement, tending to bring about both increase and
decrease in length during the period in which the cement test specimens are stored under
stated environmental conditions.
This indicates the volume of air (and other gases, if any) in a freshly mixed cement mortar,
expressed as a percentage of total volume of the mortar. The test for air content is essential to
assess the cement for its requirement with respect to air-entraining requirement.
The term is used to define the maximum tensile stress measured in force per unit cross
sectional area that a cement mortar specimen can resist before it ruptures. Concrete, a
mixture of loosely bonded sand and gravel has a low tensile strength because of its coarse
structure and hence must be reinforced to withstand the tensile stresses encountered in
structure.
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What is Flexural Strength?
Generally compressive strength is used as an overall measure for the quality of cement and
concrete. However, in specific applications like roads and runways flexural strength is more
important. The flexural strength of cement mortar / concrete is determined by subjecting a
plain prison / beam to flexure under transverse loads. Flexural strength is more sensitive to
inadequate curing and type of aggregate since the effects of non-uniform shrinkage adversely
affects flexural strength.
What is Impermeability?
Impermeability plays a primary role on the durability of concrete, which in turn depends on
the water cement ratio. In the air entrained concrete, minute air bubbles are trapped inside,
which improves the workability of the mix and also function as minute safety values by
providing room for the free water in hardened concrete to escape.
Sulphate can be found in natural and industrial wastes as well as in soils. Soluble sulphates
can react with lime and aluminates present in the hardened Concrete and form respectively
gypsum and ettringite. Both reactions involve expansion and consequent concrete
deterioration. Sulphate Resisting Cement are characterized by a low C3A content to minimize
the risk of ettringite formation.
Hydration reaction of cement develops heat. When cement is used in the Production of mass
concrete, temperature gradients generate between core and surface of the mass cause strains
and may eventually lead to cracking. Low heat cements have a reduced heat of hydration
obtained by altering the chemical composition to have low C3S and low C3A contents. This
type of cement is recommended for use for mass concrete production or for large structural
sections.
Water with low salinity or a high content of carbon dioxide are capable to dissolve hydration
lime presence in concrete and can damage the structure. Leaching resistant cement is
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produced with low C3S content which has a low development of calcium hydroxide or lime.
Their use is suggested in hydraulic works like basins, river barriers and sides etc.
Some aggregates may contain forms of reactive amorphous silica. In the presence of water,
this can react with the soluble alkali content of cement and form locally an expansive gel that
can deteriorate the concrete. In such case cements are produced to have lower content of K2O
and Na2O or to add some special pozzolana or slag material which can immediately react with
alkali and prevent subsequent reaction with aggregates in the concrete.
In blended cement production, some portion of the clinker component is replaced with a
suitable pozzolana or a slag or limestone or fly ash etc. The use of these mineral will improve
the durability and the pore structure of the hardened concrete by lowering its lime content and
porosity as a consequence of the enhanced development of calcium silicate hydrates.
Oil well cement is developed for use in oil and gas wells and is designed to set at high
temperatures and pressures in well grouting. They can also be used for sealing water wells,
waste disposal pits and geothermal wells. In order to meet the above requirements oil well
cements are made with special composition or additives use enabling to have low permeability,
good bond between rock and casing, to withstand and set under high temperature and
pressure and to protect the casing against corrosion and collapse.
As the name suggests the color of these cement is white and the mechanical properties are
comparable to those of gray cement. It is produced with suitable selection of raw materials in
which coloring elements like Iron, Chromium and manganese must be kept at the lowest
possible level. In order to ease the clinker burning, addition of fluoride is used as a mineraliser.
This kind of cement is used mainly for architectural purposes in white or colored concrete
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What is Masonry cement?
The masonry cements are those, which have low early and late strength, low shrinkage,
limited water permeability, high water retention, excellent plasticity and cohesiveness in the
fresh stage and better workability. This cement is produced by a low to medium clinker
content and the use of limestone or other mineral additions and use of air entraining agents.
Quality of cement
The quality of cement is judged by its performance in combination with water as a binder in a
material and it includes properties like setting behavior, strength development, heat
development, volume stability and durability. It is very essential to ensure that the
contribution to these properties of the cement is kept at a certain level and with variations as
small as possible to meet the demand expressed in the standard specifications and to comply
with the wishes and needs of the market.
These factors are associated with the characteristics of the materials being used for the
cement viz. Clinker, Gypsum and Additives and how they are altered during grinding and
storage.
The main raw material components required for the Cement manufacturing are the “
Calcareous ” and “ Argillaeous ” materials. The Calcareous material mainly provide CaO
( Calcium Oxide ) plus some part of other oxides. Wheras Argillaeous material mainly provide
SiO2 ( Silicon Di Oxide), Al2O3 ( Aluminium Oxide) and Fe2O3 ( Ferric Oxide).
In case of deficiency in any components then corrective materials rich in SiO2 like Sand, rich
in Al2O3 like Bauxite and rich in Fe2O3 like Iron Ore or Laterite are added in Raw mix to meet
the specification of Clinker and Cement as per International norms.
In order to regulate the setting time of the Cement, Gypsum – CaSO4.2H2O is added along
with Clinker in the final cement grinding.
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Designation Lime Stone High Grade Chalk Sandy Marble Calcareous Phosphatic Dolomitic
Lime Stone Lime Stone Marl Lime Stone
Lime
Stone
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Loss % 42.9 42.9 42.26 35.23 43.14 30.6 42.0 37.5
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Note: Of the above So3, K2O, Na2O, MgO and Cl components are undesirable for the Cement process and should be as
minimum as possible. As a consequence, Dolomitic Limestone is not desirable.
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F% 0.01 0.01 0.01 0.01 0.01 0.01 0.01
Note: Of the above So3, K2O, Na2O, MgO and Cl components are undesirable for the Cement process
and should be as minimum as possible.
Designation BauxiteType BauxiteType BauxiteType Pyrite Hematite Umber Iron Sand Sand
I II III Ash Slag Stone
SiO2 % 4.3 3.3 3.1 7.8 11.0 32.1 21.5 94.7 80.2
Al2O3 % 56.0 56.6 57.6 1.0 3.1 4.3 8.8 2.9 8.37
Fe2O3 % 22.1 9.4 15.8 84.3 77.7 37.5 57.6 0.24 3.26
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Mn2O3 % Nd Nd 0.03 0.04 1.31 5.75 Nd 0.03 0.01
Note: Of the above So3, K2O, Na2O,MgO and Cl components are undesirable for the Cement process and
should be as minimum as possible.
In the Cement Manufacturing Process, the selected raw material components are blended,
proportioned and finely ground to a powder form called as Raw Meal, which often have a
fineness of 14 – 16 % residue on 90-micron sieve. This material is heated in stages and finally
in a rotary Kiln at about 1400 Deg C. In the Kiln after the completion of chemical reactions a
sintered mass is produced which is called as Clinker. This semi-finished product is again
proportioned with Gypsum and then ground to a powder, which is called as Cement.
The following chemical reactions and phase transformations take place at different
temperature ranges.
< 100 Drying and elimination of Free water from raw H2O ( Liq) » H2O ( Gas)
material components
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600 – 1000 Dissociation of limestone and formation of CaCO3 » CaO +
intermediate products CS and CA CO23CaO+2SiO2+Al2O3 »
2(CaO.SiO2) + CaO.Al2O3
Common Control factors and their influence on the property of Clinker and Cement
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(SM) - Silica S / (A+F) 1.9 – 3.2 2.3 – 2.7 A higher SM will:
Modulus
-
Result in harder burning and High
fuel consumption.
-
Tends to cause unsoundness or
free CaO
-
Causes difficulty in coating
formation and hence the radiation
from Kiln shell will be very high.
-
Reduces the service life of
refractories.
-
Results in slow setting and
hardening of the cement.
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(AM) Alumina A / F 1.5 – 2.5 A higher AM will :
Modulus.
-
Imparts harder burning and
entails higher fuel consumption.
-
Increases the proportion of C3A
and reduces C4AF.
-
Increases both C3S and C2S
-
Reduces the liquid phase and Kiln
output.
-
Tends to render cement quick
setting and strong at early ages.
-
Increases viscosity of the liquid
phase at constant temperature.
-
If AM is too low and raw mix is
without free silica, clinker sticking
and balling is high.
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(LSF) – Lime 100 C / (2.8S 0.66 – 0.92 – 0.96 A higher LSF will:
Saturation +1.65A +0.35F) 1.02
Factor. when AM is
>0.64
-
100C / ( 2.8 S +
Makes it difficult to burn the raw
1.1 A + 0.7 F )
mix.
when AM < 0.64
-
Tends to produce unsound cement
100 (C+0.75 M)
ie.high amount of free CaO
/ 2.8S + 1.18 A
presence.
+0.65 F when M
< 2.0 -
Increases the C3S content.
100 ( C + 1.5M)
/ 2.8 S + 1.8 -
A+0.65 F when Reduces the C2S content
M > 2.0
-
Causes slow setting with high
early strength.
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Free Silica in Sf 0–3% As low as possible A higher Sf will:
different
forms.
-
Increases the power and fuel
consumption.
-
Causes difficulty in coating
formation.
-
Deteriorates the refractory lining.
-
Increases the radiation from the
kiln shell.
-
Increases the kiln exit gas
temperature.
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Magnesium M 0 – 5% 0–2% A higher M will:
Oxide (MgO)
-
Reduces viscosity and surface
tension of clinker liquid and
increase ionic mobility.
-
Favors the dissolution of C2S and
free CaO at higher temperature
and lets C3S forms more quickly.
-
Tends to ball easily in the burning
zone, which affects the Kiln
operation.
-
Leads to unsoundness by forming
periclase crystals when M > 2.0%
-
Increases C3S and melt but has
no effect on C2S(M < 2 %)
-
Volume instability when 2>M>6
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Titanium TiO2 0 – 4% 1.5 – 2.0% A higher TiO2 will:
Oxide (TiO2)
-
Results in sharp reduction in C3S
content with equal gain in C3S
content and appreciable variations
in other phases.
-
Reduces viscosity and surface
tension of the melt.
-
Reduces grain sizes of alite and
belite.
-
Causes slower setting and lower
early strength.
-
Forms darker color clinker.
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Manganese Mn2O3 0 – 4% 1.5 – 2.0 % A higher content will:
Oxide
-
Reduces the viscosity of the melt.
-
Reduces the size of the alite
crystals.
-
Reduces early strength.
-
Accelerates the combination
reaction of CaO in solid phase.
-
Lowers the apperance temperature
of the liquid.
-
Decreases hydraulic strength.
-
Tends to release free CaO by the
destruction of C3S.
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Chromium Cr2O3 0–2% 0.3 – 0.5 % A higher content will:
Oxide
-
Reduces viscosity and surface
tension of the clinker liquid.
-
Forms alite rapidly and increases
its crystals.
-
Decomposes C3S into CaO free
and C2S.
-
Increases the stability of A and
decreases that of F.
-
Increases the initial hydraulic
activity.
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Alkalies K2O + Na2O 0–1% 0.2 – 0.3 % A higher content will:
-
Improves the burnability at lower
temperature and deteriorates at
higher temperature.
-
Increases liquid and coating
formation.
-
Lowers the solubility of CaO in the
melt.
-
Breaks down the alite and belite
phases.
-
Creates operational problems like
coating and jamming in
preheaters.
-
Will lead to expansion when total
alkali level > 0.60% in cement.
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Sulfur Su 0–4% 0.5 – 2.0 % A higher content will:
compounds
-
Acts as an effective mineralizer
and modifier of the alkali – recycle
by forming less volatile
compounds.
-
Lowers the appearance
temperature of liquid phase by
100 Deg C, decreases its viscosity
and surface tension and increases
ionic mobility of oxides.
-
Increases belite formation.
-
Decomposes alite at 1250 DegC if
high alkali sulphate are present.
-
When SO3 . 2.5 – 4 %, causes
sulphate expansion.
-
Improves burning of raw mix at
lower temperature and deterioate
the same at higher temperatures.
-
Decreases hydraulic and
mechanical strength.
21
Phosphorous P2O5 0–1% 0.3 – 0.5 % A higher content will:
Pentoxide
-
Accelerates the clinkerization
reaction.
-
Reduces the intensity of internal
cycle.
-
Reduces early strength.
-
Reduces C3S content.
-
Lowers the temperature of C3S
formation.
-
Decreases the mechanical
strength of the clinker.
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Chloride Cl 0 – 0.6 0 – 0.015% A higher content will:
%
-
Operational and process related
problems expected.
-
Increases liquid formation and
melting point of the absorbed
phase is drastically changed.
-
A bypass system is required if
value >0.015%
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K2O % 0.08 1.18
Mn2O3 % Nd 0.64
P2O5 % Nd 1.52
Cl % Nd 0.16
F% Nd 0.35
Based on the availability of different types of Raw Material components, a composite Raw Mix
design to be made ( Raw Meal )which should have the following resultant chemical
composition. With this composition high quality Type I OPC - clinker can be manufactured
which will have the composition as mentioned in the table below.
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K2O % 0.15 – 0.25 0.60 – 0.80
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