Cement:

Cement is essentially a finely powdered mixture of calcium

silicate and aluminates along with small quantities of gypsum
which sets into a hard stone like mass when treated with water.
Cement is essentially a finely powdered mixture of calcium silicate
and aluminates along with small quantities of gypsum which sets into a
hard stone like mass when treated with water.
Lime + clay + water = cement
Raw material Raw materials required for the manufacture of cement are :
1) Limestone (CaCO3 ) ,
2) Clay which provides both silica and Alumina
3) Gypsum and Small amount of magnesia and iron oxide are also required for
imparting suitable colour to cement.

Average composition of Portland cement :

Lime (CaO) 50-60%
Magnesium oxide (MgO) 2-3%
Silica (SiO2) 20-25%
Ferric oxide (Fe2O3 ) 1-2 %
Alumina (Al2O3 ) 5-10%
Sulphur trioxide (SO3) 1-2%
Strong heating of clay andlime results in their fusion followed by the formation
of cement clinker which is then mixed with 2-3% by weight of gypsum(CaSO 4.
2H2 O). This leads to the formation of cement.
Types of raw material:
• Primary : the raw material which forms 85% of clinker
• Secondary : the raw material which forms less than 15% of clinker
• Tertiary: the substance which are used for the other purpose than clinker
formation.
Manufacture of cement:
• (1) Wet process
• (2) Dry process
The wet process is preferred when the raw materials i.e. limestone and clay are
soft, climate is humid and fuel is cheap. The dry process is preferred when the
raw materials are hard.
(1) The raw materials are first crushed separately in a suitable machine. They
are then mixed in the required proportion( 3 parts limestone + 1 part clay) and
grounded together finely. This grinding is done either by the dry process or by
the wet process.
(2) In the wet process, the clay is washed with water in a wash mill to remove
flint and other foreign substances. It is then mixed with requisite quantity of
limestone and pulverized in a special mill. The resulting pasty mass is then
thoroughly homogenized to get raw slurry containing about 40% water.
(3) In the dry process, the raw materials are dried and mixed in desired
proportion. The mixture is then finely powdered and passed through 300 mesh
sieves and homogenized with the help of compressed air. The homogeneous
mass is called raw meal.
(4) The slurry or raw meal is introduced into the upper end of a rotary kiln by
means of screw conveyer. The kiln consist of an inclined steel rotating cylinder,
150-200 ft long and about 10 ft diameter lined inside with fire bricks. The
charge travel downwards slowly due to the rotatory motion given to the kiln and
is heated by burning coal dust which is blown in front from the lower end. The
charge takes about 2-3 hours to cover the entire journey in the kiln.
The following changes occur:
(1) In the upper part of the kiln, the temperature is around 1000-1100K .Here
the charge loses all its water due to evaporation by hot gases.
(2) In the middle of the kiln, temperature is around 1100-1200 K. Here
limestone decomposes to form calcium oxide and carbon dioxide.
CaCO 3——–> CaO + CO2
(3) ) The lower part of the kiln, from where coal dust is blown in is the hottest
with the temperature ranging between 1770-1870 K. As the charge reaches
here, chemical combination takes place between lime, alumina and silica to
form calcium silicate and aluminates
. 2 CaO + SiO2 —> 2 CaO.SiO2
3 CaO + SiO2 ———> 3 CaO.SiO2
3 CaO + Al2O3 ——> 3 CaO.Al2O3
2CaO + Al 2O3 ——> 2 CaO.Al2O3
Due to very high temperature in this zone, about 20-30 % combines with solid
mass to form grey coloured balls called cements clinkers. The hot clinkers are
cooled by cold air and are mixed with 2-3 % gypsum and finely powdered to
325 mesh size in grinding machine. The fine powder called the Portland cement
is sieved and packed in bags.
Setting of cement :
The important constituents present in Portland cement are dicalcium silicate
( Ca2SiO4 ) , tricalcium silicate ( Ca3 SiO5) and tricalcium aluminate (Ca3 Al2O6 ).
When water is added to cement, an exothermic reaction occurs. During this
process , cement reacts with water to form a gelatinous mass which slowly sets
into a hard mass having three dimensional network structure involving - Si-O-
Si- and -Si-O-Al chains.
Tricalcium silicate sets quickly and develops considerable strength within a few
days. Dicalcium silicate sets slowly and develops appreciable strength after a
month or so. Tricalcium aluminate sets instantaneously in presence of water.
The internal strength acquired by cement is primarily due to the setting of
tricalcium aluminate.
Wet process for Portland cement:
Dry process for manufacture of Portland cement :
Portland Cement:

The Portland cement is the most basic and the most commonly
used cement in the world the Portland cement was formerly
known as ordinary Portland cement and is made by adding
gypsum into the clinker.

Simple way for representing BLOCK DIAGRAM for

manufacturing Portland cement:
Types of Cement:
1. Ordinary Portland Cement (OPC):
OPC Cement or Ordinary Portland Cement (OPC) is manufactured by grinding a
mixture of limestone and other raw materials like argillaceous, calcareous,
gypsum to a powder.

This cement is available in three types of grades, such as OPC 33 grade, OPC 43
grade and OPC 53 grade. OPC is the most commonly used cement in the world.

This type of cement is preferred where fast pace of construction is done. However, the
making of OPC has reduced to a great extent as blended cement like PPC has
advantages, such as lower environmental pollution, energy consumption and more
economical.

2. Portland Pozzolana Cement (PPC)

Portland Pozzolana Cement is a variation of Ordinary
Portland Cement. Pozzolana materials namely fly ash,
volcanic ash, are added to the OPC so that it becomes
PPC. Pozzolana materials are added to the cement in
the ratio of 15% to 35% by weight.

PPC has a high resistance to different chemical assaults on concrete. It is

widely used in construction such as:

 Marine structures
 Sewage works
 Bridges
 Piers
  Dams

3. Rapid Hardening Cement:

Rapid Hardening Cement is made when finely grounded C3S is

displayed in OPC with higher concrete.

It is commonly used in rapid constructions like the construction

pavement.

4. Extra Rapid Hardening Cement

As the name suggests, Extra rapid hardening cement gains strength

quicker and it is obtained by adding calcium chloride to rapid hardening
cement.

Extra rapid hardening cement is widely used in cold weather concreting,

to set the cement fast. It is about 25% faster than that of rapid hardening
cement by one or two days.

5. Low Heat Cement

Low heat cement that is prepared by keeping the percentage of

tricalcium aluminate below 6% and by increasing the proportion of C2S.

This low heat cement is used in mass concrete construction like gravity
dams. It is important to know that it is less reactive and the initial setting
time is greater than OPC.

6. Sulfates Resisting Cement:

This type of cement is manufactured to resist sulfate attack in concrete.
It has a lower percentage of Tricalcium aluminate.

It can also be used in concrete surfaces subjected to alternate wetting

and drying like bridge piers.

7. Quick Setting Cement

Quick setting cement which sets faster than OPC but the strength
remains the same. In this formula, the proportion of gypsum is reduced.

Quick setting cement is used for constructions that need a quick setting,
like underwater structures and in cold and rainy weather conditions.

8. Blast Furnace Slag Cement

This type of cement is manufactured by grinding the clinker with about

60% slag and it is similar to Portland cement. It is used for constructions
where economic considerations are important.

9. High Alumina Cement

High alumina cement is obtained by mixing calcining bauxite and lime

with clinker during the manufacturing process of OPC.

The most common uses are in constructions that are subject to high
temperatures like a workshop, refractory, and foundries.

10. White Cement

This type of cement is manufactured by using raw materials that are free
from iron and oxide. White cement needs to have lime and clay in a
higher proportion. It is similar to OPC but it is more expensive.

OPC PPC
It has higher strength than The strength of PPC is good than OPC in
PPC in the initial stage. long terms.
The hydration process is slower than
It has high heat of hydration
OPC resulting low heat of hydration.
making it unfavorable for mass
Therefore, it is suitable for mass
concreting.
concreting.
The presence of sulphates, It has low percentage of sulphate alkalis,
alkalies, chlorides, etc. is chlorides, magnesia and free lime in its
higher and less resistant than composition, which makes the concrete
PPC. durable.
OPC is not favorable in Show greater resistance to aggressive
aggressive weather. weather.
OPC cement are available in
three grades, such as 33 PPC is available in any specific grades.
Grade, 43 Grade, 53 Grade
It is slightly costlier than PPC. Cheaper than OPC.
Generally used for plaster and Generally used to make wall of houses
 dhalan of floor .
Cement industry in Nepal
- The scope for cement industry in Nepal is good as Nepal is rich in
limestone deposit with good consistent quality of CaO ( calcium oxide
not less than 44%) needed to make good quality cement grade clinker.
The Cement Industries grew by 15% in terms of total revenue during
2014-15 reaching 45% of national demand.
- Cement industry is one of the industries established in Nepal that aims
to use domestic limestone as the prime raw material. ...
The domestic production started in 1975 with the establishment of Himal
Cement Company Limited.
Now, there are 124 cement industries legally registered in Nepal.
- Hongshi-Shivam Cement Private Limited, a Nepal-China joint venture company,
is the largest cement factory in Nepal with a daily production capacity of 6,000 tons
- According to the Google’S view 10 best cement brand in Nepal are :

 1. Shivam Cement

 2. Sarbottam Cement

 3. Jagadamba Cement

 4. Hongshi Shivam Cement

 5. United Cement

 6. Brij Cement

 7. Ambe Cement

 8. CG Cement

 9 Tansen Cement

 10. Arghakhachi cement

- Nepali cement industries are not being able to run as per their
capacity. The main problem is the lack of electricity due to
which the industries are not able to fully capitalise their potential.
Similarly, problems in supply of raw materials and issues related
to labour and transport also hinder us from time to time.

• Let’s move to workbook:

• F.m= 20 points

1. What is cement? What is the raw material for cement production? Discuss.
(1+1)
2. What are the major steps in cement production? Describe each step in detail.
(2)
3. Write are differences between OPC and PPC cement? (2)
4. Draw the flow sheet diagram for manufacture of Portland cement.(2)
5. Mention major consideration while selecting raw materials for cement.(2)
6. What is cement clinker? Mention some additives in clinker to produce
cement.(1+2)
7. Classify cement on the basis of constituents.(2)
8. Write an essay about scope and challenge for the construction of cement
industry in Nepal.(5)