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    Cement 2021

    Uploaded by

    Mahmoud shendy
    The document discusses different types of cement, their production processes, and testing methods. It begins by defining mortar and its use in building construction. It then outlines the raw materials used to make Portland cement, including limestone, clay, and iron oxides. The production process is described as involving crushing, grinding, heating in a kiln, and grinding of the clinker product. The main cement components are identified and their chemical reactions with water, which cause solidification, are explained. Common tests for cement, including hydraulic index and setting time, are outlined. Finally, different types of cement are defined such as rapid hardening, sea water resistant, iron slag, and chemically resistant cement.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Cement 2021

    Uploaded by

    Mahmoud shendy
    3 views20 pages
    The document discusses different types of cement, their production processes, and testing methods. It begins by defining mortar and its use in building construction. It then outlines the raw materials used to make Portland cement, including limestone, clay, and iron oxides. The production process is described as involving crushing, grinding, heating in a kiln, and grinding of the clinker product. The main cement components are identified and their chemical reactions with water, which cause solidification, are explained. Common tests for cement, including hydraulic index and setting time, are outlined. Finally, different types of cement are defined such as rapid hardening, sea water resistant, iron slag, and chemically resistant cement.

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    The document discusses different types of cement, their production processes, and testing methods. It begins by defining mortar and its use in building construction. It then outlines the raw materials used to make Portland cement, including limestone, clay, and iron oxides. The production process is described as involving crushing, grinding, heating in a kiln, and grinding of the clinker product. The main cement components are identified and their chemical reactions with water, which cause solidification, are explained. Common tests for cement, including hydraulic index and setting time, are outlined. Finally, different types of cement are defined such as rapid hardening, sea water resistant, iron slag, and chemically resistant cement.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    3 views20 pages

    Cement 2021

    Uploaded by

    Mahmoud shendy
    The document discusses different types of cement, their production processes, and testing methods. It begins by defining mortar and its use in building construction. It then outlines the raw materials used to make Portland cement, including limestone, clay, and iron oxides. The production process is described as involving crushing, grinding, heating in a kiln, and grinding of the clinker product. The main cement components are identified and their chemical reactions with water, which cause solidification, are explained. Common tests for cement, including hydraulic index and setting time, are outlined. Finally, different types of cement are defined such as rapid hardening, sea water resistant, iron slag, and chemically resistant cement.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 20

    Faulty of Engineering

    Cairo University

    Building Materials (Cement)


    Tutorial (1)

    By
    Eng. Rahma H. Thabet
    Assistant Lecturer of Chemical Engineering
    10/12/2021 1
    Content
     Mortar and Solidification of mortar
     Portland Cement Raw Materials
     Production Process
     Cement Components
     Reactions of Cement Components with Water
     Testing of Cement
     Types of Cement

    10/12/2021 Eng. R. H. Thabet 2


    Mortar
    Function: Coherence of building components (rocks
    and gravel)
    Types: Aerated or Hydraulic to set and harden
    Aerated Mortar Hydraulic Mortar
    Reacts with Air to form harder mass Reacts with Water to form harder
    mass

    Slacked lime(Ca(OH)2 + Sand + CO2 Reaction of Cement with water


    (in air) = CaCO3

    If the building is not exposed to water If the building is exposed to water


    or heavy loads or heavy loads
    10/12/2021 3
    Portland Cement Raw Materials
    • Lime stone (CaCO3)
    • Clay (Kaolin Al2O3SiO2.2H2O)
    • Iron Oxides (Fe2O3)

    • There are two types of process: wet or dry process

    10/12/2021 Eng. R. H. Thabet 4


    Manufacturing Process
    Block flow diagram
    Gypsum (5%)

    Crushing Grinding Reaction Clinker Clinker


    Clinker Packing
    Raw in kiln cooling grinding
    Materials
    Cement
    final product
    Cooling
    Clinker: circular porous product, with a diameter of 3-6 cm air

    10/12/2021 Eng. R. H. Thabet 5


    400 C°
    1500 C°

    10/12/2021 6
    Production Processes
    Cylindrical Rotary Furnace
    Length 60 to 120 m- Diameter 3 to 4 m
    Tilted from the horizontal by 5 - 6%
    Rotation: one revolution per minute

    Reactions along the furnace (kiln)


    1- Remove physical water 100℃
    2- Remove Chemical water ( Al2O3.SiO2.2H2O)
    3- Calcination CaCO3=CaO +CO2 (800-900℃)
    4- Reaction of Clinker CaO+Al2O3+SiO2 (1400℃)

    10/12/2021 Eng. R. H. Thabet 7


    Cement Components
    1. Tri calcium silicate C3S
    2. Tri calcium aluminate C3A
    3. Di calcium silicate C2S
    4. Tetra calcium aluminoferrite C4AF

    C=CaO F=Fe2O3 S=SiO2 A=Al2O3

    Ferric Oxide: to lower clinker formation temperature around 1300 ℃


    Calcium Sulphate (gypsum): to retard the reaction of the cement with water

    10/12/2021 Eng. R. H. Thabet 8


    Reactions of Cement Components
    with Water
    1. Tri calcium silicate:
    -Reacts in short time with water forming (calcium hydroxide + calcium
    hydro silicate).

    2. Tri calcium aluminate:


    • Reacts with water and some of the calcium hydroxide produced from
    the previous reaction producing (calcium hydro aluminate) which
    solidifies rapidly within a period of 6 minutes to 3 hours, where the
    mortar sets. This is called the setting period.

    10/12/2021 Eng. R. H. Thabet 9


    Reactions of Cement Components
    with Water
    Gypsum retards this period, since it consumes some of the tri calcium
    aluminate and forms a weak cohesive compound
    3. Di calcium silicate:
    - Reacts slowly with water producing (calcium hydroxide + silicone
    hydroxide)

    - Reaction takes place in the first 4 weeks

    - During the next months and years, the reaction of the calcium silicate
    proceeds as long as the required humidity is available and thus
    hardening increases.
    10/12/2021 Eng. R. H. Thabet 10
    Testing of Cement
    1.Hydraulic Index

    1.7-2.2
    If <1.7  CaO ↓  C3S ↓ which is important for the setting process
    If >2.2  CaO ↑  free lime CaO + H2O Ca(OH)2 +Heat ( mortar cracks)

    Lime Saturation Test

    0.66-1.02

    10/12/2021 Eng. R. H. Thabet 11


    Testing of Cement
    2.Silica Index

    2-2.5

    <2  SiO2 ↓  C3S & C2S ↓  setting & hardness ↓


    > 2.5  SiO2 ↑  C3S & C2S↑ setting & hardness↑

    10/12/2021 Eng. R. H. Thabet 12


    Testing of Cement
    3. Magnesium oxide percentage:
    Should not exceed 5%, since its increase means that the quality of
    the used limestone is poor.

    4. Powder size ‫النعومة‬:


    The prepared cement should be very fine, such that at least 98% of it
    should pass through mesh 200 (200 pinch per linear inch).

    10/12/2021 Eng. R. H. Thabet 13


    Testing of Cement
    5. Setting time:
    In this test, the time at which a standard needle loaded with a standard
    weight cannot penetrate the prepared sample is measured.

    10/12/2021 14
    Testing of Cement
    6. Volatile materials percentage:
    • This percent should not exceed 5%,
    • indication of the presence of some humidity in the cement before
    usage

    7. Sulpher trioxide percentage:


    Should not exceed 3.5% (equivalent to gypsum%=6.5%), since the increase of
    gypsum content retards the solidification process, more than required hardening.

    10/12/2021 15
    Types of Cement
    Rapid hardening Portland cement

     Contains high %C3S which causes rapid solidification.

     Very fine, 99.5% of it pass through mesh 320.

    10/12/2021 Eng. R. H. Thabet 16


    Types of Cement
    Sea water resistant cement:

    Silica is added to reduce the amount of C3S formed

    This will decrease the formation of Ca(OH)2 in concreate pores


    making it more resistance to sulfates in sea water

    10/12/2021 Eng. R. H. Thabet 17


    Types of Cement
    Iron slag cement:
     Consists of iron slag + Portland Cement

     Lower in quality than OPC as the furnace slag is in the form of bulk
    masses which cannot be grinded or converted to fine powder

     Cannot solidify perfectly

     It is not preferable to be used in the reinforced concrete mortar

    10/12/2021 Eng. R. H. Thabet 18


    Types of Cement
    Chemicals resistant cement:
    • Used when the buildings are subjected to chemicals.
    • This cement consists of pellets which are mixed with liquid mixture to
    produce a resin (which gives the mixture the suitable solidification).
    • The carbolic cement
     Solid material: is fine sand or graphite or asbestos
     Liquid material: is a mixture of phenol and formaldehyde, who
    condense to form a resin

    10/12/2021 Eng. R. H. Thabet 19


    10/12/2021 20

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