CEMENT, PCC AND RCC

NAME: SPARDHA MEHTA

SEM/SEC/YR: V/B/2021
SUB: STRUCTURAL SYSTEM AND DESIGN
 CONTENTS

1. Cement
1.1 Uses
1.2 Elements
1.3 Chemical Composition
1.4 Portland Cement
1.5 Manufacturing process of Portland cement
1.5.1 Mixing of raw materials
1.5.2 Burning of raw materials
1.5.3 Grinding of raw materials
1.5.4 Storage and packaging
2. Concrete
2.1 Types of concrete and its uses
2.1.1 According to binding material used in concrete
2.1.1.1 Cement concrete
2.1.1.2 Lime concrete
2.1.2 According to design of concrete
2.1.2.1 PCC
2.1.2.2 RCC
2.1.2.3 Pre-stressed cement concrete
2.1.3 According to purpose of concrete
2.1.3.1 Vacuum concrete
2.1.3.2 Air entrained concrete
2.1.3.3 Light weight concrete
CEMENT 3. Aluminium and iron can be
Cement is a fine, soft, powdery-type extracted from bauxite and iron
substance. It is a fine mineral powder ore, and only small amounts are
manufactured with very precise processes. needed
CHEMICAL COMPOSITION
The raw materials used for the
manufacture of cement consist mainly of
lime, silica, alumina and iron oxide. These
oxides interact with one another in the kiln
at high temperature to form more complex
compounds. The relative properties of
these oxide compositions are responsible
for influencing the various properties of
Mixed with water, this powder transforms
cement, in addition to rate of cooling and
into a paste that binds and hardens when
fineness of grinding.
submerged in water.

Because the composition and fineness of

the powder may vary, cement has different
properties depending upon its makeup.

USES
Cement is mainly used as a binder in PORTLAND CEMENT
concrete, which is a basic material for all Portland cement is the most common type
types of construction, including housing, of cement in general use around the world,
roads, schools, hospitals, dams and ports. used as a basic ingredient of concrete,
mortar, plaster and most non-specialty
ELEMENTS grout. It is a fine powder, produced by
It is made from a mixture of elements that heating limestone and clay minerals in a
are found in natural materials such as kiln to form clinker, grinding the clinker,
limestone, clay, sand and/or shale. Four and adding small amounts of other
essential elements are needed to make materials.
cement. They are Calcium, Silicon,
Aluminium and Iron. MANUFACTURING PROCESS OF
PORTLAND CEMENT
1. Calcium (which is the main
The manufacturing procedures of Portland
ingredient) can be obtained from
cement is described below.
limestone
2. Silicon can be obtained from sand  Mixing of raw material
  Burning
 Grinding
 Storage and packaging
1. MIXING OF RAW MATERIAL
The major raw materials used in the
manufacturing of cement are Calcium,
Silicon, Iron and Aluminum. These
minerals are used in different form as per
the availability of the minerals.

Table shows: the raw materials for

Portland cement manufacture Fig: Manufacture of Cement by Dry
Process
The mixing procedure of the manufacture
of cement is done in 2 methods b) WET PROCESS
The raw materials are firstly crushed and
 Dry Process made into powdered form and stored in
 Wet Process silos. The clay is then washed in washing
a) DRY PROCESS mills to remove adhering organic matters
The both calcareous ang argillaceous raw found in clay. The powdered limestone
materials are firstly crushed in the gyratory and water washed clay are sent to flow in
to get 2-5cm size pieces separately. The the channels and transfer to grinding mills
crushed materials are again grinded to get where they are completely mixed and paste
fine particles into ball or tube mill. Each is formed, i.e., known as slurry. The
finely grinded material is stored in hopper grinding process can be done in balls or
after screening. Now these powdered tube mill or even both. Then the slurry is
minerals are mixed in required proportion led into collecting basin where
to get dry raw mix which is then stored in composition can be adjusted. The slurry
silos and kept ready to be sent into rotary contains around 38-40% water that is
kiln. Now the raw materials are mixed in stored in storage tanks and kept ready for
specific proportions so that the average the rotary kiln.
composition of the final product is
maintained properly.
 the columns of masonry or concrete and
rested on roller bearing in slightly inclined
position at the gradient of 1 in 25 to 1 in
30. The raw mix of dry process of
corrected slurry of wet process is 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 400oC temp, so this process
is known as Drying Zone. The central part
i.e. calcination zone, the temperature is
around 10000C, where decomposition of
Fig: Manufacture of Cement by Wet lime stone takes place. The remaining
Process material is in the form of small lumps
COMPARISION OF DRY PROCESS AND known as nodules after the CO 2 is
WET PROCESS OF CEMENT released.
MANUFACTURE
CaCO3 = CaO + CO2
Criteria Dry Process Wet Process
Hardness of Quite hard Any type of The lower part (clinkering zone) has
raw material raw material temperature in between 1500-17000C
Fuel Low High where lime and clay are reacts to yielding
consumption calcium aluminates and calcium silicates.
Time of Lesser Higher
These aluminates and silicates of calcium
process
fuse to gather to form small and hard
Quality Inferior Superior
quality quality stones are known as clinkers. The size of
Cost of High Low the clinker is varying from 5-10mm. The
production lower part i.e., clinkering zone has the
Overall cost Costly Cheaper temperature around 1500-1700C. In the
Physical Raw mix Slurry region lime and clay reacts to yield
state (solid) (liquid) calcium aluminates and calcium silicates.
This products of aluminates and silicates
of calcium fuses together to form hard and
2. BURNING OF RAW MATERIAL
small stones known as clinkers. The size of
The burning process is carried out in the
the small and hard clinkers varies from 5
rotary kiln while the raw materials are
to 10mm.
rotated at 1-2rpm at its longitudinal axis.
The rotary kiln is made up of steel tubes
having the diameter of 2.5-3.0 meter and 2CaO + SiO2 = Ca2SiO4 (declaim silicate
the length differs from 90-120meter. The (C2S))
inner side of the kiln is lined with
refractory bricks. The kiln is supported on
 3CaO + SiO2 = Ca3SiO5 (tricalcium
silicate (C3S))
3CaO + Al2O3 = Ca3Al2O6 (dicalcium
aluminate (C2A))
4CaO + Al2O3 + Fe2O3 =
Ca4Al2Fe2O10 (tetracalcium
aluminoferrite(C4AF))
The clinker coming from the burning zone
are very hot. To bring down the
temperature of clinkers, air is admitted in CONCRETE
counter current direction at the base of the Concrete is a composite material in which
rotary kiln. The cooled clinkers are a binding material mixed in water on
collected in small trolleys. solidification binds the inert particles of
well graded fine and coarse aggregates.
3. GRINDING OF CLINKERS Cement and lime are generally used as
The cooled clinkers are received from the binding materials, whereas sand cinder is
cooling pans and sent into mills. The used as fine aggregates and crushed stones,
clinkers are grinded finely into powder in gravel, broken bricks, clinkers are used as
ball mill or tube mill. Powdered gypsum is coarse aggregates.
added around 2-3% as retarding agent
during final grinding. The final obtained  Freshly prepared concrete till it has
product is cement that does not settle not yet set is called wet or green
quickly when comes in contact with water. concrete.
After the initial setting time of the cement,  After it has thoroughly set and
the cement becomes stiff and the gypsum fully hardened it is called set
retards the dissolution of tri-calcium concrete or just concrete.
aluminates by forming tricalcium
TYPES OF CONCRETE AND ITS
sulfoaluminate which is insoluble and
USES
prevents too early further reactions of
Concrete is classified into different types:
setting and hardening.
 According to binding material used
4. STORAGE AND PACKAGING
in concrete
The grinded cement is stored in silos, from
which it is marketed either in container  According to design of concrete
load or 50kg bags.  According to purpose of concrete
ACCORDING TO BINDING
MATERIAL USED IN CONCRETE
According to binding material used
concrete are classified into two types
 Cement concrete
 Lime concrete
CEMENT CONCRETE
The concrete consisting of cement, sand
and coarse aggregates mixed in a suitable
proportion in addition to water is called
cement concrete. In this type of concrete
cement is used as a binding material, sand
as fine aggregates and gravel, crushed
stones as coarse aggregates. In cement
concrete useful proportions of its
ingredients are 1 part cement:1-8 part
ACCORDING TO DESIGN OF
sand:2-16 parts coarse aggregates. USES:
CONCRETE 
cement concrete is commonly used in
buildings and other important engineering  Plain cement concrete (PCC)
works where strength and durability are of  Reinforced cement concrete (RCC)
prime importance.  Pre-stressed cement concrete
PLAIN CEMENT CONCRETE
Plain Cement Concrete mainly consists of
solid mass made of sand, gravel, cement
and water devoid of any reinforcement.
Concrete is remarkably strong in
compression, but weak in tension. Hence
the use of PCC as a structural material is
limited to situations where significant
tensile stresses and strains do not develop.
For example, hollow (or solid) block wall
construction, small pedestals and mass
LIME CONCRETE concrete applications. USES: Plane
The concrete consisting of lime, fine cement concrete is commonly used in for
aggregates, and coarse aggregates mixed in foundation work and flooring of buildings.
a suitable proportion with water is called
lime concrete. In this type of concrete
hydraulic lime is generally used as a
binding material, sand and cinder are used
as fine aggregates and broken bricks,
gravel can be used as coarse aggregates.
PLACING OF LIME CONCRETE:
Placing of concrete shall be completed
within three hours of adding water in case
of concrete is prepared with hydraulic
lime. Concrete should be well cured for a REINFORCED CEMENT CONCRETE
period of at least 10 days. USES: Lime It is concrete with steel bars embedded in
concrete is generally used for the sake of it. The idea of reinforcing concrete with
economy in foundation works, under steel has resulted in a new composite
floors, over roof and where cement is not material, having the potential of resisting
cheaply and easily available in required significant tensile stresses. The steel bars
quantity. (embedded in the tension zone of the
concrete) compensate for the concrete’s
incapacity for tensile resistance,  Skill is not required for casting
effectively taking up all the tension, concrete elements.
without separating from the concrete. The
bond between steel and concrete ensures  Concrete is durable, fire resisting and
strain compatibility, i.e., strain at any point rigid.
in the steel is equal to that in the adjoining
concrete. Moreover, the reinforcing steel  Concrete requires less maintenance.
imparts ductility to a material that is
otherwise brittle. DISADVANTAGES OF RCC OVER OTHER
BUILDING MATERIALS

 The self-weight of the structural

elements will be more while concrete
is used.

 Concrete has a very low tensile

strength. Hence cracks will form in the
tension zone if reinforcement is not
provided properly.

 Cracks develop in concrete, also due

to shrinkage, creep, temperature, etc.
which permit seepage of water into
the concrete. This causes corrosion of
steel reinforcement and thereby
peeling of concrete.

 Concrete has poor insulating

property.

 Dismantling and reusing of concrete

ADVANTAGES OF RCC OVER OTHER BUILDING elements are mostly not possible.
MATERIALS
 Concrete is brittle in nature and hence
 Concrete is workable when fresh and low impact resisting capacity

strong when hardens. PRE-STRESSED CEMENT CONCRETE

The cement concrete in which high
 It can be moulded into any required compressive stresses are artificially
induced before their actual use is called
shape and size.
pre-stresses cement concrete. in this type
 The raw materials required are easily of cement concrete, the high compressive
stresses are induced by pre-tensioning the
available.
reinforcement before placing the concrete,
and the reinforcement is released when
final setting of the concrete take place.
Uses: This concrete can take up high
tensile and compressive stresses without
development of cracks. The quantity of
reinforcement can be considerably reduced
by using this concrete.

ACCORDING TO PURPOSE OF
CONCRETE
According to purpose concrete is classified
into following types.
 Vacuum concrete
 Air entrained concrete
 Light weight concrete

VACUUM CONCRETE
The cement concrete from which entrained
air and excess water is removed after
placing it, by suction with the help of
vacuum pump is called vacuum concrete.
In this concrete the excess water which is
added to increase workability but not
required for the hydration of cement of
concrete is removed by forming vacuum
chamber
AIR ENTRAINED CONCRETE
the concrete prepared by mixing
aluminium in it is called air entrained,
cellular or aerated concrete. In these
concrete bubbles of hydrogen gas are
liberated which forms cell and make the
concrete cellular. USES: This concrete is
used for lining walls and roofs for heat and
sound insulation purpose.

LIGHT WEIGHT CONCRETE

The concrete prepared by using coke
breeze, cinder or slag as coarse aggregate
is called light weight concrete. The
concrete is light in weight and possess heat
insulating properties. USES: This concrete
is used in making precast structural units
for partition and wall lining.