The principal objective behind this talk is to make

an attempt to give some idea and knowledge

about the Quality of Cement, and how can we
Control it.

In addition we also discuss here the role of major

factors those affecting the quality of individual
process / in process material. Today we also
discuss here important mechanical properties of
Cement.
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HR Activities & Outlook 2007 – Sid Tuli
Slide 2 - 25.01.2007
HR Activities & Outlook 2007 – Sid Tuli
 Cements may be defined as adhesive substances containing
compounds of lime as their principal constituent and are capable of
uniting fragments of solid matters to a compact mass.

Mr. Joseph Aspdin of England patented the manufacture of improved

type of cementitious material for construction work in 1824 and
named it Portland cement because hardened stone of his cement
resembled Portland stone found in England.

Hydraulic Cement is the cement which continuously develops its

strength when kept in contact with water. And what is known as
Portland Cement, is a finely ground material consisting mainly of
components like CaO, SiO2, Al2O3, Fe2O3 and Gypsum. When mixed
with water, it forms a paste that hardens and binds other materials
called aggregates together.
Slide 3 - 25.01.2007
HR Activities & Outlook 2007 – Sid Tuli
Several types of Portland Cement are recognised having different
characteristics. The most important variables are the Rate of
Hardening, Rate and Total Extent of Heat evoluation during
hydration and the resistance of the hardened cement to attack
by sulphate solution. These characteristics are influenced by the
mineralogical and chemical composition of the cement as well as
physical factors such as fineness on grinding.

Indian Standard Specification cover 14 types of Cement and of

these 9 are commercially produced. The bulk of these cements
is accounted by Ordinary Portland Cement (OPC), Portland
Pozzolana Cement (PPC) and Portland Slag Cement (PSC).

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HR Activities & Outlook 2007 – Sid Tuli
Slide 5 - 25.01.2007
HR Activities & Outlook 2007 – Sid Tuli
 QUALITY = CUSTOMER SATISFACTION / COST

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 behaviour, Strength
development, Heat development, Volume stability and
durability.

In production of cement, it is our task to ensure that the

contribution to those properties of the cement is kept at
a certain level to meet the requirements specified in the
standard specification and to comply with wishes and
needs of the market. This emplies control of the
materials and process involved in the production of
cement.
Slide 6 - 25.01.2007
HR Activities & Outlook 2007 – Sid Tuli
 While evaluating the quality of cement we primarily
consider the properties of mortar or concrete products,
chemical composition and type of cement are only
important as far as they influence these properties. Cement
standards define test procedures and limiting values for the
major properties. The most important standardised
evaluation criteria are :

 Setting
 Workability
 setting behaviours
 Soundness
 Durability
Slide 7 - 25.01.2007
HR Activities & Outlook 2007 – Sid Tuli
 Setting refers to stiffening of a cement paste, which
changes in character from a plastic or flowing mass into
a rigid material. The time elapsing before this takes place
is known as setting time.

Depends upon
 Temperature
 Water to cement Ratio
 Characteristic of cement

Slide 8 - 25.01.2007
HR Activities & Outlook 2007 – Sid Tuli
 Strength may be defined as resistance to failure and
collapse under external load. The strength of set cement
can also be ascribed to the mechanical interlocking of the
crystals.

Depends upon
 Mix proportions & mixing time
 Quality of water & Water to cement Ratio
 Temperature
 Curing conditions
 Properties of cement
Slide 9 - 25.01.2007
HR Activities & Outlook 2007 – Sid Tuli
 The reactions which are responsible for setting and
hardening of cement are accompanied with the
liberation of heat. This liberated heat is known as
Heat of Hydration.

The heat of hydration can be an important factor in

concrete technology. It can be helpful in cold weather
concreting, or can be troublesome in mass concreting
work.

Slide 10 - 25.01.2007
HR Activities & Outlook 2007 – Sid Tuli
 Volume stability or Soundness of cement emplies
freedom from excessive expansion during hydration
of Cement paste, Mortar or concrete. Excessive
expansion cause cracks and consequently reduces
strength and Durability

The reaction involves

 Formation of ettringite
 Hydration of Free CaO
 Hydration of Crystalline MgO
Slide 11 - 25.01.2007
HR Activities & Outlook 2007 – Sid Tuli
 Durability defines the stability of concrete to
preserve the structural performance, fixed by the
designer over time; hence it plays a fundamental
role in determining the service life of the structure.

Durability of concrete is one of the most important

property in practical use. It depends on a number
of factors associated with the composition of the
concrete, characteristic of construction and
environmental aspects.
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HR Activities & Outlook 2007 – Sid Tuli
 Carbon Water
dioxide

Chlorides
Frost

Alkali
Aggregate
Reaction
Heat &
Fire
Seawater Sulphate
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HR Activities & Outlook 2007 – Sid Tuli
Slide 14 - 25.01.2007
HR Activities & Outlook 2007 – Sid Tuli
 STRUCTURE OF QC DEPARTMENT

QC Department

Testing RMH Chemical Physical

Section Section Section Section

24 Hrs working Chemically

Physical testing
checking Looking after Analyzing
Raw materials,
Samples of Handeling and Raw materials,
In process
In process Feeding of Fuel In process
Materials and
materials & & Raw mix Materials and
Finished
maintain certain additives Finished
Products
parameters products
Slide 15 - 25.01.2007
HR Activities & Outlook 2007 – Sid Tuli
 There are certain parameters, those are affecting the quality
of cement and through control of them we can control
quality of Cement. The major parameters are as under :

 Raw material Selection

 Chemical Properties of Raw mix
 Chemistry of Clinker
For Total Quality Assurance we had planned a Quality
Control Test Scheme and through the same we are able to
assure quality of our final product.
In Quality control test scheme, we prepared a plan for
inspection of in process material at various stages for
certain parameters and frequencies to obtain a finished
product of controlled quality.
Slide 16 - 25.01.2007
HR Activities & Outlook 2007 – Sid Tuli
 MATERIAL FLOW AND Q.C. CHECK POINTS
Quarry Crusher Stacker Reclaimer

Additives Add. Stock Add. Hoppers Roller press

Raw Fuel Coal Crusher Coal Mill

Raw mill

C.F. Silo
DESPATCH
QC CHECK POINTS
PH & Kiln

Pack. Plant
Gypsum Fly ash Clk. Storage

Cement Silo Cement Mill IML Stock Rope way

Slide 17 - 25.01.2007
HR Activities & Outlook 2007 – Sid Tuli
 QC TESTING SCHEME
Quarry Limestone – Drill hole Samples

Crusher Crushed Limestone Samples

Reclaimer Reclaiming Limestone Samples

Add. Hopper Additives weigh feeder samples

Raw Mill Raw meal Samples

Coal Mill Fine coal Samples

PH & Kiln Kiln Feed, Cyclone and Clinker Samples

Slide 18 - 25.01.2007
HR Activities & Outlook 2007 – Sid Tuli
 QC TESTING SCHEME
Additive Raw material receipt Samples

Raw Coal Raw coal Samples

Coal crusher Feeding coal samples

Gypsum Gypsum samples

Fly ash Fly ash samples

Cement Mill Samples of Final product (Cement)

Packing Samples of Packed cement

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HR Activities & Outlook 2007 – Sid Tuli
 BASIC RAW MATERIALS

The classification of common raw materials for

manufacturing of cement is as follows :

Raw Materials

Principal Supplementary Special additives

Corrective Grinding
Calcareous Argillaceous Mineraliser
materials aids
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HR Activities & Outlook 2007 – Sid Tuli
 MATERIALS AND THEIR SOURCES

Lime Stone, marl, Sea sludge, Lime sludge

Calcareous from Paper, Carbide or Sugar Plants etc.

Clay, Soil, Shale, Slate, Volcanic rocks, Fly

Argillaceous
ash etc.

Corrective
Bauxite, Laterite, Sandstone, Iron ore etc.
materials

Mineraliser Fluorspar, Na2SiF6, Gypsum etc.

Grinding Surface active agents like TEA, Di-Ethylene

aids Glycol, Sodium pyro phosphate etc.
Slide 21 - 25.01.2007
HR Activities & Outlook 2007 – Sid Tuli
 Raw mix or kiln feed is a finely ground blend of
calcareous, argillaceous and / or additive /
corrective material mixed in predetermined
proportion.

The various components in a raw mix are so

carefully selected that in combination, they
satisfy a few chemical parameters known as
module values responsible for producing clinker
on firing. These are as follows :
Slide 22 - 25.01.2007
HR Activities & Outlook 2007 – Sid Tuli
 Silica Modulus

Silica Modulus (SM) = SiO2/(Al2O3 + Fe2O3)

A high silica modulus can :

• Result in harder burning and high fuel consumption
• Causes difficulty in coating formation and hence the
radiation losses from shell are high
• Deteriorates the life of kiln lining
• result in slow setting and hardening of cement

A Low silica modulus can :

• Result in easy burning, Low Fuel consumption.
• Creates excessive Liquid, Wash the coating and make an
attack to bricks.
Slide 23 - 25.01.2007
HR Activities & Outlook 2007 – Sid Tuli
 Alumina Modulus

Alumina Modulus (AM) = Al2O3/ Fe2O3

A high Alumina modulus can :

• Impart harder burning and initiate higher fuel consumption
• Increase the proportion of C3A and reduce C4AF
• Reduce the liquid phase kiln output and life of kiln lining
• Tend to render quick setting and strength at early age.
• Increase the viscosity of liquid phase at constant
temperature.
A Low Alumina modulus can :
• Create Fluid Slag, Lower early strength and Lower heat of
Hydration.
Slide 24 - 25.01.2007
HR Activities & Outlook 2007 – Sid Tuli
 Lime Saturation Factor

LSF = CaO/(2.85 SiO2 + 1.18 Al2O3 + 0.65 Fe2O3)

A higher Lime Saturation factor can :

• Make the raw mix difficult to burn
• Tend to produce unsound cement
• Increase C3S content
• Cause slow setting with high early strength

A Low LSF modulus can :

• Make Raw mix easy to burn.
• Lower Strength of Cement.
Slide 25 - 25.01.2007
HR Activities & Outlook 2007 – Sid Tuli
 During clinkerisition, the oxides are converted into clinker
phases and change the mineralogical structure of the material.
The resultant clinker mainly consists of following mineral
compounds :

Tri Calcium Silicate (Alite) C3S 3CaO.SiO2

Di Calcium Silicate (Belite) C2S 2CaO.SiO2
Tri Calcium Aluminate C3A 3CaO.Al2O3
Tetra Calcium Alumino Ferrite C4AF 4CaO.Al2O3.Fe2O3

The clinker minerals are not pure compound but mixed crystal
phases which contain constituent of other phases in small
amounts and combination of mixed crystals. Each phase has its
significant effects on the quality of cement.
Slide 26 - 25.01.2007
HR Activities & Outlook 2007 – Sid Tuli
 CALCULATION OF POTENTIAL CLINKER COMPOSITION
Potential means possible but not actual. R.H. Bogue developed
a method for calculating the clinker minerals. The formula are
as follows :

C3S = 4.071 CaO – F.Cao - 7.600 SiO2 - 6.718 Al2O3 - 1.430 Fe2O3

C2S = 2.867 SiO2 - 0.7544 C3S

C3A = 2.650 Al2O3 - 1.692 Fe2O3

C4AF = 3.043 Fe2O3 (if A/F > 0.64)

Slide 27 - 25.01.2007
HR Activities & Outlook 2007 – Sid Tuli
 The basic properties of Clinker compounds :
Tri-calcium Silicate (C3S)

Tri-calcium Silicate contains all the essential properties of

Portland Cement. Its hydration is rapid and it undergoes an
initial and final set within few hours after gauging and when
properly prepared shows no sign of unsoundness. C3S attains
the greater part of its strength in early ages.

Di-calcium Silicate (C2S)

Di-calcium Silicate exhibits no definite setting time and the
gauged mass sets very slowly over a period of few days. C2S
produces little strength at early ages but gains steadily in
strength at letter ages.
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HR Activities & Outlook 2007 – Sid Tuli
 Tri-calcium Aluminate (C3A)
Tri-calcium Aluminate gives ‘flash set’ on gauging with water
and this is accompanied with evolution of much heat. It gives
some strength at one day but shows no subsequent
development of strength. The presence of C3A increases the
rate of hydration and strength development of C3S.

Tetra-calcium Alumino ferrite (C4AF)

Tetra-calcium Alumino ferrite hydrates rapidly but its

contribution to strength still remains uncertain. Though setting
occurs in a few minutes after gauging, it does not show any
sign of ‘flash set’ and some heat is also evolved. It imparts the
colour of cement.

Slide 29 - 25.01.2007
HR Activities & Outlook 2007 – Sid Tuli
 The clinker is obtained from burning of raw materials in kiln.
The compound composition of clinker is as follows :

C2S

C3A
C3S
C4AF

MgO
Free CaO
K/Na2SO

Slide 30 - 25.01.2007
HR Activities & Outlook 2007 – Sid Tuli
 The clinker minerals hydrates and gives strength in
following manner :

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We continual working on Production of Superior
Quality and Highly durable Cement, capable to resist
attack of all the destructive agencies and give Long
life to our Building Structures.

“We believe that our Marketing team is our

Preliminary Customer and we always try to
sell them satisfaction rather than Cement”
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