CEMENT

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CEMENT
http//www.tancem.com/images/inner/projects/gemini
.jpg

• Stephanie M. Murillo Maikut

http//www.math.lsu.edu/bogdan/photo-albums/polan
d-poznan/square-town-houses.jpg
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INTRODUCTION

• Definition Cement is a crystalline compound of
  calcium silicates and other calcium compounds
  having hydraulic properties (Macfadyen, 2006).

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• History
• Lime and clay have been used as cementing
  material on constructions through many centuries.
• Romans are commonly given the credit for the
  development of hydraulic cement, the most
  significant incorporation of the Romans was the
  use of pozzolan-lime cement by mixing volcanic
  ash from the Mt. Vesuvius with lime.
• Best know surviving example is the Pantheon in
  Rome
• In 1824 Joseph Aspdin from England invented the
  Portland cement

• (http//www.holcim.com/NZ/EN/id/71772/mod/gnm20/pa
  ge/editorial.htm)
• (http//pubs.usgs.gov/of/2005/1152/2005-1152.pdf)
• http//www.artchive.com/artchive/r/roman/roman_pan
  theon.jpg

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Types of Cement
Cements are considered hydraulic because of their
ability to set and harden under or with excess
water through the hydration of the cements
chemical compounds or minerals There are two
types Those that activate with the addition of
water And pozzolanic that develop hydraulic
properties when the interact with hydrated lime
Ca(OH)2 Pozzolanic any siliceous material that
develops hydraulic cementitious properties when
interacted with hydrated lime. HYDRAULIC
CEMENTS Hydraulic lime Only used in specialized
mortars. Made from calcination of clay-rich
limestones. Natural cements Misleadingly
called Roman. It is made from argillaceous
limestones or interbedded limestone and clay or
shale, with few raw materials. Because they were
found to be inferior to portland, most plants
switched.
(http//pubs.usgs.gov/of/2005/1152/2005-1152.pdf)
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Portland cement Artificial cement. Made by the
mixing clinker with gypsum in a 955 ratio.
Portland-limestone cements Large amounts (6
to 35) of ground limestone have been added as a
filler to a portland cement base. Blended
cements Mix of portland cement with one or more
SCM (supplementary cemetitious materials) like
pozzolanic additives. Pozzolan-lime cements
Original Roman cements. Only a small quantity is
manufactured in the U.S. Mix of pozzolans with
lime. Masonry cements Portland cement where
other materials have been added primarily to
impart plasticity. Aluminous cements
Limestones and bauxite are the main raw
materials. Used for refractory applications (such
as cementing furnace bricks) and certain
applications where rapid hardening is required.
It is more expensive than portland. There is only
one producing facility in the U.S.
(http//pubs.usgs.gov/of/2005/1152/2005-1152.pdf)
(Macfadyen, 2006).
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GEOLOGY (RAW MATERIALS)

• The fundamental chemical compounds to produce
  cement clinker are
• Lime (CaO)
• Silica (SiO2)
• Alumina (Al2O3)
• Iron Oxide (Fe2O3)

Raw materials used in the production of clinker
cement
Fly ash by-product of burning finely grounded
coal either for industrial application or in the
production of electricity
(Macfadyen, 2006) (Hoffman, 2006)
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Clinker compounds in Type I portland cement
(Macfadyen, 2006) www.recycleworks.org/images/flya
sh_concrete.gif
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SOURCES OF CaCO3

• Sedimentary deposits of marine origin (limestone)
• Marble (metamorphosed limestone)
• Chalk
• Marl
• Coral
• Aragonite
• Oyster and clam shells
• Travertine
• Tuff
• LIMESTONES
• Originate from the biological deposition of
  shells and skeletons of plants and animals.
• Massive beds accumulated over millions of years.
• In the cement industry limestone includes calcium
  carbonate and magnesium carbonate.
• Most industrial quality limestones is of
  biological origin.

(Macfadyen, 2006) (Kussmaul, 2003) http//en.wikip
edia.org/wiki/ImageLimestoneshale7342.jpg
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SOURCES OF ARGILLACEOUS MINERALS

• Argillaceous mineral resources
• Clay and shale for alumina and silica
• Iron ore for iron
• Other natural sources of silica are and alumina
  are
• Loess, silt, sandstone, volcanic ash, diaspore,
  diatomite, bauxite
• Shales, mudstones, and sandstones are typically
  interbedded with the limestone and were deposited
  as the inland waters and oceans covered the land
  masses. Clays are typically younger surface
  deposits

(Macfadyen, 2006) http//en.wikipedia.org/wiki/Ima
geShaleUSGOV.jpg
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MARKETING

• Wide distribution of plants minimizes the cost to
  customers.
• In any market even though cement must meet
  certain specifications there are other factors
  that dominate, such as
• Delivered cost
• Quality
• Product consistency
• Technical assistance and
• Sales relationship with the user companies
• Factors that drive the consumption of cement in
  the marketplace
• Economic growth
• Private and governmental capital investment
• Population growth

(Macfadyen, 2006)
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MINING METHODS
Limestone deposits are mainly extracted by bench
mining in which holes are charged with ammonium
nitrate and fuel oil explosive and blasted The
rock is excavated with front end loaders (10 m3
capacity) and loaded into 70 to 90 tons haul
trucks and then transported to the primary
crusher Marl and chalk normally do not require
blasting. A trend is to use in pit moveable
primary crushers and belt conveyors to transport
the rock to a fixed secondary crusher, thereby
reducing the number of trucks and haulage
distance Underground mining of limestones is
not typical, in the U.S one plant obtains its
limestone from underground operation, using room
and pillar mining method. Clay and shale
normally extracted using front end loaders and
loaded into haul trucks. When they occur as
overburden the clays and shales not used are
stored and often reused for reclamation in the
mined out areas of the quarry
(Macfadye, 2006) http//www.heta4.com/imagesandgra
phics/images/frontendloader.gif
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PROCESSING
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(Macfadyen, 2006)
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USES

• Uses
• Main use is in the fabrication of concrete and
  mortars
• Modern uses
• Building (floors, beams, columns, roofing, piles,
  bricks, mortar, panels, plaster)
• Transport (roads, pathways, crossings, bridges,
  viaducts, tunnels, parking, etc.)
• Water (pipes, drains, canals, dams, tanks, pools,
  etc.)
• Civil (piers, docks, retaining walls, silos,
  warehousing, poles, pylons, fencing)
• Agriculture (buildings, processing, housing,
  irrigation)

(http//pubs.usgs.gov/of/2005/1152/2005-1152.pdf)
(http//www.holcim.com/NZ/EN/id/71772/mod/gnm20/pa
ge/editorial.html) (http//en.wikipedia.org/wiki/M
ortar_28masonry29) http//www.wpclipart.com/wor
king/construction/concrete_block.png http//iranda
ily.ir/1383/2116/html/005991.jpg
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SUBSTITUTES

• It competes in the construction industry with
  concrete substitutes
• Alumina
• Asphalt
• Clay brick
• Fiberglass
• Glass
• Steel
• Stone Wood
• Some materials like fly ash and ground granulated
  furnace slugs have good hydraulic properties and
  are being used as partial substitutes for
  portland cement in some concrete applications

(http//minerals.usgs.gov/minerals/pubs/commodity/
cement/cemenmcs07.pdf)
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PRODUCTION
Data in thousand metric tons
http//minerals.usgs.gov/minerals/pubs/commodity/c
ement/cemenmcs06.pdf
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http//minerals.usgs.gov/minerals/pubs/commodity/c
ement/cemenmcs07.pdf
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World production of hydraulic cement by region
(http//pubs.usgs.gov/of/2005/1152/2005-1152.pdf).
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U.S production and consumption of portland cement
(http//pubs.usgs.gov/of/2005/1152/2005-1152.pdf)
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RESOURCES
Although individual company reserves are subject
to exhaustion, cement raw materials (especially
limestone) are widespread and abundant, and
overall shortages are unlikely in the future
(http//minerals.usgs.gov/minerals/pubs/commodity/
cement/cemenmcs07.pdf)
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REFERENCES
Hoffman, G., 2006 Pozzolans and supplementary
cementitious materials. Pages 1161-1172 in
Industrial Minerals and Rocks 7th edition. Edited
by J.E. Kogel, N.C., Trivedi, J.M. Barker S.T.
Krudowski. Littleton, Colorado SME Macfadyen,
J.D., 2006 Cement and cement raw materials.
Pages 1121-1136 in Industrial Minerals and Rocks
7th edition. Edited by J.E. Kogel, N.C., Trivedi,
J.M. Barker S.T. Krudowski. Littleton,
Colorado SME http//www.holcim.com/NZ/EN/id/71772
/mod/gnm20/page/editorial.htm ?Consulted April
2007? http//pubs.usgs.gov/of/2005/1152/2005-1152.
pdf ?Consulted April 2007? http//www.artchive.com
/artchive/r/roman/roman_pantheon.jpg ?Consulted
April 2007? http//www.recycleworks.org/images/fly
ash_concrete.gif ?Consulted April
2007? http//en.wikipedia.org/wiki/ImageLimestone
shale7342.jpg ?Consulted April 2007? http//en.wik
ipedia.org/wiki/ImageShaleUSGOV.jpg ?Consulted
April 2007? http//www.heta4.com/imagesandgraphics
/images/frontendloader.gif ?Consulted April
2007? http//en.wikipedia.org/wiki/Mortar_28mason
ry29 ?Consulted April 2007? http//www.wpclipart.
com/working/construction/concrete_block.png
?Consulted April 2007? http//irandaily.ir/1383/21
16/html/005991.jpg ?Consulted April
2007? http//minerals.usgs.gov/minerals/pubs/commo
dity/cement/cemenmcs06.pdf ?Consulted April
2007?\ http//minerals.usgs.gov/minerals/pubs/comm
odity/cement/cemenmcs07.pdf ?Consulted April
2007?