1.Cement Cement is a mixture of Calcium silicate and Calcium
Aluminates obtained by heating clay with limestone. CaCO 3 + Al 2
SiO 7 --------> 2CaSiO 3 + Ca 2 Al 2 O 5 + CO 2 Composition :
The important raw materials used for the manufacturing ordinary
Portland cement are: Calcium Oxide(CaO) =60 to 65% Silica (SiO2)
=20 to 25% Aluminum oxide (Al 2 O 3 ) =4 to 8% Ferrous oxide(Fe 2 O
3 ) =2 to 4% Magnesium oxide(MgO) =1 to 3% Gypsum (CaSO 4.H 2 O) =4
to 5% Water. =Variable amount
Slide 4
1.The initial setting of cement is due to the action of
aluminates. 2. Further gain in strength is due to Tri-silicate. 3.
Di-silicate takes 14 to 28 days to add to the strength. 4. Gypsum
is used to control the setting time of cement. 5. Magnesium oxide
is used for heat insulation and as an antacid. 6. Incomplete
burning of clinker leaves free lime in it which causes expansion
and disruption of concrete after use. 7.Lime stone sets and goes
hard even under water Importance of raw materials in cement
Slide 5
THE CEMENT MANUFACTURING PROCESS quarry raw grinding and
burning grinding, storage, packing, dispatch
Slide 6
THE CEMENT MANUFACTURING PROCESS 1. BLASTING : The raw
materials that are used to manufacture cement (mainly limestone and
clay) are blasted from the quarry. Quarry face 1. BLASTING2.
TRANSPORT 3. CRUSHING AND TRANSPORTATION : The raw materials, after
crushing, are transported to the plant by conveyor. The plant
stores the materials before they are homogenized. quarry 3.
CRUSHING & TRANSPORTATION 2. TRANSPORT : The raw materials are
loaded into a dumper. crushing conveyor Next dumper storage at the
plant loader
Slide 7
Manufacture of Cement Cement could be manufactured by any one
of the two methods: 1.Dry process 2.Wet process
Slide 8
In both these process the four distinct operations of; 1.
Crushing and Grinding, 2. Mixing of Raw material, 3. Heating slurry
in a rotary kiln, 4. Mixing and grinding of Clinker with Gypsum.
1.Dry process2.Wet process
Slide 9
1. Crushing and Grinding In this process lime stone and Clay
are crushed and ground separately to fine powder in the crusher.
conveyor storage at the plant Raw mill Raw mix Raw grinding
Slide 10
The powdered limestone is mixed with clay in proper proportion
(75% limestone and 25% clay). Water is then added to it so as to
get a thick paste. The resulting paste is called Slurry. It is fed
into the rotary kiln. 2. Mixing of Raw Material
Slide 11
3. Heating Slurry in a rotary kiln Rotary kiln is a long
cylinder 8-10 feet in diameter and 100-250 feet in length. The kiln
rotates horizontally on its tracks. As the kiln rotates, the
(slurry) materials move downward due to its rotary motion with
regard to temperature. kiln cooling preheating clinker 2. BURNING :
The raw mix is preheated before it goes into the kiln, which is
heated by a flame that can be as hot as 2000 C. The raw mix burns
at 1500 C producing clinker which, when it leaves the kiln, is
rapidly cooled with air fans. So, the raw mix is burnt to produce
clinker : the basic material needed to make cement. burning
Slide 12
4. Clinker Formation The resulting product obtained from kiln
is known as cement clinker. This has the appearance of greenish
black or grey colored balls varying in size from peas to nuts.
cooling clinker
Slide 13
5. Mixing and grinding of clinker with Gypsum After cooling the
clinker is mixed with 4-5 % gypsum and is then ground to very fine
powder. This fine power is cement ready for use. clinker storage
Gypsum and the secondary additives are added to the clinker. Finish
grinding 1.GRINDING : The clinker and the gypsum are very finely
ground giving a pure cement. Other secondary additives and
cementations' materials can also be added to make a blended
cement.
Slide 14
Following are some of the important kinds of cements
manufactured to suit the different requirements; 1. Rapid hardening
strength cement. 2. Quick setting cement 3. High alumina cement 4.
Portland slag cement(cement made from chalk and clay) 5. Low heat
cement 6. White cement 7. Coloured cement Different types of
cement
Slide 15
This cement gains strength faster than the ordinary Portland
cement. its initial and final setting times are the same as those
of ordinary cement. It is used for such structures as are to be
subjected to heavy loads eg. Repair of bridges and roads etc. it is
more costly than ordinary cement.
Slide 16
It sets faster than the ordinary Portland cement. Its initial
sitting time is 5 minutes and the final setting time is 30 minutes.
It is used for making concrete that is required to set early as for
laying under water or in running water. Initial setting time being
very little there is always the danger of concrete having undergone
initial setting during mixing and placing. As such this cement is
only used only in exceptional circumstances.
Slide 17
It is manufactured by fusing together a mixture of bauxite and
lime stone in correct proportions and at high temperatures. The
resulting product is ground finely. It develops strength rapidly.
it resists well the attack of chemicals especially of sulphatees
and of sea water. Its ultimate strength is much higher than that of
ordinary cement. its initial setting time is more than 2 hours and
the final set takes place immediately thereafter. most of heat is
given out by it in the first 10 hours as a result of which it can
be conveniently used in freezing temperature but in thin layers in
normal temperature.
Slide 18
It is obtained by mixing Portland cement clinker, gypsum and
slag in proper proportions and grind it finely. This cement has
properties very much similar to those of ordinary Portland cement
with the following improvements. 1. It has lesser heat of
hydration. 2. It has better resistance to soils, sulphate alkali
metals, alumina and iron. 3. It has better resistance to acidic
water. This cement is used in marine works.
Slide 19
Heat generated by cement while setting may cause the structure
to crack in case of concrete. Heat generation is controlled by
keeping percentage of Tri-calcium aluminates and Tri-calcium
silicate low. Its initial and finale setting times are nearly the
same as ordinary cement but the rate of its developing strength is
very low. Low heat cement is used in underground mining and marine
concrete
Slide 20
It is a cement with pure white colour and having same
properties as those of ordinary Portland cement. Greyish colour of
ordinary cement due to iron oxide as such white cement is
manufactured from white chalk and clay free from iron oxide. this
cement is much more costly than ordinary cement.
Slide 21
by mixing suitable pigments ordinary Portland cement could be
given red or brown colour. For other colors 5 to 10% of desired
pigments are ground with white cement. Pigments used in cement
should be chemically inert and also durable so as not to fade due
to the effect of light sun or weather.
Slide 22
Under various trade names some patent products have been put on
the market by different companies. These if added to cement mortar
or cement concrete in specific proportions make the mortar/concrete
impervious. These chemicals may be in powder, liquid or paste form
If these are used in excess then the setting of cement is
affected,(Pudlo and Impermo) are the popular foreign water
proofers. Indian products are Cico,Acoproof and proofit.
Slide 23
storage, packing, dispatch 2. STORAGE, PACKING, DISPATCH 2.
STORAGE, PACKING, DISPATCH :The cement is stored in silos before
being dispatched either in bulk or in bags to its final
destination. silos dispatch bags
Slide 24
Portland cement is a finally ground materials. It therefore
readily absorbs moisture even from the atmosphere. It is therefore
essential to protect it from dampness during storage. Lack of
proper care may cause setting of cement or reduction in its
strength due to partial setting. Following precautions must as such
be taken in storing cement. 1. Walls, roof and floor of the
building in which cement is to be stored should be completely water
proof. 2. In case the cement stored is newly constructed then its
interior should have been thoroughly dried before cement is stored
in it.
Slide 25
3. Doors and windows should be properly fitted and should be
kept shut. 4. Except in case of dry concrete floor the cement bags
should be stacked on the wooden planks. 5. The bags should be
stacked away from walls. 6. Bags should be piled close together. 7.
Bags should be piled in header stretcher fashion and not more than
15 bags high. 8. While removing cement from store do not take out
bags from one tier only. step back two or three tiers. 9. For
temporary storage of cement at site of workbags should not stacked
on the ground. Minimum numbers of bags needed should be piled up on
raised dry platform and covered with trapauling.
Slide 26
2.Glass A hard and brittle material which is usually
transparent is called Glass. Raw Materials: The important raw
materials used for the manufacturing of glass are: Sand(SiO 2 ),
Soda (Na2O) Calcium carbonate (CaCO3) Feldspare(Al 2 O 3.6SiO 2 ),
Borax(B 2 O 3 ), Arsenic Oxide (AsO 3 ), Cullet (Crushed
glass).
Slide 27
Manufacture of Glass The manufacturing procedure may be divided
into four major phases: 1. Mixing, 2. Melting, 3. Shaping, 4.
Annealing.
Slide 28
1. Mixing A mixture of Sodium Carbonate (Na 2 CO 3 ), Sand(SiO
2 ), Cullet and other ingredients is ground to fine powder in
grinding machines. 2. Melting The charge is fed to one end of large
tank. The mass is heated to 1400 1550 C. Heating is continued until
the evolution of CO 2, SO 2 and other gases. It is allowed to cool
down to 1100 1300 C so that viscosity of the mass is suitable to
prepare glass ware.
Slide 29
3. Shaping Molten glass is given the desired shape by blowing,
by casting in moulds or by pressing between rollars. Shaping is
possible at a temperature at which glass is in liquid state. The
choice of shaping technique depends upon the shape of the article
e.g. bottle, bulbs, glass tubes etc.
Slide 30
4. Annealing The Heating and control cooling of substances
especially glass to relive stress is called Annealing. If the
articles are cooled suddenly, there is internal strain and the
articles are likely to crack. To avoid it these must be cooled very
slowly. This process of slow cooling is known as annealing. For
every type of glass, there is a definite annealing
temperature.
Slide 31
Types of Glass: 1.Soda Lime Glass: It is used for making window
glass, containers of all kinds, flat glass, table ware bottle,
mirrors.
Slide 32
2.Silica Glass: It is used for the manufacture of mercury
vapour lamps, telescope mirror etc.
Slide 33
3.Borsilicate Glass: It is used for the manufacture of
laboratory glassware.
Slide 34
4.Lead Alkali Glass: It is used for making electric light bulbs
and shield.
Slide 35
5.Opal Glass: A milky white translucent or opaque glass. It is
used in instrument for transmission of specific wave lengths and
plates. 6.Optical Glass: These glasses are used in scientific
instruments e.g. Periscope, Microscope and Spectacles etc.
Slide 36
7.Colored Glass: Colored Transparent Glasses are essential for
both technical and scientific purposes e.g. In buildings,
cupboards, eye spectacles and table ware etc.
Slide 37
8.Glass Ceramics: They are being used in various electronic
devices and as cook serve freeze utensils.
Slide 38
9.Fibrous Glass: Fiberglass is used for a variety of purposes.
The most common uses of fiberglass include thermal and sound
insulation,
Slide 39
WELCOME TO THE WORLD OF PAINTS
Slide 40
3. Paints Covering material (liquid) used to improve appearance
and to protect the substrate from the weather attack is called
paint.
Slide 41
Characteristics of a good Paint It should have good spreading
power. It should work smoothly and freely with brush It should form
durable, tough. color of paint should not fad or change. It should
become surface dry in about 9 hours and hard enough to take up
another coat in 24 hours. It should not crack on drying. It should
give a smooth and pleasing appearance showing no brush marks on
drying.
Slide 42
A paint is a liquid containing a colored material (Pigment) in
suspension which can be applied as a thin film to the surface by
brushing, spraying or dipping. Thus, a paint is a homogenous
mixture of two basic components: 1. Solvent like water, alcohol and
oil. 2. Solute like pigments and resin(Cellulosic materials).
Slide 43
Types of Paint On the basis of nature of solvent paints can be
divided into two groups: 1. Water Based paints, 2. Oil Based
paints. 1. Water Based paints: In water based paints, solvent is
water which carries a pigment.Paint based on water are called
emulsion paints 2. Oil Based paints: In oil based paints, solvent
is oil or alcohol with some pigment.
Slide 44
1.Enamel paints: it is a good paint and is used for buildings.
2.Cllulose paints: Its cost is more and is used for automobiles,
aircrafts and other costly things 3.Aluminium paints: It is used
for painting electric, telegraph pole etc. 4.Distember paint: It is
used for painting stone wall etc.
Slide 45
Ingredients of Paints The constituents of Paints with a brief
description are out-lined below: 1. Resins: They are cellulose
derivatives and give strength and toughness to the film. Example:
Cellulose Acetate, cellulose nitrate and linseed oil. 2. Thinner of
Solvents: They dissolves solutes. Examples: Turpentine, Xylol
etc.
Slide 46
1. Drier: They increase the drying of the film. Examples: Zinc,
Cobalt and lead. 2. Pigments: They give attractive color and
protect against weather effect. Examples: White(TiO2), basic lead
carbonate, Zinc Oxide and Zinc sulphate.
Slide 47
5. Stabilizers: They stabilize the film and prevent its
decomposition. Example: Urea. 6. Fillers: These ingredients prevent
cracking and give elasticity to the film. Some oils such as Custer
oil and Linseed oil are used as fillers.
Slide 48
PAINT COMPOSITION PAINT PIGMENTBINDERSOLVENTADDITIVE ICIS
Copyright - 2012, All Right are reserved
Slide 49
Manufacture of Paints The various steps need to produce paints
are of physical nature. In a good paint, all the ingredients must
be completely mixed. In an oil base paint, the necessary pigments
is ground with oil in a powerful mechanical mixer. The paints is
then transferred to tanks to meet thinners and other additives.
Powerful agitators produce a homogeneous mixture in the form of a
paint. Centrifuges or pressure filters are used to remove any large
size particle of dirt. This paint is poured into cans or drum and
moved to storage.
Slide 50
PAINTS CAN BE APPLIED BY: Brush Roller Spray Gun
Slide 51
GENERAL: Tar, Bitumen and Asphalts form a group of interrelated
material widely used in the field of civil Engineering in damp
roofing buildings, water proofing basements, water proofing roofs,
painting timber and steel and for constructing metal led roads.
Here we study their origin, properties and uses.
Slide 52
Bitumen: A heavy fraction from oil distillation (also occurs as
part of natural asphalt). Tar: A viscous liquid obtained from
distillation of coal or wood. Rarely used in construction currently
in the UK. Asphalt: A mixture of bitumen and mineral filler. Note
that Hot Rolled Asphalt is a road surfacing material Binder: A
material used to hold solid particles together i.e. bitumen or
tar.
Slide 53
Destructive Distillation: A process by which organic substances
such as wood, crude oil, coal, and oil shale are decomposed by heat
in the absence of air and distilled to produce useful products such
as gas,, oils, tar and asphalt etc.
Slide 54
Slide 55
It is a dark black viscous liquid. Depending up on its source
of origin tar is classified into the following 3 categories. a)
Coal tar b) wood tar c) Mineral tar
Slide 56
it is obtained as a byproduct in the destructive distillation
of coal or as a by product in the manufactured of coal gas. It is
used for many purposes such as, Coating of wooden poles, sleepers,
iron poles and latrine walls etc. A) COAL TAR:
Slide 57
It is obtained by distillation of resinous wood. Wood tar
contains creosotes which have a characteristic odour and consist of
a mixture of hydrocarbons, phenols and other aromatic derivatives
and as such it has strong preservative properties. They are used
for timber preservation. B) WOOD TAR
Slide 58
It is a black or brown viscous substance consisting of
hydrocarbons and their derivatives. Mineral tar is obtained by
distillation of bituminous shales (soft plate rocks) It posses good
water proofing and adhesion properties and is used largely for road
construction, Water proofing or protective coating and electrical
insulation. C) MINERAL TAR
Slide 59
Coal tar pitch is a black or dark-brown amorphous residue
produced by the distillation or heat treatment of coal tar. It is a
solid at room temperature and exhibits a broad softening range
instead of a defined melting temperature. It is a valuable
ingredient in the product of a number of water proofing protective
and binding compounds employed in masonry, steel and timber
structures. it is also used for water proofing concrete structures,
To fill the hole or crack in buildings to keep the water out side.
Coal tar pitch
Slide 60
Bitumen is a non-crystalline solid or viscous material, having
adhesive properties and is derived from petroleum. It is readily
soluble in carbon disulphide. It is either brown or black in color
and may occur naturally, but are usually made as end products from
distillation of or extracts from selected petroleum oils.
Slide 61
Uses of bitumen: Dam grouting(used b/t tiles on wall) Dam
linings, protection(a layer to cover inside surface) Dyke
protection(long thick wall to stop flood water) Ditch
linings(channel to take away water from field) Drainage gutters,
structures Embankment protection Groynes(a low wall built at the
sea to prevent area)
Slide 62
Jetties(platform where boat can be tieted) Levee protection
Membrane linings, waterproofing Reservoir linings Swimming pools
Used in road construction
Slide 63
Asphalt is a natural or an artificial mixture in which bitumen
is associated with inert mineral matter. The word Asphalt should
always be qualified by indication of its origin or nature. Natural
asphalt is termed as Native asphalt. Natural asphalt obtained from
lakes is termed as lake asphalt Natural asphalt obtained from rocks
is termed as Rock asphalt
Slide 64
Asphalt is used in road making. It is used in water
proofing.
Slide 65
GENERAL: Plastics mostly being synthetic materials are
available in market in a variety of forms to suit varied
requirements. It is finding newer and newer usages in construction
and is replacing convential materials like timber and steel etc. It
is used for making fittings like electric
switches,holder,insulators, seats and domestic furniture.
Slide 66
A light strong material that is produced by chemical processes
and can be formed into shapes when heated Plastics:
Slide 67
1)These are available in a variety of shapes and textures.
2)These can be mould to any shape or size. 3)These are quite light
in weight. 4)These can easily be install (to fixed) 5)These are not
attacked by insects or fungi. 6)These have good electrical
insulation properties. 7)These withstand moisture, oil and grease.
8)These have high resistance to weathering and corrosion. PTOPERTIS
OF PLASTICS
Slide 68
There are two main types of plastics; 1.Thermoplastics
2.Thermosetting plastics TYPES OF PLASTICS:
A type of plastics that can be easily shaped and bent when it
is heated and that becomes hard when it is cooled.
1.THERMOPLASTICS:
Slide 71
A type of plastics that undergo chemical changes on moulding
and the product obtained after moulding is chemically changed. The
plastics are durable and fairly strong. 2.THERMOSETTING
PLASTICS:
Slide 72
1.plastics for decorative purposes just like in buildings.
Moreover, their characteristics are constantly improved, thus
contributing to reducing the cost and increasing the efficiency of
buildings Plastics in Building and Construction applications
Slide 73
2.plastics for irrigation and drainage pipes
Slide 74
3.plastics for drinking water pipes
Slide 75
4.plastics for insulation materials: the act of protecting with
a material that prevent sound, heat and electricity to pass
through.