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Cement is manufactured through a closely controlled chemical combination of calcium, silicon, aluminum, iron and other ingredients.
Common materials used to manufacture cement include limestone, shells, and chalk or marl combined with shale, clay, slate, blast furnace slag, silica sand, and iron ore. These ingredients, when heated at high temperatures form a rock-like substance that is ground into the fine powder that we commonly think of as cement.
Bricklayer Joseph Aspdin of Leeds, England first made portland cement early in the 19th century by burning powdered limestone and clay in his kitchen stove. With this crude method, he laid the foundation for an industry that annually processes literally mountains of limestone, clay, cement rock, and other materials into a powder so fine it will pass through a sieve capable of holding water.nbsp
Cement plant laboratories check each step in the manufacture of portland cement by frequent chemical and physical tests. The labs also analyze and test the finished product to ensure that it complies with all industry specifications.
The most common way to manufacture portland cement is through a dry method. The first step is to quarry the principal raw materials, mainly limestone, clay, and other materials. After quarrying the rock is crushed. This involves several stages. The first crushing reduces the rock to a maximum size of about 6 inches. The rock then goes to secondary crushers or hammer mills for reduction to about 3 inches or smaller.
The crushed rock is combined with other ingredients such as iron ore or fly ash and ground, mixed, and fed to a cement kiln.
The words cement and concrete are both of Latin origin, reflecting the likelihood that the ancient Romans were the first to use the substances. Many examples of Roman concrete construction remain in the countries that encircle the Mediterranean, where Roman builders had access to numerous natural cement deposits. Natural cement consists mainly of lime, derived from limestone and often combined with volcanic ash. It formed the basis of most civil engineering until the eighteenth century, when the first synthetic cements were developed.
Another form of strengthened concrete, prestressed concrete, was issued a U.S. patent in 1888. However, it was not widely used until World War II, when several large docks and bridges that utilized it were constructed. Rather than reinforcing a highly stressed portion of a concrete structure with steel, engineers could now compress a section of concrete before they subjected it to stress, thereby increasing its ability to withstand tension.
Today, different types of concrete are categorized according to their method of installation. Ready- or pre-mixed concrete is batched and mixed at a central plant before it is delivered to a site. Because this type of concrete is sometimes transported in an agitator truck, it is also known as transit-mixed concrete. Shrink-mixed concrete is partially mixed at the central plant, and its mixing is then completed en route to the site.
The manufacture of concrete is fairly simple. First, the cement usually Portland cement is prepared. Next, the other ingredientsx2014aggregates such as sand or gravel, admixtures chemical additives, any necessary fibers, and waterx2014are mixed together with the cement to form concrete. The concrete is then shipped to the work site and placed, compacted, and cured.
Concrete manufacturers expect their raw material suppliers to supply a consistent, uniform product. At the cement production factory, the proportions of the various raw materials that go into cement must be checked to achieve a consistent kiln feed, and samples of the mix are frequently examined using X-ray fluorescence analysis.
The deterioration of the U.S. infrastructure has shifted the highway industryx0027s emphasis from building new roads and bridges to maintaining and replacing existing structures. Because better techniques and materials are needed to reduce costs, the Strategic Highway Research Program SHRP, a 5-year 150 million research program, was established in 1987. The targeted areas were asphalt, pavement performance, concrete structures, and highway operations.
The Center for Building Technology at NIST is also conducting research to improve concrete performance. The projects include several that are developing new methods of field testing concrete. Other projects involve computer modeling of properties and models for predicting service life. In addition, several expert systems have been developed for designing concrete mixtures and for diagnosing causes of concrete deterioration.
Another cement industry trend is the concentration of manufacturing in a smaller number of larger-capacity production systems. This has been achieved either by replacing several older production lines with a single, high-capacity line or by upgrading and modernizing an existing line for a higher production yield. Automation will continue to play an important role in achieving these increased yields. The use of waste byproducts as raw materials will continue as well.
American Concrete Institute. Cement and Concrete Terminology. 1967.
Mindess, S. Advances in Cementitious Materials. The American Ceramic Society, 1991. Vol. 16 Ceramic Transactions.
Oct 25, 2018nbsp018332Heres my full answer for the process diagram task below. The diagrams below show the stages and equipment used in the cement-making process, and how cement is used to produce concrete for building purposes. This task comes from Cambridge IELTS book 8 The first diagram illustrates the process of cement manufacture, and the second diagram shows the materials that go into the production
The Cement Manufacturing Process - Advancing Mining. Aug 20, 2015 Cement manufacturing is a complex process that begins with mining and then grinding raw materials that include limestone and clay, to a fine powder, called raw meal, which is then heated to a sintering temperature as high as 1450 176C in a cement
The Cement Manufacturing Process Advancing Mining. Cement manufacturing is a complex process that begins with mining and then grinding raw materials that include limestone and clay, to a fine powder, called raw meal, which is then heated to a sintering temperature as high as 1450 176C in a cement kiln.