The whole truth about the connecting link: how and from what cement is made

Cement is one of the most common building materials. It is used both as a component for preparing solutions and as an independent product. It is used as a binder that, when interacting with water, forms a plastic mass, and then, when dried, becomes a hard stone-like material. Let's talk about what cement is made of in production.

Cement is the most demanded product used in construction

Chemical composition of cement

These products are used equally widely across the globe. Builders in ancient Rome already knew how to make solutions that had hydraulic properties. Today, world developments have stepped far forward. Humanity has learned to create a product that can harden not only in dry conditions in the air, but also in humid ones.

Today, countries such as China, the USA and India are considered leaders in production. Moreover, China produces several times more products than the other two leaders combined, the pace of construction in the Celestial Empire is also extremely high. Plants for the production of products are erected in close proximity to the points of extraction of raw materials so that the cost of delivery of components does not affect its cost.

So what is cement made of? Its composition may vary slightly depending on the type. For example, let's take the most popular type of cement - Portland cement, which is most in demand in construction. It includes:

Cement is an ideal material for decorating front staircases and building facades

In addition, additives are added to it.The chemical formula of cement has not been determined, as there are different types and brands of the product. For the producer and the consumer, the indicators of the mineralogical composition provide much more important information.

Production stages and regulatory documentation

It's time to find out how cement is made. It should be noted that this production belongs to the category of complex. Technically, it is a process of mixing clinker and gypsum.

Cement plant in Spassk-Dalny, Primorsky Krai

The manufacturing process can be divided into two main stages:

Cement is obtained in one of the following ways:

The choice of technology directly depends on the quality of raw materials. At all stages of production, the laboratory determines the characteristics of future products, in accordance with established standards. Russia has a GOST system. Each type of cement has its own technical conditions, which it must meet. Most of the standards have been adopted since the days of the Soviet Union. Most often used:

Main product features

Specifications are determined according to the product brand. It is indicated on the packaging in the form of numbers with the letter "M" in front. In fact, the number means compressive strength and is a conditional value.

Cement grade M400 produced by CJSC "Eurocement Group"

Let's discuss the main characteristics of the product.

A structure using cement must withstand severe loads

Product types by area of ​​use

Before we get to the question of how to make a cement standard, let's talk about the types that are produced and used everywhere today.

Several types of cement are produced today

Many people mistakenly believe that bThe concrete structure itself is quite durable. This is not true. When exposed to aggressive media, cement bonds are destroyed, therefore in construction it is very important to correctly selecttype and brand of products.

It looks like clinker

Whatcementclinker

Before describing the technological process in detail, let us touch on the main component of cement - clinker. This granular intermediate product is obtained by firing a mixture of clay and limestone in a kiln at a temperature of + 1450 ° C. Limestone requires 3/4, and clay - 1/4. They can be replaced with materials of similar quality. Limestone is chalk, marl or other rocks.

Margel is one of the limestones

In the process of firing, melting occurs, as a result of which granules of different sizes are formed - clinker. When it is ground and combined with additives, mainly gypsum, cement is obtained.

What cement is made of: the main raw material

The basis of any type of modern product is a minimum of components. They are all created by nature. At the heart of cement:

Let's talk about each of them in more detail.

Chalk quarry

Carbonate rocks are chalk, marl, limestone and shell limestone, calcareous tuff, and marble. All of them are used in the production of cement, the only exception is marble. The exact amount of a component is determined by analyzing its properties and content. The rock may contain gypsum, quartz, dolomite. The more substances with a crystalline structure are present in its composition, the harder it melts.

The clayey rocks used in the production of cement are clay, loam, loess, montmorillonite, shale. Clay is a rock of sedimentary origin with a fine structure. Its main quality is plasticity in contact with water. It also tends to swell.

Clay is a plastic material

To adjust the composition, manufacturers add additives containing silicon, iron, alumina. Waste from other industries is most often ordered for them, for example, dust from blast furnaces or pyrite cinders.

Pyrite under an electron microscope

Additionally, the composition of cement may include mineralizers, belite sludge, and other waste from industries.

How cement is made in production: three main methods

As we said earlier, there are several ways to make cement in an industrial setting. Three main methods:

Dry method

Depending on the properties of the feedstock, a production scheme is selected. The dry method is divided into the following stages:

It looks like a rotary kiln of a cement plant

This production method is considered to be the most profitable and less energy consuming.

Wet way

This method involves grinding the components and adding water to them. The result is not flour, but raw sludge. It goes into the kiln for roasting, and then into the refrigerator. The cooled clinker is ground and, if necessary, additives are added.

Differences between dry and wet methods

Combined method

In this case, first, raw sludge is obtained by the wet method, then it is dewatered, and granules are obtained. They go through the oven used in dry production. As a rule, the expediency of this method is based on the quality of the feedstock and the reduction in the cost of the final product.

Any of the methods requires the most thorough mixing of raw materials and the finest grinding. The product should be smooth. Finished products are stored in cement silos, which are towers. In them, the cement is aerated, which prevents it from caking. Products are packed in paper bags or not packed, but sent in bulk.

Cement silos ELKON

How and from what cement is made: video

We offer you to watch a video about the stages of cement production:

How to make cement at home

You can make your own cement. However, this will require two types of equipment:

The output will be cement grades with a low degree of strength (not higher than M200), as a result, such a product can be used only for lightweight concrete structures. Another problem: it will be difficult to perform analyzes, so the quality of the cement will be lame.

Factory made cement

You will need 75% and 25% chalk and kaolin, respectively. The raw material is crushed in a mill to a homogeneous powder. It must mix well before entering the oven. After firing, grinding is performed again, then it is necessary to add 5% gypsum to the resulting mixture. The product is ready! Whether you bought the product or made it yourself, you will need information on how to make the grout.

Cement mortar

How to prepare grout

To start construction work, you will need to prepare a cement mortar. Every man should know how the mixture is made. Cement-based mortars are of different types, but they all have the same basic composition.

Masonry mortar

The composition of the cement mortar

Three components are required for the preparation of a cement mixture:

Sand, gravel, crushed stone and other components are used as filler. The most important rule when receiving is the observance of proportions.

Mortar for plaster

Cement slurry proportions

The proportions are calculated depending on the type of work and the type of cement. For example, a mortar of cement and sand is used to floor screed.

An expert's point of view

Dmitry Holodok

Technical Director of the repair and construction company "ILASSTROY"

"The more additives in the mortar, the slower the mortar will set."

To make a mortar for brickwork, you will need to follow the proportions of cement and sand according to the table:

Related article:

Saving on cement will lead to a decrease in the grade of the finished mortar. To prepare a three-component solution from sand, crushed stone and cement, products of the M400 and M500 brands are used.

Table of proportions for mortar under the foundation

How to dilute cement correctly

To prepare the correct technological solution, carefully read the instructions. For each type of work, a certain brand of solution is used:

The solutions are prepared either in a special pallet or in a concrete mixer. The latter will help to get a homogeneous mixture with a minimum of effort.

Preparation of concrete mix

To prepare the mixture, sand (preferably clean) is combined in the required proportion with cement and thoroughly mixed. Add water. It is advisable if it is sedimentary water, not tap water. Pouring in water, continue kneading. The resulting concrete mixture must be used within an hour and a half.

If the quality of cement depends on the manufacturer and raw materials, then the quality of the concrete mix depends only on you!

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