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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

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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

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THE CEMENT MANUFACTURING PROCESS quarry raw grinding and burning grinding, storage, packing, dispatch

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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

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Manufacture of Cement Cement could be manufactured by any one of the two methods: 1.Dry process 2.Wet process

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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

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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

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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

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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

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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

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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.

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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

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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.

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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.

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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.

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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.

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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

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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.

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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.

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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.

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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

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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.

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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.

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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).

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Manufacture of Glass The manufacturing procedure may be divided into four major phases: 1. Mixing, 2. Melting, 3. Shaping, 4. Annealing.

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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.

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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.

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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.

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Types of Glass: 1.Soda Lime Glass: It is used for making window glass, containers of all kinds, flat glass, table ware bottle, mirrors.

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2.Silica Glass: It is used for the manufacture of mercury vapour lamps, telescope mirror etc.

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3.Borsilicate Glass: It is used for the manufacture of laboratory glassware.

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4.Lead Alkali Glass: It is used for making electric light bulbs and shield.

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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.

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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.

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8.Glass Ceramics: They are being used in various electronic devices and as cook serve freeze utensils.

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9.Fibrous Glass: Fiberglass is used for a variety of purposes. The most common uses of fiberglass include thermal and sound insulation,

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WELCOME TO THE WORLD OF PAINTS

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3. Paints Covering material (liquid) used to improve appearance and to protect the substrate from the weather attack is called paint.

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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.

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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).

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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.

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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.

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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.

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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.

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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.

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PAINT COMPOSITION PAINT PIGMENTBINDERSOLVENTADDITIVE ICIS Copyright - 2012, All Right are reserved

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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.

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PAINTS CAN BE APPLIED BY: Brush Roller Spray Gun

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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.

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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.

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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.

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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

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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:

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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

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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

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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

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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.

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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)

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Jetties(platform where boat can be tieted) Levee protection Membrane linings, waterproofing Reservoir linings Swimming pools Used in road construction

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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

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Asphalt is used in road making. It is used in water proofing.

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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.

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A light strong material that is produced by chemical processes and can be formed into shapes when heated Plastics:

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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

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There are two main types of plastics; 1.Thermoplastics 2.Thermosetting plastics TYPES OF PLASTICS:

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Cellulose acetate Cellulose nitrate polythene PerspexPVCPVA

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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:

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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:

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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

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2.plastics for irrigation and drainage pipes

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3.plastics for drinking water pipes

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4.plastics for insulation materials: the act of protecting with a material that prevent sound, heat and electricity to pass through.

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5.plastics for fittings

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6.plastics for floor and wall coverings

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7.plastics for roofing

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8.plastics for waterproofing

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9.plastics for window and door profiles