Cement clinkers are formed by heating limestone, clay, bauxite, and iron ore sand in a kiln, then ground with gypsum to make cement. Portland cement is the most commonly used type. Cement production has environmental impacts, but by-products can be reused. Cement mixed with water forms a strong alkaline solution and should be handled with caution.
Cement clinkers are formed by hot working of concrete elements in a kiln. Limestone, clay, bauxite and iron ore sand in specific proportions are heated in a rotary kiln at 2,770° Fahrenheit (1,400° Celsius) until they begin to form lumpy ash, also known as cement clinker. These are usually ground with gypsum to produce the fine powder, later mixed with liquid to make cement, although some manufacturers ship clinker in its lumpy form to reduce dust.
Cement is heavily relied upon to make mortar, mortar and concrete, and cement clinkers are the first stage, after firing, in the production of cement. Cement has strong adhesion properties when mixed with gypsum and water to form a hydration reaction, and forms about one-tenth of the concrete, mixed with rocks, sand and other materials, and used in building construction around the world. Concrete’s high versatility makes it an ideal tool for building projects of all shapes and sizes, from high-rise buildings to poolsides. Concrete can also be recycled when it has outlived its usefulness and reconverted into cement clinker through careful processing.
The most commonly used cement in the world is Portland cement, which is formed at high temperatures that chemically combine ingredients into new components, including calcium silicates and calcium aluminates. When cement clinkers are ground with about 5% gypsum, they form Portland cement. These compounds allow concrete to harden when combined with water and form strong bonds that can withstand pressure, water immersion, and other elements.
Natural raw materials can be used in a kiln to form cement clinker, although other materials with the correct chemical composition are also used, such as fly ash from coal burning, kiln slag and other industrial by-products. Depending on the purpose for which the concrete is intended, slightly different chemical formulations are used to increase strength, add resistance to sulfates, make the concrete tolerant of low temperatures, form expansion concrete that will not shrink after setting, or create concrete for masonry, which is not intended for concrete mixes. If consumers are unsure which concrete formulation is appropriate for a project, they should consult an expert source to confirm that they are using the material best suited to their needs.
The production of cement clinker has environmental ramifications, starting with the dust, noise and vibrations caused by the extraction of natural raw materials. Cement kilns also consume a significant amount of fuel and polluting equipment is used in most stages of cement production. However, some of these effects are offset by the reuse of slag, fly ash and silicate by-products. Furthermore, many cement producers use other agricultural and industrial by-products to fuel their kilns, contributing to the disposal of these materials.
Cement, mixed with water, forms a very strong alkaline solution. Gloves and eye protection should always be worn when working with cement, and the cement should be washed off the skin immediately to prevent injury to the skin. Once the concrete hardens, it can be handled without precautions.
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