Pakistan is a country that is wealthy in cement raw material.

Cement, being one of Pakistans major industries, has been playing an essential role in the socio-economic growth of the country. While the industry has seen its highs and lows in the recent past, it has improved during the last couple of years. The growth in current years is the result of the development of export markets and an increase in production ability

History

In 1921 the first cement plant was established in the city of Wah. During its independence in 1947, Pakistan acquired four cement plants. In 1972 the cement industry was nationalized and the State Cement Corporation of Pakistan was established. The cement industry was privatized in 1990 which led to the setting up of new plants.

Cement Market
Pakistan's cement market, which at present consists of 29 cement plants, is divided into two separate regions, North and South.

The northern region consists of the provinces of Punjab and NWFP.

Some of the major cement manufacturers in this region are: o D.G. Khan o Lucky Cement o Maple Leap

The southern region consists of the province of Sindh and lower parts of Balochistan.

Some of the major cement manufacturers in this region are: o Attock o Zeal Pak o Thatta

Cement production capacity in the North is 35.18 million tons {80 percent} while in the South it is only 8.89 million tons {20 percent}.

Exports

According to the Global Cement Report, Pakistan has been ranked 5th in the worlds cement exports because of high demands in nearby countries Pakistan Cement Industry produces a surplus of cement which is exported mainly to Afghanistan, India, Africa and the Middle East.

Demands
Factors behind the increase of demand in cement:

Major construction projects such as dams Reconstruction of schools and stores Real estate development projects

Cement Information What is Cement? Cement is a material with adhesive and cohesive properties that makes it capable of bonding mineral fragment into a compact and rigid mass. The word cement seems to have been derived from the middle age English cyment, and Latin caementum. The latter word caementum meant rough quarried stone or chips of marble from which a kind of mortar was made more than 2000 years ago in Italy. During the Middle Ages term cement or sement

generally was made for a mortar. Common lime, hydraulic lime, gypsum plaster, pozzolana, natural and Portland cement are few of the material, which are used for cementing purposes. These cementing material may be classified into two groups: Non-Hydraulic: Non-hydraulic cement do not have the ability to set and harden under water but requires carbon dioxide from air to harden e.g. non-hydraulic lime and plaster of Paris. Their cementing prosperity arises from the re absorption of gases that were expelled during their processing. Their products of hydration are not resistant to water. Hydraulic: Hydraulic cement is defined as cement having the ability to set and develop strength in air or under water and which are insoluble in water after they have set. Such cement harden even in the absence of air and form a solid product which is stable in water and can be safely used in all structures in contact with water. Hydraulic cement includes hydraulic limes, Portland cement (both basic and blended), oil-well cement, white cement, colored cement, high alumna cement, expensive cement regulated and hydrophobic cement etc. Quarrying and crushing The primary raw material for cement manufacture is calcium carbonate or limestone. This is obtained from the quarry where, after the removal of overburden, the rock is blasted, loaded into trucks and transported to the crusher. A multistage crushing process reduces the rock to stone less than 25 mm in diameter. Most modern cement factories are located close to a source of limestone as about 1.5 tons of limestone is needed to produce one ton of cement.

Blending and storage The crushed rock is stored in stockpiles where, by a carefully controlled process of stacking and reclaiming across the stockpile, blending takes place and a uniform quality of raw material is achieved. Systematic sampling and laboratory testing monitor this process. The other raw materials, normally shale, iron ore and sand, are also stored in stockpiles.

Raw milling and homogenization

Carefully measured quantities of the various raw materials are fed, via raw mill feed silos, to mills where steel balls grind the material to a fine powder called raw meal. Homogenizing silos are used to store the meal where it is mixed thoroughly to ensure that the kiln feed is uniform, a prerequisite for the efficient functioning of the kiln and for good quality clinker. Burning The most critical step in the manufacturing process takes place in the huge rotary kilns. Raw meal is fed into one end of the kiln, either directly or via a preheater system, and pulverized coal is burnt at the other end. The raw meal slowly cascades down the inclined kiln towards the heat and reaches a temperature of about 1 450 C in the burning zone where a process called clinkering occurs. The nodules of clinker drop into coolers and are taken away by conveyors to the clinker storage silos. The gas leaving the kiln is cleaned by electrostatic precipitators prior to discharge into the atmosphere.

Cement milling The cement mills use steel balls of various sizes to grind the clinker, along with a small quantity of gypsum to a fine powder, which is then called cement. Without gypsum, cement would flash set when water is added and gypsum is therefore required to control setting times. The finished cement is stored in silos where further blending ensures consistency.

Quality assurance Extensive sampling and testing during the manufacturing process ensures the consistency and quality of the end product. Testing takes place at the stages of the manufacturing process indicated by the symbol. Cement despatch Cement is despatched either in bulk or packed in 50 kg bags and distributed from the factory in rail trucks or road vehicles. The 50kg bags are either packed directly onto trucks or can be palletised. The pallets can be covered by a layer of plastic to offer further protection from the elements.

Types Of Cement: The types of special cement now being produced can be roughly classified in the following six categories according to the special purpose for which these have been designed. These are:

1. Rapid hardening cement.

2. 3. 4. 5.

6.

Cement resistant to chemical attack of certain soil and aggregates. Low heat of hydration cement. Better protecting cement for steel reinforcement. Better workability and whether resisting cement. Decorative cement and other special cement. Rapid Hardening Cement: Under this category following two cement have the desired properties of fast development of strength viz. the Portland Rapid Hardening Cement and High Aluminum Cement. Their specific characteristics are as follows: Rapid Hardening Cement (Type III of A.S.T.M): This cement has high early strength, its equal to or better than 3 Days strength of OPC. This is achieved by having high contents of tricalcium silicates in its composition. It is mostly used in intended to release the framework within 24 hours or so for subsequent use in the mass production of RCC elements. The respective 1,2,3,7 and 28 days strengths (in equivalent P.S.I figures) of this cement under British specifications, German standard, and A.S.T.M. Japanese and Pakistan standards for mortar cubes are as follows: German Standard 4350 7975

B.S. 1 day strength 2 days strength 3 days strength 7 days strength 28 days strength 4200 6670

Astm 1800 3500 -

Japanese 923 1846 3266 4686

Pakistan 4205 5220 6670

The difference in strengths given above is basically due to difference in all standards the 3 days strength is nearly 1-1/2 to 2 times of O.P.C. The disadvantages of this cement beside its higher cost are its high heat of hydration, which renders it unsuitable for mass concreting projects. High Aluminum Structural Cement: This cement is used where very rapid setting and very high early strength are required. This cement has strength at one day nearly equal to 28 days strength of O.P.C. Its setting is so fast that it must be put in place within a few minutes of

its in

mixing. generally plugging leakage dams

It

is

used in

etc.

or

putting in pile foundations where limited time is available for setting of cement before the seepage water build up occurs. In Pakistan it has been used in some specific locations in terbela dam. Abroad it has been used in buildings where it was found essential to remove the framework after one or two days. This cement besides its high cost has the disadvantages of the high heat of hydration and retrogression in strength in time. There have been some structural failures due to miscalculation of its final strength after some years of use especially in humid and hot atmosphere. This cement has however excellent heat registering qualities and is therefore extensively used in Kilns, boilers and Furnace linengings. Cement resistant to chemical attack especially of Sulphate and Organic acids or Soil and active Silica of aggregate. In this category the following cement can be included: 2-A 2-B 2-C 2-D 2-E 2-A Highly Sulphate Resistant Cement Moderately Sulphate Resisting Cement Portland Blast France Slag Cement. pozzolana Cement Low Alkali Cement Highly Sulphate Resisting Cement H.F.R.C The most important and the most widely used chemical resistant cement is H.S.R.C cement High concentration of sulphate salts is present in seawater and in the soil near seashores. These salts are sometimes present in soil and in the submit water even thousands of miles away from the sea. Even Terbela Dam site was found not free from sulphate and H.S.R.C had to be used in foundations at

the site. The sulphate salt severally attack concrete can start within months. This cement has lower 3 days strength than OPC and also its capacity to protect reinforcement steel in structures exposed to atmosphere action is lower than OPC and hence not recommended for usual R.C.C. work in super structures. 2-B Moderately Sulphate Resisting Cement (M.S.R.C.) This cement has been developed as a compromise Cement having the good properties of sulphate resistance to some extent and of good alkalinity like that of OPC which useful for reinforcement protection and also of early strength development better than Highly Sulphate Resisting Cement. No standard exists for this cement in the B.S and P.S. specifications but under ASTM it is designed as Type II. The three days minimum strength of OPC, H.S.R.C & H.S.R.C is 1800, 1200 and 1500 PSI respectively under ASTM. This cement though better than H.S.R.C in many respects is not as resistant to sulphate as H.S.R.C and should not be used in foundations near the seashore. Incidentally the O. P. cement produced in most of the Cement Factories around Karachi are confirming to the ASTM specifications for this type II and hence more resistant to mild sulphate attack than the cement produced in the factories in other parts of country. 2-C Portland Blast Furnace Slag Cement: This cement has well to moderate resistance to sulphate attack from soil. This cement has some other very desirable qualities of stability details of which follow below under item 3C. 2-D Pozzolana Cement: This cement has well to moderate resistance to sulphate attack from seawater or soil containing sulphate. 2-E Low Alkali Cement: This is a variety of ordinary Portland cement in which the total alkali contents of cement has been controlled to remain below 0.6%. With this reduced percentage

of alkali contents the danger of alakie of cement attacking the active silica contents of aggregate is eliminated. Generally we do not have active aggregate of this type in Pakistan but on each large scale-concreting project, test of alkali aggregate reaction must be performed to enshore safety of the project. Certain varieties of Chert-stone found in Pakistan contain active Silica and would require low alkali for making concrete. Low Heat of Hydration Cement: Normal and Rapid Hardening Cement generate lot of heat during the setting and hardening process so much so that the structure under concreting can crack. This can occur specially while poring large messes of concrete in confine spaces like those of Dam and Bridge pier foundations. In order to avoid this problem cement of low Heat of hydration have been developed some of which are as listed below: 3-A Low Hear of Hydration Cement (type IV of A.S.T.M.)

3-B Portland blast Furnace Slag Cement 3-C Pozzolana Cement

3-D Super Sulphate Cement 3-A Low Hear of Hydration Cement (type IV of A.S.T.M.): This is cement specially meant for the concreting of structures where large masses of concrete have to be poured at one time. Generally it is specified that heat of hydration on 7 days will not exceed 250Kg. This is achieved by making this cement with larger percentage of di-calcium silicates in its contents than normally presents in OPC. In A.S.T.M this cement is designated as type IV and under BS as LHP. Under German standards its type is LAHORE with symbol as N.W. while the Japanese equivalent is type L.H.P with symbol as M.H.C. The disadvantage of this cement is its slow development of strength and is therefore not used at sited where rapid hardening or other specific qualities are required. 3-B Slag Cement: This is another variety of low heat cement. Grinding 35% to 65 % of granulated

blast furnace slag with ordinary Portland cement clinker produces it. The higher the slag contents, the lower are the 3 and 7 days strengths but better is the resistance to chemical attack. Under German standards as much as 90% slag can be used with type HOZ cement and under Japanese standard up to 70% in the type BSCC. This cement is slower hardening compared to OPC- its strength compared to OPC in ASTM being as follows: OPC 1,800 2,800 4,000 B.F SLAG CEMENT 760 1,400 3,000

3 days strength 7 days strength 28 days strength

This cement besides being a low heat cement has also the advantage of being medley sulphate resistant although it cannot replace the highly sulphate resistance cement for marine piles and foundations. This cement has excellent resistance to weak organic acids present in the soil and has also the very desirable quality of protecting reinforcement steel better than any other cement. 3-C Pozzolana: Grinding various proportions of natural pozzolana, tars or volcanic ash with ordinary Portland clinker makes this cement. It is very good cement in the sense that it has good workability properties in addition to having low heat and moderate sulphate resisting properties. It has been used extensively in the 37KM long causeway connecting Dhahran with Bahrain in the gulf. So far in Pakistan we have not been able to locate useful pozzolana deposits, but there are indication that there may be good deposits of this material in the overburden of coal deposits of Sindh. 3-D Super Sulphate Cement: This is another variety of low heat cement. Its standards exist under B.S but not under A.S.T.M. it is made by grinding about 70-80% B. F. Slag with about 10% gypsum and 1-2 % Portland clinker or lime. This cement is also middy resistant to sulphate attack. It is very finely ground cement and its early strength at 3 day is comparable to OPC although under the BS its 7 days strength is required to be comparable to at least the 3 days strength of OPC. This cement is also good masonry cement due to its good workability but it can be used in RCC and other construction work in the same manner as OPC is used with excellent results. Cement For Better Protection of Reinforcement against Corrosion: The basic steps for the prevention of resulting of steel in concrete is to use such cement

aggregate and mixing water as are basically free from chlorides, maximum contents of chlorides in concrete being limited to 0.02 % by weight. The following properties in cement are essential for greater protection of steel: 1. Cement to be with minimum percentage of Chlorides says not exceeding 0.01 per cent. Portland Cement preferably having about 6 to 8 per cent Tricalcium Aluminates. Cement made with slag as additive.

2. 3.

If the Tricalcium Aluminates is less than 5 per cent as per ASTM the cement will not have the capacity to neutralize the stray Chloride entering into concrete and thus fail toward off the effects of Chlorides. The properties of slag cement with about 35 percent slag and 60 per cent Portland Clinker are superior to other cement in this respect. Cement for Better Workability and Wealth E.W. Resistance These are cement, which are render the corresponding concrete more workable than other normal cement. This quality is necessary where high compatibility and better weather resistance is demanded. Because of greater workability the concrete made from this cement can achieve much higher strength due to lower water cement ratios achievable compared with other cement. This property is given to the cement by addition of the entraining agents like lime or other plasticisers so that the remix and to place in position. Some of the cement belong to this category are: Air Entraining Cement: Under ASTM four different types of cement have been classified as air-entraining version for normal Rapid-hardening and Sulphate Resisting Cement and each concrete thus made is more workable and attains higher weather resisting property compared to their non-air entrained versions. Blended Hydraulic and Masonry Cement and Grouts: This cement is basically made for plastering and grouting. Standards have been laid down for this cement both in the British and ASTM specifications. In fact under ASTM

there are at least 10 versions of Masonry cement. Some of the standards are for OPC based cement with or without air entraining agents while others are for sulphate resistance and low heat versions. This masonry cement is made by addition of plasticizing materials like lime, ground silica, slag or Pozzolana and air- entraining agents etc. Portland Cement clinkers during grinding. Decorative Cement Oil Well and other Special Purpose Cement: This cement is basically of properties similar to O.P.C except that it is made from such raw materials, which contain the least amounts of coloring pigments like traces of iron, manganese and chrome. Basically this cement has higher Tricalcium Aluminates in its contents than OPC and therefore subjects to sharp attack by sulphate from any source.

Portland cement is the most commonly used type of cement in the world today. Portland cement can be found in both concrete and mortar, not to mention other construction mediums such as stucco and some types of grout, where it acts as a binding agent. On a chemical level, Portland cement is a fine powder comprised of a minimum of 66% calcium silicate, with the remainder largely being a mix of aluminum, and iron. Portland cement is a hydraulic material, which requires the addition of water in order to form exothermic bonds, and is not soluble in water

Portland Pozzolana Cement is manufactured by blending pozzolanic materials, OPC clinker, and gypsum either grinding them together or separately. Today Portland Pozzolana Cement is widely in demand for industrial and residential buildings, roads, dams, and machine foundations.

Statement of Installed Production Capacity cement

North Zone As on April 2012

Sr. No.

Name Of Unit Clinker

Operational Capacity Cement 1,102,500 1,575,000 1,228,500 3,600,000 1,086,750 1,102,500 504,000 1,134,000 2,110,500 2,110,500 3,433,500 819,000 1,197,000 2,110,500 2,677,500 3,912,000 3,370,500 2,047,500 2,030,250 37,152,000

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Askari Cement Limited - Wah Askari Cement - Nizampur Bestway Cement Limited - Hattar Bestway Cement Limited - Chakwal Bestway-Mustehkum Cement Limited - Hattar Cherat Cement Company Limited-Nowshera Dandot Cement Limited - Jehlum Dewan Hattar Cement Limited - Hattar D.G.Khan Cement Limited - D.G.Khan D.G.Khan Cement Limited - Chakwal Fauji Cement Company Limited - Fateh Jang Fecto Cement Limited - Sangjani Flying Cement Limited - Lilla GharibWal Cement Limited - Jehlum Kohat Cement Company Limited - Kohat Lucky Cement Limited - Pezu Maple Leaf Cement Factory Limited - Daudkhel Lafarge Pakistan Cement Company Limited - Chakwal Pioneer Cement Limited - Khushab Sub Total (North Zone)

1,050,000 1,500,000 1,170,000 3,428,571 1,035,000 1,050,000 480,000 1,080,000 2,010,000 2,010,000 3,270,000 780,000 1,140,000 2,010,000 2,550,000 3,725,714 3,210,000 1,950,000 1,933,571 35,382,85 7

South Zone 1 2 3 4 5 Al-Abbas Cement Limited - Nooriabad, Dadu Attock Cement Pakistan Limited - Hub Chowki, Lasbela Dewan Cement Limited - Dhabeji Lucky Cement Limited, - Indus Highway, Karachi Thatta Cement Limited - Thatta 540,000 1,710,000 750,000 3,428,571 300,000 567,000 1,795,500 787,500 3,600,000 315,000