Leslie Struble Paul Livesey Peter Del: Complete Guide & Down

Portland Cement is the definitive textbook of the cement of the same name: the volume by Dr Gerry Bye, the Portland cement chemist of the long career, with the editing of Paul Livesey and the technical editing of Professor Leslie Struble and the contribution of Peter del Strother: the book that the modern generation of the cement scientists call the natural successor of the classic texts: the third edition carries the whole of the subject: the raw materials, the clinker chemistry, the manufacture, the hydration, the microstructure, the properties of the concrete and the environmental performance: the complete portrait of the grey material that shapes the built world.

The Complete Cement Technical Package (931 files including the books, the Excel tools, the courses and the presentations: $249.99 one-time: instant download via the PayPal payment) includes this Portland Cement third edition PDF with its chapters, equations, micrographs and its appendices: the researcher, the cement chemist, the quality engineer and the student of the material science read the full book in this file: this article walks the book: the raw materials and the manufacture first, the chemistry of the clinker second, the hydration third, the concrete properties fourth, the durability and the environment last: the reader finishes with the integrated view of the most consumed manufactured material on the planet: about four billion tons a year.

The title of the catalog entry records the names of the editors and the contributors (Struble, Livesey, del Strother) because the printing credits them together with the author Gerry Bye: the catalog of the package shortens the entry to the names of the contributors, and the actual book is the Portland Cement of Dr Bye in its third edition: the reader of this article receives the honest map: the editions, the authors and the content of the volume as published: the book of the cement of the world, poured into this PDF of the package.

1. The Birth and the Definition of the Portland Cement

The book opens with the history and the definition: the Portland cement is the invention of the 19th century, the name from the stone of the Portland island of England, and the definition of the modern standard: the hydraulically setting binder made from the clinker of the limestone and the clay materials burned to the partial fusion, with the gypsum additions:

• The standard definitions: the EN 197-1 of Europe and the ASTM C150 of the United States: the Portland cement of the standards and the common cements: the strength classes, the composition ranges and the certification: the vocabulary of the cement languages of the world found in the first chapters;
• The Portland clinker: the product of the burning of the raw mix: the four main minerals, the C3S (the alite), the C2S (the belite), the C3A (the aluminate) and the C4AF (the ferrite), plus the minor phases and the free lime: the minerals are the base of all the cement properties;
• The scale of the industry: the world production of the cement of about the four billion tons, the CO2 of the industry and the energy problem: the problem of the cement is the problem of the world, and the book is the fundamental of the professional answer;

The Portland cement is the manufactured material of the greatest mass of the world: all the concrete of the life of the modern cities: the bridges, the towers, the dams, the roads: the story that the book tells: from the chemistry of the stone in the quarry to the strength of the concrete in the structure.

2. The Raw Materials and the Raw Mix Design

The second chapter puts the kiln into the geology: the raw materials of the cement:

• The limestone and the clay: the natural raws of the cement: the limestone of the high calcium, the marl, the chalk, the slate and the corrective additives: the chemical requirements: the calcium oxide of the raw 65-70%, the silica, the alumina and the iron in the right balance: the book gives the chemistry of the raw materials of the typical plants and their national varieties;
• The mix design: the proportioning of the raw mix for the target clinker: the lime saturation factor, the silica ratio and the alumina ratio: the calculations verified with the examples: the grindability of the raw mix and the burnability of the kiln feed linked to the moduli;
• The raw processing: the quarry blasting, the crushing, the stockpiling and the homogenization: the preblending beds and the blending silos: the raw mix control by the X-ray fluorescence of the plant: the entire raw chain of the plant as the book describes it;
• The alternative raw materials: the fly ash, the blast furnace slag, the correctives of the waste, the slurries: the use of the industrial by-products in the raw mix: the circular economy of the cement industry, described in the book with the chemistry and the economy side by side;

The chapter carries the message of the raw mix: the clinker chemistry is decided at the raw material stage: the lime saturation and the moduli are written by the raw design; the kiln only executes the chemistry that the raw engineer decided: the book teaches both the decision and the execution: the raw preparation is half of the quality control of the plant.

The quality of the quarry: the variability of the limestone bed, the face sampling, the daily assays and the storage strategy: the book explains the statistics of the raw control: the target mean and the standard deviation of the kiln feed, the blending power of the prehomogenization costs and the correction of the falling lines: the entire logic of the raw quality of the world’s plants from the geological sample of the deposit to the belt of the raw mill: this is the engineering of the starting point of the process, and the mixture of the deposit determines the cost of the burning for the whole life of the plant.

3. The Manufacture: The Kiln and the Process

The manufacture chapter explains the process of the whole industry:

• The process routes: the wet process, the semi-wet, the semi-dry and the dry process with the preheater and the precalciner: the modern dry process of the world standard: the book gives the flowsheets of every route and the energy ladder of the industry, from the wet slurry kilns of the history to the modern lines;
• The kiln: the rotary kiln, the combustion, the flame, the heat transfer, the burning zone, the clinker formation: the reactions of the kiln from the feed through the decarbonation at the 850-900 degrees to the final sintering of the burning zone: the book describes the operation of the burning of the clinker with the phase reactions and the parameters;
• The energy and the fuels: the specific heat consumption of the modern plants, the coal and the alternative fuels, the waste heat recovery: the thermal efficiency of the dry process measured against the practical: the treatment of the fuel substitution and its process consequences:
• The finished product line: the cement mills, the clinker, the gypsum, the additives, the packing and the dispatch: the final process of the plant: the quality control of the cement before the market: the standards of the dispatch and the logistics of the cement world:

The manufacture chapter is the chapter of the process engineer: the book faces the chemical theory with the plant operation: the engineer of the plant reads his kiln in the chemical language, and the chemist reads the plant in the operational language: the two languages of the book merge into the process picture of the whole route from the quarry to the silo.

4. The Clinker Chemistry and the Phase Formation

The classic core of the book: the chemistry of the clinker:

• The phase chemistry: the formation of the alite and the belite, the melt of the clinker, the C3A and the C4AF: the clinkerization as the sequence of the solid state and the melt reactions: the development of the phase composition with the burning time and the temperature:
• The clinker minerals: the crystal chemistry of the alite (the M forms and the triclinic), the belite, the aluminate and the ferrite: the solid solutions, the impurities and the minor elements (the alkalis, the sulphur, the chloride, the phosphate) and the phases that they form in the clinker:
• The burnability: the reactivity of the kiln feed, the combination of the lime, the free lime test and the litre weight: the book links the minerals of the feed to the burning temperature and the residence time: the burnability of the mix evaluated at the design stage of the plant:
• The clinker microscopy: the examination of the clinker polished sections under the reflected light: the identification of the phases by the optical microscopy, the polished and the etched surfaces: the microstructure of the well-burned and the under-burned clinker: the microscope as the quality instrument of the plant laboratory:

The clinker chemistry chapter is the deepest of the book: the professional reference of the clinker phases: the researcher and the plant chemist both live on its pages: the phase diagram of the cement, the melting of the charges and the compartmentalization of the clinker: the chapter recompiles the historical depth of the analytical cement chemistry.

The quantitative face of the chemistry: the Bogue calculation of the phase composition and its limitations, the microscopical counting of the phases and the X-ray diffraction of the modern laboratory: the book explains the practice of the quality chemist: the free lime control of the burning, the alkali and the sulfate balance of the kiln, the identification of the phases by the polished sections: the analytical foundations of the plant quality control: the chapter is written so that the process data of the morning shift find their explanation in the phase chemistry of the afternoon.

5. The Hydration of the Cements

The hydration chapter is the second pillar of the structure of the book:

• The hydration of the silicates: the hydrolysis of the C3S producing the C-S-H gel and the portlandite, the calcium hydroxide: the stoichiometry of the hydration, the heat, the kinetics and the rate laws: the development of the microstructure with the age: the C3S the fast and the C2S the slow: the two silicates of the strength of the cement;
• The hydration of the aluminates: the C3A reaction with the water and the sulfates: the mitigation of the flash set by the gypsum: the ettringite AFt and the monosulfate AFm: the hexagonal hydrates of the interlayered phases: the role of the gypsum in the control of the setting;
• The heat of hydration: the calorimetry of the cement: the curve of the heat of the hydration with the hours: the thermal correlations: the planning of the precast and the mass concrete, the cooling and the early strength: the heat released by the cement in the structure;
• The hydration products: the C-S-H phase, the CH, the AFt and the AFm: the microstructure of the blends: the porosity and the strength: the modern electron microscopy of the hydration products, the nanometre scale: the modern picture of the hardened cement paste in the book:

The hydration chapter moves the reader from the kiln to the concrete: the cement is the powder only for the hours of the transport; in the mixer it begins the second story of the hydrate crystals: the gel of the ages, the strength of the 28 days and the durability of the decades: the book tells this second story with the modern science of the hydration.

The reaction engines of the paste: the supplementary pozzolanic materials consume the calcium hydroxide and extend the binder while the limestone fillers participate in the early reactions: the admixture chemistry of the set and the workability: the superplasticizers, the retarders and the strength accelerators of the site: the chapter gives the place of the gypsum optimization, the sulfate balance and the alkali content of the cement in the setting of the mix: the hydration understanding of the book is the toolbox of the concrete chemistry and of the troubleshooting of the cement plants, from the false set of the silo to the flash set of the mixer.

6. The Microstructure and the Performance of the Hardened Cement

The microstructure chapter:

• The C-S-H gel: the calcium silicate hydrate of the variable composition: the porosity of the gel: the C-S-H of the cement paste the main volumetric phase: the influence of the water-cement ratio: the density of the hardened paste: the distinction of the capillary porosity and the gel porosity:
• The pore system: the pore size distribution: the mercury intrusion porosimetry of the cement: the percolation of the capillary network: the transport of the ions in the porous paste: the relations of the porosity to the strength and the durability: the two families of the pores and their consequences:
• The strength development: the compressive strength at the 1, 7, 28 days and the year: the influence of the water-cement ratio, the temperature and the age: the strength of the standard mortars: the strength equations of the book: the limestone of the porosity:
• The electron microscopy: the SEM and the microstructure of the paste: the inner and the outer products, the residual clinker phases: the interfaces and the matrix: the ITZ, the interfacial transition zone between the paste and the aggregate: the microcracking of the hardened material:

The chapter explains the link of the microstructure to the engineering: the statistics of the cubes of the laboratory are the result of the chemistry at the microscopic scale: the book connects the two: the material engineer reads the property tables of the concrete with the images of the microscope in his head: the scientific view of the hardened cement and its strength.

7. The Cement Manufacture and the Environmental Challenge

The modern chapters of the third edition: the environment of the cement:

• The CO2 of the cement: the process carbon dioxide from the decarbonation of the limestone in the kiln and the chemistry of the fuel combustion: the book: the two streams of the emissions and the reduction paths: the thermal efficiency, the alternative fuels, the clinker factor and the capture:
• The energy and the decarbonisation: the specific energy of the process, the waste heat recovery and the cement electrification: the roadmap of the net-zero operations: the steps of the book with the numbers of the industry: the carbon sequestration of the long term:
• The alternative fuels: the waste-derived fuels and the biomass in the kiln: the substitution rate of the installations: the behaviour of the wastes: the process consequences and the trace emission controls: the circular economy of the cement kiln of the future:
• The dust and the emissions: the air pollution control of the raw plants: the fabric filters, the reactors of the deNOx, the mercury control: the stack monitoring and the environmental permits: the environmental annex of the cement plant of the modern world:

The environment chapters are the chapters of the present: the classic Portland story meets the century of the carbon: the book does not finish at the kiln chemistry: it explains the future of the clinker: the net-zero cement, the capture-ready installations and the blended cement factor: the debate, the theory and the industrial status: the book of Bye, Livesey, Struble and del Strother is the current reference of the present and of the future together.

8. The Types of Portland and the Special Cements

Chapter of the cement family:

• The Portland types: the type I-V system of the ASTM and the CEM I-V of the EN the 197: the sulfate-resistance, the heat-controlled, the alkali-limited cements: the special cements of the white and the masonry: the consistency of the standards over the cement family: the table of the book the orientation of the reader:
• The blended cements: the slag, the fly ash (the pulverised fuel ash), the limestone (the Portland-limestone): the composition limits, the strength classes and the environments: the modern cements of the lower clinker factor: the sustainable cement families of the current standards:
• The white cement and the oil well: the white cement of the iron-poor raws, the oil well cements of the deep reservoirs: the chemistry of the special demands, the hydration and the retarders: the standard cement is a family, not a single line:
• The cements of the future: the calcined clays of the trim (the LC3), the belite clinkers, the calcium aluminate, the new binder concepts: the research of the frontiers: the book ends its road at the front of the science of the binders:

The typology chapter is the practical reference of the engineer: the engineer of the world finds his cement in the table of the types: the book is the navigation from the dozens of the cement names to the chemistry of the phases: the cement of the project, of the standard and the environment: the map is in the volume.

The choice of the type in the project: the engineer of the structures selects the cement for the exposure: the sulfate-resistant type for the ground waters, the low-heat type for the massive pours, the low-alkali for the reactive aggregates, the white for the architectural surfaces: the technical chapters of the book convert each project condition into the cement specification: the EN composition letters and the ASTM types appear with their internal chemistry: the designer reads the exposure and writes the cement: the volume supplies the science of the choice of the cement family for every structure of the built world.

9. The Use of the Cement in the Concrete

In the final technical chapters the book shows the cement at its destination: the concrete:

• The cement in the mix: the cement, the aggregates, the water and the admixtures: the workability, the slump and the mix design: the concrete of the site carrying the intact strength of the cement: the dosage of the code and the placement of the structures:
• The durability of the structures: the freezing-thawing, the sulfate, the carbonation, the chloride of the reinforcement, the alkali-silica reaction: the durability of the structures against the attacks: the cement engineer in the lifetime of a bridge: the concrete and the cement of the book:
• The chemical tests of the cement: the setting, the soundness, the strength, the heat, the fineness: the standard test methods: the quality of the laboratory of the plant and of the third party: the data of the quality: the cement of the book with all the quality tests of the production:
• The service life: the life of the structures, the diagnosis of the failures and the repairs: the modern structures and the hundred years of design: the cement in the building of the world: the responsibility of the envelope:

The final technical chapters close the loop: from the quarry to the concrete and from the chemistry to the durability: the reader of the book covers the complete cycle: the cement of the chemist, of the process engineer and of the concrete technologist: the one book with the complete cycle of the cement: the goal, the guide and the reference.

The quality system of the cement in the book: the chemistry of the release tests and their statistics: the strength control of the production, the conformity of the product and the procedures of the third-party: the book carries the direct connection of the plant quality to the properties of the concrete on the site: the sampling, the retention and the certificates of the deliveries: the engineer of the quality department finds in the final chapters of the reference the reliable map between the chemistry of his mill and the behavior of the concrete of his customer: a chapter, in fact, of the industrial relationship.

10. The Frequently Asked Questions

Is this book the same as the Lea’s Chemistry of Cement?

No: the two books are the different, and both are in the package: the Lea (the large multi-authored reference volume) is the encyclopedic collection: this book of Bye is the coherent textbook, the single-author monograph with the direct style and the deep chemistry: the Portland Cement of Dr Bye is the recommended read from cover to cover: the Lea is the reference of the lookup: the package offers both to the reader.

What is the position of the third edition against the older editions?

The third edition carries the modern material: the low-clinker cements, the carbon capture, the sustainability agenda and the modern microscopies: the editors Livesey, Struble and the contributor del Strother update the chemistry of the classic to the current picture: the classic of the book has the new edition of the present day: the third edition is the edition of the current science.

The reader who does not practice the chemistry: can he use the book?

Yes, with the patience: the book is written for the cement scientist, but the engineering chapters (the manufacture, the concrete, the environment) are readable by the plant engineer: the chemistry chapters demand the effort and reward the reader: the package companions even help: the operative handbooks and the courses of the package complete the production, and the fundamentals of the chemistry of the book return in the operations: reading the book together with the handbooks is the pipeline recommended by the package.

The book covers the complete science of the cement?

Yes: the chemistry of the Portland, the hydration, the phases, the microstructure, the cement types and the behavior in the concrete: the honest note: the specialist topics of the special binders (the refractory, the CA, the geopolymer, the deep well) are covered in depth by the dedicated books of the package (the Special Inorganic Cements volume, the refractory handbooks and the well cementing files): the Portland book: the monolith of the standard cement, and the specialties surround it in the same archive.

What does the engineer of the plant get from the reading?

The understanding: the process problems are the chemistry: the sulphur cycles, the alkali, the coating and the clinker quality: the diagnosis of the strength problems from the chemistry: the engineer reads the chemical roots of the plant symptoms: the book of the cement chemists in the hands of the plant: the best plant engineers of the industry classified the science of this book: the chemistry of the plant: the book of the shelf of every serious cement engineer.

11. Conclusion

Portland Cement of Dr Bye: the book of the most manufactured material of the humanity: the raw materials, the clinker, the hydration, the properties and the environment: the full cycle of the cement: the particles of the book: the science of the powder, the detail of the reactor, the honesty of the challenges: the new edition of the three generations of the cement science (Bye, Livesey, Struble and del Strother) refreshes the classic in the eyes of the cement of the current century: the material of the built world: written with the science of the materials: and the reader who closes the volume finishes the complete journey of the material: from the limestone of the quarry to the concrete of the final structure, the entire science of the engineered material assembled in the single reference: the definitive textbook of the Portland cement for the generation of the chemistry: the book of the cement of the world.

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