Cement Production and Quality Control

Introduction

This course exploring the quality control of cement manufacture, including the different quality control challenges faced by different cement factories around the world, plus the philosophies, testing, tools, and equipment used to address those quality control challenges. Also, this course is intended for structural and civil engineers who are interested in quality control and QA with the most recent non-destructive testing for concrete and steel structure.

Objectives

Module 1: explores the quality control challenges presented by cement manufacture. Cement is a hydraulic binder used in conjunction with other materials whose performance can only infer and predicted during its manufacture. As a consequence, there is an overriding requirement to minimize variability in material composition and processing throughout the manufacturing process. Quality assurance systems must be developed to control the composition of all inputs to the manufacturing process and all processing conditions. Cement products may be developed for multiple applications but the requirement to minimize variation remains paramount.
Module 2: Statistical process control (SPC) relies on the centering of quality targets on the requirements of the customer or application, followed by the reduction of the variation about those targets to ensure that non-compliant material is never produced. It is therefore the methodology to be used in the quality control of cement manufacture and the main topic of module 2 of the course. This use of statistical process control needs to extend far beyond the laboratory and composition testing of the materials. It needs to be extended to control the manufacturing conditions within the process. Progressive reduction of variation using SPC techniques leads to continuous improvement which is demanded of all quality management systems.
Module 3: we explore the detail of quality control throughout the cement manufacturing process. Raw material chemistry control and raw mix design, kiln feed particle size and reactivity control, clinker real mineralogy control via microscopy, or XRD. Cement surface area and particle size distribution, gypsum dehydration and calcium sulfate mineralogy, extender quality, and storage or transportation considerations. Finally the physical testing of cement to ensure that the manufacturing quality control addresses the needs of the cement in its concrete and mortar applications.

Module 4: The participants will be familiar with all quality management techniques and procedures and the available non-destructive testing for concrete and steel structure projects.

Training Methodology

This is an interactive course. There will be open question and answer sessions, regular group exercises and activities, videos, case studies, and presentations on best practice. Participants will have the opportunity to share with the facilitator and other participants on what works well and not so well for them, as well as work on issues from their own organizations. The online course is conducted online using MS-Teams/ClickMeeting.

Who Should Attend?

This training course is suitable for a wide range of professionals but will greatly benefit:-

• Cement and Civil Engineers
• Construction Engineers
• Project Managers
• Construction Managers
• Quality Assurance and Quality Control professionals

Course Outline

• ISO 9001 requirement
• Total Quality management system
• Quality assurance
• Quality control
• Who will perform the quality control?
• Pareto chart
• Process chart for ready mix plant
• Coefficient of variation
• Auditing the construction site quality

The nature of concrete variability

• Concrete materials properties
• Aggregate QC
• Cement QC
• Concrete mix QC
• Submittal steel sections QC
• Check laminar and porosity in steel sections

Quality control for concrete forum 

• Pouring concrete in hot and cold weather
• Workability test for concrete
• Cube and cylinder test
• The replacement of the steel bars
• The permissible deviation in erection steel structure
• Comparison between different Non-destructive test
• Core test
• Rebound hammer
• Lock test
• Load test
• Ultrasonic test

Welding procedure

• Materials that is using in welding in steel structure
• Understanding the welding symbol
• The precaution in welding process
• The reasons of welding defects.

Differentiate between Non-destructive tests

• Magnetic particle test procedure
• Penetration test procedure
• Radiographic test procedure
• Radiographic test precaution
• How to define the defects from RT film
• Ultrasonic test procedure