DOCUMENT RESUME ED 379 513 CE 068 364 AUTHOR Taylor, … · CEMENT is an acronym for Continuing Education Means Excellence Now. and Tomorrow. Participation in the CEMENT Program is

DOCUMENT RESUME

ED 379 513 CE 068 364

AUTHOR Taylor, Mary LouTITLE CEMENT. "A Concrete Experience." A Curriculum

Developed for the Cement Industry.INSTITUTION Orangeburg-Calhoun Technical Coll., Orangeburg,

SC.

SPONS AGENCY Office of Vocational and Adult Education (ED),Washington, DC. National Workplace LiteracyProgram.

PUB DATE 94

NOTE 109p.; For related documents, see CE 068 362-367 andCE 068 370-373. Printed on colored paper..

PUB TYPE Guides Classroom Use Teaching Guides (ForTeacher) (052)

EDRS PRICE MF01/PC05 Plus Postage.DESCRIPTORS Adult Basic Education; *Adult Literacy; *Basic

Skills; "Cement Industry; Inplant Programs; *JobSkills; *Learning Activities; *Literacy Education;Manufacturing; On the Job Training

IDENTIFIERS *Workplace Literacy

ABSTRACTThis instructor's guide contains 11 lesson plans for

inplant classes on workplace skills for employees in a cement plant.The 11 units cover the following topics: goals; interpretingmemoranda; applying a standard set of work procedures; qualities of asafe worker; accident prevention; insurance forms; vocabularydevelopment; inventory control forms; job-related spelling andmathematics applications; and standard and military time. Lessonobjectives, materials needed, job-related materials, pre- andposttests and a glossary also are included in the guide. (KC)

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Reproductions supplied by EDRS are the best that can be madefrom the original document.

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EMENT"a concrete experience"

U.S DEPARTMENT OF EDUCATIONOlive or Educahonat Research and Improvemeni

EDUCATIONAL RESOURCES INFORMATIONCENTER (ERIC)

.41 This document has been reproduced asreceived from the person or organizationoriginating it

Minor changes have been made toimprove reproduction quality.

Points of view or opinions stated in thisdocument do not necessarily representofficial OERI position or policy

a curriculum developed for the Cement Industry

FESICOPY AVAILABLE

2

Introduction:

Teacher Notes&

Course Goals

3

Project VISIONS

CEMENT Lesson Plans

developed by: Mary Lou Taylor, Instructorat Holnam, Inc., Holly Hill

fora National Workplace Literacy Grant

received byOrangeburg-Calhoun Technical College

Orangeburg, SC

These lesson plans were developed for use at Holnam, Inc. a cementmanufacturing plant in Holly Hill, South Carolina. When possible some of theactual company forms have been used to provide practice for participants on theactual forms. The participants range in educational level from 2 years of formaleducation to High School graduates and everywhere in between. The range of skillsis likewise varied. Activities were developed to appeal to a wide range of skills andall are done using collaborative group techniques. The participants are encouragedto talk among themselves in the group and share ideas openly without the fear ofjudgment by others. This is the main principle by which the classes are run. AtHolnam, the majority of employees have been with the company for more than 15years. They have proven themselves to be capable of performing above theirexpected level given their educational backgrounds. They are valued and trustedworkers.

CEMENT is an acronym for Continuing Education Means Excellence Nowand Tomorrow. Participation in the CEMENT Program is voluntary and off theclock. All participants are paid by the company for their time in class.

"The contents of this curriculum were developed under a grant from the Department of Education.However, these contents do not necessarily represent the policy of the Department of Education, andyou should not assume endorsement by the federal government."start with it in this class.

"i ?instructor Xotes

The lessons in this curriculum were developed for use at Holnam, Inc. acement manufacturing plant in Holly Hill, SC. These were used as part of aNational Workplace Literacy Grant awarded to Orange-Calhoun TechnicalCollege for use at three sites.

The lesson plans included in this publication are representative of thoseused throughout the eighteen (18) month grant period. Some of the lessonsare presented in one or two classes when in actuality they were introduced,practiced, and reviewed in several classes. The format should lend itself toeasy adaptation.

The classes at Holnam were named CEMENT, an acronym which standsfor Continuing Education Means Excellence Now & Tomorrow. Classparticipants ranged in educational level was from two years of formalschooling to High School graduates. There ability range was likewisescattered.

To address this varied audience, collaborative groups, whole language,and a technique called active reading were used. Active reading, ?is° knownas Reciprocal Reading, models good reading and thinking skillssimultaneously (an article on this method is included in the reference sectionof this curriculum). If you are not familiar with the active reading technique,please take the time to read the article as this has been a most helpful tool.

You will notice that many of the lessons in this curriculum are presentedto the participants in the form of a memo. The memo format is used to allowparticipants to become familiar with the format and provide a class-relatedreading exercise, thus allowing the participants to become comfortable withboth reading and receiving memos in order that they will be able to generatetheir own memo in response to a directed question in later lessons.

The role of the instructor in these lessons is more akin to that of afacilitator. Participants are encouraged to talk among themselves and askquestions of each other to collectively solve the situation they are assigned.They are allowed to call on the instructor when there is a problem reachinggroup consensus. The interaction provided in these activities serves as a

5 BEST COPY AVAILARE

basis for the introduction of the "team" concept that is being studied by thecompany as they are preparing for changes and modernization.

When the classes with math skills are conducted, the instructor may haveto leave the role of facilitator and enter the instructor's role. This will dependon the level of your group, often is was necessary to conduct these classesthrough a guided practice approach. Time is spent thoroughly discussing theaspects of each problems and the solutions are worked on the board whileparticipants work them on paper.

Separate pre and post tests are included with these plans and are found inthe addendum labeled "Pre-Test and Post Test." These tests are competency-based and teacher developed for use with this specific curriculum.

Good luck in using these activities, I hope that you will find them helpfulin your setting.

I wish to thank the various employees of the Ho lnam Plant in Holly Hill,South Carolina for their gracious help and support of the program.

Course Goals and Objectives are found on the next page.

6

Curriculum Goals - Holnam, Inc.CEMENT Program

GOALS:I. To involve participants in learning activities that will increase their self-confidence

and prepare them for the future.

II. To conduct class sessions using collaborative group techniques that encourageparticipation and enhance participants competencies in speaking, listening, reasoning

. and problem solving abilities on the job.

III. To conduct task analyses in order to identify the underlying skills necessary foremployees to perform their job competently and to use these skills as the basis for thecurriculum.

IV. To focus on the basic skills of reading , writing and math that are necessary tocompetently complete their jobs and to prepare them for advancement as jobs areupgraded and/or modernized.

V. To improve productivity and safe working habits through building of workerawareness of their role in the performance of these skills

OBJECTIVES:At the conclusion of classes, the participants will be able to:

1. State the purpose of a memo with 100% accuracy.

2. Improve their knowledge and use of work-related vocabulary with a minimumof 90 % accuracy.

3. Demonstrate an understanding of the use of formulas used in refractory math bysolving problems with a minimum of 90% accuracy.

4. Demonstrate a working knowledge of the 24-hour clock system.

5. Develop an awareness of the Inventory Control Process used in the Packhouseand the related math that accompanies this system.

6. Enter data on forms correctly.

7. Complete a pre and post asstasment of skills and exhibit a minimum of 10%improvement of scores.

7

Curriculum

for

CEMENT

8

Lesson # 1

LESSON OBJECTIVES:

Upon completion of this lesson the participants, working in collaborativegroups, the whole group, and individually, will be able to:

1) state in their own words a brief explanation of what a goal is.2) set at least two short term educational goals for cycle3) participate in a class discussion (group brainstorm) on goal

setting.

Materials:Memo #1Copies of course goalspaperpencils/pensIndividualized Education I-lans (IEP)

Instructor Materials:Newsprint padmarkerstape

MEMO #1

To: Continuing Education FoundationFrom: Lou TaylorDate: July 8, 1994Subj: Goal Setting

What is Goal SetijneA goal is something that we want to do or achieve. We set goals by selecting things

that we want to achieve and sometimes we put a time frame with the goal. We can choosepersonal goals like going on a vacation, painting the house, buying a new car, havinganother child, or saving for our retirement. Or we can set educational goals likeimproving our writing, working to get our GED, going to a Technical College, graduatingfrom college, or to generally improve our thinking and reasoning skills. At work, the planthas a production goal of 1,043,668 tons of clinker for this year(1994).

As you can tell some of these goals may take a long time to complete and some canbe done in a relatively short period of time. For example, saving for your retirement maybe something you start on the very first day you work and continue for thirty or moreyears while painting the house may be done during your next long weekend. When we setgoals that will take a long time to complete, we call these long term goals. The goals thatwe can accomplish in a short period of time are called short term goals.

How will we use goals in this class?In class today, we are looking at the educational goals we can set for ourselves both

long term and short term. In order to set short term goals we will need to look at whatwill be covered in class. You will receive a pink sheet with the class goals for cycle III(these are the goals that I have set for the class). I want us to look at these one at a timeand set our goals by what it will take to achieve the class goals. This way we will all beworking to meet the same goals and together we will each accomplish what we want outof the class. By setting goals we know what we want and then we can work to achieve.it.

ASSIGNMENT:Pay close attention as we discuss each of the course goals. I will be making notes

and putting them up around the room. When we go through all of the cycle goals, it willbe time for you to select which of the goals you want to be your goals for this cycle. Thecounselor will assist you in getting your goals down on paper. I will assist in meeting thegoals through class instruction and you will assist yourself by coming to class and workingto meet the goals that you have set for yourself.

Together Everyone Achieves More !!!

10

Curriculum Goals - Holnam, Inc.CEMENT Program

GOALS:I. To involve participants in learning activities that will increase their self-confidence

and prepare them for the future.

II. To conduct class sessions using collaborative group techniques that encourageparticipation and enhance participants competencies in speaking, listening, reasoningand problem solving abilities on the job.

III. To conduct task analyses in order to identify the underlying skills necessary foremployees to perform their job competently and to use these skills as the basis for thecurriculum.

IV. To focus on the basic skills of reading , writing and math that are necessary tocompetently complete their jobs and to prepare them for advancement as jobs areupgraded and/or modernized.

V. To improve productivity and safe working habits through building of workerawareness of their role in the performance of these skills.

OBJECTIVES:At the conclusion of classes, the participants will be able to:

1. State the purpose of a memo with 100% accuracy.

2. Improve their knowledge and use of work-related vocabulary with a minimumof 90 % accuracy.

3. Demonstrate an understanding of the use of formulas used in refractory math bysolving problems with a minimum of 90% accuracy.

4. Demonstrate a working knowledge of the 24-hour clock system.

5. Develop an awareness of the Inventory Control Process used in the Packhouseand the related math that accompanies this system.

6. Enter data on forms correctly.

7. complete a pre and post assessment of skills and exhibit a minimum of 10%improvement of scores.

11

Lesson #2

LESSON OBJECTIVES:

Upon completion of this lesson, the participants, working in collaborativegroups, will be able to:

1) evaluate the "Placing Material in Wetlands" memo and answer thelisted questions.

2) compare the two memos about "Designated Parking ..." byanswering the listed questions and

a- speculate on the possible cause of the delay in painting theclay tanks.

b- report out and participate in class discussion to reach aconsensus on the cause of the delay.

Materials:Memo #2"Placing Material in Wetlands" memo"Designated Parking Areas While #1, 2, and #3 Clay Tanks are Being

Painted" memos dated 2/03/94, and 3/02/94 revisionspencils/pens

12

MEMO # 2

TO: CEMENT ClassesFROM: Lou TaylorDATE: 7 February 1994RE: Company Memos

We have discussed that memos are sent out for many reasons. In thisclass we will look at three company memos that have been sent out this year.Look over them and answer the following questions about each.

1) What was the purpose of this memo? (what is it telling us about)

2) Have you received a copy of this memo before? YES or NOIf you answered no, have you been told the information in the memoby your supervisor?

3) Would the information in the memo help you to perform your jobbetter? YES or NO

If you answered YES, how would it help you to do a better job?

If you answered NO, why do you think the memo was sent?

4) What was the topic of each memo? (hint: RE:)

5) Compare the two memos from Larry Shingler and Robert West:p What is the original date of these memos?--> Why were they revised?-> What do you think is the cause of all the delays in painting the

clay tanks?

13

HOLNAM/SANTEE INTEROFFICE MEMOTo: ALL PERSONNEL AT THE HOLLY HILL PLANTFrom: WPT

Subject PLACING MATERIAL IN WETLANDS

Date: SEPTEMBER 2, 1993CC:

IT IS AGAINST THE REGULATION OF EPA AND THE U.S. ARMYCORP OF ENGINEERS TO FILL ANY MATERIAL IN A WETLAND.

IN FACT THEY WILL NOT EVEN LET YOU REMOVE A STUMPFROM WETLANDS BECAUSE IN THE PROCESS DIRT WILL FALL BACKIN THE HOLE WHICH IS A VIOLATION.

NO ONE, EMPLOYEE OR OTHERWISE MAY HAUL, DEPOSIT, ORMOVE DIRT IN ANY AREA OF THE PLANT OTHER THAN THEPERMITTED MINE AREA WHICH IS BOUNDED BY THE NEW HOMEBRANCH DITCH ON THE WEST, NORTH AND EAST AND THE ROADSAT THE EDGE OF THE QUARRY ON THE SOUTH EAST, SOUTH AND .1,.SOUTH WEST.

IF THERE IS A NEED TO MOVE OR PLACE DIRT IN ANY OTHERPLACE ON THE PLANT SITE PERMISSION MUST BE OBTAINED FROMEITHER ROBBIE MIMS OR MYSELF.

THIS CAN BE A FEDERAL OFFENSE AND THE COMPANY CAN BESEVERELY FINED IF THIS RULE IS NOT STRICTLY FOLLOWED.

SUPERVISORS,

PLEASE GIVE A COPY OF THIS MEMO TOEACH OF YOUR EMPLOYEES.

14

'iOLNAM. INC.

TO: ALL EMPLOYEES

FROM: RWS, LS

DATE: 10/18/93 REVISED 02/03/94

SUBJ: DESIGNATED PARKING AREAS WHILE #1.2. AND #3 CLAYTANKS ARE BEING PAINTED

THE PARKING LOTS NEXT TO THE SLURRY BASINS AND THE KILNS WILL BECLOSED 7:00 A.M. TO 6:00 P.M. DAILY FROM 10/27/93 THRU 3/7/94WHILE #1.2 8, 3 CLAY TANKS ARE BEING PAINTED. ALL EMPLOYEES MUSTPARK THEIR VEHICLES NEXT TO THE 1,000.000 GALLON STORAGE TANK EASTOF THE SOUTH SCALE.

***REMEMBER, DURING THE PARKING RESTRICTION, EMPLOYEES SHOULD NOTDRIVE BY OR NEAR #1,2, OR 3 CLAY TANKS WHILE THEY ARE BEINGPAINTED.

THANK YOU FOR YOUR COOPERATION.

ROBERT WEST LARRY SHINGLER

RWS/PARK

PLEASE NOTE THAT PARKING PERMITS REMAIN ON FILE WITH L, SHINGLER'.IF YOU WANT TO FARA YOUR CAR IN THE AREA AND HAVE NOT SIGNED APERMIT. PLEASE SEE L. SHINGLER.

NEITHER HOLNAM, INC. NOR THE PAINTING CONTRACTOR WILL BERESPONSIBLE FOR ANY DAMAGE DONE TO YOUR VEHICLE.

15

LIOLNAM. INC..

TO: ALL EMPLOYEES

FROM: RWS. LS

DATE: 10/18/93 REVISED 03/02/94

SUBJ: DESIGNATED PARKING AREAS WHILE #1,2, AND #3 CLAYTANKS ARE BEING PAINTED

THE PARKING LOTS NEXT TO THE SLURRY BASINS AND THE KILNS WILL BECLOSED 7:00 A.M. TO 6:00 P.M. DAILY FROM 10/27/93 THRU 3/28/94WHILE *1,2 & 3 CLAY TANKS ARE BEING PAINTED. ALL EMPLOYEES MUSTPARK THEIR VEHICLES NEXT TO THE 1,000,000 GALLON STORAGE TANK EASTOF THE SOUTH SCALE.

***REMEMBER, DURING THE PARKING RESTRICTION, EMPLOYEES SHOULD NOTDRIVE BY OR NEAR #1,2, OR 3 CLAY TANKS WHILE THEY ARE BEINGPAINTED.

THANK YOU FOR YOUR COOPERATION.

ROBERT WEST LARRY SHINGLER

RWS/pARK

PLEASE NOTE THAT PARKING PERMITS REMAIN ON FILE WITH L. SHINGLER.IF YOU WANT TO PARK YOUR CAR IN THE AREA AND HAVE NOT SIGNED #'FERMI T. PLEASE SEE L. SHINGLER.

NEITHER HOLNAM, INC. NOR THE PAINTING CONTRACTOR WILL BERESPONSIBLE FOR ANY DAMAGE DONE TO YOUR VEHICLE.

16

Lesson # 3

LESSON OBJECTIVES:

Upon completion of this lesson the participants will be able to apply astandard set of work procedures in work settings after first:

1) arrange a standard set of work procedures in a logical order.2) arrange a list of procedural steps which go under each of the work

procedures (they will evaluate and organize the procedures undereach appropriate work step.)

3) when given a completed list of "Procedures to Follow for All Work",the participants will compare their work for accuracy.

Class ProcedureDiscuss how is work done, when you do a job do you follow certain procedures

every time. If you answered yes, how did you learn the procedures that you follow didsomeone teach you or was it by trial and error. This exercise will take the guess work outof following work procedures. We developed a list of work procedures and somesubsteps under each one. You will first receive the four main steps, notice that they arenot in any particular order. Work in your group to decide what the order should be forthese steps. Everyone in your group must agree on the final answer. Have the groupsreport out their results and the whole class will then discuss and decide on the order of themain steps.

Once agreement has been reached on the main steps, hand out the sub- steps andhave the participants, again working in small groups, categorize the sub-steps by whichmain step they should fall under. Group consensus must be reached before reporting outthe findings. As before, the whole class must reach consensus when compiling the smallgroup results into a class result.

Now the instructor will distribute the Work Procedure handout with the informationon it and the class will compare their results with the actual procedures. Discuss anydiscrepancies and also make students aware that some of these steps may fit under morethan one category.

Hand out the "Procedures To Follow For All Work Checklist" and a copy of thework order. Ask the participants to usP the work order to answer the questions posed onthe checklist. Allow the participants to work in small groups to do this activity. Haveeach group elect a spokesperson to report their answers. Have the participants discuss ifthey think these procedures would help them to better perform their daily duties.Class Materials:

Work Procedure Handouts Chalk or Marker Boardchalk or markers for board Paper/pencil for studentsProcedures to follow for all Work Checklist

17

Work Procedures - Main Steps

Someone has gotten these four steps out of order. You need to arrange thesteps in order. The steps have a blank in front of them for you to number thestep.

On completion:

Gather the materials needed to do the job:

Evaluate the job:

Start the job:

18

Problem Solving

Work Procedures - Sub-Steps

The steps listed below are suggestions that can go under the WorkProcedures that you just put in order. Look at these steps and discuss whichprocedure they should go with. When you decide where they go put thenumber of the step in the blank beside it.

visual inspection of the site

check your work

do you have the materials with you

have supervisor sign off work order

use necessary safety procedures and precautions

assess whether or not you need help or special tools

return tools to their proper place

follow step-by-step procedures to complete the job

discuss with co-worker(s) type of work to be done

where do you go to get the tools

clean-up work area

Problem Solving

Procedures to Follow for all Workthe Complete List

1. Evaluate the Job.- visual inspection of the site- discuss with co-workers type of work to be done- assess whether or not you need help or special tools

2. Gather the Materials Needed to do Job.-.do you have them with you- where do you go to get the tools

3. Start the Job.- follow step-by-step procedures pertaining to the job- use necessary safety procedures and precautions

4. On Completion.- check your work- have supervisor sign off work order- return tools to proper place- clean-up work area

.

4.

Procedures To Follow For All Work - a Checklist

1) Evaluate the Job.

Do a visual inspection of the area.Will any special preparation, precaudons, or safety equipmentbe needed? YES NO If yes, please list:

Discuss with co-workers the type of work to be done.Have you done this type of work before? YES NOIs it a routine job? YES NOIn no, what makes this job different from the ordinary?

Assess whether or not you need help or special tools to completethis job. YES NO

If yes, list what you will need:

2) Gather Materials Needed for the Job.

Do you have the tools and materials with you? YES NO

If no, where do you go to get the tools and equipment you need?

3) Start the Job.

Use all necessary safety procedures and precautions. What arethese, please list:

Follow the step-by-step procedures pertaining to the job. List thestep-by-step procedures you would follow to complete this job:

4) On Completion.

Check your work.Is the job completed to your satisfaction? YES NOIf no, why not?

Clean-up the work area.Have you cleaned up the work site? YES NOIf no, why not?

Have your supervisor sign off the work order.Did you do this? YES NOIf no, why not?

Return tools and equipment to proper place.Did you have to get special tools or equipment? YES NOIf yes, where do they need to be returned to?

22

Lesson #4

LESSON OBJECTIVES:

Upon completion of this class, the participants will be able to:

1) Brainstorm in small groups and add at least three(3) additional itemsto the Qualities of a Good Worker" list.

2) Discass the causes of accidents using a handout (A) sheet providedby the instructor and state the four areas that are most likely to causeaccidents.

3) Utilize the information from the discussion and handout A to classifyaccidents into the four categories that were discussed.

Assignment: Distribute three (3) page handout "HAZARD RECOGNITIONCHECKLIST", ask students to review this for the next class.

Materials:Handouts:A) Qualities of a Safe WorkerB) Causes of AccidentsC) Safety ExerciseD) Case StudyE) Hazard Recognition Checklist

Overhead transparency of Safety ExerciseOverhead ProjectorOverhead Marker PensPaper and Pencil for Participants

23

QUALITIES OF A SAFE WORKER

* HAVE A CLEAR HEAD WHEN HE COMES TO WORK

* KEEP HIS MIND ON THE JOB/TASK

* CHECK MACHINE/EQUIPMENT WORKING PROPERLY

* ALWAYS MAKE SURE WORKING IN A SAFE AREA

* HAVE PROPER SAFETY EQUIPMENT (ppe)

* CEMENT

SAFETYCauses of Accidents: Points to Ponder

1) Lack of KnowledgeIt is estimated that a large number of work accidents are caused by a

lack of knowledge on the worker's part. The worker who has not beenproperly trained, misinterprets instructions, or obtains inaccurate informationis the most likely to make mistakes and have accidents. A lack of knowledgecan cause accidents in any job, not just where dangerous machinery ofequipment is used. Workers should have the knowledge to perform a jobaccurately and safely before they begin to work.

2) Lack of SkillsMost jobs require that workers possess certain skills if the job is to

be performed accurately and safely. In order for a worker to become skilledin a job there must be a desire to learn the skills needed, to receive properinstruction, and to practice. The lack of skills can also cause accidents in anyjob and the worker needs to be aware of his/her expected performance skills.

3) Poor Work AttitudeA worker's attitude towards safety on the job affects the number of

accidents that occur. Having a positive attitude toward safety can helpprevent accidents that occur. Every worker needs to think safety and get intothe habit of doing all job tasks in a safe manner. A worker's attitude towardsafety is reflected by the way he/she feels about certain safety practices andshows up in his/her behavior on the job. There are many elements whichdemonstrate attitudes which are directly related to worker safety and thesafety of fellow workers.

4) Unsafe EnvironmentThe environment that a person works in can affect the number of

accidents that are likely to occur. Research has indicated that about 15% ofall accidents can be caused by worn, dull, broken. or defective tools. Moreaccidents occur in some jobs, such as construction, that in other areas, suchas office work.

Source SC Department of Education, Safety Unit

CENTERSafety Exercise

Directions: Look at the following examples of accident causes and decide ifthey are due to:

1) lack of knowledge 3) poor work attitude2) lack of skill 4) unsafe environment

Put the numbers 1, 2, 3, or 4 on the line in front of the cause.

Using equipment improperly.Poor ventilation.Improper lifting.Defective tools or equipment.Poor housekeeping.Operating equipment without authority.Failure to use personal protective equipment.Operating equipment at improper speeds.Improper loading or placement of equipment or supplies.Poor illumination (lighting).Inadequate warning systems.Excessive noise.

Now that we've looked at causes for accidents, let's take time to see what wecan do to help prevent accidents from happening in the first place.

Working with your group brainstorm a list of some of the qualities of safeworkers. Use the space at the bottom of this sheet to make your list (use theback if you need more room).

26

HOLNAM/SANTEE CEMENT COMPANY - HOLLY HILL, SCHAZARD RECOGNITION CHECKLIST

************************************************************************In accordance with the Mine Safety & Health Administration (MSHA), you are notauthorized to enter upon Holnam/Santee property until you have read this notice andacknowledged its content by signing the appropriate sheet. Anyone entering thesepremises may encounter certain hazards. By law, you must be informed of their existenceand how to avoid them. Read carefully and then sign the accompanying sheet.************************************************************************1. TRAFFIC: Observe proper traffic patterns, signs, and posted speed limits.2. MOVING MACHINERY: Be alert, keep clear, make sure operator knows

your whereabouts.3. TRIPPING OR FALLING : Exercise care when stepping over or around

obstacles or when walking in work areas or on stairways. Use handrails.4. FOREIGN OBJECTS IN THE EYE : Wear safety glasses or goggles at all

times in the plant.5. FALLING OBJECTS/OVERHEAD OBSTRUCTIONS : Wear hard hats in

plant at all times.6. FALLING OBJECTS: Wear safety shoes if performing any work. Look for

incorrectly stored or stacked material.7. INJURY FROM LIFTING: Use correct procedure and obtain help if needed.8. DUSTY AREAS: Wear a dust mask or respirator in dusty areas. Inquire as

to need.9. NOISE: Wear ear protection in designated areas.10. FIRE: Do not smoke or use any flame producing device in posted areas.11. WELDING OR EXHAUST FUMES: Avoid prolonged stays in areas of strong

concentration of fumes or engine exhausts.12. WELDING & FLASH BURNS TO THE EYE: Avoid welding areas. Do not

look at flash without appropriate eye wear use.13. FIRE OR EXPLOSION OF FLAMMABLE GAS: "NO SMOKING OR

OPEN FLAME" signs are posted in storage areas for compressed gas, fuels,lubricants, etc. DO NOT SMOKE OR USE ANY FLAME PRODUCINGDEVICE LN THESE AREAS.

14. PRESSURE VESSELS: Use proper methods when handling gas cylinders.Secure against falling or being knocked over. Keep upright and cap whennot in use. Open valves slowly; release pressure before removing caps orinspection plates. Check pressure gages and DO NOT use malfunctioning gages.

15. ELECTRICAL: Do not work on energized electrical apparatus. Shut downand lock out.

16. IMPROPER TOOL USE: Select and use proper tools, in good repair, for job.17. GROUND CONTROL & HIGH WALLS: Do not work near unsafe ground

conditions of i..igh walls. Tow or move unit to a safe area.

27

18. MATERIAL STORAGE BINS, HOPPERS, OR TANKS: To work in theseareas. or in high places a safety belt and lifeline, properly attached, adjusted andanchored must be worn. In all cases the "buddy" system must be used.

19. WEATHER: Avoid extreme weather conditions such as thunderstorms, rain, hail,and wind. When possible, slippery conditions must be corrected for safe footing.

20. DO NOT LEAVE DESIGNATED AREA: Unescorted trips through the plantare not allowed.

21. EQUIPMENT: Unauthorized use of Holnam/Santee equipment is prohibited.22. FIRST AID & MEDICAL CARE: A first-aid room is located in the central part

of the plant adjacent to the lunch room. Medical care is available in Holly Hill.23. ACCIDENT OR INJURY: Immediately report any accident or injury to a

member of Holnam/Santee management.24. CONTRACTORS working on Holnam/Santee property must observe all MSHA

and Holnam/Santee safety standards. Tools and equipment must be maintained ingood condition with proper safety devices and operated by qualified and trainedpersons. By copy of this notice you accept responsibility to discuss these ruleswith your employees working on Holnam/Santee property.

25. EMERGENCIES: A contingency plan for emergencies is in place and personnel aretrained to implement the plan if necessary. A complete copy is available in the Safety& Personnel Department for your review. Emergency evacuation procedures areestablished and attached for your information and implementation should the needoccur.

ALWAYS EXERCISE COMMON SENSE AND GOOD JUDGMENT. YOUARE RESPONSIBLE FOR YOUR ACTIONS AND THOSE UNDER YOURCONTROL AT ALL TIMES WHILE ON HOLNAM/SANTEE PROPERTY.

28

Lesson #5

Lesson Objectives:

Upon completion of this class participants, working in small groups, will beable to:

1) When given a case study of an accident and its subsequentdisciplinary action on the employee involved evaluate and state:A- the real cause of the accident;B- if they feel the actions taken against the employee were justified,

too harsh, or not adequate; andC- how of if they would have handled the situation differently.

2) Discuss the information on the "Hazard Recognition Checklist" andbe able to recognize potentially hazardous situations 'n theworkplace.

Class Materials:Handouts:

1) Case Study2) Hazard Recognition Checklist - active reading activity

(distributed as homework assignment in class 4)Overhead transparencies of Hazard Recognition ChecklistOverhead ProjectorOverhead Marker PensPaper and Pencil for Participants

29

CEMENTHolnam, Holly Hill

SAFETYCase Study - What Caused this Accident?

Judy is a laborer in the Maintenance Shop. Her regular job is to assist incutting out patterns of sheet metal and welding. One day a truck arrived atthe shop with a sheet metal delivery. The other workers had gone to lunchand no one was around to unload the metal. The truck driver was in a hurt'and asked Judy if she would unload the truck. Judy did not want to lookdumb and helpless so she attempted to unload the sheet metal with a forklift.She had seen other workers use the forklift, but she had never used it herself.When she tried to pick up the metal, it slipped and fell to the ground, justmissing the buck driver. Judy was suspended from work for one weekbecause of the incident.

1) Look back at the "Points to Ponder" sheet and decide what was thereal cause of Judy's accident?

2) Do you feel that Judy should have been suspended? If you think sheshould not have been suspended, then what should have happened toJudy?

Source: Safety Unit, S.C. Department of Education

3o

Lesson # 6

LESSON OBJECTIVES:

Upon completion of this lesson the participants will be able to:

1) correctly complete insurance benefit forms with proper information.2) file the completed open enrollment insurance form with the personnel

office.3) take a CLOZE test.

Class Procedure:One of the classes had been set aside for the topic of Insurance Jargon, ironically the

time for the class coincided with the open enrollment for the company insurance. Intalking with the personnel office, it was noted that an inordinate amount of time would bespent by the personnel staff reviewing the insurance forms with the employees andcompleting the forms for them. I was asked if I would be able to help out, so I developedsome activities using the forms and worked with the participants to actually complete theirforms in class. This turned out to be very rewarding to the participants who felt greatabout being able to turn in their forms without asking for help for the first time.

Participants will bring their Open Enrollment Packets to class, first actively read thememo from Bonnie Connelly. Ask them what kind of information do they expect to findin this memo. Go through the memo one paragraph at a time asking questions to the classas you go. Explain any vocabulary words that they may be unsure of. Encourage theparticipants to ask questions of you as you read.

Next, we'll look over the three page memo from Linda Strouse. Scan over the memotaking note of the headings. Which headings apply to you or contain information that youmay be interested in? Look at the chart on page 2, what information does it contain?Look at the box on page 3, which forms does it tell you to return?

Look at the pink sheet, it has 1994 Benefit Election Form Instructions at the top.This will guide us through the completion of the benefits election form, find it in yourpacket and let's complete it. First, is the information at the top correct? If not, change it.Now, go through the numbered sections (1-5) one at a time completing only those youwant to participate in. If you want to take part in the spending accounts, complete theinformation for numbers 3 and 4. If you want to take out the voluntary personal accidentplan, complete the information on this sheet at number 5, you must also fill out a separateenrollment form for this policy which is in the Personnel Office. Add together theamounts from all the plans and enter your total where it says "sum". Now sign and datethis form.

Go back to the pink sheet, the bottom half has the Instructions for completing theEmployee Information Form (sheet). Now let's find the 1994 Employee InformationForm, is the information on this form correct? Is your name, address, and otherinformation on the top of the form correct, check it carefully? Are the names social

31

security numbers, coverage, birth date, sex and relationship of your dependents correct?Do you need to add someone to this form or take someone off of the form? Is theinformation under full-time student, handicap, and Medicare columns correct? Does youspouse have other insurance, check yes or no? If yes provide the name of the insurancecarrier and the policy number. The last thing you do, when all the information is correct,is to sign and date the form.

Ask the participants to leave out their insurance enrollment forms so that whilethey are doing the next activity you can check over the forms .

Distribute a CLOZE exercise to the participants and take a few minutes to explainthe procedure. Provide them with a list of the missing words. Allow about one hour forthis activity, DO NOT TELL THEM THIS IS A READING TESTI !!!! That will"freak out" some of the participants. Better yet, tell them this is a test to show how wellthey can solve abstract problems when given clues to work with and will be used by you,the instructor, to help in the development of materials to use in class. Above all put theparticipants at as much ease as possible, do not make a big deal out of this exercise. Tellthe participants that a score of 50% is considered good on this type of exercise. Don't letthem feel that this is an impossible task!

Class Materials:Insurance Benefits Form1994 Benefit Election Packet (each employee had one of these mailed to their

home address)Linda Strouse MemoBonnie Connelly MemoCLOZE Test

32

OCTOBER 21, 1993

HOLNAM - INTERNAL MEMORANDUM

TO: ALL EMPLOYEES

FROM: BONNIE CONNELLY

RE: 1994 OPEN ENROLLMENT INFORMATION - EMPLOYEE BENEFIT PLANS

THE ENCLOSED PAPERWORK COVERS INFORMATION REGARDING YOUR 1994 BENEFITPLANS. AND MUST BE COMPLETED AND RETURNED BY NOVEMBER 5, 1993. IF WE DONOT RECEIVE YOUR COMPLETED FORMS BY THE DEADLINE, YOU WILL AUTOMATICALLYRECEIVE "EMPLOYEE ONLY" MEDICAL AND DENTAL COVERAGE AND THE OTHERBASIC BENEFITS PROVIDED BY HOLNAM. IF YOU NEED HELP COMPLETING THE FORMSOR WANT TO COMPARE WITH LAST YEAR'S INFORMATION. PLEASE CONTACT SANDRAGRIFFIN OR ME.

IN ADDITION TO THE OTHER INSURANCE BENEFITS PREVIOUSLY OFFERED. IN 1994 THECOMPANY IS MAKING VOLUNTARY PERSONAL ACCIDENT INSURANCE COVERAGEAVAILABLE TO YOU. A BROCHURE OUTLINING THE COVERAGE AND PREMIUM COST ISENCLOSED WITH YOUR PACKET. THE PREMIUM IS DEDUCTED EACH PAY PERIOD ON A"BEFORE TAX" BASIS. IF YOU ARE INTERESTED IN PURCHASING THIS COVERAGE. PLEASEPICK UP AN APPLICATION FROM THE PERSONNEL DEPARTMENT.

PLEASE DO NOT WAIT UNTIL THE LAST MINUTE TO COME BY THE PERSONNELOFFICE IF YOU NEED HELP COMPLETING YOUR PAPERWORK. THE LONGER YOUWAIT, THE LONGER THE LINE GETS!

REMEMBER, THE PAPERWORK MUST BE COMPLETED BY EVERYONE, EVEN IF NOCHANGES ARE MADE FROM LAST YEAR

NOTE TO SALARIED EMPLOYEES: THE PERSONAL ACCIDENT INSURANCE HAS BEEN01-1-LRED TO YOU FOR SEVERAL YEARS. IF YOU DO NOT HAVE IT AND WISH TO ENROLL,GET YOUR APPLICATION FROM PERSONNEL.

33

1g44 BENEFIT ELECTION FORM imgliRUCTIONS

Verify name, location, date of birth, hire date,jauid employee number.

#1 - choose the medical coverage that best Ida your needs.

#2 7 Choose the dental coverage that Wert tits yoirr-ceede.

#3 If you want to enroll In we neatth caia.spendng acoaurtt.lffll inihelerhourit you Want Withhekffrompurvents-frionthivIweeklypaiy*:'

#4 - if you have eligible dependents for cad day care or elderly clepermient care and want to amain 41+4dependent care epencing account Its In the amountyou want withheld from your serni-monthlvarireaerereme7

#5 - Choose me Voluntary Personal Accident Insurance If you want to elm* m IC Be sure to choose the Correctcoverage (single/family) and the dollar amount of coverage. Fill in the semi-monthly premium, which you canfind included in the interoffice memo enclosed. This will be deducted from your semi-monthly pay.

Total #1, #2, #3, #4, .5 - This is the total amount that will be withheld from your semi-monthly/weekly pay.

if you need more information, please refer to your Benefit Handbook, contactyour location manager or the CorporateHuman Resources office.

*V you need an application or brochure, please contact your location manager or the Corporate Human Resourcesoffice.

INSTRUCTIONS FOR COMPLETING THE EMPLOYEE INFO SHEETVerify that all information is correct. Be sure your address, employee number, marital status, and work location iscorrect.

Verify Social Security numbers, dates of birth, student status, handcap status, and Medicare status on yourself andyour dependents.

Choose, with a check mark, what coverage you want for yourself and your eligible dependents: HMO, MED (medical),DENT (dental).

Be sure to sign your name at the bottom of the form and fill in the date.

Return it to Corporate Human Resources along with your 1994 Benefit Election Form.

PLEASE REMEMBER: COVERAGE YOU SELECT IS THE COVERAGE YOU KEEP UNLESS YOU HAVEA FAMILY STATUS CHANGE DURING THEYEAR. CONTACT YOUR LOCATION MANAGER OR THE CORPORATEHUMAN RESOURCES OFFICE 1MTHIN 30 DAYS OF THE CHANGE SO YOU WLL BE ABLE TO MAKE THENECESSARY CHANGES. IF YOU DO NOT NOTIFY US WITHIN 30 DAYS, YOU WILL NOT BE ALLOWED TO MAKETHE CHANGE.

topitair,41/4

31BEST COPY AVAILABLE

: : .: ..".4,de 1 1 ce..3 IF 4.. .. .

COMPANYS COPY 1994 BENEFITS ELECTION FORMACTIVE NON-UNION HOURLY EMPLOYEE

NAME: BIRTH DATE: / / HIRE DATE: / /LOCATION: EMPLOYEE NO:

PLEASE SELECT YOUR BENEFIT COVERAGE FOR 1994 AND WRITE THE COST OF EACH OPTION YOUCHOOSE ON THE APPROPRIATE LINE. SIGN THE FORM AT THE BOTTOM AND RETURN THE ORI-GINAL TO THE CORPORATE HUMAN RESOURCES DEPARTMENT IN DUNDEE, MI FOR PROCESSING.ALL RATES SHOULD BE ENTERED AS WEEKLY AMOUNTS.

1. HOLNAM MEDICAL 80%/20% WEEKLYCOVERAGE FOR:

SPENDING ACCOUNTS: WEEKLY3. HEALTH CARE ACCOUNT.

01 ME ONLY $ .00 ENTER WEEKLY AMOUNT,02 ME & ONE DEPENDENT $ 5.77. UP TO $ 60.00 $03 ME & MY FAMILY $ 11.54

2. DENTAL PLANCOVERAGE FOR:

01 ME ONLY $ .0002 ME & ONE DEPENDENT $ .0003 ME & MY FAMILY $ .00

4. DEPENDENT CARE ACCOUNT.

ENTER WEEKLY AMOUNT,UP TO.$ 48.00 FOR EACH DEPENDENTBUT NO MORE THAN $ 96.00

5. VOLUNTARY PERSONAL ACCIDENT:

01 SINGLECOVG:02 FAMILYCOVG:

COST: $

COST: $

COMPANY PAID COVERAGE FOR

BASIC AD&D INSURANCEBASIC LIFE INSURANCESICKNESS & ACCIDENT

TOTAL WEEKLY COST OF YOUR ELECTIONS (SUM 1 + 2 + 3 + 4 + 5) $

I HAVE INDICATED MY 1994 BENEFIT ELECTIONS ABOVE. I UNDERSTAND I CANNOT CHANGEMY ELECTIONS BEFORE 1995 UNLESS MY FAMILY STATUS CHANGES. I AUTHORIZE HOLNAM TO

D THE DEDUCTION AMOUNTS ON A BEFORE TAX BASIS FROM MY 1994 WEEKLY PAY.WITHHO

4111 DATE SIGNATURE

10/19/93

35

HOURLY

G/W DIVN: 004

Please review the coverage and cost of the Medical Plan, as well as that ofthe other Plans outlined on the Election form, before making your finalselection. Review theenlosedstuctireasonnetnoureneiciorgpltsyornloeenormat'onfs. Rememberthat your selections will be in effect for all of 1994 unless you experiencea qualified change in family status.

NOTE: If we do not receive your completed 1994 Open Enrollment forms byNoysgmEAL1993, you will automatically receive "employee only" medicaland dental coverage and the other basic benefits provided by Eolnam.

You pust returq:

- the Company copy of the Benefits Election form (keep theemployee copy for your records)

the Employs. Information form

the application form for Personal Accidental Death and Dis-memberment coverage only if you are changing coverage levelsor are enrolling in the plan for the first time.(form can be obtained from your personnel or facility manager)

If you have any questions regarding 1994 benefit elections, your personnel orfacility manager can help you get the answers or call Linda Strouse, Vicki.Viers or Debbie Murphy in the Corporate Human Resources department in Dundee,Michigan at 1-800-831-9507.

4111Again, carefully review the enclosed materials, complete and return theappropriate forms to your local manager, if so directed, or to the CorporateHuman Resources department in Dundee, MI.

DUE DATE IS NOVEMBER 8, 1993

36

Intercompany Correspondence

TO:

FROM: Linda StrouseBenefits Administrator

DATE: October 15, 1993

All U.S. Holnam Salaried and Non-Union Hourly Employees

SUBJECT: Open Enrollment Information for the 1994 Benefit Plan Year

At this time each year, we request that you enroll in benefit plans forthe coming year. The following information provides a brief overview ofthe various plans provided to you. Please refer to your Benefits Handbookfor more complete information regarding Holnam's benefit plans.

MEDICAL & DENTAL PLANS

As in the past, Holnam will offer alternative choices for medical plancoverage to those employees who reside in areas where Holnam offers an HMOoption. You may elect to have medical coverage provided by either theCompany's indemnity plan (Great West Life) at the 80/20 co-insurance level,or through an HMO where HMO's are available. Specific information andenrollment forms for HMO's offered in your area may be obtained from yourfacility manager. The employee share of the 1994 semi-monthly medical costfor Holnam's Medical Plan and for the HMO (if available) are printed on theenclosed 1994 Benefits Election form.

SPENDING ACCOUNTS

Health care and dependent care spending accounts will again be offered for the1994 Plan Year. The spending accounts allow you to have pre-tax deductionstaken each pay to help you pay for eligible health care and dependent careexpenses.

The Corporate Human Resources department in Dundee, Michigan will administerthe Spending Accounts. The simile= amount for which a reimbursement checkwill be issued is $25.00. Blank Spending Account Reimbursement forms areavailable from your personnel or facility manager.

The use of the Spending Accounts requires careful planning on your part, butpit can prove to be a valuable tax savings feature for you.

PERSONAL ACCIDENT INSURANCE PLAN

The Personal Accident Insurance Plan provides accidental death anddismemberment protection for you and your family. Coverage is available ina benefit amount which you select. The Personal Accident Insurance Plea isnew for this year at the non-union hourly facilities.

't you are not presently enrolled and wish to obtain coverage for 1994 or ifyou wish to change the amount of your coverage, you must complete theVoluntary Personal Accident section on the Benefits Election form and Alsosubmit a separate application form. A brochure explaining the plan and anapplication form are available from your personnel or facility manager.

37

For your convenience, the coat of coverage under this voluntary plan isoutlined below:

WEEKLY COST SEMI-MONTHLY COST

BENEFIT EMPLOYEE FAMILY EMPLOYEE FAMILYMOUNT ONLY PLAN gNLY PLAN

$ 10,000 $ .09 $ .14 $ .20 $ .3020,000 .18 .28' .40 .6030,000 .28 .42 .60 .9040,000 .37 .55 .80 1.2050,000 .46 .69 1.00 1.5060,000 .55 .83 1.20 1.8070,000 .65 .97 1.40 2.1080,000 .74 1.11 1.60 2.4090,000 .83 1.25 1.80 2.70100,000 .92 1.38 2.00 3.00125,000 1.15 1.73 2.50 3.75150,000 1.38 2.08 3.00 4.50175,000 1.62 2.42 3.50 5.25200,000 1.85 2.77 4.00 6.00225,000 2.08 3.12 4.50 6.75250,000 2.31 3.46 5.00 7.50300,000 2.77 4.15 6.00 9.00

NOTE: Coverage cannot exceed 10 times your annual salary.

SUMMARY

The choice of benefit plan participation is very important for you and yourfamily. Your decision is for the full calendar year 1994, so make sure thechoice is right for you. Remember that all of the above deductions are takenon a pre-tax basis from your regular paycheck. As a result, we must complywith certain government regulations which do not allow you to change yourelection during the year, unless you show proof that your family status haschanged. If you incur a change in family status, a status change form andapplicable enrollment forms must be completed and received by the CorporateHuman Resources department WITHIN 30 DAYS of the family status change. IF YOUFAIL TO MEET THIS REQUIREMENT, YOU WILL NOT BE ALLOWED TO MAKE A CHANGE INYOUR COVERAGE ELECTION UNTIL THE NEXT OPEN ENROLLMENT PERIOD. A change infamily status is considered to be:

a. your marriageb. your divorceC. birth or adoption of a childd. death in your immediate familye. spouse's commencement or termination of employmentf. either spouse or employee changing from part-time to full-timeemployment status or vice versag. either employee or spouse taking an unpaid leaveh. significant change in health coverage of spouse attributable tothe spouse's employment.

33

NAME:

LOCATION:

ADDRESS:___

EMPLOYEE NO.:

1994 EMPLOYEE INFORMATION FORM

SA1ARIED:

HOURLY:

MARITAL STATUS:

DATE OF HIRE:

01 - SINGLE

02 - MARRIED

03 - DIVORCED *

* 04 - WIDOW(ER)

05 - SEPARATED

TELEPHONE:

BIRTHDATE:

SEX:

SPOUSE AND DEPENDENT INFORMATION

**

**

**

**

PLEASE VERIFY PRINTED

INFORMATION., CORRECT ANY ERRORS AND FILL

IN MISSING INFORMATION.

INDICATE DESIRED COVERAGES BY MARKING

AN

XIN THE APPROPRIATE COLUMNS

FOR SPOUSE AND EACH DEPENDENT.

COVERAGE

NAME

FULLTIME

STUDENT

HANDICAP

MEDICARE

SSNO

HMO

MED

DENT

BIRTHRATE

SEX

RELATIONSHIP

(YES/NO)

(YES/NO)

(YES/NO)

* *

SELF

SPOUSE/DEPENDENTS HAVE OTHER INSURANCE

COVERAGE

YES

NO

NAME OF CARRIER:

POLICY NUMBER:

EMPLOYEE SIGNATURE:

RETURN COMPLETED FORM

TO:

HOLNAM, HUMAN RESOURCES DEPARTMENT---- '-

6211 NORTH ANN ARBOR ROAD

PO BOX 122

DUNDEE, MI 48131

33

IMO

%P

I

DATE:

40

CEMENTOoze Exercise

Directions: Use the word list to help you fill in the blanks in the followingexercise. You may recognize this as a passage from the Ho lnam brochure(the gray book).

demand increased after producedrotary furnaces business ableand of they wentplant easy Company forbegan supply paralleled beltdeveloped phase tons

The story of the Holnam Holly Hill cement plant begins with the visionand desire of its founders to be a pact of the growth in this region. The plant'sfounders, Mr. W. J. Colvin Mr. L. E. Miller, were in thelumber . To meet the needs increasedconstruction and development, in 1963 started building thecement . Three years later itoperating as Santee Cement

The plant's growth has that of the sunIn the 1960's, the for construction material rapidlyas development flourished. In fact, the original plant(which was to produce 350,000 tons of cement per year)

into production, it was to see thatdemand cement was greater than . As aresult, a second of the plant was whichincreased the plant's capacity three-fold to 1,200,000 ofcement.

The plant has two cement kilns, the rotating cylindricalwhere cement is actually . Our largest

cement kiln is 18 1/2 feet in diameter and 580 feet long. It is the secondlargest cement kiln in the United States.

41

Lesson # 7

LESSON OBJECTIVES:

Upon completion of this lesson, the participants, working in collaborativegroups, will be able to:

1) identify and list words that they are unsure of the meaning orpronunciation.

2) demonstrate the ability to use the dictionary as a reference to clarifymeaning and pronunciation.

3) demonstrate the ability to completely fill out the InsuranceReimbursement Form by handing in a completed form they will fillout in class.

4) collect the information needed to complete a dependent InsuranceInformation Sheet and maintain this as a future reference.

Materials:Memo #7Insurance Reimbursement Forms

(Medical -white form- and Dental -yellow form- are separate formsthat require exactly the same information)

Insurance Information Sheetpencils/pens

42

MEMO # 7

TO: CEMENT ClassFROM: M. L. TaylorDATE: 12 January 1994RE: Insurance Forms

The main task for this class is to learn how to complete an insurance form,This will enable you to take advantage of the medical and dental insurancebenefits that are offered to you. First, you need to read over the form. Asyou are reading, write down word(s) you do not know the meaning of orcannot pronounce. After you do this by yourself, discuss with your group theword(s) you have written down: does any one in your group have the sameword(s); are there words that you are able to help others with; are therewords that others could help you with?

When you finish, all the groups will report their discussions to the class. Iwill list the words on the board as we discuss them. Stop me and askquestions if you do not understand.

Next, we will take the time to go back through the form and discuss theinformation that goes in each block. You will notice that there is someinformation that you may not have, such as; spouse's soccial security number,and dependent's birthdates and social security numbers. To help you get thisinformation, you will fill in the Insurance Information Sheet that I will giveyou. If you do not have the information needed with you, complete this sheetat home and bring it to the next class. This sheet will be very important toyou in the future as you file your insurance claims.

After we have thoroughly discussed the form, you will complete it.Remember, you are to fill in the information as if you were actually filing thisclaim.

I will be moving around the room to help you, if you get stuck and I am busyask someone near you. I want to see your completed form before you leave.

Keep the completed form to use as an aid any time that you need to file amedical (white form) or dental (yellow form) insurance claim.

43

Insurance Information Sheet

In the next class we will be completing an Insurance Claim Form, in order tocomplete this form for one of your dependents you will need to know someinformation about them.

Complete the list of the information on this page and bring it to the next class.Also, you will keep this sheet with completed copy of the Claim Form to usewhen you need to send off an Insurance Claim Form in the future.

Nam seen n lenNm R ti 1

1.

2.

3

4.

5.

6

7.

8.

Full-time Student Name of College Handicap Medicare

1.

2.

4,

5

6

7.

4 -1

'ART A EMPLOYEE STATEMENT Failure to Answer All Questions May Delay Paymentloyee's Name Street Address City or Town Zip Code

1.

Plan Number Social Security No.50852

2. must be Completed Must be Completed

Certificate Number

II Appkoable

Are You Still Employed?

Yes No

If No, Date Last Worked

Date of Birth

3.

Marital Status Name of Your EmployerHOLNAM INCSingle Divorced

Married Widowed

Occupation

6pouse's Date of Birth4.

Spouse's Social Security No. Is your Spouse EmployedYes No

If Yes, Name and Address of Spouse's Employer

Are You or Your Dependents Covered Under Another Group Insurance or Government PlanSuch as Medicare, an HMO or Automobile No Fault Coverage. Which Will Also CoverAny of the Medical Expenses on the Claim?

S. Yes No

If Yes, Name and AddressPolicy Number r ID NFamily Member Holding Policy

Is Claim For a Dependent? If Yes, Dependent Name

(first) (last)

SexMale ISFemale

Date of Birth RelationshipTo Employee

If Dependent is a Child, Are YouEntitled to a Tax Exemption?

Yes No6. Yes NoIf Child, is She/He Married? Is Child Over 19?

Yes No

If Yes, Full Time Student?

Yes No

If Yes, Name of School6(a) Yes No

Is Claim for an Accident/ Date Where Did It Occur?Time i

While Working?Yes No

How Did it Occur?7. Yes No

SIGN HERE IF YOU WANT BENEFITS

Date

PAID TO DOCTORIHOSPITAL

SIGN HERE FOR ALL CLAIMS I hereby authorize any insurance co. hospital. or physician to release

Date

all information which may have a bearing on benefits payable under this plan of benefits9.

PART B DOCTOR OR SUPPLIER Complete and Return to Patientof Birth . Date First Consulted for

ConditionHas Patient Ever Had Sameor Similar SymEtoms?

0 Yes LI No

Referring Physician

Date Patient Able to Return to W Dates of Total DisabilityFromFrom Throu h

Dates of Partial DisabilityFrom Through

Is Condition Related To WorkIncurred Injury or Illness/

Yes No

Diagnosis or Nature of Illness or Injury Relate Diagnosis to Procedure in Column D

1.

.2.

by Reference to Numbers 1, 1' 1, etc. or DX Code.

3

ADate

ofService

BPlace

ofService

C Fully Describe Procedures, Medical Services or S..ippliesFurnished for Each Date Given

o

DX Code(ID: )

E

ChargesProcedure Code(Identify: ) (Explain Unusual Services or Circumstances)

Signature of Physician or Supplier

Signed Date

Total Charges AmountPaid

BalanceDue

Provider's SocialSecurity No /Tax 10 No

Physician's or Supplier's Name, Address, Zip CodeTelephone No.

( )PLACE OF SERVICE CODES

I IIHIINPATIENT HOSPITAL 0.4PATIENT S HOME 7 INHINURSING NOME(OHIOUTPATIENT HOSPITAL 5 OAT CARE FACILITY I WMSKILLED NURSING KKolitry3 (0)DOCTOR S OFFICE 6 NIGHT CARE FACILITY MVO 9 AMBULANCE

IS (OilOTHER LOCATIONStl ouINDEPENDENT LABORATEOW

OTHER MEDICAL1SURGICAL FACILITY

SEE REVERSE SIDE FOR FILING INSTRUCTIONS

45BEST COPY AVAIIIM.P

PART A EMPLOYEE STATEMENT Failure to Answer All Questions May Delay PaymentEmployee's Name Street Address City or Town Zip Code

1.

Plan Number50852

2. Must be Completed

Social Security No.

Must be Completed

Certificate Number

If Applicable

Are You Still Employed?

Yes No

If No, Date Last Worked

Date of Birth

3.

Marital StatusSingle DivorcedMarried Widowed

Nam* of Your Employer HOLNAIA INC Occupation

Spouse's Date of Birth4.

Spouse's Social Security No. Is your Spouse Employed

I Yee No

If Yes, Name and Address of Spouse's Employer

Are You or Your Dependents Covered Under Another Group Insurance or Government PlanSuch as Medicare. an HMO or Au °mobile No Fault Coverage, Which Will Also CoverAny of the Dental Expenses on the Claim?

&Yes No

If Yes. Name and AddressPolicy Number/ ID NFamily Member Holding Policy

Is Claim For a Dependent? If Yes, Dependent Name

if I rat) (last)

SexMaleFemale

Date of Birth RelationshipTo Employee

If Dependent Is a Child, Are YouEntitled to a Tax Exemption?

Yes NoS. Yes NoIf Child, is She/He Married? Is Child Over 19?

Yes No

If Yes, Full Time Student?

Yes No

If Yes, Name of School -

W(s) Yes No

Is Claim for an Accident? Date.

Time:Where Did It Occur? While Working?

Yes NoHow Did it Occur?

7. Yes No

SIGN HERE IF YOU WANT BENEFITS

DatePAID TO DOCTOR/HOSPITALS.

SIGN HERE FOR ALL CLAIMS I hereby authorize any insurance co., hospital, or physician to release

Date

all information which may have a bearing on benefits payable under this plan of benefits.9.

11111PART B DENTIST'S STATEMENT

PATIENT'S NAME (First name, middle initial, last name)

CHECK ONE:

PATIENT'S DATE OF BIRTH

DENTISTS PRE-TREATMENT ESTIMATE1:1 DENTISTS STATEMENT OF ACTUAL SERVICES

HAS ANY OTHER GROUP INSURANCE CARRIER BEEN BILLEDFOR THESE SERVICES?

YES NO

IDENTIFY MISSING TEETH WITH "X"

ACIAt

CatREMARKS FOR

UNUSUAL SERVICES

IS TREATMENT RESULTOF OCCUPATIONAL ILLNESSOR INJURY

NC YES IF YES, ADVISE DATE AND DETAILS

IS TREATMENT RESULTOF AUTOMOBILE OROTHER ACCIDENT

IF YES. ADVISE DATE AND DETAILS

IF PROSTHESIS. ISTHIS INITIAL PLACEMENT

IF NO , REASON FOR REPLACEMENT DATE OF PRIORPLACEMENT

IS TREATMENTFOR ORTHODONTICS

DATE APPLIANCES PLACED

EXAMINATION AND TREATMENT PLANLIST IN ORDER FROM TOOTH NO. i THROUGH TOOTH NO 32 USE CHARTING SYSTEM SHOWN.TOOTH DESCRIPTION OF SERVICE

a OR SURFACE (INCLUDING X-RAYS, PROPHYLAXIS. MATERIALS USED, ETC.)LETTER LINE NO.

DATE SERVICEPERFORMED

MO. DAY YEAR

PROCEDURENUMBER FEE

I

2

3

4

56

7

8

Signature of Dentist

Signed Date

Total Charges AmountNod

BalanceDue

X-Rays Enclosed Provider's Social Dentist's Name. Address, Zip CodeYes No Security No./Tax ID No.

Telephone No.

)

SEE REVERSE SIDE FOR FILING INSTRUCTIONS

46BEST COPY AVAILABLE

Lesson # 8

LESSON OBJECTIVES:

Upon completion of this class the participants, working in collaborativegroups, will be able to:

1) distinguish the uses for the first four forms used in the InventoryControl.

2) correctly add columns of pre-recorded inventory count.3) record inventory count in the proper space on forms 1 - 4.

Materials:Memo # 8Forms 1, 2, 3, and 4 used for Inventory Control recordspaper/pens/pencilscalculators

4 7

A

Memo # 8

To: CEMENT ClassFrom: Lou TaylorDate: July 20,1994Subj: Inventory Control

We are having some problems with the Inventory Control Process being usedin the Packhouse. Let's take some time and review all of the forms beingused. We will work with these forms during classes 8 and 9.

There are seven (7) forms used in the entire process and we will go throughthem one at a time. I have numbered the forms (1-7) in the order that they areused. Forms 1, 2, 3, and 4 are used to record the actual floor count. Forms 5,6, and 7 are used to total (or tally) forms 1 - 4.

In this class, we will be looking at the first four forms. These forms are setup to record the actual count of products on the floor. The number of paDetscounted is recorded in a box under the product type. Forms 1, 2, and 3 haveproduct names and/or type and how high the pallet is stacked preprinted atthe top of the form. The products on forms 1, 2, and 3 are usually kept ininventory. Form 4 is left blank because there are some products that are notusually found in inventory but that we have on hand for various reasons.When you find a product that is not listed on forms 1 -3 then you use form 4.You must remember to write the product name, type or identifying codenumber on the form, then count and record how high the pallet is stacked andthe number of pallets.

When you look at forms 1- 4, you will noticed that they already have numbersrecorded on them. Look closely and you will see that these numbers have notbeen totaled. Your assignment is to total each column on these four forms.Record your answers in the area marked "Total Pallets for Inventory." Whenyou finish we will review your answers.

We will work with forms 5, 6, and 7 in the next class.

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111111111111111111111111111111111 1111111111111111111.

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INK 11111111111111111111 mmmam :m11=1011111111111111111111111111111111, MEM NM

BAGS ON. ROKEN

ALLETS

SOTALALLETSN FLOOR

INUSALLETSOARED ONLATSFTERNVENTORYS TAKEN

SANTEE WHITECEMENT

47 HIGH

SANTEE WHITE MORTASEALMORTAR - TYPE S LIME

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BEST COPY AVAILABLE 5

Lesson # 9

LESSON OBJECTIVES:

Upon completion of this lesson the participants, working in collaborativegroups, will be able to:

1) distinguish the uses for Inventory Control forms 5, 6, and 7.2) enter correct information in the appropriate boxes on the above

mentioned forms.3) multiply to find the number of bags on a pallet.

Materials:Memo # 9Inventory Control forms 5, 6, and 7paper/pens/pencilscalculators

Memo # 9

To: CEMENT Class-From: M.L. Taylor

Date: July 22, 1994Subj: Inventory Control

In class #8 we concentrated on the first 4 of the forms. Now we will spendour time going over the rest of the forms.

Forms 5, 6, and 7 are used to compile all the information from the first fourforms. In order to complete these forms you will need to look at the formswe completed in class #8.

Let's begin with form 5, look at the information that we will enter on thisform. Do we have this information? Where is it? Type I, II, III, N, M, CLS,HPS, HS (75 lb) are all on form 1. Santee White Type S, Santee WhiteCement, and Mortar Seal Lime are on form 3. Look at form 1, type I, what isthe total for inventory of that column? (333 pallets) Enter the number ofpallets in the last column on form 5 marked "Total Pallets." How do you findout how many bags are in inventory? (multiply the number of pallets by howmany bags on a pallet) So, if type one is stacked 7 rows high with 5 bags onone row, then there are 35 bags on a pallet of type I (7 x 5 = 35). Now tofind the number of bags on 333 pallets multiply 333 by 35. (333 x 35 =11655) Enter the 11,665 in the column for "Total Bags."

Follow the same procedure for each product. Be careful when figuring howmany bags are on a pallet. Watch the number high, this changes for someproducts. There are always 5 bags on one row.

Before you start form 6, check off all the product that you entered onto form5 from forms 1 and 3. Are any products not checked off? (yes, CLM andStucco) Look over forms 6 and 7. Are CLM and Stucco listed on them? (no)Where should we put the information on CLM and Stucco? (on form 5)Notice that the last four lines on form 5 are blank. We can write CLM andStucco in the "Type" column and record the information for these productsthere.

55

Memo #9, page 2

Look at form 6, where is the information for these products listed? (form 2)-Enter the inforthation from form 2 onto form 6.

Form 7 is blank. Is there a information to put on this form? (yes, from form4) Carefully enter this information. Remember to write the product name ortype identification code in the "Type" column and watch the how highnumbers.

INVENTORY - STOCK ON FLOOR

DATE:

MONTH:

TYPE TOTAL BAGS ITOTAL PALLETS

IX

X

35 =

IIX

X

35 =

IIIX

X

35 =

NX

X

45 =

X

X

45 =

CLSX 45

X

=

HPSX

X

45 =

H(75S 1b)

X

X

45 =

SANTEEWHITETYPE S

X

X

40 =

SANTEEWHITECEMENT

X

X

35 =

MORTARSEALLIME

=-

X

X

50 =

=

=========

= = =

X

X

X

X

X

X

X

X

TE/sbr(14)

TYPE


MONTH:

DATE:

TOTAL BAGS TOTAL PALLETS

BUFFMORTAR X-4'5 .= i X

ROSET MORTAR X 45 = I X

I BROWNMORTAR X 45 = I X

BLACKE MORTAR X 45 = I X

SALMONN MORTAR X 45 = X

REDMORTAR======DARKMORTAR

X 45 = X

X 45 = X

BUFFMORTAR X 45 = X

T ROSE

YMORTAR X 45 = X

BROWNP MORTAR

Ask- BLACK

NIPMORTAR

H SALMONMORTAR

REDS MORTAR

X 45 = X

X 45. =

X 45 = I X

X 45 = I X

DARKMORTAR X 45 = I X

BUFFMORTAR X 45 = X

T ROSEMORTAR X 45 =

BROWNP MORTAR

X

X 45 = I X

E BLACKMORTAR X 45 = I X

C SALMONMORTAR X 45 =

L =RED

S MORTAR X 45 === == =

X

X

DARK 45MORTAR X = I X

= = =

TE/sbr(14)

53

TYPE


DATE:

MONTH:

TOTAL BAGS ITOTAL PALLETS

x

x

x

x

x

x

x

x

xr

x

x

x

Lesson # 10

LESSON OBJECTIVES:

Upon completion of the lesson, the participants, working in collaborativegroups, will be able to:

1) arrange eight (8) words in alphabetical order.2) evaluate the dictionary definition of a word used in the

workplace.3) identify an alternative resource, other than the dictionary, to aid

in the defining of words.4) enter date into their Vocabulary Handbook5) evaluate and solve work-related math problems using

multiplication or division.

Materials:Memo #10 (contains word list and math problems)DictionariesCement Glossarypencils/pens

60

MEMO # 10

To: CEMENT ClassesFrom: Lou TaylorDate: February 16, 1994Subj: 1) Workplace Vocabulary

1) Refractory Math

First, you will use the eight words below and find their definition in thedictionary. It may be helpful to put the words in alphabetical order first.Then find the word, read the definiticm and ask yourself, "Does this tell methe meaning of the word as I use it at work?" If it does, write the definition inthe vocabulary section of your Vocabulary Workbook. If it does not, then goon to the next word and repeat the process. When you finish, we will discussthe words that you could not match the definition anduse at work.

marl shim

fly ash refractory

palletizer finish mill

needles slurry

You will write the definitions in the vocabulary section of your notebooks,this begins on page 5.

The second task is to solve the problems on the following page. We havegotten some of the figures for the kiln outage and are reviewing the formulasto order supplies. Let's look over the problem carefully and use the formulasto help order the supplies. The formulas to solve the problems are given.

61

A) If a 6" (0.5 foot) thick layer of castable (refractory) is to be installed,what is the volume of the refractory?

Volume = length x width x heightOR

Volume = area x thicknessVolume = 581.2 square feet x 0.5 ft.

B) What will be the weight of the refractory?Weight = cubic feet x weight per cubic footWeight = 290.6 cubic feet x 160 pounds per cubic foot

C) The refractory material requires 3% water for mixing. How muchwater will be required for mixing?

Water = weight of refractory X 0.03

D) Stainless steel needles (4%) will be added to the mix to preventcracking. How many pounds of needles will be needed?

Pounds of needles = weight of refractory x 0.04

E) The mixer only holds 2000 pounds of dry refractory mix at a time.How many mixes will be required?

Number of Mixes = weight of refractory - 2000

62

Lesson # 11

LESSON OBJECTIVES:

Upon completion of this lesson the participants, working in collaborativegroups, will:

1) state the difference between military and standard time.2) state that military time runs on a 24 hour clock.3) record given standard times in military notation.4) translate military time into standard time format.

Materials:Memo # 11Standard and Military Time Handouts

1 - Standard and Military Time (2 page explanation and exercise)2 - Standard and Military Time Worksheet #1

paper/pens/pencilsthinking caps

6 3

Memo #11

To: Continuing Education FoundationFrom: M. L. TaylorDate: July 6, 1994Subj: Military -vs- Standard Time

As you are aware, Military Time is used throughout the plant on shift logsand on work orders. Today we are going to learn about using of the MilitaryTime system. We'll begin by looking over the attached information sheet andthen we'll complete a worksheet (or two) on using this "new system."

While the Military Time system is new to us, it has been in use for manyyears. Remember that this is a different way to tell time than the way we areused to (called Standard Time) and that means it is not necessarily harder -just different!

So pay attention and ask questions as we learn a different way to tell time.

6 4

e

Standard and Military Time

We use Standard Time to tell the time of the day. Standard Time uses a_12 hour clock- and the abbreviations A.M. and P.M. to show morning or

evening.

In the military, time is told on a 24 hour clock and the abbreviationsA.M. or P.M. are not used. When we first hear time stated in Military Time,it sounds funny because we are not used to it. There are 24 hours in a dayand it is important to remember that midnight is the 2400 hour (or the end ofthe day). Time for the next day begins at 0001 (1 minute after midnight)when the new day is just one minute old. Military Time is written with fourdigits, the first two digits represent the hour of the day and the last two digitsrepresent the minutes. Look at the example below that shows how MilitaryTime is written and what the place value of the numbers are:

0000

hour minutes

Some examples of Military Time and their conversion to Standard Time arelisted below to help you understand.

Examples:Military Time Standard Time

1) 0815 8:15 AM2) 0630 6:30 AM3) 1400 2:00 PM4) 1200 12:00 Noon5) 2045 8:45 PM

Why do I need to know about Military Time?

At Holnam the Supervisors Shift Logs are kept with Military Time notingthe occurrence of anything that happens during their shift. You may hearMilitary Time being referred to in the Control Room or by your Supervisorsand not known what they meant. Well hang on we're about to break theirsecret code!

65

Military Time, page 2

Standard and Milita(y Time Exercises

Reading Military Time:

0800 is said "zero eight hundred hours" or "eight hundred hours"

1130 is said "eleven thirty hours"

1545 is said "fifteen forty-five hours"

2310 is read "twenty three ten hours"

Now try to write the time in Military Time for the words below:

1) seventeen twenty-six hours

2) zero three fifteen hours

3) twenty-one thirty hours

4)

5)

6)

7)

8)

9)

ten nineteen hours

zero one twelve hours

nine twenty-five hours

twenty-four hundred hours

zero fifteen hours

four thirty-five hours

10) sixteen fifty-five hours

66

Standard and Military Time - Worksheet #1

Write the following Standard Times in Military Time.

1) 4:14 P.M. =

2) 7:00 A.M. =

3) 5:00 P.M. =

4) 2:30 A.M. =

5) 3:45 P.M. =

Write the following Military Times in Standard Time:

6) 0815 =

7) 2345 =

8) 1700 =

9) 1930 =

10) 2115 =

11) 0830 =

12) 1445 =

13) 2400 =

14) 1115

15) 0600 =

67

Lesson # 12

LESSON OBJECTIVES:

Upon completion of this lesson the participants, working in collaborativegroups, will:

1) compose and submit a written memo concerning the class topics thathave been covered and their thoughts on these topics and includesuggestions for future classes.

2) review the use of military time and demonstrate proficiency bycompleting exercises with at least 90 % accuracy.

3) identify mistakes and correctly solve refractory math problems whengiven problems with incorrect answers.

4) identify and correct mistakes on an Inventory Control form.

Materials:Memo #12Memo Response FormRefractory Math Exercise Sheet (with mistakes in the math)Inventory Control Form 7 (with mistakes)paper/pens/pencilscalculators

Memo #12

To: CEMENT ClassFrom: Lou TaylorDate: August 10, 1994 .

Subj: 1) Class Assessment Memo2) Review of

a - Military Timeb - Refractory Mathc - Inventory Control Form 7

First, I need your advice. Please write a memo to me with your thoughtsabout the CEMENT Program. Tell me how you liked the classes, what youliked best, what you liked least or did not like at all. Also, tell me what youwould like to learn about in future classes which will start soon.

I really value your opinion and will use your comments to help plan what wewill cover in future classes.

Next, we will review some of the topics from this round of classes. We willstart with Military Time. You will receive an exercise sheet with examples oftime, follow the directions on the page.

The next task involves checking some work on refractory math. Pretend thatyou have done the math on the worksheet and are checking it to turn in. Useyour calculators to check the math and make corrections when you find amistake.

The last task involves finding mistakes on Inventory Control Form 7. Becareful there because some of the figures are correct. HINT: check all of thetotals and the math to figure out the number of bags.

Wow! There's a lot of work to get done in this class, so let's get busy.Remember that you are working in your groups and can help each other out.

69

To:

From:

Date:

Subj:

Memo Response Form

ri' 0

Standard and Military Time

Here are some examples of Standard and Military Time:12:45 A.M. = 12:45 A.M. (standard) = 1245 (military)9:00 A.M. = 9:00 A.M. (standard) = 0900 (military)5:15 P.M. = 5:15 P.M. (standard) = 1715 (military)9:00 P.M. = 9:00 P.M. (standard) = 2100 (military)

Remember: Military Time uses a 24 hour clock. Write the followingtimes in both Military and Standard times.

3:15 P.M. =6:00 A.M. =12:00 A.M. =(Noon)

6:00 P.M. =4:30 P.M. =11:00 A.M.=12:00 P.M. =(Midnight)4:45 A.M. =10:30 A.M. =8:00 P.M. =

Standard Military

Next, here are some excerpts from the Shift Log. Notice that the time is inMilitary format. Change the time to Standard.

A) Work order HH339988 written at 0900.B) Repairs to Wash Mill completed at 1430.

C) W.O.W. for repairs to slurry line at 1730.D) Repairs to slurry line completed at 2200.E) Work begun on WO JJ000009 at 1130.

71

Refractory Math Exercises

1) Compute the weight of castable refractory with a volume of 290.6 cubicfeet. Castable refractory weighs 160 pounds per cubic foot.

Weight = cubic feet x 160

43,136 = 269.6 x 160

2) The refractory material requires 3% water for mixing. How much waterwill be required for this job?

Water = weight of refractory x .03

1294.08 = 43136 x .03

3) Stainless steel needles will be added to the castable refractory to preventcracking. To calculate the amount of needles needed multiply the totalweight of the refractory by 4%.

Pounds of Needles = weight of refractory x .04

1725.44 = 43136 x .04

4) The mixer holds 2000 pounds of dry refractory at one time. How manymixes will be required to complete this job?

Number of mixes = weight of refractory -- 2000

215.68 = 43136 -- 200

7 2

e

Pre-Test

and

Post Test

73

CEMENTParticipant Pre-Survey

Name: Date:

Directions: Solve the following problems. Read over all the informationcarefully and take your time to answer. THINK !!!

Section I - Refractory Math

Information:* The circumference of the kiln is 58.1 feet.* Refractory work is to be done on a 12 foot length of the kiln.* The area that the refractory will cover is 697.2 square feet.* Watch out for decimal points !

1) How many stainless steel anchors will be required for installation?There are four anchors needed for each square foot of installation.n = (square feet) x (anchors per square foot)

697.2 x 4 =

2) If a 6" (.5 foot) thick layer of castable refractory is to be installed, whatwill be the volume of the refractory?

v = (area) x (thickness)

697.2 square feetx .5 fool__

Cement Pre-Survey, page 2

HQW much wattr will be required for mixing? The refractory weighs55,776 pounds.

n = (weight of refractory) x (3%)

55,776 poundsx .03

4) The mixer only holds 2000 pounds of dry refractory at a time. Howmany mixes will be required for this job?

n = (weight) - (2000)

2000) 55,776

Section II: 24 - Hour Clock

Directions: There are several questions below that state the time using the 24hour clock. Look at the times and choose the correct standard time thatmatches it.

1) The work was completed at 0715. When is 0715?a) 7:15 AMb) 7:15 PMc) 5:27 AM

Cement Pre-Survey, Page 3

2) The accident occurred at 1400. When is 1400?a) 1:40 PMb) 2:00 PMc) 10:40 AM

3) Can the job be done before 2230? When is 2230?a) 2:30 AMb) 10:30 PMc) 3:20 PM

4) The work was finished at 0845. When is 0845?a) 8:45 AMb) 8:05 PMc) 6:45 PM

Section III: Vocabulary

Directions: Match the following words to the correct definition by writingthe word on the line in front of the definition.

Marl Clinker Refractory Jackhammer

The product of the kiln which is used to make cement.

A rock drill operated by compressed air.

Kiln lining that can withstand high temperatures withoutfusing.A soft raw material, one of the ingredients for cement.

Section IV Packhouse Inventory (Math)

Directions: Look at the next page (page 4), this is one of the counting sheetsfor the Inventory Control Process in the Packhouse. It is partially filled out,please add each of the columns and enter the total in the box labeled "TotalPallets for Inventory".

76

gib

t

CEMENTParticipant Post Survey

Name: Date:

Directions: Solve the following problems. Read over all informationcarefully and take your time to answer. THINK ! ! !

Section 1 - Military Time (the 24 hour clock)Directions: Next, here are some excerpts from the Supervisor's Shift Log.The times are stated in Military Time. On the line at the end of eachstatement write the Standard Time for the Military Time given in thesentence.

1) Repairs on #4 raw mill completed at 0300 hours.

2) WO 640921GR work began at 1530 hours.

3) #1 Kiln shut down at 0615 due to hot spots.

4) #4 Raw Mill up and running at 0315.

5) WO 399599YX completed at 2200.

Section 2: Refractory MathDirections: Solve the following problems. Since we have been learning touse the calculator during this cycle, you are allowed to use the calculator tosolve these problems.Information:

* The circumference of the kiln is 58.1 feet.* Refractory work is to be done on a 16 foot length of the kiln.* The area that the refractory will cover is 929.6 square feet.* Watch out for the decimal points! ! !

6) How many stainless steel anchors are needed for the installation?There are four anchors required for each square foot installed.

(square feet) x (anchors per square foot) = n926 x 4 =

78

CEMENT Post Survey, page 2

_2) If a 6" .(.5 foot) thickness of castable refractory is to be installed, whatwill be the volume of the refractory?

(area) x (thickness) = v

3718.4-x .5 =

8) What will be the weight of the refractory? Refractory weighs 160pounds per cubic feet.

(volume) x (weight per cubic foot) = refractory weight

1859.2 x 160 =

9) Stainless steel needles are added to the refractory mix. If 4% of themix is to be needles, how many needles will be needed?

(weight) x (.04) = needles needed

297472 x .04 =

10) The 3% water needed to mix the refractory will weigh 8924.16 pounds.Since water is measured in gallons, we must convert pounds to gallons.A gallon of water weighs 8.3 pounds. If we divide weight of the waterby 8.3, we will get how many gallons of water will be needed.

(weight of water) - (8.3 pounds per gallon) = gallons of water

8924.16 - 8.3 =

11) The mixer holds 2000 pounds of dry refractory at one time. How maymixes will have to be made?

(weight of refractory) - 2000 = number of mixes needed

297472 - 2000 =

79


Section III: Company MemoDirections: On the next page (page 4) is a memo from Sandra Griffm, pleaseread it carefully and answer the following questions.

12) What is this memo about?A) Group Universal Life (GUL) Enrollment

B) A problem with the seagull population in the marsh west ofthe plant.

13) What will you find enclosed in the letter?A) A letter form Linda Strouse from Ho lnam, Inc.

B) A letter form the CIGNA Group Insurance with additionalinformation and enrollment form.

14) If you do not get this new plan on your spouse and dependents, do youhave to turn anything in?

A) No, just throw it all away.

B) Yes, everyone must turn in the election form whether youget the insurance or not.

15) When does all the information from you need to be turned in to Sandra?A) February 18, 1994

B) February 25, 1994

C) February 23, 1994

Section IV: Inventory ControlDirections: On page 5 of this survey is an Inventory - Stock on Floor sheet.You will notice that the form is not filled out completely, please fill out theform and check the work that is already on it. (there could be a mistake)

80

.,:f.1.11"1ER*LA :t 6:F.113.ES:P 0:14 D:EN 6E'

To:

From:

Date:

bject:


li HOLNAM INC

ALL EMPLOYEES(WHO HAVE LOST SUPPLEMENTAL AND/OR DEPENDENT LIFE COVERAGE)

S. GRIFFIN

FEBRUARY 18, 1994

GROUP UNIVERSAL LIFE (GUL) ENROLLMENT

YOU WILL FIND ENCLOSED A LETTER FROM LINDA STROUSE, HOLNAM, INC. AND A LETTERFROM CIGNA GROUP INSURANCE WITH ADDITIONAL INFORMATION AND ENROLLMENT FORMFOR THE GUL PLAN. THIS IS A FOLLOW UP OF THE LETTER YOU PREVIOUSLY RECEIVED FROMLINDA REGARDING ELIMINATION OF YOUR SUPPLEMENTAL LIFE AND DEPENDENT LIFEINSURANCE COVERAGE BY HOLNAM. (THIS IS LIFE INSURANCE ONLY AND DOES NOT AFFECTYOUR MEDICAL INSURANCE COVERAGE).

YOU NO LONGER HAVE ANY LIFE INSURANCE COVERAGE THROUGH HOLNAM, INC. ON YOURSPOUSE AND/OR DEPENDENTS. PLEASE READ ALL INFORMATION CAREFULLY AND RETURN TOPERSONNEL AS SOON AS POSSIBLE. THERE IS A PLACE ON BACK OF ENROLLMENT FORM TOSIGN IF YOU DO NOT ELECT TO ENROLL, THEREFORE, EVERYONE SHOULD RESPOND, EVEN IFYOU DO NOT CHOOSE TO ENROLL.

WE WILL NEED THESE BACK NO LATER THAN WEDNESDAY. FEBRUARY 23 IN ORDER TO HAVETO CIGNA BY FEBRUARY 25. IF YOU HAVE ANY QUESTIONS OR NEED HELP WITH YOUR FORM,I PLAN TO BE IN THE PLANT LUNCHROOM MOST OF THE DAY WEDNESDAY, OR YOU CAN GIVEME A CALL ANYTIME BEFORE THEN.

REMEMBER, DEADLINE IS FEBRUARY 23, 1994.

81



DAT,:: 51/41174MONTH: toy

TYPE TOTAL BAGS TOTAL PALLETS

I

II

34 X 35 = tiCi0

56 X 35 =

III

====

N

403 X 35 =X =

of X 45 =

1156 34

141 1

sT X 45 = -0 "7

4r;ZA.1.5-

CLS

TIPS

=====

( 75 lb)IC

,1q1 X 45 =

--Aka X 45 =

1/45-

?4 X 45 =

SANTEE L 0 X 40 =WHITE

TYPE S X

1/1,35-

- == = == = == 1 ===========....==========^== 1 =SANTEE X 35 =WHITECEMENT X========= =====MORTAR 2 (,, X 50 =SEALLIME I X== ======= ===== = =

X

IOSO

4oo

/000X= = == =ass == ====X

X========= === == = ======== ======= =======X

X

X

X

==

=

===== =.= ====-======.== == = = =======TE/sbr(14) 82

Reciprocal

Reading

83

TEACHER'S GUIDEFOR PERFORMING WORK:

TASK # 01

L PROCESS AND CONTENT OBJECTIVES

*

A. GENERAL STATEMENT: One objective of this course is to get the participantsto use a specific technique tc, develop good reading skills. Reading is considered aprocess skill here since we read in the workplace to perform a task. Reading in thiscourse is regarded as a tool to perform work better.

Reading aloud in class is required in this particular technique but it is not intendedto embarrass anyone. Reading aloud is done to develop each participant's readingand comprehension skills. The lesson is based on a technique called ReciprocalTeaching, explained in more detail below. You will see that the Reciprocal Teachingtechniques reinforce and support the different kind of teaching methods this courseemphasizes.

A content objective of TASK 01 is to have the participants understand thecooperative (not competitive) nature of the learning that will take place in thiscourse. Just following the Reciprocal Teaching method reinforces this cooperativemethod of learning.

Another content objective is to get the participants to understand the process thatwill be used in this course. (Notice how process can become content! This is anexample of the integration of process and content.) This objective is importantbecause this course is not like the school courses that emphasized abstractacademic learning. Most adult participants in a workplace literacy course did not doparticularly well In the regular classroom. Therefore, this course will be conductedas a dialogue among participants and teacher about reading, learning, thinking, andproblem-solving.

Notice how the methods of Reciprocal Teaching reinforce the goals set forth in theMEMO TO THE CLASS.

B. BACKGROUND: The Reciprocal Teaching reading activity was inspired by anarticle entitled "Students Make Gains Taking Turns 'Being '')e Teacher'," [ThinkingAbout Thinking, found in Education Week Special Reoort, October 9, 1991, pages14-151. Here's a brief excerpt to indicate how it works:

The children learned to ask for clarification when they cameupon words they did not understand. They took turns "being the

84

TEACHER'S GUIDE FOR PERFORMING WORK: TASK # 01

teacher" and asking their classmates questions about the texts thatthey were reading. And they practiced summarizing aloud thepassages that they had read and predicting what would happen next.

The four strategies that undergird the reciprocal-teaching method are--the product-of-years of study on how experts read and comprehend material.

The activities--summarizing, questioning, clarifying, and predictingwere chosen because they offer a dual function: They teach pupils to readand, at the same time, to monitor their understanding.

Don't dismiss these ideas because they are directed at children. The strategies arevery pertinent to anyone wanting to improve his/her reading ability. (I havemodified the suggested methods,below based for use with adults. Thismodification is not intended to detract from the underlying soundness of themethod.) The entire article gives more of the background for using this technique.

Annemarie Sullivan Palincsar and Ann L. Brown, the developers of ReciprocalTeaching, state the basis of the method in ASCD's 1.989 Yearbook:

Reciprocal Teaching focuses less on teacher explanation and strategies,----patting-greater emphasis-onles.ehers-and-students collaborating to bring

meaning to the text.At the heart of Reciprocal Teaching is a dialogue about the meaning of

the text. The dialogue is structured with the use of the four strategies thatpromote comprehension of text and monitoring of comprehension.

The teacher and students take turns leading this dialogue, breakingthe text into segments (initially by paragraphs). The discussion is focused ongenerating questions from the text, summarizing the text, clarifying portionsof the text that impaired understanding, and predicting the upcomingcontent, based on clues that are provided by the content or structure of thetext.

Annemarie Sullivan Palincsar and Ann L. Brown, "instruction for Self-Regulated Reading," in Toward the Thinking Curriculum: CurrentCognitive Research, edited by Lauren B. Resnick and Leopold E.Klopfer, ASCD 1989 Yearbook, page 33.

C. MODIFICATIONS: For those of you who are familiar with this method, I havemade a few changes based on the fact that the participants will be adults and not:elemerrtary_strro'ents;-Palincsar and Brown suggest-introductory lessons with theinstructor assuming principal responsibility for leading the discussion. Modelingreading the first paragraph is the only introductory lesson as such provided here.Of course, the teacher has to explain how the material will be read and the kindsof questions that are encouraged. The most important aspect of the introduction ofthe activity is to assure the participants that mistakes in reading and answers areacceptable. When the text is being read, the teacher should be prepared to startthe discussion and help it along only if the participants have not. In other words,every opportunity should be given to the participants themselves to start the

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questioning and clarifying. Of course the teacher has to ask for the start of thesummarizing stage and the start of the prediction stage at appropriate points andacts as a guide in the use of the methodology.

II. CONDUCTING-THE EXERCISE

A. SET THE ATMOSPHERE: Since Reciprocal Teaching requires participants toread, ask and answer questions, and otherwise actively participate in classroomactivities, you must make It clear to the participants that making mistakes is allright. Emphasize that It Is acceptable to make mistakes because that is how thelearning will develop. Unless all participants feel comfortable to participate, noteveryone will learn. It is the entire class', including the instructor's, responsibilityto cooperate so that everyone has an opportunity to growand learn.

B. HAVE LEARNERS TURN TO PERFORMING WORK, TASK # 09, IN THEIR

TASKBOOK

C. MODEL: Read the first paragraph aloud.

Be deliberate, go slow, read every word. After the first sentence, stop andThink Aloud about the word different. "Something can only be differentdepending on what classes / had before. How can the writer know the classwill be different since he or she doesn't know me? I am going to look for anexplanation from the writer on how the class will be different or I won'tbelieve him or her."

Ask for other questions from participants. Get the participants in the habit ofasking these questions and looking for the answers in the remaining text.

Read the second sentence (slowly) and Think Aloud: "The writer tells me here thatI will not work by myself. I'm not sure I like that. I thought I always workedby myself in school. Well, that Is one reason for the writer saying the classwill be different. I certainly don't understand the fact that the teacher is notgoing to give me information. That's what teachers are paid for and why Icame to this program. If the teacher doesn't give me information, where willI get it?"

Ask for other comments from the participants on this sentence only. Again,get the participants in the habit of asking these questions and looking for theanswers in the remaining text.

Read the third sentence (slowly) and Think Aloud: "First, the words 'activelyInvolved' are underlined. This means that the writer thinks they areimportant. It may also be an explanation of why this class will be different.Was I actively involved in my education before? Listening to a teacher doesnot actively involve me. That's whe ' the writer meant that this class will be

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.110111.


different. But I was confused by the list. First there were the letters A andB. Then there were numbers. I'm not sure what that means. It might meanthat the most important things we will do in this class are think and learn-how to learn. What does learn how to learn mean? In fact, what doesthinking mean? Is it the same as the right answer?"

don't like reading aloud. But if I am going to improve my reading, readingaloud can help. I'll have to wait and see how this is handled. Explaininganswers is a way to get actively involved . Maybe this has something to dowith thinking also. Taking part in group activities is different from classes Iused to attend. I don't know what using resources mean. Does this haveanything to do with the teacher not giving me information but I may have touse resources to get It?"

ASK:

Do you have any comments about the techniques of clarifying, questioning,summarizing, and predicting.

TELL:

* in reading aloud in this class, you can also ask questions about how topronounce a word or what a word means. These kinds of questions areencouraged. In addition getting help from the dictionary, we will also beexploring how to determine what a word means from context.

Does anyone know how to determine what a word means from context?(Ask for learner's suggestions first. If none are forthcoming, you can explorethe Issue of using context for word meaning with any reading text you haveavailable.)

D. GUIDE THE LEARNERS IN READING ALOUD THE NEXT PARAGRAPH OF THEMEMO: Call on a learner to read the second paragraph. It's only four words buthave someone do it and ask for clarification, questions, summary, and predictions.Daring the reading, all participants, including the reader and you can stop thereading and ask for clarification of meaning and/or pronunciation. When questionsare raised, allow the participants all the time necessary to come up with answersthemselves. You can focus and direct the answers only after the participants haveattempted to come up with answers. Let the knowledge come from theparticipants.

Below are suggested questions to stimulate discussion in this phase. You will haveto determine if these questions are appropriate for the level of the class. If they arenot, then maybe one of the goals of the course would be to bring the class to thelevel where these questions are appropriate.

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What do you think the word means?

What do you think the word means in the context of this paragraph?

Are there other meanings for the word ? What are the othermeanings?

How do you know that word in this paragraph means and not

HAVE A LEARNER READ ALOUD THE PARAGRAPH AGAIN: If the reader ishesitant and there are many interruptions, have the paragraph read again. (Youmight have the paragraph read again anyway the first few times this technique isused.) Try to have participants connect what these paragraphs say with theopening paragraph you had read. Try to make as many connections as possible,because that's what reading is, making connections to what we already know orhave already read.

F. GUIDE LEARNERS IN SUMMARIZING THE PARAGRAPH: Then ask someoneother than the reader to summarize what the paragraph said. Have otherparticipants comment on the summary or give a different version. Again, guide theparticipants' summaries toward a model of a good summary.G. GUIDE A DIFFERENT LEARNER IN REPEATING THE PROCESS FOR EACHPARAGRAPH: This process should be used with each paragraph of the MEMO TOTHE CLASS, even if it takes a long time. Don't forget you are attempting to havethe participants experience a new way to learn to read with comprehension.

This guide can't predict what you will find about the reading abilities of yourparticipants: but be prepared to use every possible opportunity to overcomeproblems. If a problem is really basic, stop and have them read other, lower levelmaterial, doing all four steps--questioning, clarifying, summarizing, and predicting--until reading improves. If the class can handle the reading level of the memo, justcontinue the TASK as outlined below, because many of the TASKS in this courseare based on this method and it will be used again with the other workplacematerial.

H. GUIDE THE LEARNERS IN A DISCUSSION OF THE ISSUES RAISED BY THESYLLABUS: After the entire MEMO TO THE CLASS has been read in the manneroutlined above, discuss in general the participants' reaction to the kind ofclassroom described in the memo. Explain to them that everyone is responsible forhis/her own learning. It is the teacher's responsibility to create an atmosphere thathonors the slogan: "Cooperate, don't compete."

I. LEARNER'S PERFORMING WORK: TASK 01 IS REPRODUCED BELOW.

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Cement

Glossary

89

CEMENT P ANT

GLOSSARY

111,011AIIII11! IIIONNE/ raw

Compiled by

C. F. CLAUSEN and W. R. DERSNAH

Reprinted from PIT and QUARRY, March and April, 1965

9 0

NUCLEARAUTOGENOUS

SPECTROPHOTOMETER

PROGRAMMING

DTA

DATA LOG

TV

EXPANSIVE CEMENT

XRD

CEMENT

PLANT

GLOSSARY

COMPUTER

Compiled by

C. F. CLAUSEN' and W. R. DERSNAH"

During their visits to nearly all the cement plants in the United'sates and Canada, the authors have frequently observed collo-quialisms and widely differing usage of technical and operationalterms in the field of cement manufacture. It is their hope that thisglossary of words specific to cement making may be helpful instandardizing the terminology for the benefit of writers, secre-taries, readers, speakers, and audiences, and that it will be usefulto students and new employees in cement plants.

Since PIT AND QUARRY published the original CEMENTPLANT GLOSSARY in April and May, 1956, manufacturingequipment and methods, as well as control procedures, have be-come considerably more sophisticated, as reflected in this revisedand enlarged second edition.

The few trade names mentioned in the glossary are includedonly because they have assumed a generic meaning.

The authors are grateful to Messrs. William Lerch (retired),H. H. Steinour (Portland Cement Association), and J. R. Tonry(Alpha Portland Cement Co.) for valuable comments and sug-

Dyndoe Cement CPortland Cement Associellso

n a

gestions.

BEST COPY AVAILABLE

91

AABRASION-RESISTANTREFRACTORY

Hard-fired, dense, high-duty fire-clay bricks (alumina-silica, con-taining less than 50 percent alu-mina) which resist physical wearor abrasion.

ACID REFRACTORYHigh-silica and alumin?-silica re-fractories. Alumina-siliza materi-als vary in refractoriness or resist-ance to high temperatures; thehigher the alumina content, thegreater the refractoriness.

A.C.L. (trade name)(see LEPOL KILN)

ACOUSTIC MILL FEEDCONTROL

An electronic instrument used forcontrol of mill feed rate based onchanges in the noise level of themill.

ADDITIONMaterial, other than gypsum orwater, which is interground withclinker, in amounts not to exceed2 percent. Includes grinding aidsand air-entraining agents.

ADDITIVEA material added to the slurry orraw materials, during or aftergrinding, such as grinding aids ordefiocculants, or to the kiln feedto change the burning character-istics of the raw mix or increasealkali volatilization.

AGITATIONThe mixing and homogenizationof slurries or finely ground pow-ders by air or mechanical means.

AGITATORA rake or paddle, often with jetsfor compressed air, to mix ormaintain suspensions in slurries.

AIR-COOLED JACKETJacket around a burner pipe, openat both ends, to allow cool outsideair to be drawn along the out-side of the burner tip by the fuelor air-fuel mixture as it leaves thetip.

AIR DEFICIENCYThe lack of sufficient oxygen toallow complete combustion of thefuel in the kiln. Results in com-bustibles in the waste gases.

AIR-ENTRAINING CEMENTCement into which has been inter-ground a small amount of an air-entraining agent such as certainrosins, resins, or fatty acids. Dur-ing the mixing of concrete or mor-tar, the use of air-entraining cc-

meat produces air-entrainedconcrete or mortar.

AIR LIFTElevating equipment wherebyslurry or dry powder is conveyedupw-ards through pipes by meansof compressed air.

AIRPERMEABILITY TESTA measurement of the fineness ofportland cement or any finely di-vided powder; expressed as sur-face area in square centimetersper gram.

AIR-QUENCHING COOLERCooler in which the hot clinkerpasses over grates with cold airforced up through the load forrapid cooling.

AIR SEPARATORAn upright cylindrical-conical amparatus, with internal rotatingblades, which separates varioussized fractions of ground mate-rials by centrifugal force. Fineparticles are discharged as prod-uct; oversize is returned to themill as tailings.

AIRSLIDE (trade name)Enclosed conveyor in which finelyground materials are transportedby gravity over a slightly inclinedporous fabric. Air supplied belowthe fabric keeps the powderedmaterial fluid.

AIR-SWEPT MILLA ball or tube mill in which thefinely ground particles arc re-moved by a stream of air passingthrough the mill.

ALKALIA substance having marked basicpropertiesgenerally sodium orpotassium oxides or hydroxides.(see also LOW - ALKALI CE-MENT)

ALUMINAAluminum oxideA120a.

ALUMINA REFRACTORYBrick composed essentially of alu-mina and silica, with the aluminain proportions ranging between 40and 70 percent.

ALUMINOUS CEMENT(Trade names: "Ciment Fondu,""Lumnite," and others) Consistsessentially of monocalcium alu-minate (CaO- A1201) and is madefrom such raw materials as baux-he and limestone, heated tocomplete fusion. Has high-earlystrength and refractory properties.

ANGLE OF REPOSEThe angle between the horizontaland the natural slope of loosematerial (such as cement), below

which the material will not slide.ANHYDRITE

Anhydrous calcium sulphateCaSO4. Gypsum from which thewater of crystallization has beenremoved, usually by heatingabove 325 deg. F. Naturalanhydrite is less reactive thanthat obtained at 325 deg. F.

ANIONA negative ion; a negativelycharged atom or group of atoms.It is attracted to the anode duringelectrolysis.

ANTHRACITEA hard, natural coal which con-tains approximately 85-95 percentcarbon and a low percentage ofvolatile matter.

APRON FEEDER(see PAN FEEDER)

ARC SPECTROGRAPHYSpectrographic identification ofelements in a sample of mate-rial, heated to volatilization in anelectric arc or spark.

ARENACEOUSComposed largely of sand.

ARGILLACEOUSComposed primarily of clay orshale.

ASHThe inorganic residue remainingafter the combustion of a fuel.

ASH RINGKiln ring near the discharge endpromoted by the fallout of ashparticles on the load or lining.

ATTRITION(1) Wear and tear. (2) Grindingin which size reduction is accom-plished by rubbing or friction.

AUGERA boring tool, particularly fordrilling rock.

AUTOCLAVEHigh-temperature, steam pres-sure container for laboratory test-ing of volume stability of con-crete, neat cement or mortarspecimens.

AUTOGENOUS GRINDINGGrinding with few or no grind-ing media in relatively large-diameter, short mills where thecascading load produces theimpact.

AUTOMATIONUse of self-regulating produc-tion or processing machinery ac-tuated by "feed-back" or byCOMPUTERS.

AUXILIARY KILN DRIVEStationary reserve engine, usuallydiesel or gasoline, to be connectedto kiln drive in case of power

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failure, to prevent warping of theshell.

BBACKSPILL

The material which spills out ofthe feed end of the kiln when theflow of slurry is obstructed bychains or mud rings.

BAG-TYPE DUST COLLECTORCollector in which dust is trappedwhen dust-laden air is passedthrough porous bags.

BALL COATINGReconsolidation of finely ground,dry material on the surface of thegrinding media which inhibitsfurther comminution.

BALL MILLHorizontal, cylindrical, rotatingmill charged with large grindingballs and having a diameter ap-proximately equal to the length.

BALL-AND-RACE MILLVertical grinding mill for dry rawmaterials, coal or clinker. Thematerial is ground by steel balls(8 in. to 12 in. diameter) ro-tating horizontally in a race.

BARREL(1) Weight measure for portlandcement corresponding to 4 bagsof 94 lb. each. One Americanbarrel of cement is 376 lb. net(Canadian 350). Most othercountries use a ton of (a) 2,000lb. (20 bags @100 lb.), or (b)1,000 kilos (20 baes e 50 kg.).(2) Wood or metal containerformerly used for shippingcement.

BASIC REFRACTORYKiln lining made from magne-site or chrome ore. These bricksexhibit greater refractoriness andbetter resistance to chemical at-tack by slags and metallic oxidesthan the alumina or silica types.

BATHTUB ZONEThat zone of a kiln (the calciningor burning section) which is ofgreater diameter than the re-mainder of the kiln.

BAUXITERaw material composed primarilyof A1203 2H20 together withquantities of Si02 and Fe203.

BELT CONVEYORConveyor by which dry materialsare transported on a continuousflat or slightly curved belt ofrubber and/or fabric travelingover rollers.

BENEFICIATIONImprovement of the chemical or

physical properties of a raw ma-terial or intermediate product bythe removal of undesirable com-ponents or impurities.

BIN-DICATOR (trade name)A biti level indicator which maybe installed at various points inbins; silos, hoppers, -chutes andconveyor boxes. Each unit isequipped with a diaphragm andcounterweight suited to the ma-terial in the bin.

BIN SYSTEM(Coal grinding and firing)

Arrangement incorporating a sys-tem of bins for pulverized coalfrom which it is fed to the streamof primary air and carried into thekiln. Not used with DIRECTFIRING (cf.).

BITUMINOUS COALSoft coal which contains 50 to 80percent carbon and which whenheated yields considerable volatilematter.

BLAINE APPARATUSAir permeability apparatus formeasuring the surface area of afinely ground cement, raw ma-terial, or other product.

BLASTINGRemoving rock from a quarry wallby means of explosives. Explo-sives are deposited in holes drilledin the rock and spaced to pro-duce fragmentation.

BLEEDINGThe accumulation of water onthe surface of a mortar or con-crete caused by the settlement ofthe solid materials within themass.

BLENDINGCombining the contents of twoor more bins, tanks or silos ofraw materials or cement to ad-just the analysis of the final prod-uct.

BLENDING BINA bin into which the contents oftwo or more bins are pumped forblending.

BLINDINGThe filling or plugging of theopenings in a screen by the ma-terial being separated.

BLOCK CAVINGA method of mining materialfrom the top down in thick suc-cessive layers or blocks. Eachblock is undercut over the greaterpart of its bottom area and thesupporting pillars blasted out. Asthe block caves and settles, thecover over the block follows.

The valuable material is re-moved through crosscuts andshafts.

BOWL CLASSIFIEREquipment for separating coarseand fine particles in cement rawmaterial slurry, ground with sur-plus water.

BOWL MILLVertical grinding mill in whichmaterials are ground betweencentrally suspended rollers and arevolving annular ring.

BOX TIRE (see TIRE)BRADLEY MILL (trade name)

(see ROLLER MILL)BREAKER PLATE

Heavy, wear-resistant liners forJAW CRUSHERS or ROLLCRUSHERS.

BRIDGE CRANEA crane which travels on wide-ly separated rails, usually abovea storage area.

BRIQUETTEA molded specimen of mortarwith enlarged extremities and acenter cross section of one squareinch, used for measurement oftensile strength.

BRITISH THERMAL UNIT (BTU)The amount of heat required toraise the temperature of onepound of water 1 deg. F. at ornear its point of maximum den-sity.

BULK LOADINGLoading of unbagged cement incontainers, specially designedtrucks, railroad cars or ships.

BURN, BURNING(1) Combustion of fuel. (2) Sin-tering or near-fusion in a kiln, re-sulting in chemical combination ofthe raw materials and formationof clinker.

BURNABILITYThe ability of raw materials toreact chemically on heating. Softerand more finely ground and inti-mately mixed raw materials of theproper chemical content combineinto cement clinker more readily.Relatively high contents of ironand alumina facilitate burning(through fluxing action), whereassilica has the opposite effect.

BURNER (or BURNER MAN)The operator who controls theburning process of a cement kilnby making changes in fuel, feedrate, kiln speed, draft, etc., so asto produce a quality clinker at thehighest possible rate, with mini-

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mum consumption of fuel andproper conservation of equipment.

BURNER GLASSESSpecial glasses for viewing theburning operation in a kiln. Blueor green glasses containing cobaltor iron stop the passage of infra-red rays.

BURNER PIPEThe pipe through which the fuel(coal, oil, or gas), and usuallypart of the combustion air, isblown into the kiln.

BURNER'S PLATFORMThe platform or floor at the lowerend of the kiln on which are lo-cated controls, and where theburner regulates the operation.

BURNING ZONEThe zone near the discharge endof the kiln in which the dried andcalcined raw materials are chemi-cally converted to portland ce-ment clinker at temperatures near2800 deg. F.

BUSHY FLAME(see TURBULENT FLAME)

BUTTSTRAPSteel band for riveted joints inkilns or mills.

B. & W. MILL (trade name)(see BALL AND RACEMILL)

CCALCAREOUS

Composed primarily of calciumcarbonate.

CALCINATORMachine for drying and preheat-ing slurry through intimate con-tact with hot kiln exit gases, pass-ing in counterflow through a ves-sel charged with heat-exchangingelements. Normally little if anycalcination (liberation of CO2)takes place.

CALCINING ZONEThat zone in the loin where cal-cium carbonate is decomposedinto CaO and CO2 at tempera-tures near 1600 deg. F.

CALIBRATETo determine and correct forerror in the readings of a measur-ing device.

CALIBRATION TANKSmall tank equipped with float orelectronic probe, and electricallyremote-controlled by kiln-oper-ator, located between kiln feederand feed pipe. In the automaticmeasuring cycle th; time of fillingthe tank is recorded on a stop

watch on the control panel. Ta-bles for various water contentprovide actual kiln feed rate(solids) with 0.1% accuracy.

CALORIEA unit of heat: (1) the amountof heat required to raise the tem-perzure of one gram of water1 deg. C. (2) in food and fuelvalues (h e a t consumption inkiln) the amount of heat re-quired to raise the temperature ofone kilogram of water 1 deg. C.(called a "large" calorie, being1000 times the "small" calorie).

CALORIMETERAn instrument for measuring heat,such as the quantities of heat lib-crated by the combustion of afuel. In cement laboratories afuel is burned in a "bomb," sus-pended in a volume of water, andthe heat given off during thecombustion of the fuel is calcu-lated from the resulting increasein the temperature of the water.

CAPACITY(1) RatedThe maximum pro-duction predicted from the equip-ment dimensions, characteristicsand performance. Annual ratedcapacity of kilns and entire plantsusually determined as total pro-duction during best three con-tinuous months, divided by thenumber of days, multiplied by365. (2) ActualThe annualproduction attainable under nor-mal operating conditions, usuallyabout 90 percent of rated capacity.

CARBONA chemical element forming aconstituent of coal, petroleum,limestone and other carbonates.

CAR T:PA hoisting mechanism used toraise one side or one end of aspecially designed railroad car ortruck, or its body, to dump thecontents.

CASCADINGThe rolling and falling motion ofgrinding balls in a mill, or ofclinker in a ki:n, as the equip-ment rotates. In mills, particular-ly, the movements of grindingmedia in a trajectory from a posi-tion near the top to the point ofimpact at the bottom.

CASTABLE REFRACTORYRefractory material which ismade into a paste or slurry andplaced to form a MONOLITHIClining.

CATIONA positive ion; a positivelycharged particle, atom or groupof atoms. During electrolysis thecations travel towards the cathodeor negatively charged electrode.

CEMENTAny chemical binder, such asglue, paste, etc., used to makebodies adhere to each other. (seePORTLAND CEMENT)

CEMENT COOLEREquipment for cooling finishedcement after grinding. May con-sist of water-jacketed screw con-veyor with water-cooled impellershaft and blades, or a verticalcylinder, with the outside cooledby running water and along theinner surface of which a thinlayer of cement is moved bycentrifugal action.

CEMENT PAINTA combination of cement (usu-ally white) and hydrated limealong with water repellents, pig-ments and accelerators, whichmay be mixed with water forapplication, usually to concretesurfaces.

CEMENT ROCKNatural, impure limestone whichcontains the ingredients for ce-ment in approximately the re-quired proportions.

CEMENTITIOUSSticky, adhesive.

CENTRALIZED CONTROLArrangement of indicating, re-cording, and regulating instru-ments in a central place (panel,console) in each operating de-partment or in one room for theentire plant

CENTRICLONE (trade name)(see LIQUIDSOLIDCYCLONE)

CENTRIFUGAL PUMP -

A pump in which a rotating im-peller inside a housing givesmotion to a fluid or suspensionthrough centrifugal force. Usedespecially for slurry.

CENTRIFUGEEquipment used to reduce themoisture content of a slurry-orsuspension by means of rotation,with resulting centrifugal force.Functions essentially as a THICK-ENER but with the force ofgravity increased many times.

CHAIN BALANCEA laboratory balance or scale inwhich small changes in weight onone side of the balance are

94

achieved by lengthening or short-ening a small chain attached toone balance arm.

CHAIN SYSTEMA system of chains suspended inthe feed end of a kiln to promoteheat transfer to the raw mix..

CHALKA soft limestone composedchiefly of the shells of smallmarine life.

CHARGEThe amount of grinding media ina ball- or tube-mill.

CHECK POT(see CALIBRATION TANK)

CHERTAn impure, flintlike rock, con-sisting mainly of silica (Si02).

CHOKETo make changes in a flame byreducing the velocity or percent-age of primary air. A choke in afuel pipe might be a constrictionwhich would reduce the nozzlevelocity of the air-fuel mixtureand usually the flame length.

CHURN DRILLQuarry drill for primary blastholes. Consists of a weight whichis hoisted up and down in thedrill hole and with an auger at-tached to its underside, so shapedthat it makes a fraction of a turnevery time it strikes the bottom.

CHUTEAn inclined trough down whichfluids or solids may flow or slideto a lower level by gravity.

CIRCULATING LOADThe proportion of separator tail-ings to new mill feed. Often statedin percent

CLAMSHELL BUCKETThe bucket on a quarry shovel orstorage crane which opens as aclamshell to pick up a load.

CLAYAn earthy, plastic material high insilica, alumina, and iron.

CLAY SLIPA suspension of clay in waterprepared for ease of handling andproportioning.

CLINKERThe fused product of a kiln whichis ground to make cement.

CLINKER BREAKERA series of hammers or roll crsinstalled at the discharge erd ofa clinker cooler, to break lumpsfor more rapid cooling.

CLINKER-CEMENT BRICKSRefractory bricks for rotary kilnsmade in cement plants from

screened clinker, portland cementand very little water, tamped byhand or machinery, s t o c k e d,watered, and air-cured. No chem-ical reaction will take place inkilns between such bricks andthe load.

CLINKER CONVEYORAny drag, chain, bucket, belt, panor vibrating conveyor used tomove clinker from the burningdepartment or storage.

CLINKER COOLEREquipment used to cool clinkerby motion or air. Includes dragchain, air-quenching, rot a r y,planetary, inclined grate, vibrat-ing.

CLINKER CRUSHER(1) (see CLINKER BREAK-ER) (2) Separate jaw or roll-crusher for clinker installedahead of grinding mills.

CLINKER MILL(see FINISH MILL)

CLINKER RINGA buildup in or near the back ofthe burning zone of a kiln inwhich melted or fused raw ma-terials have adhered to the kilnlining in excessive amounts.

CLINKER SCALEMechanical or nuclear scale pro-viding a continuous record ofweight of clinker produced, suchas leaving clinker cooler.

CLINKER STORAGEThe area (covered or exposed tothe elements) or silos in a ce-ment plant where clinker is storedor aged before grinding.

CLOSED-CIRCUIT GRINDINGGrinding system in which millproduct is passed to a screen orseparator so that fines may be re-moved from the circuit and over-size (tailings, sands) returned forfurther grinding.

CLOSED - CIRCUIT TVCameras and monitors connectedby wires without use of antennas.

COAL STORAGEThe storage area (often in thesame building or location asclinker and raw material storage)where stocks of coal are main-tained.

COATING(1) Crust of raw mix, clinker,and ash deliberately formed andmaintained in the burning zone ofa rotary kiln for protection of thelining.(2) (see also BALL COATING)

COLLOIDAny substance in a certain stateof fine division in which theparticles range in diameter fromabout 0.2 to about 0.005 micron.

COMMINUTIONProgressive reduction in size bycrushing, grinding or pulverizing.

COMPARATORAn instrument used for measuringchanges in length of testspecimens.

COMPARTMENT MILLTube mill in which division headsor partitions are used to divide themill into two or more compart-ments charged with varying sizedmedia.

COMPEB MILL (trade name)A compound or compartmentmill in which the preliminarycompartment is c h a r g e d withlarger media, or rods (Rodpeb-mill), so that it takes the placeof a separate ball mill. Made upto 13 by 52 ft. in size, pulled bymotors up to 6,600 hp.

COMPOUNDChemical substance composed ofor produced by the union of sev-eral elements. The four major po-tential compounds of portlandcement are tricalcium silicate,dicalcium silicate, tricalcium alu-minate and tetracalcium alumino-ferrite.

COM PUTER(Data processing system) Ag-

gregate of electronic instrumentsto which information may befed (input) and pr oc es s edthrough previously programmedinstructions for arithmetical pro-cedures, and which delivers ther e s u l t s of these calculations(output).Analog computers translatemathematical equations into phys-ical (electric) quantities for solu-tion of the problems, similar to aslide rule. In digital computersthe mathematical quantities arerepresented by symbols or count-ers, similar to desk calculatorsor abaci.Business computers accept pro-grams and input from human op-erators and produce solutions toproblems of cost accounting, or-ders, shipments, billing, inventory,warehousing, payroll, and pre-ventive maintenance,Process computers (productionline control) receive input of

95

process variables from sensinginstruments and, based on math-ematical studies, actuate controldevices to produce or maintainintended temperature, load, pres-sure, draft, flow, speed, compo-s it i o n, fineness, etc. Intendedbenefits include stable operation,increased production, improvedefficiency, labor economy, im-proved uniformity, complete op-erating records, and alarm for offlimits.

CONCAVEXGrinding balls characterized bysurface indentations which pro-duce both concave and convexareas in the surface.

CONDUCTIONTransmission of heat through abody without motion of the bodyas a whole.

CONE CRUSHER(see GYRATORY CRUSHER)

CONICAL MILL(see HARDINGE MILL)

CONSISTENCYThe fluidity of mortar or slurry(closely related to workability)measured by its flow, or of con-crete measured by its slump.

CONSTANT HEAD FEEDERA raw mix or slurry feederequipped with supply tank andoverflow to assure a constantpressure at the discharge pipe.

CONSTANT WEIGHT FEEDER(see WEIGHING FEEDER)

CONSTRICTIONA narrowing of the free path offlow such as a darn in a Elm

CONTINUWEICH (trade name)( WEIGHING FEEDER)

CONVECTIONTransfer of heat by currents in agas or liquid resulting from dif-ferences in density.

CONVEY-O-WEIGH (trade name)(see WEIGHING FEEDER)

COOLER FANLarge, rotating fan used to forceair through a clinker cooler.

COOLING HISTORYSuccessive time and temperatureintervals through which clinkerpasses after burning zone in kiln.Cooling history has importantinfluence on crystallographic andgrinding properties.

COQUINA SHELLS1/2- to 3/4-in, sea shells foundalong present or former salt-water shore lines. Used as cal-careous Taw material.

COULTER COUNTERLaboratory apparatus for deter-mination of number and size ofparticles suspended in liquidand passing through an aperturein an electrically conductivesystem.

COUNTERFLOWProttss arrangement whereby afluid (gas, water) travels in con-tact with, but in opposite directionto, a material (clinker, slurry, rawmeal) for exchange of heat orconcentration.

CRADLE FEEDERRaw material feeder for grindingmill consisting of a chute, at thefoot of a bin, through which theflow of crushed rock is main-tained and controlled by the rock-ing motion of a curved plate.

CROSS SYSTEMA system of segments or crossesof steel or refractory material inthe upper end of a kiln and atright angles to the axis. Aids inheat transfer by increasing thesurface area exposed.

CURTAIN CHAINSChains suspended in the feed endof the kiln in lengths approxi-mately 3/4 of the kiln diameterand with only one end of eachlength attached.

CYCLINGThe alternate surging of load in akiln resulting in excesses and de-ficiencies of heat for properburning.

CYCLONEConical sheet steel vessel forseparation of solids from fluids(air or water) by centrifugalaction.

CYLPEBS (trade name)("Cylindrical pebbles") Cast orclipped cylindrical grinding mediafor tube mills, approximately 1/2in. in diameter and 1 in. long.

DDAM

(see CLINKER RING and MUDRING)

DAMPERA valve, plate, or set of adjust-able louvres in a flue used toregulate the draft.

DATA LOGGINGScanning and recording (type-out or memory tapes), at regu-lar intervals, of process data(temperatures, drafts, weights,speeds, analyses, etc.), prepara-

tory to adoption of COMPUTERcontrol.

DEAD BURNED GYPSUMCaSO4 (see ANHYDRITE).

DEFLOCCULATIONThe dispersion of flocs or agg,lom-crated particles of finely groundmaterials. (cf. SLURRY THIN-NERS).

DIAPHRAGMPartition, such as used to separatechambers in compartment mills.

DICALCIUM SILICATEOne of the four potential com-pounds in portland cement: "C2S"=(CaO)2SiO2=Ca2SiO4. Con-tributes to high ultimate strength.

DIFFERENTIAL THERMALANALYSIS

(DTA) Indication of chemicalreaction by diffential thermocou-ple recording of temperature in-creases in sample under investi-gation compared with a thermallypassive control sample, heateduniformly and simultaneously.

DIFFUSION FLAME(see LAMINAR FLAME)

DIRECT FIRING.Blowing powdered coal directlyinto kiln from a UNIT PUL-VERIZER without BIN SYS-TEM.

"DIRTY" TAILINGSRejects from separators contain-ing quantities of fines suitable forthe finished product.

DISK FEEDERA rotating disk or table uponwhich feed is continously de-posited through a telescope pipeand which is equipped with anadjustable knife edge to divert adetermined amc,ant of feed into amill.

DISPERSANTA material which deflocculates ordisperses finely ground materialsby satisfying the surface energyrequirements of the particles.Used as a SLURRY THINNERor GRINDING AID (cf.).

DOLOMITEA limestone or marble rich inmagnesium carbonate. Must belimited in raw materials for ce-ment manufacture.

DORRCLONE (trade name)(see LIQUID--SOLIDCYCLONE)

DRAFT GAUGEUsually a manometer for meas-uring the static pressure of thegases passing through a flue.

96

DRAG CHAIN COOLERA ladder-shaped chain approxi-mately 1 to 11/2 ft. in width usedto convey and cool clinker byagitating it so that new surfacesare constantly exposed.

DROP BALL ("Skull cracker")A heavy weight which is raisedby a crane and dropped on largepieces of rock in the quarry forcrushing, to eliminate the needfor secondary blasting.

DROP-OUT BINDust housing (dust chamber) atfeed end of rotary kiln, for col-lection of coarsest dust particlesin kiln exhaust.

DROSSSlag, skimmed from smelting ofmetals such as tin and aluminum.Occasionally used as a cementraw material.

DRYING ZONEThat zone near the feed end ofthe kiln, in which the moisturein the load evaporates, usually attemperatures between 400-1200deg. F.

DRY PROCESSProcess for cement manufacturein which the raw materials areground, conveyed, blended andstored in a dry form.

DUCTAn enclosed passage or pipe forthe flow of gases or fluids.

DUMBBELL KILNA kiln in which the center sec-tion is of a lesser diameter thanthe ends.

DUST CHAMBERThe chamber or housing at thefeed end of a kiln where coarsedust is trapped or depositedthrough changes in gas velocity.

DYNACLONE (trade name)(see BAG TYPE DUSTCOLLECTOR)

EECONOMIZER

Chamber beyond the waste heatboilers in which further heat re-covery is attained by using theheat from exhaust gases at tem-peratures of 400-600 deg. F. toheat feed water for the boilers.

ELECTRIC EAR(see ACOUSTIC MILLFEED CONTROL)

ELECTROSTATIC DUSTPRECIPITATOR

\,___Collector for fine dust, particular-ly in kiln gases. Dust laden airis passed through a large cham-

ber where the dust particles arcionized by contact with chains orrods connected to one pole of ahigh-voltage rectifier, and thenattracted to and collected on thesides of tubes or collector platesconnected to the other (ground-ed) Role. Collectors are rappedperiodically to discharge dust.

ELEVATORRoller chain on which are at-tached heavy steel buckets whichcarry loads to higher elevations.Usually driven by a pair oftoothed sprockets at the head endand equipped with automaticbrakes to prevent reversal if thedrive breaks down.

ELUTRIATIONPurification by washing andstraining or decantation. Air elu-triation represents separation orpurification by removing particlesizes or forms with varying den-sities through the use of airp r e s s u r e. (The reverse ofsedimentation. )

ENDOTHERMICChemical reaction requiring thecontinued absorption of heat suchas the calcination or decomposi-tion of limestone.

EROSIONFormation ofin the coatingnear the nose,ure to intense

gullies and ridgesor lining of a kilnfrom direct expos-heat of the flame.

EVAPORATING ZONE(see DRYING ZONE)

EXCESS AIRThat proportion of the air enter-ing the kiln which takes no partin the burning process and passesfrom the kiln with the waste gases.

EXOTHERMICChemical reaction in which heatis given off after the action com-mences. Examples: hydration ofcement, and clinkering in theburning tone in kilns.

EXPANSIVE CEMENTCement made to expand forcompensation of shrinkage or toinduce tensile stress in reinforc-ing steel (post-tensioning). Maybe made as a mixture of (a)portland cement, alrminous ce-ment, and gypsum, or (b) port-land cement, a stabilizer, and anexpansive agent produced byburning of gypsum, bauxite, andchalk. Both methods are believedto result in the formation ofhydrated or anhydrous calciumsulfoaluminates in the paste.

FFALSE SET

A manifestation of an abnormalearly hydration reaction in whichrigidity or partial setting of thepaste occurs in a few minutes.When the stiffened paste is re-mixed even without the furtheraddition of water it resumes itsplasticity and no loss of strengthoccurs.

FEED-BACK CONTROLAdjustments of feed, speed, andother process components, basedon analyses of subsequent prod-uct samples.

FEEDOWEIGHT (trade name)(see WEIGHING FEEDER)

FEED PIPEThe pipe through which the feedmaterial to a mill, kiln or tank isconveyed.

FEED SYNCHRONIZATIONAdjusting the speed of a feederto correspond to changes in kilnspeed through automatic electricalor mechanical devices.

FELDSPARAny of a group of crystallineminerals composed primarily ofaluminum silicates.

FERRIFEROUSComposed largely of iron ma-terials.

FERRIS WHEELFeeder with cups or bucketswhich pick up and move productsin the manner of a ferris wheel.

FESTOON(see LOOP CHAIN)

FIELD JOINTSJoints in kilns where the prefab-ricated sections are assembled onsite by means of welding or butt-straps.

FILTER AIDChemical added to slurry to facili-tate filtration.

FILTER CAKESlurry remaining on the filtercloth after water has been re-moved, with the residual moisturebeing approximately 40-50 per-cent of the original.

FILTRATEThe fluid which passes throughfilter.

FINES(see SEPARATOR FINES)

FINISH DEPARTMENTThe department in a cement plantwhere clinker is ground intocement.

FINISH GRINDINGThe grinding of clinker into fin-

97

ished cement usually with the ad-dition of 3 to 6 percent gypsum.

FINISH MILL(1) Usually a tube mill in whichthe final stages of clinker grindingare accomplished. (2) The entirefinish grinding department.

FLAME PHOTOMETERAn instrument used to determineelements (sodium and potassiumin portland cement) by the colorintensity of their unique flamespectra resulting from introducinga solution of a compound of theelement into a flame.

FLAME PROPAGATIONPassing of a flame through an air-fuel mixture. Excessively highfuel-stream velocities may resultin unstable ignition; low fuel-stream velocities, less than thespeed of propagation, often re-sult in backfiring.

FLAME VELOCITY(see NOZZLE VELOCITY)

FLASH SET(see QUICK SET)

FLINT PEBBLESHard pebbles of approximatelyspherical shape formerly used inball and tube mills as grindingmedia.

FLOATING TIREA KILN TIRE (cf.) slightlylarger than, and not fastened to,the kiln; held in position by alter-nate projections on supportingshoes between it and kiln shelland being free to rotate.

FLOCCULATIONAccumulation or agglomerationof fine particles into masses orflocs.

FLOTATIONBeneficiation of raw materialslurry by means of surface activeagents, agitation, and introduc-tion of compressed air as finebubbles. Depending on the agentused, impurities such as carbonor excess of silica, alumina oriron are carried to the surfaceas a foam which is skimmed off.Used for beneficiation in somecement plants where correct mixcannot be obtained by blendingof available raw materials.

FLOURThat part of the ground raw ma-terials or cement of exceedingfineness, generally 25 to 30 mi-crons or smaller in size.

FLOW TABLELaboratory instrument used inmaking flow tests for consistency

of mortars or concretes in tests ofhydraulic cement.

FLOW TROUGH (BURMISTER)Laboratory instrument used tomeasure consistency of mortar tobe used for measurement of aircontent. No longer included in

--specifications.FLUE

(see DUCT)FLUE DUST

Clinker or raw-material dusttrapped in flues or pipes becauseof changes in gas temperature,velocity, or direction.

FLUIDIZATIONAeration of dry powder to makeit behave as a fluid.

FLUXA material used to promote fusionor melting.

FLUXO PUMP (trade name)Pneumatic conveyor for dry pow-ders, such as cement, consistingof a pressure tank in which thecement is aerated and a transportpipe through which the materialis forced by compressed air only.

FLY ASHResidue of fused sphericallyshaped particles from burning ofpowdered coal. Available frompower plants using DIRECT FIR-ING coal mills. May be used (1)as an argillaceous-siliceous coin-ponent of cement raw mix; and(2) as an addition to concrete, de-pending on carbon content anduniformity.

FORWARD CONTROLCalculation of mix proportionsbased on analyses of raw ma-terial samples.

FOXHOLE(see TUNNEL)

FREE LIMECaO in clinker and cement whichhas gat combined with Si02,A1203 or Fe203 during the burn-ing process, usually because ofunderburning, insufficient grind-ing of the raw mix, or the pres-ence of traces of inhibitors.

FRIABLEEasily crumbled or pulverized.

FULLER COOLER (trade name)(see INCLINED GRATECOOLER)

FULLER-KINYON PUMP(trade name)

A pneumatic conveyor for pulver-ized materials which embodies aspecially designed worm or screwrevolving in a closed chamber.Compressed air is introduced atthe discharge end of the conveyor

so that the mass becomes aeratedand semi-fluid, in which state itis carried to its destinationthrough a transport pipe line.

FUSIONAct of melting together.

GGAMMA RADIATION GAUGE

Radioactive sender and receivingunits located at opposite sides ofslurry pipe for measuring, indi-cating, recording, and controllingmoisture content.

GANG MOLDA mold for cubes, bars, orbriquettes in which two or moreare made or cast at a time.

GAS ANALYZERAn instrument using the principleof chemical combination or cata-lytic combustion in which a sam-ple of gas may be collected andanalyzed for oxygen, carbon di-oxide and combustible materials.(see also ORSAT)

GELA jellylike material. Particularlythe cementitious matrix ("paste")formed by the hydration of ce-ment particles in concrete ormortar.

GILLMORE NEEDLESA pair of weighted, flat-endedneedles of different cross sectionfor determing initial and finalsetting times of hydrauliccements.

GLORYHOLE SYSTEMA method of mining using a sys-tem of haulageways beneath theblock of material which has hadits top surface exposed by the re-moval of overburden. Connectingwith the haulageways are chutesthat extend up to the surface. Theexcavation of the material beginsat the top of the chute, and thebroken ore is removed by loadingit out from the chutes into carson the haulage level. The materialis worked from the top down.

GRAB SET(see FALSE SET)

GRANITEA very hard natural rock, con-sisting essentially of quartz, feld-spar, and mica.

GRAVIMETRIC ANALYSISQuantitative chemical analysisbased on weight of samples, resi-dues, precipitates, etc.

GRIFFIN MILL (trade name)(see ROLLER MILL)

9 8

GRIN DAB I LITYThe response o: a material togrinding effort. Can be measuredin a number of ways. A currentgrindability test measures it ingrams of product material pro-duced per revolution of a testmill. The more grams producedper revolution, the easier a mate-rial is to grind and the higher isthe grindability.

GRINDING AIDSCertain chemical additives whichaid in tube mill grinding by re-ducing ball coating or by dis-persing the finely ground product

GRINtok NG BALLS(see GRINDING MEDIA)

GRINDING MEDIAHard, free-moving charge in aball or tube mill between whichparticles of raw material, coal,or clinker are reduced in size byattrition or impact. Usually ofsteel, and spherical in shFpe withgraded sizes, the maximum in aball mill being about 3 to 4 timesthe maximum feed size.

GRIZZLYScreen for large rocks made ofheavy steel bars or rails.

GYPSUMCaSO4 n 21120Hydrated calci-um sulphate added to portlandcement clinker and intergroundin the ratio of about 3 to 6 per-cent to control the setting time ofthe cement paste.

GYRATORY CRUSHERA crusher for rock or clinker inwhich a steel center cone rotateseccentrically to crush the materialagainst the outside cylindrical orconical steel wall.

HAMMER MILLSecondary crusher in which rap-idly rotating bars or hammerspass between grates tc crush ma-terial by impact. The tolerancebetween hammers and grate usu-ally is 1 inch or less.

HARDINGE MILL (trade name)A conical ball mill with agraded charge, designed so thatlarger balls will segregate in thatportion of the mill where the conehas the largest diameter.

HEAT BALANCEA method of accounting for allthe heat units supplied, trans-

ferred, utilized in, and lost froma kiln.

HEAT EXCHANGEREquipment such as chains, quad-rants, lifters, etc., which facilitatesthe transfer of heat from the gasesto the load in a kiln or preheater.

HEAT OF HYDRATIONThe heat given off by cementpaste during the chemical com-bination of cement with water.An exothermic process.

HEAT VALUEHeat value of a solid fuel is ex-pressed in B.t.u.'s per pound offuel on as-received, thy, or mois-ture-and-ash free basis. Heat val-ues for gases, in B.t.u.'s per 1000cu. ft., and for liquid fuels, inB.t.u.'s per gallon, are usuallycomputed by adding together theheat contributed by the constitu-ent gases or hydrocarbons.

HELICAL CHAINEach chain length in a CHAINSYSTEM is advanced along thekiln shell longitudinally as well ascircumferentially. The total cur-tain is in the form of a spiralalong the shell.

HEMATITEAn important ore of iron, Fe203,red when powdered.

HEMIHYDRATEA hydrate which contains one-half a molecule of water to onemolecule of the compound. In ce-ment, Ca SO, 1/2H20 (partiallydehydrated gypsum, or Plaster ofParis) is most commonly known.

HERCULES MILL (trade name)(see ROLLER MILL)

H IGH- EARLY - STRENGTHCEMENT

Cement (Type III) characterizedby producing earlier strength inmortar or concrete than regularcement.

HIGH LIME ROCKLimestone which contains ap-proximately 75 percent or moreof calcium carbonate.

HOLDING POINTThe va'ne selected as a basis forcontrolling rk..v material propor-tions, usually depending on thecarl onate reading of the raw mix.

HOMOGENIZERA bin or tank in which fluids orpowdsiirs are thoroughly mixedand blended by compressed air,paddles or rakes.

HOPPERA receiver or receptacle with

bottom discharge in which sub-stances arc placed to be passedor fed to a mill.

HOT SPOTAn exterior area of the kiln shell,usually in the burning zone,which becomes heated to a tem-perature sufficient to cause theshell to be red hot or to glow.Usually caused by the loss ofcoating or lining.

HUM-MER SCREEN (trade name)Screening device for separatingmaterials in which electric vibra-tion is applied to a taut screeningsurface.

HYDRATIONChemical combination ,-;; cementwith water.

HYDRAULIC CEMENTCement capable of setting underwater.

IIGNITION LOSS

The percentage loss in weightwhen an as-received sample is ig-nited to constant weight at 900-1000 deg. C. for short periodsof time.

IMPACTOR (trade name)Large HAMMER MILL

IMPINGETo strike directly upon (as aflame may impinge on the loadm a kiln).

INCLINED GRATE COOLERAn enclosed,, inclined system ofmoving grates. Clinker droppedon the high end moves progres-sively to the lower, discharge endwhile cool air is forced throughthe grates and load from below.

INDICATORAn automatic apparatus whichshows, by the position of a point-er or level of a liquid, the tem-perature, speed. or level of equip-ment or process.

INDUCED DRAFTFlow of gases through the kilncreated by a suction fan.

INFRARED SPECTROSCOPYUse of spectrophotometer for de-termination of infrared absorp-tion spectra (2.5 to 18 micronwave lengths) of materials. Usedfor detection, determination, andidentification of organic materialsand the reaction between ()manicadmixture and concrete compo-nents.

99

INSOLUBLE RESIDUEThe material remaining after ce-ment is treated successively withhydrochloric acid and sodiumhydroxide solutions of specificconcentrations f o r designatedperiods of time.

INSUFFLATIONPractice of adding dust to thecoal in a burner pipe.

INSULATING REFRACTORYA good grade of refractory fire-clay brick with a large percent-age of open pore space. This openpore space may be about 70-75percent as compared to approxi-mately 20 percent for high-dutyfireclay brick.

INTERLOCKINGInterconnecting of electrical con-trols to assure that a series ofmotors can be started only in thecorrect sequence, or that they areall disconnected at the 'same timeto prevent congestion of mate-rial in conveyors and processequipment.

INTERSTICE BINA bin formed by the exteriorwalls of three or more silos orbins, so placed as to enclose theadjacent space on all sides.

IONAn electrically charged particle,atom, or group of atoms.

IRON-ALUMINA RATIOFe2Os

A1203Varies from plant to plant,

depending on raw materials andtype of cement being produced.At some plants the reciprocal isused for control.

IJACKHAMMER

A rock drill operated by com-pressed air.

JAW CRUSHERCrusher consisting of two plates,farther apart at top than at bot-tom, one movable and one sta-tionary. The movable plate whichis attached at the upper end, isgiven a reciprocating motion bymeans of an eccentrically oper-ated arm. Feed is crushed as itpasses down between the twoplates.

NUCLEARAUTOGENOUS

SPECTROPHOTOMETER

PROGRAMMING

DTA

DATA LOG

TV

EXPANSIVE CEMENT

XRD

CEMENT

PLANT

GL 1 SSA Y

K

PART II

KAOLINWhite-colored clay, principallyaluminum silicate, of low ironcontent, used as raw material inthe manufacture of white cement.

KILNPiece of equipment in which theproperly ground and propor-tioned raw mix is dried, calcined,

COMPUTER

and burned into clinker at a tem-perature of 2600 to 3000° F. Canbe of the rotary, shaft, fluid-bed,or traveling grate type; fuel maybe coal, oil or gas.

KILN BASIN(see SLURRY BASIN)

KILN BEDDINGThe degree of filling by the loadin a rotary kiln, normally 3 to 10percent of the free cross section.

1 0 0

KILN DEPARTMENTThe department of a cementplant which includes the kilnswith all auxiliaries (feeders,drives, coolers, dust collectors,burner's platform, fans, dampers,and fuel injection device).

KILN GUNSpecial industrial 8-gauge gunused for shooting down clinkerrings or for breaking up largeclinker balls in rotary kilns. Leador zinc pellets may be fired. Thekiln gun is sometimes used forscaling in quarries or mines.

KILN HOODRefractory-lined steel plate hous-ing around discharge end ofrotary kiln, furnished with open-ings for fuel pipe, radiation py-rometers, observation openings,and cleanout doors.

KILN INCLINATIONThe lengthwise slope in a verticalplane of a rotary kiln from feedend to discharge end; usuallystated in inches per foot (e.g. rfsin. per ft.), less frequently in per-cent (such as 4 percent).

KILN INSULATIONMaterial, such as diatomaceousearth, placed between kiln shelland refractory lining to minimizeheat loss.

KILN LININGA layer of refractories, 6 in. to9 in. thick, placed inside a rotarykiln to protect the steel shellagainst heat and abrasion.

KILN PAINTHeat-resistant paint sometimesapplied to outside of rotary kilnsfor protection, and to reduce heatloss.

KILN PIERConcrete or steel support for ro-tary kiln, one pier located undereach set of supporting rollers forthe kiln tires.

KILN PITCH(see KILN INCLINATION).

KILN QUADRANTCross-plates installed in the feedend of a rotary kiln to divide theload into several streams for in-creased surface and heat transfer.

KILN SEALAdjustable plates or rings in-stalled around feed end or dis-charge end of rotary kiln for pre-vention of infiltration of air.

KILN SHELLThe cyclindrical outer mantle of arotary kiln made of steel plate,3/4 in. to 11/2 in. thick. Shipped in

sections and riveted or welded to-gether during erection. Oftenequipped with stiffener rings tomaintain cylindrical shape.

KILN SLOPE(see KILN INCLINATION)

KILN SPEEDSpeed-of rotation of rotary kilnstated in revolutions per hour(rph), less frequently in secondsper revolution.

KOMINUTER (trade name)Ball mill, sometimes equippedwith planetary or annular screens,for grinding raw materials andclinker.

LLAMINAR FLAME

Rotary kiln flame, all parts ofwhich flow essentially paralleland in the same direction. Mixingoccurs by molecular diffusiononly.

LAMINAR FLOWIn laminar flow, particles of thesubstance move in parallel layersor laminae sliding over particlesin adjacent laminae but not mix-ing with them.

LAZY ''LAMEKiln flame characterized' by slowundulating movements, approxi-mately following the velocity ofthe flow of surrounding air.

LID RATIO"Slenderness." Length of rotarykiln divided by diameter. Variesbetween 25 (for short kilns), and40 (for long kilns).

LEPOL KILN (trade name)Combination of a relatively shortrotary kiln and a preheater em-bodying a traveling grate, con-veying a layer of nodulized rawmix towards the kiln, while hotexit gases are drawn through thelayer. Provides high fuel economy.

LIMECalcium oxide -CaO.

LIME RATIOCa0

Ratio of lime toSi02-1-R208silica plus alumina and iron. Usedas check of chemical compositionof raw mix.

LINER PLATES(see MILL LINER)

LINING(see KILN LINING)

LIQUIDSOLIDCYCLONERelatively small conical separa-tor, operating in closed circuitwith wet grinding mill, for sepa-rating slurry into coarse and finefractions by centrifugal action.

LITER WEIGHT TESTMethod of determining the densi-ty in grams per 1000 cc of clinkerof uniform, screened size. Indi-cates degree of burning and, bycorrelation, the free lime.

LOADMaterial being ground in a millor burned in a kiln.

LOOP CHAINLength of chain, suspended atboth ends, inside upper fourth ofrotary kiln to increase heat trans-fer from hot gases to load.

LOUVRE DAMPERDamper, for control of kiln draft,consisting of a set of horizontal.rectangular plates which, like avenetian blind, can be adjusted tovarious angles through a gearmechanism. Installed in the ductbetween kiln and draft fan.

LOW-ALKALI CEMENTCement containing less than 0.6percent alkalies, calculated aspercent Na20 + 0.658 timespercent K20. Specified in somecases for use in concrete madewith reactive aggregates. Alkaliesoriginate from raw materialsand/or fuel.

LOW C;COn STONELimestone for cement raw mate-rials containing less than 75 per-cent calcium carbonate.

LOW HEAT OF HYDRATIONCEMENT

Cement (Type IV) characterizedby low percentages of tricalciumaluminate and tricalcium silicate.When used in concrete it gener-ates heat more slowly than theother four types of cement.

LUMINOSITYQuality of flame giving off largeamounts of light and heat throughradiation.

MMAGNETIC FLOW METER

Line instrument for measuringslurry flow, used to govern regu-lating valve on discharge of kilnfeed slurry pump.

MAGNETITEMagnetic oxide of iron, Fe304.An important ore of iron.

MARELEHard crystalline limestone(Ca CO3). Rarely used as a ce-ment raw material because of thelarge amount of power requiredto crush and grind it.

MARL- Loose or soft calcareous raw ma-

1 0 1

terial. In some places, brokenmarine shells mixed with clay; inother places, fine, soft limestoneand clay; sometimes very fine,loose almost pure calcium car-bonate precipitated by under-ground rivers when reaching thesurface.

MASONRY CEMENTCement used in masonry mortarconstruction.

MASTER GEARAnnular gear ring around rotarykiln or ball or tube mill to whichthe rotation is transmitted from amaster pinion.

MASTER PINIONGear wheel on end of drivingshaft of motor or speed-reducer,transmitting rotation to a mastergear of a kiln or mill.

McCASL1N CONVEYOR(trade name)Raw material or clinker conveyorconsisting of buckets which moveboth vertically and horizontally,and which can be adjusted forloading and discharging at vari-ous points.

MATHEMATICAL MODELArithmetical equation relating thevariables of a process in rigidterms. Used in computer simula-tion of industrial processes.

MELTThe 20-30 percent of the mass ofraw material which has becomemolten during clinkering ("liquidphase"). Consists primarily ofthe alumina and iron compounds.

MICRON1ZER (trade name)Laboratory mill for reduction ofmaterial to micron size by high-speed impact and particle-against-particle grinding, actuated bycompressed air.

MICROSCOPIC ANALYSISQualitative and quantitative iden-tification of minerals (includingcement compounds) and distri-bution of phases in polished,etched samples by reflected light.

MILL CHARGEGrinding media (balls, cylpebs,concavex, slugs or flint pebbles)with which a grinding mill ischarged.

MILL LINERSHeavy cast or manganese steelplates mounted inside grindingmills to (1) protect mill shellagainst abrasion from load andcharge, (2) improve cascadingand grinding action, and (3)sometimes classify grinding media.

MILL SCALEHigh-iron waste material ob-tained from rolling mills in steelplants and often used as a com-ponent of the raw mix when TypeII -or Type V cement is manu-factured.

MILER .The operator who controls thegrinding operation of one or sev-eral mills by regulating feed rate,speed, circulating load, water, ad-ditions or additives, etc., so as toobtain maximum production atthe desired fineness and viscosity.

MINERALIZER(see FLUX)

MINERALOGICAL ANALYSISApplication of DTA, XRD, ormicroscopy (see these), for iden-tification of cement compoundsinstead of by gravimetric analysis.

MIXINGAfter raw material components(such as limestone, shale or clay)have been ground to the desiredfineness and blended in the cor-rect proportions, the slurry or dryraw meal goes through a processof mixing to insure completehomogeneity. Equipment used in-cludes tanks or basins with me-chanical or air agitation, circula-tion by pumping, or fluidizationof dry meal with compressed air.

MIXING BASIN(see SLURRY BASIN)

MODERATE HEAT OFHYDRATION AND SULPHATE-RESISTANT CEMENT

Cement (Type II) generatingheat more slowly during hydra-tion in concrete than Types I, IIIand V, although faster than TypeIV; also makes concrete more re-sistant to attack by sulphate-con-taining water than Types I and

MODULUSOne of several ratios nsed in cal-culating the chemical composi-tion of the raw mix. For exam-ples, see LIME RATIO, SILICARATIO and MOLECULAR RA-TIO.

MOLECULAR RATIOCa0 SO3

56.08 80.06(60.06 101.94 159.68

Si02 A1203 Fe203A ratio of lime, sulphur, silica,alumina, and iron based on themolecular weights.

MOLY-COP (trade name)Special grinding media for balland tube mills. Made of an alloysteel containing molybdenum andcapper.

MONOLITHICA structure cast entirely in solidconcrete. (Literal meaning:"made as one rock.")

MSA PARTICLE SIZEANALYZER (trade name)

Laboratory instrument for meas-uring size distribution of particlesbetween 40 and 0.1 microns.Settling is produced by gravity(for coarse particles) and cen-trifugation (for fine particles);results are calculated from ratiosof sediment heights observed incapillary tubes.

MUD RINGAn annular accumulation of part-ly dried or stiffened slurry on thelining or shell near the feed endof a wet process kiln.

MULTIPLE GAS DISCHARGEBilateral funnels extending fromcenter of kiln through openings inthe kiln shell, through which thekiln gases are withdrawn fromkiln into hood or dust chamber.This system permits using only avery small opening in the end-plate of the kiln for accommoda-tion of the feed pipe, thus pre-venting back-spill.

MULTISTAGECrushing and grinding raw ma-terials or clinker in several suc-cessive operations, each step re-sulting in greater fineness. Ex-amples: Primary followed bysecondary crusher s; ball-mills(preliminators) followed by tubemills; and 2-, 3-, or 4-compart-ment mills.

NNATURAL CEMENT

The product obtained by finelypulverizing calcined argillaceouslimestone. The temperature of cal-cination shall be no higher thanis necessary to drive off carbonicacid gas.

NATURAL DRAFTDraft in kiln created only by tem-perature and volume changes ofexhaust gases and height and in-side diameter of the stack.

NATURAL FREQUENCYCONVEYOR

Horizontal or slightly inclinedconveyor for dry materials, con-sisting of a pan or trough sus-

1 02

pended from springs, the convey-ing action being caused by length-wise reciprocal movements ofthe trough. The number of thesemovements per in i n u t e (freeoscillations) depends on theweight and design of the pan andframe, length, weight and rigidityof the springs, and weight ofmaterial.

NATURAL CASA combustible gas issuing fromthe earth's crust through naturalopenings or bored wells. Consistsessentially of methane with smallamounts of ethane, propane, bu-tane, hydrogen, oxide of carbon,nitrogen, helium, hydrogen sul-phide, etc.

NEAT CEMENTMixture of portland cement andwater (with no coarse or fine ag-gregates) used for grouting or forstudies of the performance of ce-ment paste.

NEUTRAL REFRACTORYRefractory which is neither defi-nitely acid nor definitely basic.The most nearly neutral of allcommon refractory materials ischrome ore.

NEUTRON ACTIVATIONDetermination of trace compon-ents in a sample by detecting andinterpreting beta or gamma radi-ation induced by irradiating thesample with thermal velocity orhigh energy neutrons.

NI-HARD (trade name)Grinding media and mill linersmade of special alloy steel con-taining nickel.

NODULES(1) Moist, ball-shaped lumps ofraw materials containing 10-12percent water, up to 1 in. in di-ameter; used as feed to semi-dry-process rotary kilns, shaft kilns,or Lepol grates. (2) Lumps ofnearly dried slurry sliding out ofchain section and passing downthrough wet-process rotary kiln.Depending on a number of op-erational factors and physicalcharacteristics of the raw mate-rials, nodules contain between 5and 12 percent residual moisture.The physical strength of the nod-ules has a considerable influenceon kiln capacity, heat economyand dust loss.

NODULIZERMachine for producing nodulesfor semi-dry-process kilns or Le-pol grates. May be (1) an in-

dined rotating drum, approxi-mately 9 ft. diameter and 15 ft.long, or (2) a rotating disc, up to30 ft. diameter with a rim, in-clined about 30 deerees fromhorizontal. In both cases the dryraw mix is sprayed with waterand dules are formed by "snow-ball" action.

NOSE CASTINGSHeat resistant metal segments forholding kiln lining at dischargeend.

NOSE RING(see ASH RING)

NOZZLE VELOCITYThe speed, frequently given infeet per minute, of fuel (gas) orfuel-air-mixture (gas, oil or coal)entering the kiln, measured orcalculated at the tip of the burn-er pipe.

NUCLEAR MAGNETICRESONANCE

Qualitative and quantitative de-termination of elements in a sam-ple by observation of the reso-nance characteristics of atomicnuclei in an applied magneticfield.

NUCLEAR SLURRYDENSITY GAUGE

Electronic instrument, located onmill discharge stream, to controlmoisture content in slurry byregulating water feed, or in slurrystorage basins by regulating"trim" water.

OBSERVATION HOLEOpening in hood at front end ofrotary kiln through which theburning, flame, consistency ofclinker load, filling, position ofcalcined raw mix and burningzone can be observed.

OIL WELL. CEMENTCement used under high pressureand temperature in sealing waterand gas pockets during the drill-ing of oil wells. Sometimes con-tains special retarders to meet therequirements of use.

ON-LINEMeasuring or analyzing equip-ment located on process stream,instead of in separate laboratory.

OPEN CIRCUITGrinding arrangement wherebymaterial passes through a mill andis ground to the desired finenessin one pass, without classificationand regrinding.

ORIFICEA mouth-like or throat-like con-stricted opening in a pipe or duct.

ORSATManually operated, portable ap-paratus for analyzing kiln wastegases in which carbon dioxide,oxygen and carbon monoxide aresuccessively removed from agiven volume of gas tested bypassing through chemical solu-tions.

OSCILLATING CONVEYORConveyor in which the pan ortrough is suspended by a numberof pendulums and is moved back-ward and forward with a rela-tively long oscillation. Actuatedby mechanical means.

OVERBURDENLayer of soil or unusable rock orother earth formation on top ofraw materials in quarries. Mayvary in thickness from a fewinches to over 50 feet, necessitat-ing removal (stripping).

OVERBURNEDCement clinker is considered"overburned" if it has been ex-posed to too high a temperature.This results in formation of toomuch "liquid phase" during theclinkering process and too denseand hard-grinding clinker.

OVER LIMEDA raw-mix is "overlimed" if itcontains more CaO than requiredfor the chemical combination withsilica, alumina and iron oxide.This may result in the presenceof uncombined or "free" lime inthe clinker and finished cement.

OXIDIZING FLAMEKiln flame to which more pri-mary and secondary air is suppliedthan required for complete com-bustion. At the high temperaturein the burning zone, the excessoxygen maintains the iron in theclinker as "ferric" iron, resultingin darker and greenish cement.

PPACK SET

(see STICKY CEMENT)PACKER

Workman, operating machine forpacking cement in paper bags.

PACKING MACHINESeveral makes of machines forpacking cement in paper bags areused. They are semi-automatic;the packer slips the bag on thespout and starts the filling whichis shut off at exactly 94 lb. net

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weight. On some machines thepacker then releases the bag, onothers it is done automatically.Capacities range from 900 to2200 bags per hour.

PALLETSPortable disposable or re-usuableplatforms for storage or transportof bagged cement.

PAN FEEDER(1) Rugged, slow-moving con-veyor consisting of over-lapping,heavy, cast steel or manganesesteel pans, used for feeding"shovel-sized" lumps of rock,from quarry-cars, evenly to a pri-mary crusher. (2) Short, vibrat-ing, trough-type feeder for drymaterials.

PARTITIONSlotted cast steel or alloy steelgrate separating two chambers ina compartment mill.

PASTE(see GEL)

PATA small laboratory-prepared neatcement sample, on glass backing,with a flat surface for settingtime tests using Gilimore or Vicatneedles.

PECK CARRIER (trade name)(see McCASLIN CONVEYOR)

PELLETS(see NODULES (1) )

PERICLASEHard burned crystalline mag-nesium oxide.

PERIPHERAL DISCHARGEDesign of ball- or tube millwhereby the ground product isdischarged through openings inthe mill-shell.

PERIPHERALINSTRUMENTATION

Sensing instruments integratedwith, and feeding input informa-tion on process to a computer.

PERMEABILITY APPARATUS(see BLAINE APPARATUS)

pHDesignation of acidity of water orsolutions (amount of hydrogen-ions) defined as pH. log

CHwhere CH is the concentrationof hydrogen irons in gramsper liter. One liter of "neutral"water contains--1

10,000,000gr. of

free hydrogen-ions, so the pH ofneutral water is:

1log1

=7.

10,000,000

PHASE(1) A single homogeneous stateof matter (vapor, liquid, solid,plasma.) (2) Condition of clink-er in burning and initial coolingzones, as "solid phase," and"liquid phase" (indicating moltenclinker material)..

PITHole in the ground where rawmaterials are excavated; especial-ly "clay pit."

PITOT TUBEApparatus for measuring the ve-locity of flow of air, water, orother fluids.

PIV GEARSpeed reduction unit with adjust-able ratio. Often used on kilnfeeders to permit changes in thesynchronized feed rate.

PLANETARY COOLERA cooler consisting of a numberof cylinders built around and par-allel with the shell at the dis-charge end of a rotary kiln; thehot clinker leaves the kiln throughthese cylinders in counterflowwith cooling air, which then en-ters kiln as secondary combustionair. Examples of planetary cool-ers are "Solo," "Unax," and"Vickers" coolers.

PLASTER (of Paris)CaSO4 1/2H20. Gypsum fromwhich 3/4 of the chemically boundwater has been driven off by heat-ing. When wetted it recombineswith water and hardens quickly.

PLUMEDark, as yet unignited, part of aflame, closest to the nozzle of theburner pipe. Its length dependson the temperature and velocityof the primary combustion air and,if coal is the fuel, its finenessand volatile content.

PLUNGER PUMPWater, oil, or slurry pump con-sisting of reciprocating plungers.

PNEUMATIC CONVEYOREquipment for transport by com-pressed air of pulverized or gran-ular dry material such as coal,raw-meal, or cement.

POIDOMETER (trade name)(see WEIGHING FEEDER)

PORTLAND BLAST-FURNACESLAG CEMENT

An intimately interground mix-ture of portland cement clinkerand granulated blast-furnace slag.The slag constituent shall not beless than 25 percent ano shallnot exceed 65 percent of the: port-

land blast-furnace slag cement.PORTLAND CEMENT

The product obtained by pulver-izing clinker consisting essential-ly of hydraulic calcium silicates,to which no additions have beenmade subsequent to calcinationother than wat...r and/or untreatedcalcium sulpha.; except that ad-ditions not to exceed 1.0 percentof other materials may be inter-ground with the clinker at theoption of the manufacturer, pro-vided such materials in theamounts indicated have beenshown to be not harmful by testscarried out or reviewed by com-mittee C-1 on Cement of theA.S.T.M.

PORTLAND POZZOLANCEMENT

An intimately interground mix-ture of portland cement clinkerand pozzolan, or an intimate anduniform blend of portland cementtnd fine pozzolan. The pozzolanconstituent shall not be less than15 percent, by weight, and shallnot exceed 50 per c e n t, byweight, of the portland-pozzolancement.

POZZOLANA siliceous or siliceous and alu-minous material, which in itselfpossesses little or no cementitiousvalue, but will, in finely dividedform and in the presence of mois-ture, chemically react with cal-cium hydroxide at ordinary tem-peratures to form compoundspossessing cementitious proper-ties. Natural pozzolans are com-monly of volcanic origin; artificialones include FLY-ASH and cal-cined clay or shale.

PREHEATERInstallation for heating raw mixor slurry ahead of their entry intorotary kiln proper, to improveover-all fuel economy. Hot exitgases are passed through preheat-ers in counterflow.

PRELIMINATORShort, large diameter ball mill forfirst-stage grinding of raw ma-terials or clinker in a multi-Ragegrinding system.

PREMATURE STIFFENING(see FALSE SET)

PREVENTIVE MAINTENANCESystem of planned maintenancebased on foreknowledge of neces-sity of repairs and past historyof performance, to forestall unduedeterioration of equipment, build-

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ings, roads, fences, etc., and pre-vent breakdown and interruptionof production.

PRIMARY AIRThat part of the combustion airin a rotary kiln which is blown inwith the fuel.

PRIMARY BLOWERCentrifugal blower delivering pri-mary air to kiln. In case of directfiring it also draws air throughthe unit pulverizer.

PRIMARY DRILLINGDrilling of holes in rock forma-tion for explosive charges forprimary blasting, commonly donewith rotary or churn drills.

PROGRAMMING(see COMPUTER)

PROPORTIONING FEEDEREquipment for feeding compo-nents of raw materials or clinkerand gypsum to mills in prede-termined amounts, and automat-ically mainiaining the set propor-tions.

PUFFINGUneven combustion in rotary kilnresulting from incorrect balancebetween amount of fuel, combus-tion air and kiln draft.

PUG MILLTrough-shaped vessel equippedwith mixer blades spaced along ahorizontal shaft, for mixing andconveying moist sticky materials,such as clay or filter cake, or formixing collected kiln dust withslurry.

PULSATING SCREEN(cf. VIBRATING SCREEN)

PUMPABILITYThe ease with which a slurry canbe pumped. Depends partly uponthe viscosity (inversely) of theslurry, which in turn depends onwater content, fineness, particlesize gradation, and degree of dis-persion.

PYRATOR (trade name)Combined drying and grindingmill for coal, in which heatedgrinding media enter the mill withthe feed.

PYROMETERApparatus for measuring hightemperatures in the burning zoneof rotary kilns or in exhaust gases;includes electrical thermocouples,optical and recording pyrometers.

PYZEL KILN (trade name)Upright, cylindrical reactor forclinkering fluidized raw-meal.

QQUARRY

Place where substantially dry,rock-type raw materials are exca-vated in the open. Unless under-ground mining is used, most ce-ment_plants have one_or. morequarries for different componentsor types of raw materials.

QUARRY BENCHLevel platform or shelf used toavoid operating with excessivelyhigh quarry face.

QUARRY FACEVertical side of quarry.

QUARRY FLOORBottom level of quarry wherepower shovels (loading at foot ofquarry face) and railroads andtrucks are operating.

QUENCHINGCooling rapidly by air or water.

QUICK SETManifestation of rapid setting ofcement paste accompanied by theevolution of relatively largeamounts of heat.

QUIESCENTWithout agitation, particularly inregard to storage-of slurry.

el RADIATIONA process by which heat and lightare transmitted through gases. Inrotary kilns a luminous flame(coal or oil) transmits more heatto the load and to the lining byradiation than a non-luminousflame (gas).

RADIATION PYROMETER("Electric eye") Pyrometer, lo-cated just outside front end ofkiln, and aimed at on clinker orlining (not flame) in burning zoneto record temperature.

RAKE CLASSIFIERMachine for separating coarseand fine particles in cement rawmaterial slurry, ground with sur-plus water. The coarse particlesgravitate to the bottom and arescraped up an incline by a set ofblades, whereas the fine particlesremain in suspension and flowover the edge of the classifier.

RAT HOLEColloquial for (1) chain systemTUNNEL (which see). (2) Thecenter funnel in a dischargingtank or silo formed when rawmaterials or cement hang uparound the edge.

RAW DEPARTMENTGeneral designation of equipment

buildings and operations pertain-ing to preparation of kiln feed.Often .ubdivided into crushing,raw grinding, and blending de-partments.

RAW MATERIALSNaturally occurring rocks or ma-terials, or waste products, suit-able for cement manufacture.

RAW MATERIAL STORAGEExposed or covered stockpiles,bins or silos for crushed but asyet unaround raw materials.

RAW MEALFinely ground mixture of raw ma-terials as used for kiln feed in dry-process plants.

RAW MIXSlurry or raw meal ground to de-sired fineness and correctly pro-portioned and homogenized readyfor burning.

RAYMOND BOWL MILL(trade name)

(see BOWL MILL)RECIPROCATING FEEDER

(see VIBRATING FEEDER)RECORDER

Instrument which makes a chartor graph (circular or strip) of theperformance of equipment, tem-perature, draft, fuel consumption,exit gas analysis, fuel-air-ratio,etc. These charts provide a rec-ord of operation valuable to man-agement as well as to operatorsby showing recent history.

RECUPERATOREquipment which reclaims heatthat would otherwise have beenlost. Most clinker coolers are alsorecuperators, returning some ofthe clinker heat to the kiln.

RED MUDWaste product from the manu-facture of alumina (aluminumoxide); being high in Fero, it isoften used as a raw material forcement

RED SPOT(see HOT SPOT)

REDUCING FLAMEKiln flame to which insufficientcombustion air is supplied. Atthe high temperature in the kilnthis condition may tend to convertiron in the clinker to "ferrous'compounds, giving the cement alight, tannish color.

REFRACTORYKiln lining which can withstandhigh temperature without fusing.

REVOLUTION COUNTERAn instrument for indicating thetotal number of revolutions of apiece of machinery, such as mill,

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kiln, etc. May be located at themachine or electrically connectedto a counter on a control panel.

RHEOLOGYThe science dealing with flow ofmaterials. Applies to pumping ofraw material slurry and placing ofconcrete.

RIBBON SCREWScrew conveyor with continuoushelical blade.

RIFFLINGPassing a sample of crushed rock,ground materials, clinker or ce-ment through a riffle to obtain anumber of smaller, uniform sam-ples. A riffle is a rectangular boxwithout top or bottom, the in-terior of which is divided byplates into a system of compart-ments and chutes.

ROD MILLCylindrical mill (as a tube mill)in which the grinding media con-sist of steel rods, extending thefull length of the mill. The cas-cading and grinding action is gen-erally similar to the action of ballsin a bail mill. Used extensivelyfor coarse grinding in ore miningindustries and occasionally in ce-ment manufacture.

ROLL CRUSHERCrusher consisting of one or tworolls, sometimes equipped withman-a;-ese steel teeth. Pieces ofrock are crushed between the ro-tating rolls or between one rolland a stationary breaker plate.

ROLLER MILLA vertical mill in which centrallysuspended rollers rotate and areforced against a large ring by cen-trifugal force to pulverize raw ma-terials or clinker.

ROTARY COOLERCylindrical, rotating cooler forclinker; inclined 5-10 percentand located under the dischargeend of a rotary kiln. It moves thehot clinker to a conveyor and letscooling air pass through in theopposite direction.

ROTARY DRILL(see PRIMARY DRILLING)

ROTAI,Y KILNCylindrical (8- to 25-ft diame-ter) 200 to 760 ft. long, slowlyrotating (60 to 90 r.p.h.) kiln, in-clined approximately 1/2 in. perfoot toward its discharge end; forburning cement raw mix intoclinker. Lined with refactorybricks and often equipped withinternal heat-exchangers.

SSANDS

Tailings, usually from a RAKEor BOWL CLASSIFIER

SCALPERA screen for removing a relativelysmall quantity of considerablyoversize particles. Used on feedmaterial for grinding mills.

SCOOP FEEDERSlurry feeder for rotary kiln, con-sisting of a casing in which theslurry is maintained at a constantlevel, and a slow-moving wheelwith two hollow scoops discharg-ing through the hollow shaft.

SCREW CONVEYORConveyor for dry material or slur-ry consisting of a steel or con-crete casing enclosing a continu-ous helical strip projecting from arotating shaft.

SCREW FEEDERShort screw conveyor arrangedfor feeding dry pulverulent ma-terial.

SCRUBBERType of dust collector in whichdust-laden gases are cleaned bypassing through fine sprays ofwater.

SECONDARY AIRThat part of the combustion airin a rotary kiln which is notblown in with the fuel.

SECONDARY COMBUSTIONBurning which takes place in thekiln beyond the actual burningzone. May be caused by toocoarsely ground coal or inade-quate mixing of fuel and combus-tion air. Believed to be a causeof clinker rings.

SECONDARY DRILLINGDrilling of holes for explosivecharges in pieces of rock whichhave been blasted loose duringprimary shooting in quarries, butwhich are still too large for han-dling by shovels or for feeding toprimary crushers.

SEGMENT(I) A section of a number ofsuspension arrangements whichcombined make a complete circleof the kiln for certain loop chainsystems. (2) A lifter or feed-endconstriction.

SEGREGATIONSeparation of coarse and fine par-ticles. May occur in stockpilesfor crushed rock or clinker, or inslurry conveyors and tanks.

SEPARATOR FINESThe finer of two fractions intowhich raw material or cement hasbeen divided in an air-separator.Normally conveyed to silos or toa mill for still finer grinding.

SEPARATOR TAILINGSThe coarser of the two fractionspreviously mentioned. Returnedto mill for further grinding orconveyed to another mill for finegrinding.

SETTLING BASIN(see THICKENER)

SETTING TIMEThe time required for a neat ce-ment paste to attain a certain de-gree of rigidity as measured bythe Gillmore or Vicat needles.

SHAFT KILNVertical cylindrical stationary kilnfor burning lime or cement clink-er. Pelletized raw mix is fed atthe top, and finished clinker with-drawn continuously from the bot-tom through rotating grates andair-locks. Has smaller capacitybut somewhat better fuel economythan rotary kilns.

SHAKER CONVEYOR(see OSCILLATING CONVEY-OR)

SHALERocky clay, high in alumina, silicaand iron oxide, but low in lime.Used as argillaceous raw mate-rial.

SHOT- Primary or secondary blast of ex-

plosives in mine or quarry.SHROUDED SCREW CONVEYOR

Screw conveyor with a close-fit-ting casing.

SIEVELaboratory equipment for testingfineness of dry powder, consist-ing of fine copper mesh screenmounted in a brass ring. Finenessis indicated as X percent passingor retained on a No. Y meshsieve, Y indicating number ofmeshes per linear inch.

SILEX LININGProtective lining for tube millsmade of a hard siliceous rock.

. Used when iron-contaminationmust be avoided, as in the manu-facture of white cement.

SILICASilicon dioxide-Si02.

SILICA RATIOSiOt1.n,

2wf,,Ratio of silica to alumina

plus iron. A check of chemicalcomposition of raw mix some-

106

times used in cement plants.SILICA ROCK

Hard mineral, high in silica(SiOa), such as quartz and sand-stone. Used as a raw materiaL

SILICATESalt of silicic acid. In cement di-and tricalcium silicates are twoof the important components.

SILICONIZED GLASS-BAGSDust-collector bags of w o v encloth of glass fibers, treated withprotective layer of silicone. Ableto withstand higher temperaturesthan cloth bags (f.i. cotton) andare used in kiln exhaust dustcollectors.

SILOCylindrical container for rawmeal, clinker or cement. Gener-ally 20-30 ft. diameter and 60-90ft. high, built of concrete andequipped with extracting and con-veying equipment underneath.

SINTERTo cause to become a coherentsolid mass by heating withoutthoroughly melting.

SINTER GRATEKiln incorporating a slowly trav-eling, horizontal grate on whichthe combustion and clinkeringtake place. The nodules, madefrom raw mix, clinker dust, fueland water, burn on top of a pro-tective lay e r of under-burnedclinker.

SKIPULTER (trade name)(see OSCILLATING CONVEY-OR).

SLACKFine coal screenings.

SLAGBy-product from blast furnaceiron and steel production. Con-tains lime, silica, alumina andiron oxide in such proportionsthat it may be used as an argil-laceous raw material for cement

SLAG CEMENTFinely divided material consist-ing essentially of water-quenched,granulated blast-furnace slag andhydrated lime. It shall consist ofat least 60 percent water-quenched, blast-furnace slag byweight

SLIDE DAMPERWinch-operated, large, rectangu-lar steel and firebrick slide, whichmay be raised or lowered insidea duct to increase or throttle thenatural kiln draft.

SLIDE SHOE BEARINGSpecial type bearing for steel-tire

(riding ring) for ball mill, con-sisting of steel shoe on which thetire slides, and mechanism formaintaining protective oil film.

SLUGSDisc-shaped punchings of steelplates, or cylindrical cuttings ofsteel rods, usedas inexpensivegrinding media in tube mills.

SLURRYSuspension of ground raw ma-terials in water.

SLURRY AGITATORMechanism, incorporating t h econstant or intermittent use ofcompressed air, to prevent sedi-mentation or segregation inSLURRY BASINS or TANKS(cf). In tall cylindrical slurrytanks air is used exclusively; me-chanical agitators or combinations(stationary or traveling) are usedin cylindrical, oval or rectangularbasins.

SLURRY BASINLarge concrete or steel containerfor raw material slurry, equippedwith SLURRY AGITATORS(cf). BLENDING BASINS re-ceive slurries from different grind-ing mills; MIXING BASINS areused for homogenization of slur-ry; CORRECTING BASINS re-ceive slurries of predeterminedchemical composition in correctproportions to produce final rawmix; KILN BASINS serve as stor-age for one or several days' sup-ply of finished slurry.

SLURRY DRYEREquipment for utilization of hotkiln exit gases for partial or totaldrying of slurry before it is fed tothe kiln. Frequently designed asa drum charged with chains orspecially designed heat-exchangeelements.

SLURRY FEEDEREquipment for feeding slurry tokilns or mills at controlled rates.(el FERRIS WHEEL andSCOOP FEEDER)

SLURRY FILTERContinuously operating drum ordisc-type filter for removing partof the water from slurry by appli-cation of vacuum. Special typesof filter cloth are used to resistwsar and rot. Depending on fine-

.ness and plasticity of the slurry,the water content may be re-duced 15-20 percentage points.

SLURRY TANKSServe same purpose as SLURRYBASINS (cf); BASINS are gen-

erally larger in diameter than inheight and made of concrete;TANKS are generally smallerand taller and often made ofsteel plate.

SLURRY THINNERSA number of organic or inorganicchemicals or waste productswhich, when added in smallamounts to the raw mix at thefeed end of wet grinding rawmills, make it possible to produceslurry with less than normal wa-ter without loss of fluidity. Theuse of_ such slurry results in re-duced fuel consumption, morekiln and raw mill production, andlarger slurry basin capacity. Themost successful slurry thinners aresodium carbonate, sodium sili-cate, several polyphosphates, lig-no-sulphonates (w a s t e sulfiteliquor) and certain treated peat,wood, and bark products.

SNAPPY FLAMEShort, brisk kiln flame, of ratherhigh temperature and nozzle-ve-locity, resulting from a high per-centage of primary air, fine grind-ing or atomization of the fuel, andeffective mixing of fuel and air.

SNOWMANFormation of sticky clinker fol-lowing discharge from rotary kiln.

SOAKING(1) Saturating with water. (2)Prolonged exposure of clinker toheat. Kilns may be designed (oroperated) to produce a "soakingheat" (to drive off alkalies). Be-fore the advent of coolers andair-quenchers, the red-hot clink-er was sometimes left in a "soak-ing pit" before being conveyedto storage.

SOLO COOLER (trade name)(see PLANETARY COOLER)

SORPTOMETERInstrument for rapid, accuratedetermination of surface area ofsolids, based on thermal conduc-tivity recordings of quantities ofnitrogen adsorbed on cooled sam-ple and desorbed by warm sam-ple.

SPALLINGChipping or crumbling of the ex-posed surface of kiln refractories.

SPECIFIC PRODUCTIONKiln production per unit of vol-ume or surface.

SPECIFIC SURFACEThe sum of the area of the sur-face of all the individual particlescontained in one gram of a mate-

107

rial; given in square centimeters.Sometimes simply called "SurfaceArea."

SPECTROPHOTOMETERInstrument for measuring inten-sity of radiant energy of desiredfrequencies absorbed by atomsor molecules. Substances are an-alyzed by converting the absorbedenergy to electrical signals, pro-portional to the intensity of radi-ation. (See also INFRAREDSPECTROSCOPY)

SPIDER(1) Structural steel rotatingframework supporting harrows inv,ashmill or air pipes in slurryagitators. (2) (see YOKE)

SPIRALSuspension pattern for chain sys-tem in rotary kiln in which theends of each chain loop are sep-arated a certain distance longi-tudinally in the kiln and at thesame time a certain number ofdegrees in a circle transverse tothe kiln axis.

SPITZEROversize particle in ground rawmix.

SPRING GEARMaster spur gear for rotary kilnfastened to shell by spring platestangential to kiln and so orientedthat they are under tension only.

STABILITYRegularity of kiln operation.Avoidance of fluctuating loads orcycling.

STACK GASKiln exhaust gas leaving throughstack. Often referred to as exitgas.

STAR BIN(see INTERSTICE)

STICKY CEMENT(Including Stockhouse Set andPack Set.) Finished cementwhich develops low or zero flow-ability during or after storage insilos, or after transportation inbulk containers, hopper-bottomcars, etc. Believed to be causedby (a) interlocking of particles;(b) mechanical compaction; (c)electrostatic attraction betweenparticles. (cf. WAREHOUSESET)

STIFFENER RINGSteel ring, commonly of a rec-tangular cross section, welded tooutside of kiln shell to mimimizeelliptical deformation.

STOCKHOUSE SET(see STICKY CEMENT)

STRIPPINGRemoval of overburden (cf.) inquarries.

SULPHATERE'. iSTANTCEMENT

Portland cement designated TypeV, low in tricalcium aluminate,which makes concrete less sus-ceptible to attack by water whichcontains sulphates.

SUPER-DUTY REFRACTORYHighly refractory, fire-clay brickfor kiln lining. Has low porosity,high resistance to fluxing andthermal spalling, and strengthand constancy of volume at hightemperatures.

SURFACE AREA (S.A.)(see SPECIFIC SURFACE)

SURGE BINBin or tank, not used for storage,but inserted in process to absorband equalize fluctuations in flowof material.

SUSPENSION PREHEATERA system of cyclones and raiserpipes in which dry process kilnfeed is preheated in contact withkiln exit gases.

SWIRL POT(see VORTEX FEEDER)

SYNCHRONIZATION(see FEED SYNCHRONIZA-TION)

SYNCHRONOUS MOTORA.C. motor, whose speed is di-rectly proportional to the numberof cycles of the current.

TABLE FEEDER(see DISK FEEDER)

TAILINGSSee SEPARATOR TAILINGS)

TEMPERING AIRCold air mixed with hot kiln exitgases to reduce their temperaturefor protection of draft fan.

TETRACALCI U MALUMINOFERRITE

C4AFOne of the four potentialcompounds in portland cement.4CaO A1203 Fe2O3 = Ca4Al2Fe2010.

THERMOCOUPLEA pair of dissimilar metals sojoined as to produce a thermo-electric effect when heated. Themagnitude of the thermo-electriceffect shows the temperature towhich the metals have beenheated

THERMOPILEA group of thermocouples actingjointly to produce electric energy,especially when used as a galva-

nometer to measure temperature.THICKENER

Large basin for slurry which hasbeen ground with excess water.Suspended particles gravitate tobottom (underfiow), whereas sur-plus water runs over edge.

THIXOTROPYA change in structure of a ma-terial towards greater liquiditybrought about by agitation orstirring. The material usually willrebuild itself in time if not pre-vented from doing so by external-ly applied forces.

THROUGHPUTThe total tonnage passing througha grinding mill in a CLOSEDCIRCUIT (cf.); equal to newmill feed plus separator tailings.

TIREHollow or solid cast steel ridingring for kiln or mill.

TITRATIONDetermination of the calcium-carbonate content of raw-mate-rials or raw-mix, dissolved in hy-drochloric acid, by measuring thesmallest amount of alkali whichwill neutralize the solution, asindicated by a color change.

TOEOuter lower edge of loose rockwhich has been blasted fromquarry face.

TRAMP IRONStray pieces of iron, pipe, brokentools or grinding media found inthe process flow. Removed byelectromagnets and screens.

TRICALCIUM ALUMINATECaAOne of the four potentialcompounds in portland cement.3CaO A1203 = Ca3A1208. Con-tributes to low setting time.

TRICALCIUM SILICATEC3SOne of the four potentialcompounds in portland cement.3CaO SiO2 = Ca3SiO3. Attainshigh strength rapidly.

TRUNNIONPivot or end of shaft or mill, rest-ing in bearing for support of ro-tating machinery. Grinding millsare often fed and dischargedthrough hollow trunnions.

TUBE MILLCylindrical rotating mill, chargedwith grinding media; the lengthis several times the diameter.

TUNNELThe open space in a kiln chainsystem below the freely suspend-ed chains. Usually about V4 to 1/2of the kiln diameter.

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TURBIDIMETERApparatus for measuring the spe-cific surface of cement or raw mixby the reduction in intensity of alight beam passing through a sus-pension of the material in a fluid.

TURBULENT FLAMEA flame in which the directionsand velocities of the fuel andgases supporting combustioncause agitation and more com-plete mixing and rapid combus-tion.

TURBULENT FLOWFlow is said to be turbulent whenits path lines are irregular curveswhich continually cross eachother and form a complicated net-work which in the aggregate rep-resents the forward motion ofthe entire stream.

UUNAX COOLER (trade name)

(see PLANETARY COOLER)UNI DAN MILL (trade name)

(see COMPARTMENT MILL)UNIKOM MILL (trade name)

(see COMPARTMENT MILL)UNIT PULVERIZER

Coal mill for service to one indi-vidual kiln, drying and grindingin one operation and operatingas DIRECT FIRING.

VVALVE BAG

Paper bag for cement, eitherglued or sewn, made of 4 or 5plies of Kraft paper and com-pletely closed except for a self-sealing paper valve throughwhich the cement is introduced.

VANDERWERP RECUPERATOR(trade name)

Slotted heat-resistant steel blocksat the discharge end of a kilnthrough which secondary air isadmitted for cooling and quench-ing the clinker.

VIBRATING CONVEYORConveyor in which the pan ortrough is mounted on cantileverspring bars or rocker arms, andis actuated by mechanical meansor electromagnetic impulses.

VIBRATING FEEDERFeeder actuated by an electro-magnetic vibrator. The rate offeed is controlled by the ampli-tude of vibration imparted to thetrough.

VIBRATING MILLGrinding mill for raw materials orclinker, the motion of which con-

sists of high-frequency vibrationswith or without simultaneous ro-tation.

VIBRATING SCREENScreen for separation of crushedrock, slurry or dry ground ma-terial from preliminators intocoarse and fine fractions; vibrat-ing matt= produced by an eccen-tric or electromagnet.

VI AT NEEDLEA weighted needle for determin-ing initial and final setting timesof hydraulic cements.

VICKERS COOLER (trade name)(see PLANETARY COOLER)

VISCOMETERLaboratory or continuously oper-ating line instrument for deter-mination of viscosity of slurry orfresh concrete.

VISCOSITYResistance to flow. Measure (in-versely) of the fluidity of slurry.

VOLATILE MATTERThe hydrocarbons contained incoal which are readily vaporizedand burn earliest during the com-bustion in kilns.

VOLATILIZATIONThe process of driving out andvaporizing the alkalies fromcement raw materials during theburning process. Effective volatil-ization depends on temperature,thickness of bedding, size of nod-ules, and time.

VOLUMESURFACEDimensionless quantity (Vs) in-corporating the volume and in-ternal surface of a rotary kiln,used in calculating production.

VORTEX FEEDERWet process kiln feeder in whichintimate mixing of slurry and re-turned kiln dust is obtained bya rapid centrifugal motion im-parted to the slurry.

wWAREHOUSE SET

The partial hydration of cementstored for periods of time and ex-posed to atmospheric moisture.

WASH MILLMachine for disintegration ofclay, chalk or marl in water;consisting of a set of harrows,suspended from a spider, anddragging rapidly through a cir-cular or hexagonal basin. Thefinished slurry is continuously dis-charged through grates.

WASTE GAS(see STACK GAS)

WASTE HEAT BOILERSystem of boilers and economiz-ers heated by the hot exit gasesfrom short kilns.

WATER COOLED JACKETA metal jacket surrounding thatportion of a burner pipe whichextends inside the kiln hood.Equipped with inlet and exitopenings and pipes so that watermay circulate through the jacketto cool the burner pipe.

WATERPROOFED CEMENTCement interground with a waterrepellent material such as calciumstearate.

WAYTROL (trade name)(see WEIGHING FEEDER)

WEIGHING FEEDERFeeder for dry materials to millsor kilns, the rate of which is auto-matically controlled, electricallyor mechanically, by the weight offeed on a moving belt.

WEICHTOMETER (trade name)Automatic weighing and record-ing device for us e with pan, buck-et, or belt conveyor.

WET PROCESSGrinding, blending, mixing andpumping cement raw materialsmixed with water. (cf. DRYPROCESS). Wet process ischosen where raw materials areextremely wet and sticky, whichwould make drying before crush-ing and grinding difficult.

WETTING AGENTChemical added to water to re-duce its surface tension. Spray ofwater containing a wetting agentspreads over larger area and isused in dust control.

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WHIRLCONE (trade name)(see LIQUID-SOLID-CY-CLONE)

WHITE CEMENTCement, conforming to portlandcement specifications, made fromlow-iron raw materials (such asKAOLIN) and burned with a re-ducing flame in the kilns.

WHIZZER BLADESRotating blades and louvres in anair separator, whose position canbe adjusted from outside.

WILFLEY PUMP (trade name)(see CENTRIFUGAL PUMP)

WORK INDEXIndex, in KWH/ton, of the ex-pected power consumption ingrinding a given rock or clinkerfrom theoretically infinite size toa fineness of 100 microns.

X-RAY DIFFRACTIONANALYSIS (XRD)

Quantitative analysis by continu-ous recording of crystalline com-pounds in cement by X-ray beam,diffracted from a flat surface ofp vdered sample, and compar-ii g the angles of diffraction withthe angles produced by knowncompounds.

X-RAY FLUORESCENCEANALYSIS

Determination of elemental com-position of a sample by identifi-cation and measurement of sec-ondary or characteristic radia-tions, caused by exposing a sam-ple to high-energy X-rays.

YYOKE

Two- or four-fingered yoke-shaped piece of cast steel used infastening chains to shell or cir-cumferential segments inside ro-tary kilns.

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DOCUMENT RESUME ED 379 513 CE 068 364 AUTHOR Taylor, … · CEMENT is an acronym for Continuing Education Means Excellence Now. and Tomorrow. Participation in the CEMENT Program is