Step 1: Find a location where limestone is plentiful.  Thankfully, much of the earth’s crust has limestone near the surface and means there is a plentiful supply. It also means that cement manufacture is mostly a local industry, produced close to where it is needed.

Step 2: Extract the limestone from a designated quarry.  Quarries today are managed to rigorous standards and many have detailed plans in place for land use and habitat management to ensure they are returned to support diverse plant and wildlife. 

Step 3: Crush the limestone rock.  Health and safety policies at quarries and indeed cement plants, and right across the production and construction chain are first and foremost in cement companies’ priorities.

Step 4: Add other ingredients to the crushed limestone such as clay or shale – grind and mix together Cement production is all really about chemistry. Although the process sounds simple the chemistry of the raw materials and the subsequent mix is very carefully monitored and controlled.

Step 5: Put the mix into a giant rotating kiln and heat up to 1,450 degree C.  Over a period of about 30 minutes a chemical process takes place which releases the C02 from the crushed rocks. Cement producers have been working hard on reducing greenhouse emissions both in the energy that is used to produce cement and looking at ways of reducing the overall emissions. There are many innovations and different methods of working to reduce the overall carbon footprint in cement production and concrete use. Kiln technology has improved significantly in recent years to ensure that the heat produced is maximised and the fuel that heats it is minimised within the process. Also, later down chain, did you know that concrete naturally re-absorbs CO2 from the atmosphere – so with good design, buildings can be an effective carbon store.  

Step 6: The heating process and the resulting chemical reactions lead to the formation of the material that in the industry is referred to as ‘clinker’. 

Step 7: You now have cement.  As a producer you might bag it up for the construction sector and wholesale trade, or transport it in bulk to concrete plants who will mix the cement with aggregates to make concrete. Most cement is transported locally – which avoids unnecessary and long miles of transportation on roads and global shipping.

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