Introduction + Pozzolana Cement

Lecture 1
Course contents

1. Pozzolana Cement
2. Portland Cement
3. Special Cements
4. Testing of Cements
5. High Alumina Cement
6. Concrete
Learning Outcomes
By the end of this course, students will be able to:
• Describe the manufacturing processes involved in making
Portland cement
• Define the types of cement and their important
characteristics
• Understand and apply properties of fresh concrete in
production
• Elaborate on types of admixtures, their roles, and
advantages
• Identify key properties required for testing cementitious
materials
Introduction of Cement

What it mean by Cement?

 Cement, in general, adhesive substances of all kinds, but, in a narrower
sense, the binding materials used in building or Engineering
construction.
 Cements of this kind are finely ground powders that when mixed with
water, set to a hard mass.
 Setting and hardening result from hydration, which is a chemical
combination of the cement compounds with water that yields
submicroscopic crystals or a gel-like material with a high surface area.
 Because of their hydrating properties, constructional cements, which
will even set and harden under water, are often called hydraulic
cements. The most important of these is Portland cement.
 History of cement
 The origin of hydraulic cements goes back to ancient Greece and Rome.
The materials used were lime and a volcanic ash that slowly reacted
with it in the presence of water to form a hard mass.
 This formed the cementing material of the Roman mortars and
concretes of more than 2,000 years ago and of subsequent construction
work in western Europe.
 The term cement, meanwhile, derives from the Latin word
“caementum”, which meant stone chippings such as were used in
Roman mortar—not the binding material itself.
 The invention of portland cement usually is attributed to Joseph Aspdin
of Leeds, Yorkshire, England, who in 1824 took out a patent for a
material that was produced from a synthetic mixture of limestone and
clay.
 He called the product “Portland cement” because of a fancied
resemblance of the material, when set, to Portland stone, a limestone
used for building in England.
 During the 20th century, cement manufacture spread worldwide. By
2019 China and India had become the world leaders in cement
production, followed by Vietnam, the United States, and Egypt.
 Highlight of cement production

1. Raw Material Extraction

• Limestone: The primary raw material is limestone, which provides
calcium carbonate.
• Clay/Silica: Other materials like clay, shale, or sand supply silica,
alumina, and iron oxide.
2. Crushing and Grinding
• Crushing: The extracted materials are crushed to reduce their size.
• Grinding: The crushed materials are finely ground to achieve a uniform
particle size, which is essential for effective mixing and reaction during
production.
3. Mixing
• The ground materials are mixed in appropriate proportions to form a
homogeneous blend. This mixture is called raw meal.
4. Preheating
• The raw meal is preheated using hot gases from the kiln. This step helps to
remove moisture and prepares the raw materials for the chemical reactions
that occur in the kiln.
 Highlight of cement production

5. Clinkering
• Kiln Heating: The preheated raw meal is fed into a rotary kiln, where it is heated
to temperatures around 1400-1600°C.
• Formation of Clinker: At these high temperatures, chemical reactions occur,
forming clinker—small, hard nodules of calcium silicates.
6. Cooling
• The clinker is rapidly cooled to stabilize its structure. This process also helps
preserve the energy in the clinker for use in grinding.
7. Grinding
• The cooled clinker is finely ground with a small amount of gypsum (to control
setting time) to produce cement. The grinding process ensures a uniform
particle size, which is crucial for the properties of the final product.
8. Storage and Packaging
• The finished cement is stored in silos to prevent moisture absorption and is then
packaged in bags or transported in bulk for distribution.
9. Quality Control
• Throughout the production process, various tests are conducted to ensure that
the cement meets specific standards and quality requirements. This includes
testing for fineness, setting time, strength, and chemical composition.
 The cement-making process, from crushing and grinding of raw materials, through
roasting of the ground and mixed ingredients, to final cooling and storing of the
finished product.
 What is pozzolana or pozzolanic material?
 A pozzolan is a siliceous and aluminous material that in itself possesses
little or no cementitious value but will, in finely divided form and in the
presence of moisture, chemically react with calcium hydroxide at
ordinary temperatures to form compounds having cementitious
properties.
 It is therefore classified as cementitious material. There are both
natural, and artificial pozzolans.
 This materials usually doesn't posses any cementitious properties, but
when it is mixed with water or moisture or lime to undergo reaction
with calcium hydroxide to form compounds possessing cement
properties.
 Classifications of Pozzolana
Pozzolan: A material that, when used in conjunction with portland
cement, contributes to the properties of the hardened concrete through
hydraulic or pozzolanic activity, or both.
Natural Pozzolans:
• These materials are derived from natural sources, such as volcanic ash,
pumice, and certain types of clay.
• They have been used for centuries in various cultures, especially in
regions with volcanic activity.
• Natural pozzolans can provide significant benefits in terms of
durability and resistance to environmental factors.
Artificial Pozzolans:
• These are manufactured materials, including fly ash from coal
combustion and silica fume from silicon production.
• Artificial pozzolans are often more consistent in quality and
performance compared to natural sources.
• They also contribute to waste reduction by repurposing industrial
byproducts. 12
 Pozzolan

 But will, in finely divided form and in the presence of moisture,

chemically react with calcium hydroxide Ca(OH)2 to form

compounds possessing hydraulic cementitious properties.

POZZOLANS

Iron oxide, calcium oxide,

Silica&Alumina magnesium oxide,
(higher amounts) alkalies
(lesser amounts)

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 NATURAL POZZOLANAS

Characteristics:
• Natural pozzolans typically contain silica, alumina, and iron oxide,
which contribute to their pozzolanic activity.
• Their particle size and specific surface area can greatly affect their
reactivity and performance in cement.
• Commonly used natural pozzolans include volcanic tuff, diatomaceous
earth, and certain clays.
Common Sources:
• Regions with volcanic activity, such as Italy, Greece, and parts of the
United States, are rich in natural pozzolans.
• Understanding the geological formations where these materials are
found is crucial for their extraction and use.
 NATURAL POZZOLANAS
1)Materials of volcanic origin (pyroclastic rocks)
 Pyroclastic rocks result from explosive volcanic eruptions which project
minute particles of melted magma into the atmosphere.
 Simultaneously, the particles are subject to a quenching process which
is responsible for their glassy state.
 The material can be deposited either on the ground or in water.
 Table 10.1 Shows that the chemical composition of incoherent volcanic
pozzolanas varies within wide limits and that silica (and alumina) prevails
over other constituents.
 2) Calcined clay

 Clays and the so-called diatomaceous earths are sedimentary rocks

which are capable of combining with lime.
 Diatomaceous earths are highly reactive towards lime owing to
their high content of amorphous silica and high specific surface
area. Small additions of diatomites to concrete improve plasticity
and reduce bleeding.
 They can be used as a partial replacement for the cement,
typically in the range of 15% to 35%, and to enhance resistance to
sulfate attack, control alkali-silica reactivity, and reduce
permeability.
 Table 10.6 shows the chemical composition of some diatomaceous
earths. The silica content increases as the clay mineral content
decreases. The opposite occurs for alumina.
Artificial pozzolanas

Overview:
• Artificial pozzolans are produced through industrial processes,
allowing for greater control over their properties.
• They are often byproducts of other manufacturing processes,
making them a sustainable option.
Examples:
• Fly Ash: A byproduct of coal combustion in power plants, known for
its fine particles and high silica content.
• Silica Fume: Produced during the manufacturing of silicon metal, it
has a very high surface area and reactivity.
• These materials enhance the performance of concrete significantly
when combined with Portland cement.
 Artificial pozzolanas
1)Fly ash
 Fly ash, the most widely used supplementary cementitious material in
concrete, is a byproduct of the combustion of pulverized coal in electric
power generating plants. Upon ignition in the furnace, most of the
volatile matter and carbon in the coal are burned off.
 During combustion, the coal’s mineral impurities (such as clay, feldspar,
quartz, and shale) fuse in suspension and are carried away from the
combustion chamber by the exhaust gases. In the process, the fused
material cools and solidifies into spherical glassy particles called fly ash.
 The fly ash is then collected from the exhaust gases by electrostatic
precipitators or bag filters. Fly ash is a finely divided powder resembling
portland cement .
Coal

Power plant

Fly ash, a powder resembling cement, has

been used in concrete since the 1930s.
 Fly ashes result from the burning of bituminous or subbituminous coal as
well as of lignite. Their chemical composition depends on the mineral
composition of the coal gangue, i.e. the inorganic part of the coal.
 Fly ash is primarily silicate glass containing silica, alumina, iron, and
calcium. Minor constituents are magnesium, sulfur, sodium, potassium,
and carbon. The color of fly ash is generally gray or tan.
 2)SLAG
 Ground granulated blast-furnace slag , also called slag cement, is made
from iron blast-furnace slag; it is a nonmetallic hydraulic cement
consisting essentially of silicates and aluminosilicates of calcium
developed in a molten condition simultaneously with iron in a blast
furnace.
 The molten slag at a temperature of about 1500°C (2730°F) is rapidly
chilled by quenching in water to form a glassy sand like granulated
material.
Blast furnace

Fig. Ground granulated blast-furnace slag

 3) SILICA FUME

 Silica fume, also referred to as microsilica or condensed silica fume, is a

byproduct material that is used as a pozzolan. This byproduct is a result
of the reduction of high-purity quartz with coal in an electric arc furnace
in the manufacture of silicon or ferrosilicon alloy.
 Silica fume rises as an oxidized vapor from the 2000°C (3630°F) furnaces.
When it cools it condenses and is collected in huge cloth bags.

Quartz
Silica fume powder.
 POZZOLANIC REACTIONS

Definition:
• Pozzolanic activity refers to the ability of a material to react with
calcium hydroxide in the presence of water to form compounds
possessing cementitious properties.
• This reaction contributes to the strength and durability of the final
concrete product.
Mechanism:
• When pozzolanic materials are mixed with water and calcium
hydroxide, they undergo a chemical reaction that forms additional
calcium silicate hydrates (C-S-H).
• This reaction not only improves strength but also helps to fill voids in
the concrete matrix, enhancing overall density.
• The formation of C-S-H is crucial for the long-term performance of
concrete structures.
 POZZOLANIC REACTIONS

 The term 'pozzolanic activity' covers all reactions occurring among the
active constituents of pozzolanas, lime and water.

 Calcium Hydroxide+ Silica+ Water → “Calcium-Silicate-Hydrate”

(C-S-H)

 C-S-H provides the hydraulic binding property of the material.

Pozzolanic Activity:

 Capacity of pozzolan to form alumino-silicates with lime to form

cementitious products. (How good how effective the pozzolan

is!)
 FACTORS THAT AFFECT THE ACTIVITY OF POZZOLANS

 Chemical Composition:
• The effectiveness of pozzolanic materials largely depends on their silica
(SiO₂), alumina (Al₂O₃), and iron oxide (Fe₂O₃) content.
• Higher contents of these oxides generally lead to greater pozzolanic
activity.
1. SiO2 + Al2O3 + Fe2O3 content
 The greater amount of these, the greater its activity.
 ASTM C 618 & TS 25 → min “SiO2+Al2O3+Fe2O3” for natural
pozzolans > 70%
 Fly Ash – ASTM
 Class C→ from Lignite or subbituminous coals
(SiO2+Al2O3+Fe2O3>50%)
 Class F→ from bituminous coals and SiO2+Al2O3+Fe2O3>70%
 Silica fume → SiO2 ≈ 85-98%
 Blast Furnace Slag→ SiO2 ~ 30-40%
Al2O3 ~ 7-19%
CaO ~ 30-50%
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 Physical Properties:
• Fineness and specific surface area are critical; finer materials typically react
more quickly and effectively.
• The morphology of the particles can also influence the interaction with cement
and water during hydration.

Amorphousness
 For chemical reaction → pozzolans must be amorphous
 Volcanic ash, volcanic tuff, fly ash, silica fume are all amorphous by nature.
 Clays → contain high amounts of silica & alumina but have a crystallic
structure! (Do not possess pozzolanic activity)
 However, by heat treatment, such as calcining ~700-900°C crystallic
structure is destroyed & a quasi-amorphous structure is obtained.
 Clay → does not possess pozzolanic property
 Burned clay → possess pozzolanic property
Fineness
 Pozzolanic activity increases as fineness increases.
 Volcanic ash, rice husk ash, fly ash, condensed silica fume are obtained in
finely divided form.
 Volcanic tuff, granulated blast furnace slag & burned clay must be ground
Lime –Pozzolana reaction and products formation, Applications.

 Pozzolans can be blended with lime (or Portland cement) to produce

blended cements that can replace pure Portland cement commonly
used in building materials such as concrete, masonry block, bricks, and
other construction units.
 Utilization of natural pozzolans in civil projects include structural
concrete, precast and prestressed elements, mass concrete, concrete
pipes, concrete masonry units, controlled low-strength materials, grout,
mortar.
 Uses of Natural Pozzolans in Concrete Applications

1. Structural Concrete
 The application of natural pozzolans in concrete structures is either in
the form of cement replacement materials or the addition rate of the
natural pozzolan.
 The natural pozzolans enhance concrete plastic properties, increase the
cohesion and workability of the mixture, as a result, reduce segregation
and facilitate consolidation, reduce permeability, and improve durability.
 2. Precast, Prestressed Concrete Elements
 Natural pozzolans help precast and prestressed concrete elements to
develop high early strength and obtain adequate durability.
 These are essential criteria in the construction of bridges, buildings, and
parking garages in which precast and prestressed concrete elements are
utilized.
 The high early strength helps early removal of formwork.

Fig. 1: Precast Concrete

 3. Mass Concrete
 Nowadays, concrete that is used in the construction of sizeable dams
contains natural pozzolans. It reduces the heat of hydration; as a result,
decreases the thermal stresses within the concrete that can cause
cracking. The heat of hydration reduction.
 Additionally, it improves sulfate resistance and declines the potential for
expansion from alkali-silica reactions.
 4. Concrete Pipes

 The use of a natural pozzolan can provide significant benefits in the

manufacture of concrete pipe. It reduces the quantity of cement and
maintain the necessary workability for pipe manufacturing.
 The natural pozzolans improve the density of concrete pipes; minimize
permeability.
 5. Concrete Masonry Units

 Natural pozzolans are used to produce concrete masonry units. It

improves plasticity and cohesion and hence helps in compaction of
concrete used in the production of masonry units.
 Assignment 1
1. Discuss why pozzolanic materials are needed in
production of cement?
2. Describe Materials and all necessary process required
in the production of Portland-pozolana cement(PPC)
3. Analyze the financial benefits of using pozzolana
cement in construction projects
4. Explain the primary Application Pozonanic cement

Submission Date: Thursday 17, 2024