PORTLAND POZZOLONA CEMENT

By Austin S. Rodrigues,
Lecturer, Government Polytechnic, Panaji.

PORTLAND CEMENT:
Portland cements are hydraulic cements
composed primarily of hydraulic calcium
silicate.
During the hydration reaction, cement
combines with water to form a stone-like mass,
called paste.
When the paste is added to aggregates, it acts
as an adhesive and binds them together to
form concrete.

THE PORTLAND CEMENT MANUFACTURING

PROCESS:

THE PORTLAND CEMENT MANUFACTURING

PROCESS:

THE PORTLAND CEMENT MANUFACTURING

PROCESS:

THE PORTLAND CEMENT MANUFACTURING

PROCESS:

RAW MATERIALS USED FOR CEMENT:

THE CALCIUM CONNECTION:

During the burning operation in the
manufacture of Portland cement clinker,
calcium combines with the other components
of the raw mix to form four principal
compounds that make up 90% of cement by
mass.
Gypsum (4% to 6%), or other calcium sulfate
source, and grinding aids are also added during
grinding.

CALCIUM COMPOUNDS:
Following are the four primary compounds in
Portland cement, their approximate chemical
formulas, and abbreviations:
Tricalcium silicate 3CaOSiO2 = C3S
Dicalcium silicate 2CaOSiO2 = C2S
Tricalcium aluminate 3CaOAl2O3 = C3A
Gypsum, calcium sulfate dihydrate, is the
predominant source of sulfate used in cement.

PORTLAND CEMENT COMPOUNDS:

RELATIVE REACTIVITY OF CEMENT COMPOUNDS:

WHAT THEY DO

Tricalcium Aluminate, C3A, liberates a large

amount of heat during the first few days of
hydration and hardening. It also contributes
slightly to early strength development.

WHAT THEY DO

Tricalcium Silicate, C3S, hydrates and hardens

rapidly and is largely responsible for initial set and
early strength.
In general, the early strength of Portland cement
concrete is higher with increased percentages of
C3S.

WHAT THEY DO

Dicalcium Silicate, C2S, hydrates and hardens

slowly and contributes largely to strength
increase at ages beyond one week.

WHAT THEY DO

Tetracalcium Aluminoferrite, C4AF, is the

product resulting from the use of iron and
aluminum raw materials to reduce the
clinkering temperature during cement
manufacture. It contributes little to strength.

WHAT THEY DO
Calcium Sulfate, gypsum is added to cement
during final grinding to provide sulfate to react
with C3A to control the hydration of C3A.
Without sulfate, a cement would set rapidly. In
addition to controlling setting and early
strength gain.
The sulfate also helps control drying shrinkage
and can influence strength through 28 days.

PORTLAND POZZOLONA CEMENT

The Portland Pozzolana Cement is a kind of

Blended Cement which is produced by either
intergrinding of OPC clinker along with gypsum
and pozzolanic materials in certain proportions
or grinding the OPC clinker, gypsum and
Pozzolanic materials separately and thoroughly
blending them in certain proportions.

WHAT IS POZZOLONA.
Pozzolana is a natural or artificial material
containing silica in a reactive form.
It may be termed as siliceous or siliceous and
aluminous material which in itself possesses little,
or no cementitious properties but will in finely
divided form and in the presence of moisture,
chemically react with calcium hydroxide at ordinary
temperature to form compounds possessing
cementitious properties.

FLY ASH:
Fly ash closely resembles volcanic ashes used
in production of the earliest known hydraulic
cements about 2,300 years ago.
Fly ash is the best known, and one of the most
commonly used, pozzolans in the world.

FLY ASH. . TO POZZOLONA

Instead of volcanoes, today's fly ash comes primarily

from coal-fired electricity generating power plants.
These power plants grind coal to a powder fineness
before it is burned.
Fly ash - the mineral residue produced by burning coal is captured from the power plant's exhaust gases and
collected for use.
Fly ash is a fine, glass powder recovered from the gases
of burning coal during the production of electricity.
These micron-sized earth elements consist primarily of
silica, alumina and iron.

POZZOLONA PORTLAND CEMENT:

It is essential that pozzolana be in a finely divided state

as it is only then that silica can combine with calcium
hydroxide (liberated by the hydrating Portland cement) in
the presence of water to form stable calcium silicates
which have cementitious properties.
The pozzolanic materials commonly used are:
Volcanic ash
Calcined clay
Fly ash
Silica fumes

THE I.S. CODES:

The Indian standards for P. P. C. have been issued in two parts

based on the type of pozzolanic materials to be used in
manufacturing of P. P. C. as given below:
IS 1489 (Part 1), P. P. C. specification (fly ash based)
IS 1489 (Part 2), P. P. C. specification (Calcined clay based)
The quality of flyash or calcined clay to be used in manufacturing
of PPC is also specified by BIS in the following standards:
IS 3812 1981 specification for flyash as pozzolana and
admixture
IS 1344 1981 specification for calcined clay pozzolana

WHY FLY AS AS POZZOLONA.

In view of the availability of good quality fly ash
in abundant quantity, the use of calcined clay
based pozzolana cement is progressively
decreasing.
The flyash is a waste product of Thermal power
Plant which creates disposal problems at
Thermal power plant site.
The yearly production of flyash in India is about
70 million tonnes per annum.

WHY FLY AS AS POZZOLONA.

Fly ash is the ash precipitated electrostatically from the

exhaust fumes of coal fired power station.
The fly ash particles are spherical and are generally of
higher fineness than cement so that the silica is readily
available for reaction.
As per IS 3812: 1981 the percentage of silica and
alumina should be minimum 70% and maximum loss on
ignition 12%.
Much superior quality fly ash is available from Indian
thermal power plants than specified in IS code.

WHY P. P. C.?
The Portland Pozzolana Cement makes
concrete more impermeable and denser as
compared to Ordinary Portland Cement.
The long-term strength (90 days and above) of
Pozzolana cement is better compared to OPC.
The pozzolanic material reacts with calcium
hydroxide liberated by the hydrating Portland
Cement and forms cementitious compounds
generally known as C-S-H gel.

WHY FLY AS AS POZZOLONA.

The flyash converts Ca(OH)2 in to useful
cementitious compound (C3S2H3) thereby
increasing the properties of hardened concrete.
The Portland Pozzolana Cement produces less
heat of hydration and offers greater resistance to
the attack of aggressive waters than normal
Portland Cement.
Moreover it reduces the leaching of calcium
hydroxide liberated during the setting and
hydration of cement.

ADVANTAGES OF P. P. C..

Spherical shape : Fly ash particles are almost totally

spherical in shape, allowing them to flow and blend
freely in mixtures.
Ball bearing effect :The ball-bearing effect of fly ash
particles creates a lubricating action when concrete is in
its plastic state.
Higher Strength : Fly ash continues to combine with free
lime, increasing structural strength over time.
Decreased Permeability : Increased density and long
term pozzolanic action of fly ash, which ties up free lime,
results in fewer bleed channels and decreases
permeability

ADVANTAGES OF P. P. C..
Increased Durability. Dense fly ash concrete helps
keep aggressive compounds on the surface, where
destructive action is lessened. Fly ash concrete is
also more resistant to attack by sulfate, mild acid,
soft (lime hungry) water, and seawater.
Reduced Sulfate Attack : Fly ash ties up free lime
that can combine with sulfate to create destructive
expansion.
Reduced Efflorescence : Fly ash chemically binds
free lime and salts that can create efflorescence
and dense concrete holds efflorescence producing
compounds on the inside.

ADVANTAGES OF P. P. C..

Reduced Shrinkage : The largest contributor to drying

shrinkage is water content. The lubricating action of fly ash
reduces water content and drying shrinkage.
Reduced Heat of Hydration :The pozzolanic reaction between
fly ash and lime generates less heat, resulting in reduced
thermal cracking when fly ash is used to replace portland
cement.
Reduced Alkali Silica Reactivity : Fly ash combines with alkalis
from cement that might otherwise combine with silica from
aggregates, causing destructive expansion.
Workability : Concrete is easier to place with less effort,
responding better to vibration to fill forms more completely.
Ease of Pumping. Pumping requires less energy and longer
pumping distances are possible.

ADVANTAGES OF P. P. C..

Improved Finishing : Sharp, clear architectural definition

is easier to achieve, with less worry about in-place
integrity.
Reduced Bleeding : Fewer bleed channels decreases
porosity and chemical attack. Bleed streaking is
reduced for architectural finishes. Improved paste to
aggregate contact results in enhanced bond strengths.
Reduced Segregation : Improved cohesiveness of fly ash
concrete reduces segregation that can lead to rock
pockets and blemishes.
Reduced Slump Loss : More dependable concrete allows
for greater working time, especially in hot weather.

A COMPARISON WITH O.P.C.:

Parameter
Setting Time

Comp. Strength

IS:1489 PPC

IS:12269 O.P.C.

Initial

30 min. (minimum)

30 min. (minimum)

Final

600 min. (maximum)

600 min. (maximum)

3 days

16 MPa (minimum)

27 MPa (minimum)

7 days

22 MPa (minimum)

37 MPa (minimum)

28 days

33 MPa (minimum)

53 MPa (minimum)

After 28 days

Higher than O.P.C.

Normal

Tensile Strength*

Lower as compared to O.P.C. Picks up

Higher in initial stages upto 28
beyond 90 days and overtakes O.P.C. in the days
later stages

Water Demand*

Less than O.P.C. hence better workability

and reduced segregation & bleeding

High

Deshuttering period

As per IS:456

As per IS:456

Curing period

Minimum 10 days

Minimum 7 days

Chloride resistance*

Better than O.P.C.

Sulphate resistance*

Better than O.P.C.

Heat of hydration

Very low

High

Durability

Considered better than O.P.C.

Generally good

ENVIRONMENTAL ADVANTAGES:
1. Each ton of Portland cement requires
about 1.5 tons of raw material for its
production.
2. Each ton of Portland cement that is
produced involves the release into the
atmosphere of about one ton of CO2.
Indeed, the cement industry is
responsible for about 7% of global CO2
emissions.
3. PPC cement is reported to show close
to zero CO2 emission during its
production (only about 100 pounds
per ton of cement).

LIMITATIONS:

Less early strength as compared to OPC.

Re-adjustment of removal of formwork is
necessary.
Early strength is due to OPC only and pozzolona
portion joins in strength only later.

THE GOA CONNECTION

As per
IS456:2000, Goa
is in Severe Zone.

THANK YOU