CEMENT

Mascrete Pro
Portland Pulverised-Fuel Ash Cement

™
 CONTENT
Pg 03 MASCRETE Pro
What is PFA?
Rheology
Pg 04 MS 1227:2003 - Specifications For MASCRETE Pro
Pg 05 Strength
Pg 06-07 Durability
Pg 08 Other Advantages
Pg 09 Constructability

PAGE 2 : MASCRETE Pro

MASCRETE Pro
MASCRETE Pro is the trade name of specially manufactured pozzolanic cement by Lafarge Malayan
Cement Berhad, Malaysia’s leader in clinker and cement production.

MASCRETE Pro is produced by controlled addition of good quality pulverized-fuel ash (PFA) to
requisite proportions of clinker and gypsum during the grinding process.

The production of MASCRETE Pro by intergrinding ensures homogeneity and consistency in the
quality of the product.

MASCRETE Pro is an economical and effective mean to modify the quality of concrete to meet
various technical requirements.

MASCRETE Pro exceeds the quality requirements specified in the Malaysian Standard MS1227:
2003 – Specifications for Portland Pulverized-fuel Ash Cement and BS EN197-1: 2000: Composition,
Specifications & Conformity Criteria for Common Cements.

MASCRETE Pro is manufactured under an effective system of testing, control and monitoring,
conforming to requirements under the SIRIM QAS International Product Certification License.

What is PFA?
Pulverized-fuel ash (PFA) is the fine ash fraction produced when pulverized hard coal is burnt at
high temperatures and pressures in the furnaces of coalfired power stations. The PFA is captured
from the flue gases by electrostatic precipitators and consists mainly of spherical fine glassy particles
with high silica and alumina content. PFA has significant pozzolanic properties and when mixed
with Ordinary Portland Cement, reacts with lime produced by the hydration of the OPC to form
stable calcium silicate and calcium aluminate hydrates. These in turn fill voids within the hardening
concrete contributing to enhanced strength and reduced permeability. The fine rounded particles
also help to reduce the water demand for a given concrete workability.

Rheology
The fineness and spherical shape of PFA imparts beneficial properties to concrete by making the
mix more cohesive, less prone to segregation and reduce bleeding. These benefits can be used
to improve the quality of surface finish and enable better compaction when used with difficult
aggregates or in lean mixes. Placing and compacting MASCRETE Pro is also made easier particularly
when pumping.

“Stronger &
More Durable”
PAGE 3 : MASCRETE Pro
 MS 1227:2003 - Specifications For MASCRETE Pro

SPECIFICATIONS ITEMS MS 1227:2003 TEST

SPECIFICATIONS METHOD

A. PHYSICAL PROPERTIES MS 522:Part 2:2005

Not less than 225
1. Fineness:Specific Surface Clause 3
Area (m2/kg)
2. Setting time (minutes) MS 522:Part 2:2005
Not less than 45 Clause 6
Initial

Final Not more than 600 MS 522:Part 2:2005

Clause 6

MS 522:Part 2:2005
Not more than 10
3. Soundness : Expansion (mm) Clause 4

4. Compressive strength (N/mm2) 2 days MS 522:Part 2:2005

Not less than 7.0
Concrete (1:Approx. 6:0.6) Clause 8

MS 522:Part 2:2005
7 days Not less than 11.0
Clause 8

28 days Not less than 23.5 and MS 522:Part 2:2005

not more than 44.5 Clause 8

B. CHEMICAL COMPOSITION MS 522:Part 3:2005

Not more than 5.0
1. % Loss Of Ignition Clause 15

MS 522:Part 3:2005
2. % Magnesia (Mg0) Not more than 5.0
Clause 12

Not more than 3.5 MS 522:Part 3:2005

3. % Sulphuric Anhydride S03
Clause 16

4. % Proportion of PFA Not less than 6 and Internal Method

not more than 35 QSMPRD 069

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 Strength
Concrete Mix proportion G40 Precast Slump (mm) Compressive Strength (MPa)
Type of
Cement Sand Water C.Aggregate Type of Dosage
Cement W/C S/A Initial 1 day 3 days 7 days 28 days
(kg) (kg) (kg) (kg) Admixture (ml)
MASCRETE
370 873 143 1040 GL 309 3700 0.39 0.46 90 31.00 47.35 64.25 74.85
Pro
OPC 370 873 155 1040 GL 309 3700 0.42 0.46 85 28.55 46.45 56.90 67.35

MASCRETE Pro Vs OPC (G40 Precast Strength)

80 74.85
67.35
70 64.25
Compressive Strength (MPa)

56.90
60

50 47.35 46.45

40
31.00
28.55
30

20

10

0
1 day 3 days 7 days 28 days

Concrete Mix Proportion G30 N Slump (mm) Compressive Strength (MPa)

Type of
Cement Sand Water C.Agg Type of Dosage Type of Dosage 0 30
60 1 3 7 28
Cement W/C S/A
(kg) (kg) (litre) (kg) Admixture (ml) Admixture (ml)
(min) (min) (min) day days days days
MASCRETE
300 902.0 159.4 977.5 P 333 1200 GL 309 1800 0.53 0.48 150 95
50 12.55 26.00 33.10 47.35
Pro

OPC 300 902.0 164.4 977.5 P 333 1200 GL 309 1800 0.55 0.48 150 78
60 10.55 22.10 29.55 45.35

MASCRETE Pro Vs OPC (G30 N - Strength)

47.35
50 45.35
Compressive Strength (MPa)

40
33.10
29.55
30 26.00

22.10
20
12.55
10.55
10
MASCRETE Pro

0
OPC
1 day 3 days 7 days 28 days

Above results based on laboratory testing under controlled conditions

PAGE 5 : MASCRETE Pro
 Durability
Chloride Permeability
Penetration of chlorides into concrete causes the embedded reinforced steel to be de-passivated and
increases the risk of corrosion. Corrosion of reinforcement in concrete structures is perhaps the biggest
single cause of premature deterioration of concrete structures worldwide. Extensive worldwide research
has demonstrated that addition of PFA has improved resistance to the ingress of chlorides (from sea
water, de-icing salts or other sources) when compared with similar quality concrete containing OPC alone.
This is a result of both reduced permeability of concrete produced by the pozzolanic reaction of PFA and
the increased chemical binding of chlorides by PFA hydrates, which effectively ‘locks up’ the chlorides
and prevents them from penetrating deeper into the concrete. This in turn reduces the chloride diffusion
coefficient and the risk of reinforcement corrosion.

It is well-known that deterioration of marine structures is a serious problem in our country. Among
others, the Concrete Society UK Technical Report No. 40 recommends that, “……PFA concrete
should be specified for marine environment……”

Rapid Chloride Permeability Test – ASTM C1202

Cement Content : 370kg/m³ Cement Content : 475kg/m³

6000.0 3000.0
5252.3 2687.5
5000.0 4697.3 2500.0
2210.3
4000.0
Coulombs

2000.0
1870.8
Coulombs

3000.0 1500.0

2000.0 1508.3 1000.0

747.3
1000.0 969.9 500.0

0.0 0.0
OPC MASCRETE Pro OPC MASCRETE Pro

28 days 56 days

ASTM C1202 : “Standard Test Method for Electrical Indication of Concrete’s Ability to Resist Chloride Ion Penetration.”

Chloride Ion Penetrability Based on Charge Passed

Chloride permeability Charge, coulombs

High > 4000

Moderate 2000 – 4000
Low 1000 – 2000
Very Low 100 – 1000
Negligible < 100
PAGE 6 : MASCRETE Pro
Time to Corrosion Initiation
The following table based on a study carried out at University of Dundee, UK, shows the time to
corrosion initiation for different fly ash content/grade combination.

Time to corrosion for different fly ash content / grade combinations

TIME TO CORROSION INITIATION

STRENGTH Years
GRADE N/mm²
Fly Ash Content %
0% 15% 30% 45%

35 15 35 55 70

50 25 60 90 >100

60 35 90 >100 >100

70 45 >100 >100 >100

MASCRETE Pro is effective in reducing the risk of alkali silica attack caused by reactive aggregates.

Sulphate Resistance
Sulphates in soils and groundwaters can cause expansion and disruption of concrete, by the
formation of the minerals Ettringite and/or Thaumasite. Both BRE Special Digest 1 and BS 8500
recognise that when PFA is combined with OPC, enhanced sulphate resistance is produced.

PFA concrete has enhanced resistance to both the Ettringite and Thaumasite forms of sulphate
attack and is permitted in all sulphate conditions apart from Sulphate Class 4m. In reality however,
the very severe class 4m conditions are hardly ever encountered in nature and PFA concrete is
widely exploited for below ground construction.

According to the relevant Guidelines for Designers issued by JKR Malaysia, Portland Pulverized-fuel
Ash Cement “…… is suitable for use in concreting works such as large foundations, pile caps, large
floor slabs, dams, pavements, water retaining structures and marine structures. Apart from providing
good workability, it is also sulphate resistant and is suitable for sulphate concentration of up to 2,500
p.p.m. This cement generally enhances concrete durability……”

Lower Temperature Rise

BS 8110 Clause 6.2 on Durability of Structural Concrete states that “when the minimum dimension
of the concrete to be placed in a single time is greater than 600 mm and especially when the cement
content is 400kg/m³ or more, measures to reduce the temperature such as using material with lower
release of heat of hydration should be considered.

To ensure the integrity and durability of mass concrete structures, it is necessary to specify the
requirements for peak and differential temperatures for mass concrete works. Reduction in peak and
differential temperatures will serve to minimise or prevent micro thermal cracking thereby avoiding
the corrosion of embedded steel reinforcement.

BS 8110: Part 2 Clause 3.8.4 stipulates that the reduction in peak temperature serves to minimize
early age thermal cracking.

PAGE 7 : MASCRETE Pro

 Other Advantages

Pumping
Successful pumped concrete combines good workability with good cohesion and resistance to
segregation. The spherical particle shape and increased fineness of PFA particles in MASCRETE
Pro produce benefits for pumped concrete. The cohesion of concrete is improved. PFA can
greatly improve the pumpability of concrete with a low cement content or with poorly graded
fine aggregates. In some cases it may be possible to pump MASCRETE Pro without the need to
modify the fine aggregate content of a conventionally placed concrete mix design.

Cost Saving
In order to achieve comparable peak temperature rise between MASCRETE Pro and OPC mix, the
placing temperature of the OPC mix needs to be lowered. The placing temperature can be lowered
by the use of chilled water. Hence there is considerable cost savings by using MASCRETE Pro
concrete, instead of using chilled water to lower the placing temperature of OPC concrete.

Compatibility with Admixture

Most available admixtures can be used with concrete containing MASCRETE Pro.

Compactibility
The compactibility of MASCRETE Pro is better than OPC concrete with the same slump.
The Vebe Test results are shown in the table:

Cement Slump (mm) Vebe Test (s)

OPC 50 5.0
MASCRETE Pro 50 4.0
MASCRETE Pro 40 5.0

“Stronger &
More Durable”
PAGE 8 : MASCRETE Pro
Constructability

Health and Safety

There are no known significant health risks
associated with MASCRETE Pro; however as
an airborne dust, it may cause irritation to the
eyes and respiratory system. Prolonged contact
with the skin may also cause skin irritation.

Environment -
CO2 Emission When we replace a single ton of cement
with fly ash, we are not only eliminating
waste from our planet but we are also
reducing the emission of 0.85 tons of CO2₂
into our atmosphere. This is a unique
win-win solution offered by MASCRETE
Pro and it is no wonder that MASCRETE
Pro is at the forefront amongst the green
technologies now being adopted all over
the world by leading organisations.

Quality Assurance of MASCRETE Pro

At every stage in the manufacturing of
MASCRETE Pro, care is taken to ensure
that the product is consistent in quality
and satisfies customers’ requirements.

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 Notes:

PAGE 10 : MASCRETE Pro

Published by Lafarge Malayan Cement Berhad
Copyright © Lafarge Malayan Cement Berhad
Published October 2009

Disclaimer clause
The information in this brochure has been obtained from a number of different sources, inhouse and third party laboratory experiments;
as such, Lafarge Malayan Cement Berhad cannot be held responsible for any inaccuracies. The information given is of a general nature
and does not address the specific circumstance of any particular situation. The guidance is given with the best intention but nothing in this
brochure shall create or be deemed to create any obligations, whether expressed or implied on Lafarge Malayan Cement Berhad. Users are
strongly advised to carry out their own test in order to ascertain the performance and suitability of MASCRETE Pro for their particular project.

PAGE 11 : MASCRETE Pro

 Lafarge Malayan Cement Berhad (1877-T)
Level 12, Bangunan TH Uptown 3,
No. 3, Jalan SS21/39, 47400 Petaling Jaya,
Selangor Darul Ehsan, Malaysia
Tel 603 7723 7800
Fax 603 7725 4122/4167
www.lafargemalayancement.com