Professional Documents
Culture Documents
9. Extended Cements
contents
9.1
INTRODUCTION
9.2
N O N - C L I N K E R M AT E R I A L S
9.2.1
G R A N U L AT E D B L A S T F U R N A C E S L A G
9.2.2
F LY A S H
9.2.3
N AT U R A L P O Z Z O L A N
9.2.4
LIMESTONE
9.3
9.4
INTRODUCTION
9.4.2
G R A N U L AT E D B L A S T F U R N A C E S L A G
9.4.3
F LY A S H
9.4.4
N AT U R A L P O Z Z O L A N
9.4.5
LIMESTONE
9.4.6
chapter 10
111
9.1
INTRODUCTION
Extended or composite cements are cements in which a
proportion of the cement consists of non-Portland Cement
clinker. This proportion is usually greater than 5% (i.e. in line
with EN197 terminology - see section 7).
Materials commonly used are:granulated blast furnace slag
fly ash
natural pozzolan
limestone
silica fume
These can effectively be inert fillers, pozzolanic or latently
hydraulic.
The production of composite cements is quite commonplace,
but there are notable exceptions such as North America.
The materials used can strongly influence:mill performance
final cement performance
Pozzolanic materials are low in CaO, but contain significant
levels of SiO2 and Al2O3 in a reactive (usually glassy) form.
These are able to react with calcium hydroxide to produce
additional cementitious calcium silicate and aluminate hydrates.
Latently hydraulic materials contain sufficient reactive CaO to
form calcium silicates and aluminate hydrates.
These reactions are however generally slower than those
involved in the hydration of Portland Cement clinker.
Consequently good curing is required to realise their
contribution to strength development.
Typical characteristics are shown in Figure 106.
9.
Pozzolan
Slag
Limstone
Si02
Al203
Fe203
Ca0
38 - 64
20 - 36
4 - 18
1 - 10
60 - 75
10 - 20
1 - 10
1-5
30 - 37
9 - 17
0.2 - 2
34 - 45
3
0.5
0.5
51
Mg0
S
S03
0.5 - 2
0.2 - 2
0.3 - 2.5
0-1
4 - 13
0.5 - 2
0.05 - 0.2
0.3
L0I
K20
Na20
2-7
0.4 - 4
0.2 - 1.5
2 - 12
1-6
0.5 - 4
0.02 - 1
0.3 - 1
0.2 - 1
42
0.1
0.02
Reactive
Phases
Low lime
silicate glass
Low lime
silicate glass
zeolite type
High lime
silicate glass
Essentially
inert
Physical
Properties
contents
chapter 9
chapter 10
to grind
crushed
EXTENDED CEMENTS
112
9.2
NON-CLINKER MATERIALS
9.2.1
GRANULATED BLASTFURNACE SLAG
Slags can be air-cooled, pelletised or granulated. In order to
possess hydraulic properties the slag must be quenched rapidly
to preserve the molten slag in a glassy form. Granulation uses
excess water and this produces the highest glass content
producing a wet sand like material (8-12% moisture is
common). Pelletised slag can also contain sufficient glassy
material. Glass content is thus important in selecting slag.
Chemical reactivity can also be important in slag selection, and
a number of "hydraulic indices" have been proposed, e.g.
H.I. =
contents
chapter 9
chapter 10
9.2.3
NATURAL POZZOLAN
The most common natural pozzolans are volcanic ashes, which
contain glassy phases similar to those of bituminous coal ash.
However the range of reactivity is greater than that of fly ash.
Some pozzolans have undergone alteration to yield zeolitic
type phases.
Chemical testing and determination of crystallinity can help to
assess their suitability. However, in most cases, practical testing
of cements, produced with blended or interground pozzolans is
carried out to assess their usefulness.
Some pozzolans, particularly those that are mainly glassy, have
little influence on water demand. However others, e.g. zeolitic
types, can have a significant influence and result in much higher
water demand.
9.2.4
LIMESTONE
Limestone is generally seen as an inert filter and the suitability is
therefore usually assessed in terms of the impurities present. For
this reason EN197 has placed a minimum of 75% calcium
carbonate, and maximum limits for clay (methylene blue
absorption) and organic carbon.
Their colour, hardness and availability (and impact on cement
making reserves) can also be important.
9.
EXTENDED CEMENTS
113
9.3
INFLUENCE ON CEMENT GRINDING
The utilisation of non-clinker materials will have a direct
influence on the milling process depending on their properties
and percentage used.
Fly Ash:
contents
Natural
Pozzolans:
9.
Limestone:
EXTENDED CEMENTS
114
chapter 9
chapter 10
9.4
INFLUENCE ON CEMENT PERFORMANCE
9.4.1
INTRODUCTION
Slag cements are typically produced with a wide range of slag
contents, e.g. anywhere between 20-80%. Fly ash is generally
limited to 20-30%, which is similar to natural pozzolans,
although these can also be used at higher levels. Limestone
cements tend to have lower levels of addition, typically 10-25%,
but in lower strength cement types can be as a high as 40% (e.g.
Thailand).
In general, cements containing significant non-clinker additions
need good curing conditions in order to obtain the full benefits
of the addition.
The influence on durability is quite complex, although
equivalent performance to OPC's can be attained when concrete
is produced at equivalent strength grades.
9.4.2
GRANULATED BLAST FURNACE SLAG
Slag cements containing up to 50% clinker replacement can
reach the same 28-day strength as the control cement containing
no slag, depending on the quality of the slag. However the
earlier strengths will be somewhat lower than those of the
control e.g. only 50%.
Slag cement is often produced by separate grinding, followed by
blending. Optimum performance is often found with a slag
fineness of 400 - 450 m2/kg, which can produce blended cement
with 100% of OPC strength at 28-days. However in some
cases, e.g. North America, slag has been ground at 550 - 600
m2/kg and parity to OPC is virtually reached at 7-days, with 28day strengths higher than the OPC control.
9.
EXTENDED CEMENTS
115
28d
7d
28d
7d
3d
3d
1d
1d
contents
chapter 9
chapter 10
9.4.4
NATURAL POZZOLAN
As already discussed the range of natural pozzolans can be quite
large and hence their influence on cement performance can also
be quite large. Like many non-clinker additions, their relatively
slow reactivity (compared to clinker) can mean that their
influence at early ages, say up to 14-days, can be merely as inert
filler. When interground at constant kWh/tonne, compared to
control OPC with no pozzolan, their influence can give (e.g. at
20% addition level):lower early strength, e.g. 40-80% of control
similar or lower 28 day strength, e.g. 75-100% of
control
higher SSA (generally)
Water demand can be significantly higher. Some typical results
are shown in Figure 108.
9.4.5
LIMESTONE
Limestones, when ignoring any deteterious influence of clay or
organic carbon, tend to be treated to have a relatively inert
influence on cement performance. The majority of performance
differences will probably arise from their influence on the
milling process and thus the resultant influence on the effective
clinker psd.
Figure 108. Examples of Using 20% Natural Pozzolan
A
1 - day
2 - days
3 - days
28 - days
90 - days
100
100
100
100
100
70
75
70
75
85
40
60
60
85
95
50
65
65
85
95
60
75
70
75
80
60
75
70
80
80
50
70
65
85
85
Slump
100
25
20
75
75
110
90
contents
chapter 9
chapter 10
9.
EXTENDED CEMENTS
116
28d
7d
28d
3d
7d
3d
1d
1d
Control
Notes:
9.4.6
INFLUENCE OF CLINKER PROPERTIES
For most composite cements the resultant strength development
is, as expected, very dependent on the inherent clinker
characteristics. As discussed, most composite cements will have:similar or marginally lower 28-day strength
significantly lower early strength
greater deterioration in properties for poor curing
conditions and low ambient temperatures