Dr J D Bapat highlights some opportunities for research in the areas of cement manufacturing and application, namely alternate fuels, new cements, mineral admixtures. He also highlights some features of the training course offered for the professionals working in cement, concrete and construction industry.

1. OPPORTUNITIES FOR RESEARCH
IN
CEMENT & BUILDING MATERIALS
Dr J D BAPAT
DEPARTMENT OF TECHNOLOGY (DOT)
SAVITRIBAI PHULE PUNE UNIVERSITY
17 OCTOBER 2014

2. WHY AM I TALKING ABOUT
CEMENT & BUILDING MATERIALS
STARTED CARRIER AS SCIENTIST AT
NATIONAL COUNCIL FOR CEMENT AND
BUILDING MATERIALS (NCB), NEW DELHI,
39 YEARS BACK (1975)
RESEARCHED IN AREAS OF ENERGY,
ENVIRONMENT, USING INDUSTRIAL &
AGRICULTURAL WASTES IN CEMENT &
CONCRETE
STILL CONTINUE TO WORK IN THE AREA

3. RAW MATERIALS & FUELS
LIMESTONE & CLAY AS THE SOURCE
OF CALCIUM, SILICON, ALUMINUM &
IRON
MOSTLY MINERAL COAL IN FINELY
GROUND FORM

4. ALTERNATIVE SOLID FUELS
• REFUSE DERIVED FUEL (RDF), TIRE-DERIVED FUEL
(TDF), MEAT & BONE MEAL (MBM), WASTE WOOD,
SEWAGE SLUDGE, PAPER & PLASTICS
• FEEDING THROUGH ROTARY KILN OR MIXING WITH
RAW MATERIALS
• REQUIRES NEW COMBUSTION EQUIPMENT OR
MODIFICATION OF EXISTING KILN SYSTEMS
• ALTERNATIVE FUELS INFLUENCE PROCESS STABILITY
& PRODUCT QUALITY
• DEPOSIT FORMATIONS IN THE ROTARY KILN
MATERIAL INLET END, KILN RISER DUCT & LOWER
CYCLONE STAGES
• CLINKER QUALITY MAY ALSO BE AFFECTED BY
MINOR COMPOUNDS FROM FUEL ASHES OR FROM
UNBURNED CARBON LEAVING ROTARY KILN WITH
CLINKER

5. BURNING WASTE FUELS
Wood Chips

6. REPLACING PORTLAND
CEMENT
 PRODUCTION OF ONE t OF PORTLAND CEMENT
EXPELS ALMOST EQUAL MASS OF CO2 IN
ATMOSPHERE
 CEMENT INDUSTRY CONTRIBUTES 5% OF THE
TOTAL ANTHROPOGENIC CO2 EMISSIONS
GLOBALLY
 MINERAL ADMIXTURES (MA) REPLACE CEMENT &
AFFECT REDUCTION IN CO2 EMISSION
 THEY ARE INDUSTRIAL & AGRICULTURAL
WASTES
 VOLUME OF THESE WASTES CURRENTLY
PRODUCED WORLDWIDE EXCEEDS THEIR
UTILIZATION

7. RICE HUSK ASH (RHA)
 RH IS PRESENTLY CONSIDERED AS
AGRICULTURAL WASTE & USED AS FUEL,WHERE
ITS POZZOLANIC VALUE LIES UNUTILIZED
 ABUNDANT AVAILABILITY OF RH IN RICE
PRODUCING COUNTRIES PROVIDES HUGE SCOPE
TO RECOVER ITS HEAT VALUE TO GENERATE
POWER & TO USE RHA PRODUCED IN CEMENT &
CONCRETE
 LARGE-SCALE APPLICATION OF RHA IN THE
CONSTRUCTION INDUSTRY REQUIRES INDUSTRIAL
& ECONOMIC POLICY PLANNING

8. RICE HUSK ASH (RHA)
 PHYSICAL & MINERALOGICAL CHARACTERISTICS OF RHA:
AMORPHOUS SILICA, SURFACE AREA, GRINDABILITY & CARBON CONTENT,
DEPEND UPON TEMPERATURE, ENVIRONMENT & DURATION OF COMBUSTION
 SURFACE SILANOL (SI-OH) SITES IN THE AMORPHOUS SILICA
RESPONSIBLE FOR THE POZZOLANIC ACTIVITY OF RHA
 TO OBTAIN SILICA IN AMORPHOUS FORM, COMBUSTION TEMPERATURE
REMAINS IN 500°C–700°C, WITH OPTIMUM TIME DURATION APPROPRIATE FOR
THE PROCESS, TO OBTAIN RHA WITH LOW CARBON CONTENT, HIGH SURFACE
AREA & MAXIMUM GRINDABILITY
 MODERN FLUIDIZED OR CYCLONIC BED PROCESSES PRODUCE RHA WITH
ABOVE 85% AMORPHOUS SILICA AND VERY LOW CARBON CONTENT IN RANGE
OF 1%–4%
 NEED TO IDENTIFY A PROCESS TO MANUFACTURE RHA ON A SMALL SCALE
NEAR PADDY FIELDS & SUITABLE FOR ADOPTION IN THE RURAL AREAS

9. RICE HUSK ASH (RHA)
 RHA, PRODUCED UNDER PROPER CONDITIONS, IS SOFT &
EASILY PULVERIZED TO DESIRED SIZE, FINER THAN CEMENT,
WITH PARTICLE SIZE < 10 MICRON & BET SURFACE AREA OF
20–40 m2/g, IN COMPARISON SF: > 15 M2/g
 SILICA CONTENT (MOSTLY AMORPHOUS): 87-96%
 UNLIKE SF OR FA, PARTICLES OF RHA ARE ANGULAR &
REMAIN POROUS EVEN AFTER SIZE REDUCTION
 IMPROPERLY GROUND RHA EXHIBITS LOW POZZOLANIC
ACTIVITY & HIGH WATER REQUIREMENT DUE TO WATER
ABSORPTION BY POROUS PARTICLES
 FINE PARTICLES OF RHA AFFECT REFINEMENT IN PORE
STRUCTURE OF CONCRETE
 USE OF RHA IN CONCRETE CAN BE CONSIDERED AS SAFE FROM
TOXICITY POINT OF VIEW
 CEMENT REPLACEMENT UP TO 30% REPORTED

10. PORTLAND LIMESTONE
CEMENT (PLC)

11. PORTLAND LIMESTONE
CEMENT (PLC)
 IMPROVED PARTICLE PACKING
 PROVIDES NUCLEATION
SITES FOR HYDRATION
PRODUCTS
LS REACTS WITH
ALUMINATES IN
CEMENT TO FORM
CARBOALUMINATES

12. PORTLAND LIMESTONE CEMENT (PLC)
LIMESTONE REQUIREMENTS: EN STANDARDS
 CALCIUM CARBONATE > 75%
 TOTAL ORGANIC CARBON (TOC): MAX 0.5%
 CLAY: MAX 1.2 g/100g

13. PORTLAND HIGH VOLUME
FLY ASH CEMENT (PHFC)
PHFC REFERS TO BLENDED CEMENT PRODUCED IN CEMENT PLANT,
WITH FA REPLACEMENT CEMENT >55%
AT PRESENT HIGH VOLUMES OF FA (>55%) ARE ADDED AS REPLACEMENT
OF CEMENT, AT RMC PLANTS, TO PRODUCE HIGH VOLUME FLY ASH
CONCRETE (HVFAC) (.) IT NECESSITATES ADDITIONAL STORAGE SILOS &
QUALITY CONTROL AT JOB SITE
PHFC IS ONE OPTION, INCREASING AMOUNT OF FA THAT CAN REPLACE
PORTLAND CEMENT (PC) FROM <20% IN CONVENTIONAL MIXES UP TO AS
HIGH AS 55%
PHFC CAN BE PRODUCED EITHER BY INTER-GRINDING FA WITH PC
CLINKER & GYPSUM OR BY BLENDING DRY FA WITH PC (.) SOMETIMES DRY
SUPER PLASTICISER IS ALSO INTERGROUND (.) PRODUCTION OF PHFC
USING INTER-GRINDING METHOD APPEARS MOST COST-EFFECTIVE &
PRACTICAL
REQUIRED TO SATISFY MINIMUM STRENGTH AS PER ASTM C1157, OF 10 &
17 MPa AT 3 & 7 DAYS RESPECTIVELY

14. PORTLAND HIGH VOLUME FLY ASH
CEMENT (PHFC)
CONCRETE WITH PHFC
RESULTS OF LABORATORY TRIALS ON PHFC WITH 55% FA*
 FRESH CONCRETE: CONCRETE WITH PHFC REQUIRED MORE SP & AEA,
AS INTER-GRINDING INCREASED FINENESS
 COMPRESSIVE STRENGTH: IRRESPECTIVE OF SOURCE & TYPE OF FA,
CONCRETE WITH PHFC DEVELOPED BETTER STRENGTH COMPARED TO
THAT PREPARED BY SEPARATE ADDITION OF CEMENT & UN-GROUND FA AT
MIXER
 CHLORIDE RESISTANCE: INTER-GRINDING IMPROVED CHLORIDE
RESISTANCE OF CONCRETE
*Ref: “Development of high-volume fly ash blended cements”, Electric Power
Research Institute (EPRI), California, USA, 2001

15. PORTLAND HIGH VOLUME
FLY ASH CEMENT (PHFC)
PHFC IS FACTORY MADE WITH FA REPLACING CEMENT AT 55%
ADDING SP TO CLINKER AT FINISH GRINDING STAGE HELP REDUCE
GRINDING ENERGY & ALSO SOLVES COMPATIBILITY ISSUES AT
CONCRETING STAGE
INTER-GRINDING FA WITH GROUND CEMENT FOR FIXED TIME PERIOD
IMPARTS BETTER CONCRETE PROPERTIES
PHFC HAS VERY GOOD RESISTANCE TOWARDS CHLORIDE PENETRATION

16. NEW MINERAL ADMIXTURES
UNDER INVESTIGATION
 ASH PRODUCED FROM BIOMASS
 CORN COB ASH (CCA)
 PALM OIL RESIDUE ASH (PORA)
 SUGARCANE BAGASSE ASH (SBA)
 WHEAT STRAW ASH (WSA)
 WOOD WASTE ASH (WWA
 SEWAGE SLUDGE ASH (SSA)
 MUNICIPAL SOLID WASTE ASH (MSWA)

17. NEW MINERAL ADMIXTURES
UNDER INVESTIGATION
BIOMASS ASH
 UP TO 20%, OF BIOMASS CONSISTS OF INORGANIC CONSTITUENTS, REFERRED AS ASH, WHICH
CANNOT BE CONVERTED TO ENERGY
 POSSIBLE TO PRODUCE PFA WITH POZZOLANIC PROPERTIES, BURNING & PROCESSING BIOMASS
UNDER CONTROLLED CONDITIONS, EITHER THRU CO-FIRING WITH MINERAL COAL OR SEPARATELY
 NECESSARY TO CONTROL THE CARBON, ALKALI, CHLORIDE & SULFATE CONTENT
 IN ADDITION, LEACHING & TOXICITY PROPERTIES ALSO NEED TO BE TESTED BEFORE ITS USE IN
CONCRETE
 POSSIBLE TO PRODUCE STRUCTURAL GRADE CONCRETE, PARTIALLY REPLACING CEMENT WITH
BIOMASS PFA TO THE EXTENT OF 20%–25%
 WATER DEMAND, REQUIREMENT OF AIR ENTRAINING AGENT & SETTING TIME INCREASE WITH THE
APPLICATION OF SUCH PFA
 DURABILITY PARAMETERS ALSO NEED TO BE TESTED, ON A CASE-TO-CASE BASIS
 STRATEGIES FOR SUSTAINABLE MANAGEMENT OF BIOMASS ASH WILL HAVE TO BE WORKED OUT,
CONSIDERING DISPOSAL COST & VOLUME, INCREASING WORLDWIDE.
 ASTM C618 PROHIBITS USE OF BIOMASS FLY ASH IN CONCRETE
 EUROPEAN STANDARD ALLOWS CO-FIRING OF BIOMASS WITH COAL, UP TO 25% ON MASS BASIS
 ON ACCOUNT OF WIDE RANGE OF BIOMASS RESOURCES & COMBUSTION CONDITIONS, UPPER LIMIT
HAS BEEN SPECIFIED FOR THE CONTENT OF ALKALI (5%), CHLORIDE (0.1%) & UNBURNED CARBON (5%).

18. NEW MINERAL ADMIXTURES UNDER
INVESTIGATION
SEWAGE SLUDGE ASH (SSA)
 TREATMENT OF WASTEWATER GENERATES SLUDGE & ITS
INCINERATION PRODUCES SSA
 ABOUT 300–400 kg ASH/t IS PRODUCED
 SINCE SSA IS A WASTE MATERIAL, ATTENTION MUST BE PAID TO
ENVIRONMENTAL IMPACT, WHEN REUSED
 IN CONCRETE, REDUCED WORKABILITY & INCREASED SETTING
TIME HAS BEEN REPORTED (.) NEGATIVE EFFECT CAN BE
COUNTERED USING SUPERPLASTICIZER (.) RESULTS ON
COMPRESSIVE STRENGTH ARE NOT UNIFORM
 IN VIEW OF THAT, 10%–15% CEMENT REPLACEMENT MAY BE
TRIED, SUBJECT TO THE SATISFACTORY LEACHABILITY TESTS

19. NEW MINERAL ADMIXTURES UNDER
INVESTIGATION
MUNICIPAL SOLID WASTE ASH (MSWA)
MILLIONS OF TONS OF MSW IS PRODUCED GLOBALLY (.) INCREASED
ENVIRONMENTAL AWARENESS, CONTINUOUSLY INCREASING LANDFILL COSTS,
SCARCITY OF LANDFILL SITES & SLOW COMPOST PROCESS UNDERLINE NEED TO
TAKE INTO ACCOUNT ALTERNATIVE DISPOSAL METHODS
 INCINERATION IS A COMMON TECHNIQUE & REDUCES SOLID WASTE BY MASS &
VOLUME, PROVIDES FOR ENERGY RECOVERY & LEADS TO COMPLETE DISINFECTION
 TOTAL AMOUNT OF MSWA GENERATION RANGES FROM 4% TO 10% BY VOLUME
&15%–20% BY WEIGHT OF ORIGINAL QUANTITY OF WASTE & FLY ASH (OBTAINED
FROM THE DUST COLLECTION EQUIPMENT) AMOUNTS TO 10%–20% OF TOTAL ASH
PORTLAND CEMENT, BLENDED WITH PFA & BFS, CONTAINING UP TO 20% MSWA, IS
FOUND TO BE GOOD IN MECHANICAL PROPERTIES AS WELL AS FOR
IMMOBILIZATION OF LEAD & SULFATE BUT SOMEWHAT LESSER FOR ZINC &
CHLORIDE, INTO STABLE, LESS SOLUBLE COMPOUNDS (.) CAPACITY INCREASES
WITH HARDENING AGE
 ALTHOUGH MSWA CAN BE ADDED TO CONCRETE AS A PARTIAL CEMENT
REPLACEMENT, THERE IS STILL SOME SCOPE FOR THE DEVELOPMENT, BEFORE IT
COULD BE EFFECTIVELY USED AS A MINERAL ADMIXTURE

20. FLY ASH IN CONCRETE:
ACKNOWLEDGEMENT
• I THANKFULLY ACKNOWLEDGE THAT WHILE MAKING
THIS PRESENTATION, I HAVE FREELY DRAWN UPON
THE INFORMATION PUBLISHED IN THE FOLLOWING
BOOK:
MINERAL ADMIXTURES IN CEMENT AND CONCRETE
AUTHOR: JAYANT D. BAPAT
PUBLISHER: CRC PRESS, TAYLOR & FRANCIS GROUP,
USA

21. TRAINING COURSE
CONTENTS
 APPLICATION OF MINERAL ADMIXTURES:
FA, BFS, SF, MK RHA
 APPLICATION OF CHEMICAL ADMIXTURES
& SUPER PLASTICISERS
 HIGH PERFROMANCE CONCRETE:
HIGH STRENGTH, SCC, RCC, LIGHTWEIGHT,
PERVIOUS, HVFAC
GROUP DISCUSSIONS, CASE STUDIES &
VIDEOS
 DETAILS: http://www.drjdbapat.com

22. TRAINING COURSE
WHO SHOULD ATTEND
 ENGINEERS WORKING AT CONSTRUCTION
SITE
 ENGINEERS WORKING WITH CEMENT,
CONCRETE INDUSTRY
 ENGINEERS WORKING WTH MANUFACTURERS
AND SUPPLIERS OF CHEMICAL ADMIXTURES
AND MINERAL ADMIXTURES
 ENGINEERS WORKING ON PRODUCT
DEVELOPMENT
 STUDENTS/RESEARCHERS
 DETAILS: http://www.drjdbapat.com

23. TRAINING COURSE
FLEXIBILITY
CONTENTS: CHOOSE AS PER YOUR
REQUIREMENT
DURATION: 1-2 DAYS
VENUE: PUNE OR YOUR HEAD OFFICE,
PLANT OR CONSTRUCTION SITE
DETAILS: http://www.drjdbapat.com

24. JOIN MY NETWORK
YOU ARE WELCOME TO JOIN ME
 FACEBOOK: Jayant D Bapat
 TWITTER: @cemcretecon & @drjdbapat
 LINKEDIN: Dr J. D. Bapat
(email: jdbapat@yahoo.co.in)
 EMAIL_1: consult@drjdbapat.com
 EMAIL_2: consult.bapat@yahoo.com
 URL: http://www.drjdbapat.com

25. NEW BLENDED CEMENTS
Thanks!!!