Portland Blastfurnace Cement PBFC/HSPBFC

OPC : Ordinary Portland Cement PBFC : Portland Blast-furnace Cement HSPBFC : High Slag Portland Blast-Furnace Cement GGBS : Ground Granulated Blast-furnace Slag

GGBS is a hydraulic cement formed from iron production and has high glassy content for reaction with OPC. The chemical composition of GGBS is almost similar to OPC. GGBS is an industrial pozzolan, different from natural pozzolans like PFA and silica fume. The granulated blast-furnace slag has to be grinded before they are mixed with OPC to form PBFC and HSPBFC. The proportions of GGBS to OPC for the two products are as follows:36% to 65% of GGBS 50% to 85% of GGBS PBFC HSPBFC

In fresh concrete, PBFC/HSPBFC produces higher workability. PBFC/HSPBFC is very efficient in lowering the heat of hydration and hence can be use for mass concreting to reduce thermal cracking. It is also used to improve the durability if concrete to chloride penetration, resistant to sulphate attack and minimize alkali-silica reaction (ASR). PBFC/HSPBFC is available in 50kg bags and in 1.5MT bulk bags.
Pulverised Fuel Ash (PFA)
PFA is the lighter and finer fraction of the ash resulting from the combustion of pulverised coal in the production of energy. The ash is extracted by filters and electrostatic precipitators. PFA particles are hard, glassy spheres which impart a ball-bearing lubricating effect to plastic concrete, therefore enhancing workability, placeability, finishability and pumpability while reducing bleeding and segregation. Due to its slower rate of hydration, PFA is use in replacement of cement (in the range of 20% to 30%) to generate less heat resulting in reduce thermal cracking when concreting massive structures like raft foundations, transfer beams, dams etc.

PORTLAND BLAST FURNACE CEMENT (PBFC)

Lafarge Portland Blast Furnace Cement is a special blended cement with low heat of hydration characteristics for mass concreting. The product

Lafarge Portland Blast Furnace Cement is a special blended cement with low heat of hydration characteristics for mass concreting. Concrete produced using Portland Blastfurnace Cement have chloride and sulphate resisting properties with improved durability.It is a cementitious construction material comprising of a combination of selected high quality ground granulated blast furnace slag and ordinary portland cement, conforming to BS 4246 (low heat of hydration) and BS 146.Our standard product, Blue Circle Portland Blast Furnace Cement, PBFCS, has a slag replacement of 65-70% and conforms to BS 4246. Essentially, granulated blast furnace slag consisting of calcium, aluminium, silica and iron, the same components found in cement but in different proportions, is ground to a fineness greater than Ordinary Portland Cement (OPC). The ground granulated blast furnace slag is dry-blended together with OPC as per requirements. The slag's latent hydraulic properties are activated in the presence of calcium hydroxide which is released when cement is mixed with water.This produces a denser calcium silicate hydrate which possesses substantial properties that are superior to OPC.

Properties/advantages of PBFC over OPC

a) Higher Ultimate Strength

Although PBFC has a slower strength gain compared to OPC in the early stages, it will eventually have a higher ultimate strength. The strength patterns can however be controlled through concrete mix design, cement and slag fineness as well as slag proportioning.The longer term and ultimate strengths are better with increase in slag addition.

b) Lower Heat of Hydration

Where the minimum dimension of the concrete to be placed at a single time is greater than 500 mm and especially where the cement content is 400 kg/m3 or more, measures to reduce the temperature such as using material with a slower release of heat hydration should be considered.Cement generates large amount of heat during the hydration process. Slag hydration is an exothermic reaction but it does not react as quickly as OPC and thus generates heat more slowly.Peak concrete temperatures are reduced.This is an advantage when thermal cracking would be a problem.

c) Better Sulphate/ Chloride resistance

Deterioration of concrete by chemical attack can occur by contact with gases or solutions of many

chemicals, but it is generally the result of exposure to acidic solutions or to solutions of sulphate / chloride salts.Solutions of naturally occuring sulphates of sodium, potassium, calcium or magnesium, as may be present in some soils and groundwaters, can cause expansion and disruption of concrete due to their reaction with C3A content in the cement.Concrete made with blast furnace slag cement had a lower content of cement thus the C3A content present is low.

d) Better Workability

PBFC has, for a given slump, a better workability.Our field practice confirms that PBFC also processes better slump retention.PBFC, due to its lower density produces more paste for a given weight.This acts as a lubricant in the mix and enhances the workability of the mix.The glassy nature of slag does not extract water from the mix.It also blocks pores and reduce bleeding.Slag helps to disperse flocculated cement particles.

e) Less Bleeding

Bleeding is the separation of solids in concrete from the water.Solids settle and water escapes through the pores and remains on the surface, which causes weakness of the top layer.The fine slag particles block pores which tends to produce a concrete which bleeds less.

f) Long Slump Retention due to the slower hydration process

g) Greater Pore Filling Capacity h) Reduced Permeability i) Greater Durability j) Reduced Risk of Alkali-Silica Reaction With Aggregates

k) Lighter Colour And Better Finishing

Application/usage of PBFC

1 - Mass concrete foundations and dam which require low heat of hydration

The control of concrete temperature and the heat generated by the hydration of cement is important to

prevent thermal cracks in the concrete mass.

In a large concrete pour, the control of concrete temperature and the heat generated by the hydration of cement is extremely important to prevent thermal cracking from occuring in the concrete mass.Although specifying a lower concrete temperature and use of insulation material around the concrete will help to reduce the difference of temperature between the core of the concrete and the surface temperature, this is not an ultimate solution.We need to moderate the heat generated by the Ordinary Portland Cement during the hydration process with another material without sacrificing the ultimate strength required.Ground granulated blast furnace slag had been extensively used as partial replacement for Ordinary Portland Cement for this purpose.As a result Portland Blast Furnace Cement (PBFC), a blend of ground granulated blast furnace slag and Ordinary Portland Cement was introduced to the construction industry.

It has now been established worldwide that PBFC will generate lower heat than Ordinary Portland Cement during the hydration process but will still be able to achieve the required strength. This is due to the low content of Ordinary Portland Cement in the blend as well as slower hydration characteristics of the blast furnace slag.However, in order to achieve the optimum advantage/blend of PBFC, the fineness of both the ingredient and mix proportion had to be consistent and controlled.We had studied various manufacturing methods and had come to a conclusion that the 2 ingredients OPC clinker and blast furnace slag with different hardness had to be ground separately in order to control their respective fineness.The ground products are then blended accurately in a blender to produce PBFC.

Our Company has selected the blending method to produce the Low Heat Portland Blast Furnace Cement in order to provide our customers with a consistent product.

2 - Marine concrete structures exposed to sea water and sulphates

PBFC with slag percentage of 60 - 70% or greater significantly improves water impermeability and resistance to Chloride attack.This is due to the fine nature and physical structure of slag.

The ability of PBFC to withstand Sulphate attack is due to:

Reduced concrete permeability Reduce amount of Calcium Hydroxide (hydration product) and reactive aluminates Ca(OH)2 + Na2SO4.10H2O -- Ca SO4.2 H2O + 2NaOH + 8 H2O Calcium Hydroxide + Sulphates --- Calcium Sulphate (Gypsum) C3A + Sulphates --- Calcium Sulfoaluminate (Ettringite)

3 - Water retaining structures where improvement in impermeability is essential

4 - Sub-structure, bored piles, pre-case piles and products positioned in soil containing chlorides or moderate content of sulphates

5 - Concrete which may consist of alkali reactive aggregates

6 - Waste treatment facilities

7 - Grouting

Adiabatic Temperature Rise (ATR) of Concrete

Cracking of Concrete
Peak temperature of thick-sectioned and mass concrete can rise until cracking in concrete may occur due to large temperature differentials. The cracking of concrete will affect structural strength, durability, and integerity.

Consequences of High Temperature

More insulation required to control temperature gradient leading to longer formwork removal time and delayed construction progress.

Higher risk of temperature differential exceeding the allowable limit. This leads to the need for investigation and possible rectification work, further delaying the construction progress and increasing cost.

Notwithstanding this, builders are often left in a dilemma due to the lack of suitable tests to verify the occurrence of thermal cracks when the allowable temperature differential is exceeded.

Permanent damage from Delayed Ettringite Formation may occur. The effect of this phenomenon is not immediate but many years later similar to the effect of Alkali Silica Reaction.

It is thus desirable that the concrete peak temperature be kept as low as practically possible.

The Cause of Temperature Rise

The reaction of cement with water produces heat causing the temperature in concrete to rise considerably.

Thick-sectioned and mass concrete, by virtue of its geometry and low thermal conductivity, retards the dissipation of heat evolved during hydration hence causing the temperature within the core to rise significantly.

The amount of heat generated in concrete depends on the cement content, type and fineness of cement, the initial concrete temperature and chemical admixtures, etc.

Singapore faces a unique situation in which cement suppliers import cement (OPC) from various countries and manufacturers, but rebrand under their own company names and supply.

Portland blast furnace cement (PBFC) and ground granulated blast furnace slag (GGBFS) are similarly imported and rebranded. Therefore, the OPC and PBFC of the same brand in Singapore may contain materials from various countries and manufacturers.

This practice in Singapore is very different from countries like Japan and Korea that manufacture their own cement. In such countries, the cement of one brand will come from the same manufacturer and therefore consistent quality can be expected.

As a result, the heat characteristics of the cement may vary from time to time. Peak temperature of mass concrete with Grade 40 using PBFC from the same supplier has been recorded to range from 62 to 90oC.

The two figures below demonstrate the variation in temperature rise of concrete samples provided by the same concrete producer using PBFC (with 65% of GGBFS) from the same cement supplier. This emphasizes the need for regular check on the adiabatic temperature rise of the concrete.

Cost-Effective Control Method

Past experience shows that conventional structural concrete with peak temperature not exceeding 70oC can be achieved by selecting suitable cementitious materials and chemical admixtures with a proper mix proportion without using ice or other cooling efforts.

The cost-effective method is to select a concrete with peak temperature less than 70C and to control temperature differential within the allowable limits with minimum insulation effort, if possible using only formwork and canvas without using polystyrene foam.

Lower peak temperature and minimum insulation effort will allow the concrete to cool sooner to the safe temperature where the formwork can be removed. This will contribute to speedy construction

Very often, to check if the temperature differential in the concrete is within the acceptable limit, monitoring by thermocouples is required. This is often costly and cumbersome and adds to the critical path of the construction process.

As an alternative, Adiabatic Temperature Rise (ATR) of concrete can be used as a control measure. With the availability of a means to measure the ATR of concrete, suitable concrete mix satisfying the temperature as well as strength, workability and durability can first be chosen by trial mix. Thereafter the ATR can be measured from a sample of the concrete during casting to ascertain that concrete of low peak temperature is being used.

If the ATR trends towards a possibility of the peak temperature exceeding the allowable limit, immediate actions can be taken to increase the insulating effort of reduce the rate of heat loss and hence sustain the temperature differential in the concrete.

In the event of non-compliance where the peak ATR exceeds the allowable limit, a numerical analysis can be carried out to evaluate the possibility of thermal cracking. This, otherwise, would not have been possible in the absence of the ATR record.

Adiabatic Temperature Rise Test

Singapore-U Technologies has the technology and expertise to measure the ATR of concrete. The ATR Chamber has been calibrated with a large number of site data to improve its accuracy and reliability.

Through these extensive calibrations, the heating mechanism has been matched with the sample shape and size so that adiabatic condition is achieved.

The test can be carried out in our laboratory or on site at the convenience of our clients.

Our ATR chamber has been widely used in Singapore to select and enforce a consistent quality assurance routine for concrete used in mass concreting in conjunction with the cost-effective control method.

We also has the expertise and tools to carry out numerical analysis to evaluate the risk of thermal cracking in the event of non-compliance.