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Brazilian Experience with

Calcined Clay Pozzolans
Vanderley M. JOHN
Antonio C V Coelho

Laboratory of Microstructure and Eco-Efficiency

Cement Production Forecast for

Brazil
200
Construbusiness
PNM 2030
160 SNIC
Cimento (M t)

PNE 2030 surf

PNE 2030 Naufrago
120

80

40
2005 2010 2015 2020 2025 2030

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Comparative energy requirements

There are several errors . A zero is missing from all of the figures;
Lime figures are wrong (~6000kJ/kg)/ burnt clay figures are optimistic!

20% of the clinker

DAY, R. L. Pozzolans for use in low-cost housing. [Calgary]:

International Development Research Centre, set. 1990.

Maximum pozzolan
allowed in Portland
Cement by country

DAY, R. L. Pozzolans for use in low-cost

housing. [Calgary]: International Development
Research Centre, set. 1990.
p.104

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Portland-Pozzolan Cements to control

AAR (USA)
25% interground calcined Monterey shale was
produced during the 1930s and 1940s.
Golden Gate Bridge
San Francisco-Oakland Bay Bridge.
25% interground calcined pozzolan,
1935 Bonneville Dam spillway on the lower Columbia River.
20% Rhyolite pumicite (on concrete mixer)
1940 to 1942 Friant Dam on the San Joaquin River in California

Stanton, T. in Symposium on Use of Pozzolanic Materials in Mortars and Concretes

(eds. Stanton, T. & Blanks, R.) 17817826 (ASTM International, 1950).

More US Experience
Wagner 1946 Oregon tuff
Ricement: 1924 Lousiana Mc Daniel 1946

DAY, R. L. Pozzolans for use in low-cost housing. [Calgary]:

International Developmetn Research Centre, set. 1990.

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Pozzolans to control AAR

Stanton (1949)
70 per cent standard cement clinker and 30 per cent
compound.
Compound: 86% Monterey shale + 14 % limestone
Compound Calcined at 1000 F (538C).
Cement:
Clinker + Gypsum 70%;
Calcined Clay 25,4%;
Limestone 4,6%
Double grinding was resorted to in order to secure a high
percentage of minus 40-micron particles.
Mortar and concrete ~strengths equal to the ref. cement
The insoluble 15.76% (0.25% of clinker.)

Stanton, T. in Symposium on Use of Pozzolanic Materials in Mortars and Concretes

(eds. Stanton, T. & Blanks, R.) 17817826 (ASTM International, 1950).

Example of separate grinding

Diatomaceous earths
have been used for many years as additions at the
concrete mixer for the primary purpose of promoting
workability and decreasing segregation. (p.5)

Stanton, T. in Symposium on Use of Pozzolanic Materials in Mortars and Concretes

(eds. Stanton, T. & Blanks, R.) 17817826 (ASTM International, 1950).

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EFFECT OF CALCINATION ON
NATURAL POZZOLANS
1. Volcanic glass
2. Opal
3. Clay
3a.. Kaolinite-type clay
3b.. Montmorillonitetype clay
3c.. Illite-type clay
3d.. Mixed clay with vermiculite
4. Zeolite
5. Hydrated oxides of aluminum
6. Nonpozzolan
Mielenz, R., Witte, L. & Glantz, O. in Symposium on Use of Pozzolanic
Materials in Mortars and Concretes (eds. Stanton, T. & Blanks, R.) 4343
50 (ASTM International, 1950).

Effect of
Calcination

500C

Mielenz, R., Witte, L. & Glantz, O. in Symposium on Use of Pozzolanic Materials in Mortars and Concretes
(eds. Stanton, T. & Blanks, R.) 434350 (ASTM International, 1950).

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Temperature of calcination

400-800C Removal of OH
Peak temperature: type of binding OH;
Peak shape and range: cristalinity, particle size,

R. Fernandez et al. / Cement and Concrete Research 41 (2011) 113122

Sneallings et all. Doi:10.2138/rmg.2012.74.6v. 74 no. 1 p. 211-278

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Effect of Calcination
45
40 Kaolinite Ilite Montmorilonite
BET surface area (m/g)

35
30
25
20
15
10
5
0
0 200 400 600 800 1000
Temp C

Temperature of calcination

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Pozzoanic reaction:
CH consumption by TG

Pozzolanic Reaction Fratini

A. Tironi et al. / Cement & Concrete Composites 37 (2013) 319327

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Calcium hydroxide consumption in

a suspension

A. Tironi et al. / Cement & Concrete Composites 37 (2013) 319327

Lime Consumption Chapelle Test

(NBR 15895:2010)

Quarcione et all. Rev. IBRACON Estrut. Mater. v.8 no.1 Feb. 2015
http://dx.doi.org/10.1590/S1983-41952015000100002

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Mechanical Strength

30% substitution by calcined clay

Compressive strength x capillary

porosity

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Calcined Clay - Brazil

+50 years long industrial experience

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Calcined Clay Pozzolans in Brazil

Alkali-Aggregate control
Technology from U California Berkeley
Roy Carlson

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DTA used to define calcining temperature

DTA criterion was to dehydroxylate without producing

crystalline phases (avoiding temperatures >900C).

AAR expansion x pozzolans

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Typical Calcined Clay Pozzolan

retained #325 (10psi water jet sieving)
<12%
4-10% typical (Agua Vermelha)
Blaine
8200 and 8500m/g
8900 typical Agua Vermelha
Density between 2,1 and 2.7g/cm (2,51 typical)
Pozzolanic activity:
lime mortar cured at 55
5x10 cm cylinders
>5,6MPa

Cement production
Mixed in the concrete
Pozzolan: (in volume)
30-40% mass concrete
15-20% structural concrete
Water demand in comparison ref. cement
~120% (cement paste)
<110% cement mortar

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Calcined Clay Production

(Urubupung, 1975)

(Andriolo, Urubupung, 1975)

Andriolo, F.R. A Utilizao da Pozolana na Construo do Conjunto Hidroeltrico de Urubupung. Centrais Eltricas de So Paulo
S.A. Abril. 1975. Fonte: http://www.andriolo-eng.com/images/publicacoes/P003.pdf , consultada em junho de 2015.

Brazil Jupia Dam

1962-1974

1.3 million m of concrete

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Jupia Dam

25% calcined clay

Ilha Solteira Dam (1965-1978)

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Brazilian Standards allow the use

of calcined clays
Type Pozzolan Limestone filler
CP II Z 14% 10%
CP IV 15-50 % 5%

At least 3 calcined clay kilns in operation.

Votorantim Calcined
Clay line (Porto Velho)

Cement CPIV 35% Calcined Clay Pozzolan

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Votorantim Clay Quarry

Porto Velho (2013)

Santo Antonio Dam, Madeira River

Porto Velho (2013)

2.5 million m pumpable concrete

0.5 million m roller compacted concrete

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Santo Antonio Dam, Madeira River

Porto Velho (2013)

Cement CP-IV 35% of calcined clay

Santo Antonio Dam, Madeira River

Porto Velho (2013)

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Jirau Dam, Madeira River

(110km far from Santo Antonio)

2.3 million m of concrete; 740kt of cement

Jirau Dam

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Calcined Clay Brazilian Production

(CSI Companies)
7000
Limestone
6000 Puzzolana
Slag
5000 Fly ash

4000
kt/year

3000

2000

1000

0
1990 1995 2000 2005 2010 2015
http://www.wbcsdcement.org/GNR-2011/Brazil/GNR-Indicator_317-Brazil.html

Calcined Clay Pozzolan in Brazil

Significant industrial experience
Considered normal pozzolan
Optimization of the process ca

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Innovation on Calcined
Clay

Limestone + Calcine Clay

(Scrivener EPFL group)

M. Antoni et al. / Cement and Concrete Research 42 (2012) 15791589

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Calcined Clay + Limestone

Calcined Clay + Limestone

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Limestone consumption

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F. L. Smidth`s Flash Calciner

Thank you!
VMJohn@usp.br
Rafael.Pileggi@poli.usp.br

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