IN CELEBRATION OF ENGINEER’S DAY

PLANT LOCATIONS & FOCUS MARKETS

(4 MTPA of Clinker Production Capacity)

I
V IV

III
II

(6 MTPA of PSC,PPC,OPC & GGBS at Surat)

VI
 Durability of concrete

 Durability may be defined as "consistent performance of the structures during

its expected life time conforming to the predetermined set parameters
and under prevailing conditions without resorting to maintenance".

 The durability of any structure is affected by loading and environmental

conditions, and natural phenomena such as rain, snow fall, floods, fire,
etc. The statistical analysis would be helpful to determine the probable cycle
and severity of such occurrences.

 The selection of cementitious material should be based on the durability

requirements.
 Concrete-Durability
 Hi-Strength Concrete is not always a Durable Concrete.
 Environmental Condition has become an important factor for durability.
Concrete Deterioration

Physical Chemical Reinforcement

Deterioration Deterioration Corrosion

Acid Sea water Alkali-aggregate Leaching

reaction

Carbonation Chlorides
THE SOLUTION WE OFFER
PORTLAND SLAG CEMENT (PSC)

I. Compressive strength at 3, 7 & 28 Days comparable with OPC 53 grade.

II. One Day Strength 15-16 MPa, sufficient for de-shuttering of structural members
as per BIS standards.
III. Consistent quality throughout all seasons.
IV. Ideal for coastal construction where sulphates and chlorides are present.
V. Provides best protection against corrosion of steel by developing dense micro-
structure of concrete.
VI. Most workable, cohesive mix easy to place and compact.
VII.Recommended in IS 456 and IRC for all types of structural members such as
Foundations, Slabs, Beams, Columns, Concrete Roads, Bridges etc.

VADRAJ CEMENT is proud to introduce PSC first time on large

scale and regular basis in Gujarat for Durable and Sustainable
construction.
 HOW PSC/ GGBS HELPS IN ENHANCING DURABILITY OF
CONCRETE
Durability of concrete is increased by incorporation of slag due to following
factors;
 Reduced Heat of Hyderation
 Refined Pore Structure
 Reduced Permeability
 Corrosion Resistance
 Chemical Resistance against
 Chloride ion penetration
 Sulphate attack
 Alkali Aggregate Reaction
 Use of PSC & GGBS for Durable and sustainable High
Performance Concrete

GGBS &
PSC
 OPC & GGBS hydration mechanism

C-S-H
OPC water Ca(OH)2
gel

C-S-H
gel GGBS

 Ca(OH)2 - Weakest component

 Higher C3S - More Ca (OH)2
 C3S Produce - 61 % CSH + 39 % CH
 C2S Produce - 82% CSH + 18% CH
 High Early Strength - High C3S
 High C3S - High heat of Hydration
 Advantages of using PSC/ GGBS
Dispersion of  Improves Ultimate
Cement Particles
Lesser Cracking & Flexural
Particle Packing
Effect Strength of

Secondary Improves PSC/ Concrete

Reaction Concrete GGBS Increased
Properties Concre durability
 Max. Reduction in
te
heat of hydration.
Improved resistance to
Acid, Chloride, Sulphate &  High
fire
Impermeability.

 Resistance to

Chemical Attacks
 Heat Of Hydration in PSC & OPC
95.17
82.27
100 72.04
Heat of Hyderation (

66.74
80 60.26
Cal/ gm)

60 42.63
40

20

0
3 DAYS 7 DAYS 28 DAYS

Temperature Rise in PSC Vs OPC & PPC Concrete

40

40
Temperature, Degree C

70
35
35 60

30 50
30

Deg C
Temp
25
30
25 C o re T e m p P P C
20
20
20 10 C o re T e m p P S C
00 5000
5000 10000
10000 15000
15000 20000
20000 25000
25000 30000
30000 35000
35000 40000
40000 45000
45000 0
Age, minute
minute 1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 49 52 55 58 61 64 67
PSC 70
PSC Concrete
Concrete OPC
OPC Concrete
Concrete
T im e in h r s
 REFINEMENT OF PORE STRUCTURE
Pore refinement results in reduction of volume of large pores (above 300
micron dia) which leads to reduction in chloride penetration
and increased resistance to Sulphate ions, Sea water, pure water
and frost action. Expansion due to alkali-aggregate reaction is also
decreased with increased slag content.

3 Days 28 Days- CSH Filling Pores

7 Days
Dense concrete resist chemical entry in Concrete

Ordinary Portland cement Ordinary Portland cement+ GGBS(PSC)

Reduce Corrosion /increase Strength

13
 Improved Water IMPERMEABILITY
 Water Permeability test, specified in Indian Standard is only applicable to Low
strength high permeability concrete. It is not suitable/ applicable to concrete with less
than 0.4 W/c ratio. For High strength and high performance concrete, that are used
today, Water Penetration Test is more appropriate to measure permeability.
 In this test, hydraulic head is applied by pressure which usually ranges between 0.1
and 0.7 Mpa(1 Bar to 7 Bars) on a specimen of concrete.
 MORST specifies the pressure application as follows
A. 1 Bar for the first 48 Hrs. B. 3 Bars for the next 24 Hrs.
C. 7 Bars for another 24 Hrs.
 At the end of four days, the depth of penetration of water is found by observation of
split surface of concrete (Moist concrete being darker).
 A depth less than 50 mm classifies the concrete as “impermeable”.
 A depth less than 30 mm as “impermeable under aggressive conditions”.
 MORST limits the depth of Water penetration to 25mm.
 DELHI METRO specifies the depth of penetration to not more than 10mm for
underground structures.

WATER PERMEABILITY RESULT** – conforming to DIN 1048

TYPE GGBS Replacement Level Mean mm
OPC 0%
21
OPC+GGBS 25%
18
OPC+GGBS 40%
15
OPC+GGBS 50%
10
**Source RMC India Readymix
Dense concrete reduce Leaching/ Porosity

Ordinary Portland Cement Portland Slag Cement

15
REDUCED PERMEABILITY IN SLAG CEMENT

POROUS BLOCK SOLID BLOCK

16
Resulting in Leaching/ Porosity

17
Resulting in Leaching/ Porosity

18
Increase workability & cohesiveness

19
 Improved Corrosion Resistant
Portland slag cement/GGBS lead to increase electrical resistivity of concrete and
reduce diffusivity of chloride ions from outside. The resistance to corrosion of
reinforced steel in concrete is enhanced due to less proportion of chloride ions available in
pore solution.
Cement Diffusivity
10-9 Cm2/g

OPC 44.7

PPC 14.7
(70:30)

PSC 4.1
(45:55)
 BETTER RESISTANCE TO CORROSION
CORROSION IN SLAB • CORROSION IN COLUMN

BETTER RESISTANCE TO CORROSION

Corrosion of reinforcement due to porosity in concrete and improper cover.

21
 Improved Sulphate Resistance
The Portland Slag Cement containing active slag in required proportion offer an improved
resistance to sulphate attack because of depletion of Ca(OH)2, lower C3A content as well as
improved water tightness of concrete.

SULPHATE ATTACK

Cement + WATER

CSH + Ca (OH)2
+ SULPHATES - SOIL / WATER

CaSO4 2H2O
REACTS WITH C3A OF CEMENT

Cal - SULPHO ALUMINATE (ETTRINGITE)

VOL. EXPANSION
SULPHATE RESISTANCE OF PSC VS OPC
Effect of GGBS in Concrete w.r.t. % Expansion

Increasing % age of GGBS in Concrete

Chloride Ion Permeability

Chloride Ion Penetrability Limits as per ASTMC 1202 -97

Charges (Coulombs) CL Ion Penetrability
> 4000 High
2000 - 4000 Moderate GGBS replacement Average
1000 - 2000 Low level
100 - 1000 Very Low 0% 2220
< 100 Negligible
25% 1034
40% 628
50% 526

Source RMC India Readymix

Improve Chloride Resistance

25
IS 456 Abstract pg 19

Notes:-

6Portland slag cement conforming to IS 455 with slag

content more than 50 percent exhibits better sulphate
resisting properties.

7Where chloride is encountered along with sulphates in

soil or ground water, ordinary Portland cement with
C,A content from 5 to 8 percent shall be desirable to be
used in concrete, instead of sulphate resisting
cement. Alternatively, Portland slag cement conforming
to IS 455 having more than 50 percent slag or a
blend of ordinary Portland cement and slag may
be used provided sufficient information is available on
performance of such blended cements in these
ALKALI AGGREGATE REACTION: PSC VS OPC
 ALKALI AGGREGATE REACTION: PSC VS OPC
Effect of increasing GGBS % in Concrete on Expansion due to AAR
Reduce Alkali-Aggregate Reaction
The use of slag cement will reduce the
potential of ASR occurring by:
• Reducing the total alkalis in the system
thus reducing the alkali-silica ratio.
• Consuming alkalis in the hydration
process, making them unavailable for the
alkali silica reaction.
• Reducing pore size and mobility of the
alkali.
• Reducing the pore liquid that reacts
with the aggregate.

29
GROUND GRANULATED BLAST FURNACE SLAG (GGBS)

 VADRAJ GGBS is sourced from a major integrated steel plant at Hazira.

 Granulated slag continuously exhibits glass content in the range of 95% and above.

 Granulated slag is ground in state- of- the- art grinding system with ideal particle size
distribution.

 Recommended for use in concrete for dense microstructure resulting in long term
durability, low permeability and very high integrity.

 IS code recommends replacement levels between 25%-70 % and more than 50% for
concrete to be used in chloride and sulphate environments.
BLAST FURNACE SLAG AFTER GRINDING
 Generation of Slag
 Slag results from fusion of raw materials used in blast furnace for production of pig
iron.

 Molten slag floats on top of molten iron at temperature between 14000C and 16000C .

 Unlike fly ash, range of slag chemical composition is very narrow because of careful
control of raw materials to produce consistent quality of iron.

 Slow cooling of slag results in formation of crystalline mineral compounds which have
little or no cementitious value.

 However, if quenched from molten state, granulated slag remains in meta-stable

amorphous, Vitreous or glassy state and possesses latent hydraulic qualities.
BLAST FURNANCE IN STEEL PLANT

STEEL PLANT BLAST FURNACE IN STEEL PLANTS

 Blast Furnace Slag

 Non metallic product.

 Consisting of glass containing silicates
and aluminates of lime.

 Developed simultaneously with

iron in blast furnace.

 Obtained by rapidly chilling

or quenching with water or steam
and air.
Slag Granulation
 Chemical Composition Of Slag
(As per IS 12089:1989)

CHEMICAL
RANGE (%)
COMPOSITION
SILICA LIME 27 - 32
ALUMINA IRON 30 - 40
MAGNESIA 17 - 31
GLASS CONTENT 0-1
0 - 17
85% MIN.

Microscopic examination reveals the glassy

nature of GGBS particles
 Chemical Composition of GGBS, OPC and PFA (% by weight)

Oxides OPC GGBS PFA

SiO2 21 32 50
CaO 64 37 2
Al2O3 6 19 27
MgO 2 8 2
Fe2O3 4 1 8
Others 4 5 10
 GGBS Attributes

Ground Granulated Blast furnace slag

is a unique cementitious material

•GGBS possesses, locked within itself,

an inherent ability
to provide strength, stiffness and
durability to concrete.

•GGBS is beneficial for Resource

Conservation and Environment
Protection.
Factors Affecting Slag Reactivity

1.Glass Content (Degree of

vetrification) 2.Chemical Composition
3.Mineralogical Composition; and
4.Fineness
 ECO FRIENDLY- GGBS
TO ACHIEVE SUSTANIBILITY
IN CONSTRUCTION
Material Embodied CO2
(Kg./tone)

Portland cement, CEM I 930 GGBS manufacture typically

Addition/s or GGBS 52
cement constituent releases 52 kg of CO2/t of
Fly ash 4

Limestone 32
GGBS: about 5% of the
Minor additional constituent 32
carbon footprint of normal
Aggregate 4
Ordinary Cement
Reinforcement 427
Sustainability with PSC/ GGBS

Re-cycle:- Raw Slag, an Industrial by-product

Reduce:- OPC Consumption, hence

CO2 emissions
Re-use:- Ca (OH)2 in the system, which will
otherwise leach the concrete
RCC in all types of foundations and super structure works.
General building construction.
Express ways.
Mass concrete works in Dams, Spillways,
Canals, Foundations etc
Under ground works, Retaining walls, culverts and drainage
works
Effluent and sewage treatment plants
Grouts and Mortars and Cement based products
Waterproofing, Plastering, brick work and finishing works
Marine works
 Global Application of GGBS/ Slag Cement for Durable Structures

 GGBS/PSC is used to make durable concrete structures rather than Ordinary

Portland Cement.
 GGBS/ PSC has been widely used in Europe, and increasingly in the
United States and in Asia (particularly in China, Japan and
Singapore) for its superiority in concrete durability, extending the lifespan
of buildings from fifty years to hundred years
 In India also importance of GGBS/ PSC has been recognised and is
being used in projects like Delhi Metro, Naphta Jhakri Hydro Project, Sardar
Sarovar, Canal linings, Mass concrete foundations in Multi Storey structures
across the country and many other important projects.
Structures built with PSC/GGBS
Structures built with PSC/GGBS
Structures built with PSC/GGBS
Structures built with PSC/GGBS
Use of PSC for Road construction by NHAI
Letter from R & B department for usage of PSC
 Commercial Benefit of Use Of GGBS in Bulk
CMD for M25 at Geo Design & Research - Vadodara
Target Strength- 31.6 Mpa

W/c Ratio= 0.48 Water Content - 175.4 ltrs.

GGBS ( CEMENT ( SAND ( 20 MM 10 MM ( ADMIXTURE Slump (After 60 PRICE PER PRICE W/O DIFFERENCE PER
Sample ID COMPRESSIVE STRENGTH(N/mm2)
Kg/ M3) Kg/ M3) Kg/ M3) ( Kg/ M3) Kg/ M3) ( Kg/ M3) minutes) CU.MTR GGBS CUM

2200 5400 800 600 550 150 7 day 28 aday

Rate per MT

30% G + 70 % C 120 264 280 1512 783 626 688 413 460 253 2.4 360 90 26 36.1 3428 3812 384

40% G + 60 % C 160 352 240 1296 783 626 688 413 460 253 2.4 360 110 24.6 34.2 3300 3812 512

50% G + 50 % C 200 440 200 1080 783 626 688 413 460 253 2.4 360 100 20.9 32.4 3172 3812 640

60% G + 40 % C 240 528 160 864 783 626 688 413 460 253 2 300 80 18.5 31.8 2984 3752 768

70% G + 30 % C 280 616 120 648 781 625 687 412 460 253 3.2 480 130 16.6 27.5 3034 3930 896
 Depletion of natural resources

For every tone of Portland cement produces 1.5 tones of limestone/shale are removed
from the landscape
NABL ACCREDITED LAB CERTIFICATION- GGBS
NABL ACCREDITED LAB CERTIFICATION- PSC
UNIQUENESS OF VADRAJ CMENT

 Reliable defence against Chloride and Sulphate attack.

 Consistent high quality products
 Durable and long lasting construction
 Cost effective cementitious materials
 Locally available and reliability of timely supply
 Cement Bags without hooks.
 Delivery of fresh cement in Bulk and Bag.
 CONCLUSIONS

PSC/ GGBS has enormous potential to extend a structure’s useful service life because it
improves concrete durability in areas susceptible to corrosion, chloride & sulphate
attack and alkali silica reaction.
Improved durability characteristics help further reduce life-cycle costs, lower
maintenance costs and makes concrete more sustainable.
The concrete produced from PSC & GGBS is lighter in colour with higher reflectivity.
Lighter coloured pavements produce higher visibility and improved safety.
Buildings and pavements that are lighter in colour reflect more light and thus help
minimize the ͚heat island͛ effect which in turn reduces the energy needed for
cooling.
Thank You