Pozzocrete is a fly ash cement replacement product that is produced from coal combustion in thermal power stations. It has unique properties that make concrete stronger, more durable, and improves workability when used to replace 20-35% of cement by weight. Pozzocrete helps make the world greener by reducing cement usage and CO2 emissions in concrete production since fly ash is a waste product. It has received various certifications and conforms to international standards for fly ash in concrete.

1. PRESENTATION AUTHOR:
G TEJASRI(IV B.TECH.)

2. “HELPING TO MAKE THE
WORLD GREENER”
POZZOCRETE

3. INTRODUCTION:
 Pozzocrete is a flyash cement replacement product.
 Its a product of the combustion of pulverised coal in
thermal power stations.
 Because of the unique nature of its creation it has
unique properties like better,
stronger and more durable
concrete when used.

4. CHEMICAL COMPOSITION:
 Pozzocrete is composed of inorganic material with a
small proportion of carbon particulate resulting from
incomplete combustion of the parent fuel, coal.
 Pozzocrete is extracted from flue gases discharged
from combustion systems by electrostatic and
mechanical processes.
CENOSPHERES

5. SALIENT FEATURES:
 It can be used in every cement Application.Replaces
25-45% of expensive OPC. Increases 28-day strength
& long term strength by 15% to 30%.
 Reduces water demand & improves workability,
impermeability, protection from sulphate attack &
chlorine penetration.
 The optimum level of replacement of Cement with
pozzocrete within the concrete mix will be between
20 – 35% by weight for normal RCC structures.

6. MANUFACTURING PLANT:

7. PROCESS OF MANUFACTURING:
 Raw fly ash is discharged into fly ash silo, is fed into
1st classification plant . By the mechanical air
classification process inclusive air/product
separation driven by ID fan, P63 is separated and
packed.
 The separated matter is fed into 2nd classification
plant, it is processed in the above process and p60 is
obtained.
 Separated matter is fed into 10/5 silo.
 Final separated matter is dispatched by tippers and
bulkers.

8. GRADES OF POZZOCRETE:
 Pozzocrete 40, 60,63 and 83 high quality PFA were
selected and industrially processed in order to obtain
maximum performance as a cement replacement
product.
 Besides these,P30,P20,P10 and pozzoplast are also
some of the grades of pozzocrete where as
POZZOPLAST is of much importance.

9. POZZOPLAST:
 Pozzoplast is a specifically graded pozzolanic
material.
 Its a liquid additive plasticizer, whose main
characteristic is to improve the workability of fresh
concrete and reduce the amount of cement used for
a particular settlement.

10. STORAGE:
 DRY FORM – Pozzocrete should be stored in silos or
sealed containers/bags
 CONDITIONED FORM – when stored in stockpiles,
keep exposed surfaces damp. Small stockpiles may
be covered with sheeting

11. DISPOSAL CONSIDERATIONS:
 Pozzocrete has no special requirements for its disposal
at appropriately licensed facilities.
 It is a “Green List” material for transfrontier
shipment.

12. IMPROVED CHARACTERS OF
POZZOCRETE IN CONCRETE:
1. WORKABILITY: Pozzocrete is much lighter than
cement;cementitious paste is greater, this allows
for more effective coating of the aggregate.
2. DURABILITY: Pozzocrete increases resistance to
chemical and atmospheric conditions. Increases
protection for reinforcement.

13. 3. HEAT OF HYDRATION: Because only part of the
cementitious material reacts immediately with the
addition of water the heat generated by that chemical
reaction is also low.
4. SETTING TIME: Part of the cementitious binder is
not reacting immediately the rate of strength growth
in the early hours after placing is reduced – so the
concrete stiffens slower allowing more time for
working and compaction and more time to mix and
place more concrete.

14. AVAILABILITY AND ECONOMY:
 Pozzocrete products are available, depending on the
product grade, in 30 kg paper bags, 50 kg HDP bags.
The P-grades (with the exception of the P10 grade)
are only available in big-bags or in bulker.
 Cost saving (Nearly by Rs.28-30 per 50 kg OPC bag).

15. BENEFITS FOR ENGINEERS AND
ARCHITECTS:
 Pozzocrete produces a high strength concrete that
accommodates the design of thinner sections.
 It permits design flexibility accommodating curves,
arches and other pleasing architectural effects.
 It ensures that the concrete will qualify as a durable
building material.
 It contributes to the aesthetic
appearance of the concrete.

16. BENEFITS FOR DEVELOPERS,OWNERS
AND CONTRACTORS:
 Pozzocrete concrete ensures speed of construction is
faster, which translates into a quicker return on
investment.
 It accommodates more creative designs
in the mix and also ensures
low-maintenance
buildings that will retain their
value over the long-term

17. MAKING THE EARTH GREENER:
 One of the greatest benefits of utilizing fly ash is building
a greener future.
 Fly ash itself is a waste product and it is a huge problem
for disposal. From each power station, thousands of tons
of fly ash are dumped into the ash lagoons every day.
 When we replace every single ton of cement with fly ash,
we are not only eliminating waste from our planet but
also we are reducing the emission of 0.85 tons of CO2
into our atmosphere

18. CERTIFICATIONS AND PRODUCT
CONFIRMATIONS:
 Pozzocrete confirms to the
Indian standard
for fly ash in concrete
 It confirms to all European
and American standards
for fly ash in concrete
 It is produced in line with
the quality control regulations
of the Bureau of Indian Standard
and the Dubai Central Laboratory

19. CERTIFICATE OF COMPLIANCE:

20. CONCLUSION:
 Pozzocrete is and eco-friendly, economical material
which improves the impermeability, workability,
strength and durability of concrete both in fresh and
hardened state.
 Hence, its launched in India recently and is
appreciated by architects and engineers. The Govt. of
India is recommending its usage in all cement
applications.