A Quality Control Scheme for a Commercial Pozzolana Plant: A Case Study of Pozzolana Ghana Ltd

Abstract

A Quality control scheme was developed for a 200 ton per day commercial pozzolana plant. The scheme was evaluated for the first 34 days of production. Statistical Process Control tech­niques were specifically applied to the mechanical properties of setting times and compressive strength. Results obtained showed that pozzolana samples tested were chemically suitable with total SiO2, Al2O3 and Fe2O3 content ≥ 70%. Mechanical tests performed were mostly under control and when out-of-control, they gave valuable indication to plant malfunction or operator errors which were promptly corrected. The results of mechanical properties tested against the three major brands of cement on the Ghanaian market showed that pozzolana gave highest compressive strengths with Dangote CEM I 42.5R ranging between 21.3 MPa - 36.3 MPa at 7 days and 33.8 MPa - 45.1 MPa at 28 days whilst lowest compressive strengths were obtained with Ghacem CEM II B-L 32.5R cement ranging between 16.3 MPa – 23.6 MPa at 7 days and 23.3 MPa – 30.7 MPa at 28 days. Compressive strengths obtained with Diamond CEM II B-L 42.5N cement were average. A mean compressive strength for all brands of ce­ment of 25.2 MPa and 33.6 MPa at 7 days and 28 days respectively were obtained.

Keywords: Pozzolana cement, statistical process control, Shewhart chart, compressive strength, setting time