DR - Mohamed Ali-UCLA Presentation

Overview
of
Practical and academic experience
Related to the role requirements
“Post-doctoral researcher - alkali silica reaction”
Introduced by:
Dr. Mohamed Ali
PhD in physical chemistry and building materials
Ain Shams University, Cairo, Egypt
1. Introduction
-In fact, based on my previous experience in the cement industry whether as a quality manager in the
local and multinational cement companies (National cement company, Kar cement group, CIF Angola
cimento, Italcementi and Heidelberg cement) or as a lecturer and postdoctoral researcher, I am confident
that my deep knowledge and experience in the cementitious materials will contribute in the role of the
job posted. My experience can be classified into:
1.1 Practical experience in the cement industry and concrete.
-In my work in the quality management system, I was responsible for quality control of the all raw
materials analysis such as: (Limestone, Clay, Iron Ore, Sand and Gypsum). Besides, complete chemical
analysis of clinker and cement via XRF followed by determination of free lime content , Chlorine
content, SO3 content and Cr(VI) via wet chemical methods. Furthermore, calibration and creation of new
applications in XRF apparatus was included in my duties. In addition, optimization of cement
characteristics by replacement of clinker with supplementary cementitious materials (SCM) such as:
(GBFS and pozzolana) also addition of chemical additives “ Grinding Aids” in the cement mill. In
addition, management of the lab technicians and chemists is under my accountability.
- Regarding to the quality assurance, I was responsible for preparation of report of water of consistency,
setting time, soundness, compressive strength and flexural strength of cement pastes and mortars.
Moreover, determination of the calorific value of the alternative fuels used instead of HFO such as: (RDF
and Biomass). Then, daily, weekly and monthly reports are delivered to the plant manager. Finally, I
have worked in RMC in the production department, was responsible for dry mix design.
- During my work in RMC, I was responsible for preparation of reports of concrete lab tests including
concrete standards tests such as: Compressive strength, workability test (using slump test and compacting
factor test) and alkali aggregate reaction through ASTM codes specific to ASR testing such as : (1) ASTM
C 289 Quick chemical test, (2) ASTM C 227 Mortar-bar method, (3) ASTM C 1260 Rapid Mortar- bar
test and (4) ASTM C 1293 Concrete prism test.
- Other lab test are embedded such as: (1) ASTM C 138 (concrete density), (2) ASTM C 1064 (concrete
temp.).
Description Testing material Test Standards/references
and
status
6–12 months duration is required. Mortar bars are stored Cement aggregate ASTM C 227
Mortar bar test
at 38°C under 100% relative humidity (RH) combination (ASTM, 2010)
Modified form of ASTM C 227 (ASTM, 2010), 14–28 d

Cement aggregate Accelerated ASTM C 1260
duration is required. Mortar bars are stored at 80°C under
combination mortar bar test (ASTM, 2014c)
100% RH in 1 N sodium hydroxide solution
Crushed material is sealed at 80°C in 1 N sodium

hydroxide solution for 24 h to measure the amount of Aggregate ASTM C 289
Quick chemical test
dissolved reactive silica. Results can be classified as (indirect method) (ASTM, 2003)
aggregate source is reactive or not
365 d are required. Specimens are placed at 38°C in

Concrete prisms ASTM C 1293
sodium hydroxide solution having alkali level of 1·25% Concrete prism test
(direct method) (ASTM, 2015d)
Na2Oe
1.2 Academic experience in the cement research
- In my master’s degree, I focused on elimination of cement production cost and reduction of CO 2
emission by replacement of clinker with supplementary cementing material (SCM) such as
(pozzolana (calcined clay/fired bricks) and ground blast furnace slag “GBFS” in presence and
absence of limestone) in order to obtain blended cements are employed for their economic and
ecological benefits. Then, production cost as well as CO 2 emission will be reduced. Furthermore,
the cement hydration characteristics improved especially at later ages of hydration as a result of
active silica of SCM react with Calcium hydroxide produced from hydration reaction of C 3S and
C2S with water to form additional CSH gel that contributes in reinforcement of cement strength
and resistance for the chemical attack particularly alkali silica reaction (ASR). Some selected
samples in various ages of hydration (2, 8, 28 and 90 days) are investigated via XRD and DTA .
- In my doctorate thesis, my research has been focused on the cement chemical additives named
“Grinding Aids” that are strongly adsorbed on the surface of cement ground particles, so that
preventing agglomeration and coating on ball and mill lining. The main purposes for their
addition are increasing the grindability of the cement and decrease the clinker content, thus
reduce CO2 emission. Furthermore, the compressive strength of the cement at early and late ages
of hydration are developed by 2-5 Mpa.
- Grinding aids used in this study were propylene glycol (PG), ethylene glycol (EG), tri ethanol
amine (TEA) and commercial grinding aid (CG). The ratios of grinding aids added were 0.03,
0.04 and 0.05 wt. % with respect to the dry cement. X-ray diffraction analysis (XRD), differential
thermal analysis (DTA) and Scanning Electron Microscope (SEM) for some selected samples
were carried out to investigate the morphology and phase composition of the formed hydration
products.
2. Research interest and achievements
My research interest has been focused on several subjects that can contribute in improvement and
development of both cement and concrete, this can be shown as the following:
2.1 Replacement of clinker with supplementary cementitious materials (SCM) such as: GBFS, Fly
ash , Silica fume and Pozzolana (natural or natural calcined) with addition of chemical admixtures
(Grinding Aids) to compensate the reduction in early strength, SCM can achieve several aims:
a. Contribute in strength enhancement of cement and concrete particularly in the late ages of hydration
due to reaction of aluminosilicates of pozzolana with the Portlandite (CH) liberated from hydration
reaction of alite (C3S) and belite (C2S) with water to form cementitious products CSH gel. According
to the equation:
2(Al2O3.2SiO2)+7Ca(OH)2 3CaO.2SiO2.H2O+2(2CaO.Al2O3.SiO2.H2O)
Aluminosilicate (Pozzolana) + CH C 2S3H2 + 2 C2 ASH
b. Decrease the permeability and chemical attack consequently Alkali-Silica Reaction (ASR).
c. Contributes in reduction of the CO2 emission due to lowering of clinker content.
d. Reduce the segregation, bleeding and heat f hydration.
e. Increase the workability of fresh concrete and Freezing-thawing.
2.2 Addition of chemical admixtures for concrete that can help in protection of concrete against the
ASR for over 10 years. To cite an example, Silane, Siloxance and lithium salts have been used before
in mitigation of ASR. ASR can be mitigated by reducing the pH of the pore solution and this has been
achieved by using low-alkali cements and/or SCMs.
2.3 Synthesis of chemical admixtures for other purposes in concrete. For example, I have produced a
chemical product that contributes in elongation of setting time and increase the workability and
durability of concrete named “ Retarder”.
3. Success Stories of my career in the cement plants
3.1 During my working as a Head of quality and development in CIF Cimento located in Angola
We have overcome the problem of high alkali content of the cement produced by optimization of the
raw materials used in the clinker production especially the raw materials are considered the main
source of the alkali like “ Clay and limestone” and this can be given as the following:
Case#1 The K2O and Na2O contents of clay (of raw mix design for raw mills ) had values of 1.23 and
1.73 respectively. While the K2O and Na2O content of limestone have the values 0.12 and 0.18
respectively.
And the raw mill proportions were: Limestone (81)%, Clay (18)%, Iron Ore (1)%,
- This mix gave Na2O eq. in clinker= 0.73 (> 0.60)
NOTE: Na2O equivalent = Na2O+ 0.658 K2O (Optimum < 0.60),
(where: M.Wt of Na2O/M.Wt of K2O= 62/94= 0.658).
Case#2 After optimization the raw materials of limestone and clay, we had K 2O and Na2O contents of
clay as 1.09 and 1.28 respectively and for limestone as 0.07 and 0.15 respectively,
And the raw mill proportions were: Limestone (81)%, Clay (18)%, Iron Ore (1)%,
- This mix gave Na2O eq. in clinker= 0.56 (< 0.60).
3.2 When I have worked in Kar cement plant located in Iraq.
Because the main factor affecting the CO 2 emission in the cement industry is the calcination process of
conversion CaCO3 to CaO and CO2. So, we have to find alternative raw materials to get the CaO in the
preheater and rotary kiln by using the lowest value of limestone in the raw mix design. To cite an
example, I have used a clay of high CaO content in the raw mix design instead of clay of low CaO
content and I have obtained the following results:
Case#1 (Before Improvement)

Using of Clay having low CaO content= (1.5-2.0)%
The raw mill proportions were: Limestone (76-80)%, Clay (19-23)%, Iron Ore (0-1)%,
Case#2 (After Improvement)
Using of Clay having high CaO content=(19-21)% is:
The raw mill proportions were: Limestone (62-65)%, Clay (34-37)%, Iron Ore (0-1)%,
Conclusion
- We get CaO required during calcination process in the rotary kiln to produce the clinker phases (C 3S,
C2S, C3A and C4AF) from the lower quantity of limestone. Thus, reduction of CO 2 emission can be
observed.
3.3 When I have worked in CIF Angola Cimento located in Angola
(a) I have studied the effect of addition of natural pozzolana imported from Madrid, Spain and I had got
the following positive results:
These results gave us a good information about the reactivity of the natural pozzolana and its ability to
increase the strength value from 7d to 28d higher than the OPC –CK control. Thus, development of
strength at later ages of hydration is notably. In addition, Blended cements assist in reduction of alkali
content. Where: (28d-7d) is the difference between the strength values at 28 d and the 7 d .
4. List of courses have been accomplished:
4.1 Management and technical courses

i) Six Sigma Green and Black Belt for process, quality and business improvement accredited from IQF.
ii) QMS and EMS based on ISO 9001:2015 and ISO 14001:2015 respectively.
4.2 Health and safety courses:
i) IOSH for managing safely.
ii) OSHA construction.
iii) OSHA general industries.
4.3 Communication skills development courses :
i) Methods of problem solving (Training & HR Development).
ii) Coaching and staff development skills from AB Management Consulting.
iii) The six circles of self-motivation from GOLD MINES (Training and Consulting).
5. Motivation statement
Over the years, I have been careful to focus on my own professional development. I have strong
communication and interpersonal skills; I am highly competent and I have experience in using
various data modeling techniques that can be used to achieve specific outcomes. Therefore, Based
on my experience due to my deep practical and academic knowledge in the cement industry and
concrete , if you hire me as a postdoctoral researcher , I feel you will be very satisfied with the
results obtained . I feel fully confident and I will get up and running in the position quickly and I
will always work with both you and my team to produce consistently positive results.

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Overview

1.1 Practical experience in the cement industry and concrete.

Modified form of ASTM C 227 (ASTM, 2010), 14–28 d

Crushed material is sealed at 80°C in 1 N sodium

365 d are required. Specimens are placed at 38°C in

Case#1 (Before Improvement)

4.1 Management and technical courses

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