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African cement infrastructure is quite complex. Apart from Northern Africa and South Africa in particular, cement plants are scarce resulting in highly unstable cement pricing. Clinker and cement are imported from overseas, e.g. from Portugal, Turkey, Pakistan, Indonesia, and China. Imports are typically determined by the lowest price, and as a result the countries of origin of products vary regularly yielding large scatter of properties. Quality control and a good quality infrastructure are thus of utmost importance for the safety of the populace, an issue, which is actually often neglected. With funding of the German Metrology Institute (PTB) and support of the SPIN project, a proficiency testing scheme for cement testing according to EN 196 was set up for African laboratories. Proficiency testing schemes, also called round robins, are inter-laboratory performance comparisons allowing participants to evaluate themselves against pre-established criteria. They are a powerful tool to help laboratories improve their performance as well as demonstrate their competences to accreditation bodies or customers. 26 laboratories from 20 nations, 18 of which from Africa, participated. The BAM Federal Institute for Materials Research and Testing acted as coordinator and provider of the scheme. The aim of the round robin was to interpret the submitted data further beyond the pure statistic analyses. The data provided a positive picture of the performance of the participants in general, but it also exhibited a number of technical fields that need improvement. The paper provides the general results of the scheme and analyses identified strengths and weak points based on the submitted and non submitted data as well as on discrepancies from the EN 196 procedures during measurements. The application of EN standards for material testing is critically discussed and since quality infrastructure is also always an issue between industrial and political stakeholders, suggestions for the mitigation of the identified shared problems are given.
South Africa and recently Nigeria are the only net exporter of cement in Africa, yet cements are imported into the country mainly on the basis of price competitiveness. This poses potential for scatter in the properties of the cements in the South African market as pricing seems to be the only determining factor that affects Portland cements imported. A survey of cements of grade 42.5N in the South African cement market was carried out to identify major players in the industry. The identified cements, which included four locally produced and one imported cement were then analysed for both chemical composition and physical properties in line with the Eurocode EN 196. Tests carried out include loss on ignition, chloride content, sulphate content, specific surface (Blaine), standard consistence, initial setting time, final setting time, soundness and flexural and compressive strength at 2, 7 and 28 days. The testing program was initiated as part of on-going Africa-wide cement testing competency program in partnership with BAM and PTB in Germany. The performance of the identified cements from the different local manufacturers and the imported cement were analysed and are presented in this paper. These results reveal some similarities and differences in the properties. Particularly of interest is the marked difference in the 28 days compressive strength of the cements. This paper shows that there is need for further tests across the cement industry as some of the cements failed to meet certain requirement as set by EN 196. The paper also recommends the use of proficiency testing schemes in the cement industry of the country to ensure the cement laboratories are providing results of high quality and at the same time act as a check to make sure these laboratories are not failing to meet standard requirements.
The African cement, concrete and construction business are growing at rapid pace. The cement sales are expected to grow tremendously until 2050. The number of newly built cement plants increases dramatically and in addition more cements are being imported from outside the continent, e.g. from Turkey, Pakistan, Indonesia, and China, driven by overcapacities in the countries of origin. This causes a high number of potentials and challenges at the same time. New cement plants can operate directly at best technological state of the art and thus incorporate more sustainable technologies as well as produce new and more sustainable products such as cements blended with sustainable supplementary cementitious materials such as calcined clays, and industrial or agricultural by products. At the same time the new variety of binding agent as well as the international imports, which are driven by price considerations, make the cement market prone to quality scatter. This puts pressure on the quality control regulations and institutions to ensure safety of construction, healthy application, and environmental safety for the population.
The paper presents possible solutions to build up the rapidly increasing African cement production more sustainably than in the rest of the world as well as the related challenges and obstacles that need to be overcome. Based on experiences with a series of pan-African cement testing laboratory proficiency schemes conclusions are made on technical, regulative and political level.
The cement proficiency testing (PT) scheme was set up by the German Metrology Institute (PTB) and the Federal Institute for Materials Research and Testing (BAM) in 2012. The PT scheme was a spin-off from a European Commission and African, Caribbean and Pacific-Group of States funded project entitled SPIN – Spearhead Network for Innovative, Clean and Safe Cement and Concrete Technologies (www.spin.bam.de). The SPIN project aimed at crosslinking experts in industry and policy making bodies, with the prospect of establishing a sustainable cement and concrete construction capacity in Africa.
After a successful first pan-African proficiency testing scheme in 2012/2013, it was decided to establish the scheme permanently and independent of the SPIN project.
The main focus of setting up a testing scheme was to enable all cement testing laboratories in Africa to evaluate their competence and efficiency in cement testing and further enhance their capacity to obtain better quality products according to their environment. The acronym developed for the PT scheme is PACE-PTS (Pan-African Cement Proficiency Testing Scheme). The framework for the PT scheme was set up jointly among the organisers and the first participants. The first PT scheme was initiated in Dar Es Salaam in 2012 followed by a final workshop in Berlin in 2013. The second PT scheme began in 2014. A final workshop was organised in Dar es Salaam in 2015. The third and current scheme was started in 2016 and the final workshop is held in Yaoundé.