Influence of fired clay brick waste additions on the durability of mortars

The use of metakaolin is known to help improve properties of Portland cement-based mortars. The presumed similarities between the characteristics of metakaolin and those of a powdered (<45 μm) fired clay brick clean waste (CBW) led to the investigation of the effect on the durability of mortars of partial replacement (10, 25 and 40 wt.%) of Portland cement by CBW. Properties such as 28 and 90 days-compressive strength, water absorption, apparent porosity, absorption by capillarity, chloride retention, carbonation depth and sulphate resistance were evaluated. The CBW-containing cured mortars showed improved strength and density, as the result of combined physical and pozzolanic pore filling effect of added CBW. However, CBW-free mortar exhibited larger spreading and, being more porous, higher sulphate resistance and ability to absorb chlorides. Optimum performance was found for the 40 wt.% CBW mortar whose compressive strength can be up to 130% higher than that of the CBW-free mortar.     

Compressive strength and drying shrinkage of fly ash-bottom ash-silica fume multi-blended cement mortars

This paper studies the physical properties, compressive strength and drying shrinkage of multi-blended cement under different curing methods. Fly ash, ground bottom ash and undensified silica fume were used to replace part of cement up to 50% by weight. Specimens were cured in air at ambient temperature, water at 25, 40 and 60 °C, sealed with plastic sheeting for 28 days. The results show that absorption and volume of permeable pore space (voids) of blended cement mortars at 28 day under all curing methods tend to increase with increasing silica fume replacement. The compressive strength of blended cement with fly ash and bottom ash was lower than that of Portland cement control at all curing condition while blended cement with silica fume shows higher compressive strength. In addition, the compressive strength of specimens cured with water increased with increasing curing temperature. The drying shrinkage of all blended cement mortar cured in air was lower than that of Portland cement control while the drying shrinkage of blended cement mortar containing silica fume, cured with plastic sealed and water at 25 °C was higher than Portland cement control due to pore refinement and high autogenous shrinkage. However, the drying shrinkage of blended cement mortar containing SF cured with water at 60 °C was lower than that of Portland cement control due to lower autogenous shrinkage and the reduced microporosity of C–S–H.     

Characterisation of ground hydrated Portland cement-based mortar as an additive to alkali-activated slag cement

The sustainable development of cement manufacturing requires extension of the raw material base, including large-tonnage waste. Hydrated mortar waste is a promising mineral resource for the production of Portland cements and alternative binders, such as alkali-activated slag cement. The influences of ground-hydrated mortar aged for 3 months on the properties of alkali-activated slag fresh and hardened pastes were performed. The results show that the properties are dependent on the concentration (2.5–60%), cement:sand ratio (1:1–3) and fineness (200–600 m²/kg) of the ground hydrated mortar; the alkali activator (sodium carbonate and sodium silicate); and the curing conditions (normal conditions and steam curing). The fresh paste properties that we considered in this study included the water requirement and the setting time; the hardened paste properties we considered were the water absorption, the density, and the compressive strength after 2, 7, 14, 28, 180 and 360 days of ageing. The ground hydrated mortar improved the early strength and the long-term strength of the alkali-activated slag paste and replaced the slag up to 50%. The factors that affecting the strength of the alkali-activated slag cement with ground hydrated mortar as an additive were, in order of influence, alkali activator type > curing conditions > cement:sand ratio > ground-hydrated mortar fineness.     

Influence of cement and aggregate type on thaumasite formation in concrete

In this study the influence of binder type on the formation of thaumasite in mortar prisms made with expanded clay lightweight aggregate (LWA) or quartz sand was examined. For this purpose mortar prisms were made, which after 28 days of curing in deionised water were exposed to a sulphate solution or deionised water. The length and weight change of the prisms was recorded in triplicate as a function of time of exposure to dry–wet cycles at 5 ± 1 °C.The influence of the binder type on the expansion in the sulphate solution can be ordered from strong to weak as follows: (1) CEM I + limestone filler, (2) CEM I, (3) CEM I + fly ash, and (4) CEM III/A. Because the porosity of the LWA was able to accommodate the growing sulphate crystals, the mortar prisms made with LWA were still largely intact after 3 years of exposure. The only exception being the mortar prisms containing limestone filler. The mortar prisms made with quartz sand and exposed to the sulphate solution were all bent, broken or disintegrated after 24 weeks. The prisms exposed to deionised water showed minimal expansion. Key factors controlling the formation of thaumasite are discussed.     

Microstructure and mechanical performance of modified mortar using hemp fibres and carbon nanotubes

Mechanical performance of modified mortar using hemp fibres is studied following various processing conditions. Hemp fibres combined with carbon nanotubes (CNT) are introduced in mortar and their effect is studied as function of curing time. The cement phase is replaced by different percentages of dry or wet hemp fibres ranging from 1.1 wt% up to 3.1 wt% whereas carbon nanotubes are dispersed in the aqueous solution. Our experimental results show that compressive and flexural strengths of wet fibres modified mortar are higher than those for dry hemp-mortar material. The achieved optimal percentage of wet hemp fibres is 2.1 wt% allowing a flexural strength higher than that of reference mortar. The addition of an optimal CNT concentration (0.01 wt%) combined with wet hemp has a reinforcing effect which turns to be related to an improvement of compressive and flexural strengths by 10% and 24%, respectively, in comparison with reference condition.     

A study on the effect of nano silica on compressive strength of high volume fly ash mortars and concretes

This paper presents the effect of nano silica (NS) on the compressive strength of mortars and concretes containing different high volume fly ash (HVFA) contents ranging from 40% to 70% (by weight) as partial replacement of cement. The compressive strength of mortars is measured at 7 and 28 days and that for concretes is measured at 3, 7, 28, 56 and 90 days. The effects of NS in microstructure development and pozzolanic reaction of pastes containing above HVFA contents are also studied through backscattered electron (BSE) image and X-ray diffraction (XRD) analysis. Results show that among different NS contents ranging from 1% to 6%, cement mortar containing 2% NS exhibited highest 7 and 28 days compressive strength. This NS content (2%) is then added to the HVFA mortars and concretes and the results show that the addition of 2% NS improved the early age (7 days) compressive strength of mortars containing 40% and 50% fly ash by 5% and 7%, respectively. However, this improvement is not observed at high fly ash contents beyond 50%. On the other hand, all HVFA mortars exhibited improvement in 28 days compressive strength due to addition of 2% NS and the most significant improvement is noticed in mortars containing more than 50% fly ash. In HVFA concretes, the improvement of early age (3 days) compressive strength is also noticed due to addition of 2% NS. The BSE and XRD analysis results also support the above findings.     

Efficiency of ground granulated blast-furnace slag replacement in ceramic waste aggregate mortar

From our previous findings, the recycling of ceramic waste aggregate (CWA) in mortar has been proved an ecological means plus an excellent outcome against chloride ingress. The CWAs were porcelain insulator wastes supplied from an electric power company, which were crushed and ground to fine aggregate sizes. In this study, to further develop the CWA mortar as an eco-efficient construction material, ground granulated blast-furnace slag (GGBS) was incorporated. The slag (having the Blaine fineness of 6230 cm²/g) was utilized as a supplementary cementitious material (SCM) at three different replacement levels of 15%, 30%, and 45% of cement by weight. The efficiency of the GGBS on enhancing chloride resistance in the CWA mortars was experimentally assessed by using a silver nitrate solution spray method and an electron probe microanalysis (EPMA). The tests were carried out on mortar samples after immersed in a 5.0% NaCl solution for 24 weeks. Another set of the mortar samples was exposed to a laboratory ambient condition for 24 weeks and then followed with a carbonation test. The test results indicated that the resistance to the chloride ingress of the CWA mortar becomes more effective in proportion to the replacement level of the GGBS. In contrast, the carbonation depth of the CWA mortar increases with the increase of the GGBS. The activeness of the GGBS was also evaluated on the basis of the compressive strength development up to 91 days. Due to its high fineness, the GGBS can be used up to 30% while the high relative strength (more than 1.0) is achieved at all ages.     

Reuse of water purification sludge as raw material in cement production

The feasibility of partial replacement of siliceous raw material for cement production with water purification sludge (WPS) was investigated by X-ray diffraction, free-lime analysis, compressive strength testing and toxicity characteristics leaching procedure (TCLP). It is found that WPS has no negative effects on the consumption of free lime and the formation of clinker minerals. The samples with WPS from 4 to 10 wt.% have higher 3 days and 7 days strengths than the control. After 28 days, however, only WPS replacements <7% increased the strength of samples. It is noteworthy that heavy metals in WPS were almost completely incorporated into the clinkers, and up to 28 days the heavy metals were not detected in the leachates. From the above results of clinker minerals, compressive strength and leaching tests, it can be concluded that WPS has the potential to be utilized as an alternative raw material in cement production.     

Free,restrained and drying shrinkage of cement mortar composites reinforced with vegetable fibres

Many investigations are realized to establish the basic mechanical properties of vegetable fibre reinforced composites (VFRC) but not their shrinkage and creep behaviour. Some works have been realized to establish the shrinkage of cement mortar matrices reinforced with cellulose fibres, but very few results has been published with regards to shrinkage of VFRC with short sisal and coconut fibres. In this paper a concise summary of several investigations is presented to establish the influence of sisal and coconut fibres on the free and restrained plastic shrinkage, early drying shrinkage cracking, crack self-healing and long-term drying shrinkage of mortar matrices. The free and restrained shrinkage were studied by subjecting the specimens to wind speed of 0.4–0.5 m/s at 40 °C temperature for up to 280 min. The self healing of cracks of the VFRC was studied by using the same specimens as for the study of restrained shrinkage which were kept further in a controlled environment with 100% relative humidity and temperature of 21 °C for up to 40 days. Drying shrinkage tests were carried out at room temperature with about 41% relative humidity for 320 days. The influence of curing method, mix proportions and partial replacement of ordinary Portland cement (OPC) by ground granulated blast-furnace slag and silica fume on the drying shrinkage of VFRC was also investigated. Finally, based on the obtained results on drying shrinkage an equation using the recommendation of ACI model B3 was adjusted and compared well with the obtained experimental data.     

Alkali-activated cements and mortars based on blast furnace slag and red clay brick waste

This study investigates the effects of adding various concentrations, sources and compositions of ground red clay brick waste (RCBW) on the properties of fresh and hardened pastes and mortars of alkali-activated slag. The method used to grind the granulated blast furnace slag (GBFS) and RCBW (separate and conjoint) is also assessed, along with the fineness (300–900 m²/kg) of the blended alkali-activated GBFS-RCBW cement, the alkali activator (sodium carbonate or sodium silicate) and the curing conditions (normal conditions or steam curing). The water requirement and setting time for the fresh pastes are also considered; and in the case of the hardened paste and mortar, the water absorption, density and compressive/flexural strength are measured after 1, 3, 7 and 28 days of aging. From the results obtained, it is demonstrated that the addition of 40% RCBW improves the 7- and 28-day strength of blended alkali-activated slag pastes and mortars, and can replace up to 60% of the slag without losing strength.     

Statistical analysis for freeze–thaw resistance of cement mortars containing marble dust and glass fiber

This paper investigated the usability of marble dust and glass fiber against the harmful effects of freeze–thaw (FT) cycles on cement mortars as experimentally and statistically. To this end, the cement mortar specimens containing marble dust (0%, 20%, 40% and 50% by volume) and glass fiber (0 kg/m³, 0.25 kg/m³, 0.50 kg/m³, 0.75 kg/m³) were prepared. The compressive and flexural strengths of the specimens were determined after being exposed to FT cycles. In order to reduce the numbers of experiments, an L₁₆ (4² × 2¹) Taguchi orthogonal array was adopted to the study. Amounts of glass fiber, percentages of marble dust and cycles of freeze–thaw, were changed to explore their effects on the compressive and flexural strengths of the mortar specimens. Statistically effects of the factors were also determined by using analysis of variance (ANOVA) method. Finally, experimental findings were compared with statistical results and a good agreement between them was achieved.     

Grey correlation analysis between strength of slag cement and particle fractions of slag powder

The particle size distributions of slag powder were investigated by Laser Scatter equipment. The influence of particle fractions of slag powder on the compressive strength of slag cement composed of 50% slag powder and 50% Portland cement was also studied by the method of grey correlation analysis. The results indicated that the volume fraction of particles 5–10 μm had a maximum positive effect on the mortar compressive strength of slag cement at 7 d and the volume fraction of particles 10–20 μm had a maximum positive effect on the mortar compressive strength at 28 d, whereas the volume fraction of particles larger than 20 μm had a negative effect on the mortar compressive strength at 7 and 28 d.     

Coupled effects of sulphate and temperature on the strength development of cemented tailings backfills: Portland cement-paste backfill

Cemented paste backfill (CPB), which is a mix of tailings, water and cement, is subjected to the combined actions of temperature and sulphate during its service life. There is a need to acquire solid knowledge on the coupled effects of temperature and sulphate on the strength of CPBs for a safe, durable and cost-effective design of CPB structures. Hence, the main objective of this paper is to use an experimental approach to study the combined effect of temperature and sulphate on the strength development and microstructure (mineralogical composition of the hardened cement paste) of CPBs. About 200 CPB specimens with various initial sulphate contents (0, 5000, 15,000, and 25,000 ppm) and cured at different temperatures (0 °C, 25 °C, 20 °C, 35 °C, and 50 °C) are tested at different curing times (28, 90, and 150 days). The results show that the coupled effect of temperature and sulphate has a significant impact on the strength and mineralogical composition of the CPB. Depending on the curing time, temperature and initial sulphate content, the sulphate can have a positive or negative impact, i.e., leads to an increase or decrease of CPB strength. The obtained results show a strong indication that the absorption of sulphate by calcium–silicate–hydrate (C–S–H) could lead to the formation of lower quality C–S–H, thereby decreasing the strength of the CPB. This study has demonstrated that the coupled effect of sulphate and temperature on CPBs is an important factor for consideration in the designing of cost-effective, safe and durable CPB structures.     

Bentonite as a natural additive for lime and lime–metakaolin mortars used for restoration of adobe buildings

This work estimates the behaviour of mortars based on lime, seeking their application as renders of adobe walls. Mortars with binder:aggregate 1:3 volumetric ratio were prepared as is traditionally used in old buildings in central parts of Portugal.Due to specificity of the support, two clays, natural clay bentonite (5 wt.%) and artificial clay metakaolin (20 wt.%) were used as additives to lime mortar to prepare 3 types of blended mortars, besides the air lime reference mortar. Mortar prisms 4 × 4 × 16 cm were analysed to assess mechanical properties and salt resistance. Moreover, the mortars were placed in three ways on old adobes taken from demolished houses and their behaviour was verified by artificial accelerated ageing test. Lastly, mortars were applied on a wall made from traditional adobes, where panels were monitored and trials with adhesion strength and Karsten tubes have been conducted. The results obtained by comparison of the characteristics from all the experimental procedures reveal that mortar containing air lime and 5 wt.% of bentonite fulfils in the best way the requirements in its use as render of adobe buildings.     

Electrostatic self-assembled carbon nanotube/nano carbon black composite fillers reinforced cement-based materials with multifunctionality

Electrostatic self-assembled carbon nanotube (CNT)/nano carbon black (NCB) composite fillers are added into cement mortar to fabricate smart cement-based materials. The grape bunch structure of CNT/NCB composite fillers is beneficial for dispersing CNT/NCB in cement mortar matrix and achieving cooperative improvement effect. The mechanical, electrically conductive, and piezoresistive behaviors of the cement mortar are investigated. The CNT/NCB composite fillers can effectively enhance the flexural strength and electrical conductivity of cement mortars, and endow stable and sensitive piezoresistivity to cement mortar at a low filler content. However, they weaken the compressive strength of cement mortar to some extent. The percolation threshold zone of cement mortar with CNT/NCB composite fillers ranges in the amount of 0.39–1.52 vol.%. The optimal content of CNT/NCB composite fillers is 2.40 vol.% for piezoresistivity and the stress and strain sensitivities can reach 2.69% MPa⁻¹ and 704, respectively.     

Compressive strength and chloride resistance of self-compacting concrete containing high level fly ash and silica fume

The influence of high-calcium fly ash and silica fume as a binary and ternary blended cement on compressive strength and chloride resistance of self-compacting concrete (SCC) were investigated in this study. High-calcium fly ash (40–70%) and silica fume (0–10%) were used to replace part of cement at 50, 60 and 70 wt.%. Compressive strength, density, volume of permeable pore space (voids) and water absorption of SCC were investigated. The total charge passed in coulombs was assessed in order to determine chloride resistance of SCC. The results show that binary blended cement with high level fly ash generally reduced the compressive strength of SCC at all test ages (3, 7, 28 and 90 days). However, ternary blended cement with fly ash and silica fume gained higher compressive strength after 7 days when compared to binary blended fly ash cement at the same replacement level. The compressive strength more than 60 MPa (high strength concrete) can be obtained when using high-calcium fly ash and silica fume as ternary blended cement. Fly ash decreased the charge passed of SCC and tends to decrease with increasing fly ash content, although the volume of permeable pore space (voids) and water absorption of SCC were increased. In addition when compared to binary blended cement at the same replacement level, the charge passed of SCC that containing ternary blended cement was lower than binary blended cement with fly ash only. This indicated that fly ash and silica fume can improve chloride resistance of SCC at high volume content of Portland cement replacement.     

Cemented paste backfill of sulphide-rich tailings: Importance of binder type and dosage

In this study, the influence of binder type and dosage on the mechanical properties and microstructure of cemented paste backfill (CPB) was investigated using ordinary Portland cement (OPC), Portland composite cement (PCC) and sulphate resistant cement (SRC). The CPB samples of OPC and PCC were observed to lose their unconfined compressive strengths (UCSs) after 56 days. This could be associated with the sulphide moiety of the tailings, i.e. the attack on hydration products by sulphate and acid internally generated via the oxidation of pyrite present. In this respect, those CPB samples of sulphate resistant-based cements (SRC and a mix of OPC and SRC) maintained good long-term strengths and stability (i.e. no loss of strength). Increasing binder dosage (5–7 wt.%) improved the UCSs of CPB samples up to 1.9-fold with no loss of strength at >5 wt.%. Decreasing water-to-cement ratio appeared to produce a beneficial effect on the UCSs of CPB samples. SEM studies have provided further insight into the microstucture of CPB and confirmed the deleterious formation of gypsum as the expansive phase. These findings have demonstrated the practical importance of binder type/dosage and water-to-cement ratio for the short- and long-term mechanical performance of CPB.     

Carbonation of ternary building cementing materials

The carbonation processes of ettringite and calcium aluminate hydrates phases developed by hydration of calcium aluminate cement, fly ash and calcium sulphate ternary mixtures have been studied. The hydrated samples were submitted to 4% of CO₂ in a carbonation chamber, and were analysed, previous carbonation and after 14 and 90 days of carbonation time, by infrared spectroscopy and X-ray diffraction; the developed morphology was performed with the 14 days carbonated samples. The results evidenced that ettringite reacts with CO₂ after 14 days of exposition time and evolves totally at 90 days; the developed hydrated phases C₃AH₆ in samples with major CAC content, also reacts with CO₂. Due to carbonation, calcium carbonate – mainly vaterite but also aragonite-, depending on the initial formulation, aluminium hydroxide and gypsum were detected.     

Durability of very high volume fly ash cement pastes and mortars in aggressive solutions

The resistance of very high volume fly ash cement pastes and mortars activated by Na₂SO₄ has been monitored following immersion for up to 90 d in 0.1 M HCl, 4.4% Na₂SO₄ and ASTM-compliant sea water. Changes in the compressive strengths of mortars and in crystalline phases, bond environments, and the microstructure of pastes following immersion were monitored. Experiments were repeated with a commercially available sulfate resistant cement. Both cements were found to present adequate resistance to both sea water and the Na₂SO₄ solution. However, both were severely degraded by acid immersion. Differences in potential degradation mechanisms based on the chemistry of the fly ash binder and the reference cement are discussed.     

Impact of hardening conditions on to stabilized/solidified products of cement–sewage sludge–jarosite/alunite

The main objective of this work is to investigate a viable alternative for the final disposal of sewage sludge from urban wastewater treatment plants using a mixture with cement and jarosite/alunite (J/A) precipitate to develop new construction materials. J/A precipitate is a waste product of a new hydrometallurgical process, which was developed in order to treat economically low-grade nickel oxide ores. In the current study two methods were used for the hardening of the stabilized/solidified products: (1) in laboratory conditions and (2) in accelerated conditions (autoclave treatment).For this purpose, mortar prism samples of 4 × 4 × 16 cm in dimension were prepared, composed of 50% sewage sludge, 30% cement and 20% jarosite/alunite. The samples were treated in an autoclave for 3 h at a temperature of 200 °C and a pressure of 16 bar as well as in laboratory conditions for 28 and 90 days. Compressive and bending strength, while chemical, XRD, thermal analysis, as well as tests of leaching, were tested according to the standard/principal methods of toxicity characteristics leaching procedure (TCLP) and CEN/TS 14405. The results indicated that stabilized/solidified products can be produced for use in construction and that the heavy metals of sludge can be contained in the cement and jarosite/alunite mixture.