Effect of activated coal mining wastes on the properties of blended cement

The large volumes of coal waste generated world-wide in mining operations are mostly deposited in refuse dumps, to the severe detriment of the surrounding groundwater and soil. After calcination under controlled conditions, this waste has been shown to exhibit high pozzolanicity, making it apt for use as an addition in the manufacture of blended cements.The present paper describes the first detailed study designed to evaluate the behavior of coal tailings from different sources. After activation at 650 °C for 2 h, this waste was used to manufacture blended cements containing 10 and 20 wt.% of the addition. Inclusion of this pozzolan did not affect the initial setting time, although the compressive strength of the blended mortars declined, by 4.7–8.3% in the 10% and by 9.76–14.9% in the 20% material. Nonetheless, the activated carbon waste (ACW) blends complied with all the requirements for Type II/A cement in the existing European legislation.     

Physico-mechanical properties and water absorption of cement composite containing shredded rubber wastes

The main objective of this study was to investigate the potential utilisation of rubber waste in cementitious matrix, as fine aggregates, to develop lightweight construction materials. Composites containing different amounts of rubber particles, as partial replacement to cement by volume, were characterised by destructive and non-destructive testing. Five designated rubber contents varying from 10% to 50% by volume were used. The 28-days physical, mechanical and hydraulic transport properties of the cement composite were determined. Analyses included dry unit weight, elastic dynamic modulus, compressive and flexural strengths, strain capacity, and water absorption. Test results of the physico-mechanical behaviour indicated that the increase in rubber content decreases the sample unit weight with a large reduction in the strengths and elastic modulus values of the composites. Results have only shown that the introduction of rubber particles significantly increases the strain capacity of the materials. However, rubbers into cement paste enhances the toughness of the composite. Although the mechanical strengths were reduced, the composite containing 50% of rubber particles satisfies the basic requirement of lightweight construction materials and corresponds to “class II”, according to the RILEM classification. Test-results of the hydraulic transport properties revealed that the addition of rubber particles tends to restrict water propagation in the cement matrix and reduces water absorption of the composite. The decrease of the sorptivity-value is favourable to the durability of the specimen structures.     

Hydration and properties of nano-TiO2 blended cement composites

Two types of nano-TiO₂ particles were blended into cement pastes and mortars. Their effects on the hydration and properties of the hydrated cement pastes were investigated. The addition of nano-TiO₂ powders significantly accelerated the hydration rate and promoted the hydration degree of the cementitious materials at early ages. It was demonstrated that TiO₂ was inert and stable during the cement hydration process. The total porosity of the cement pastes decreased and the pore size distribution were also altered. The acceleration of hydration rate and the change of microstructure also affected the physical and mechanical properties of the cement-based materials. The initial and final setting time was shortened and more water was required to maintain a standard consistence due to the addition of the nano-TiO₂. The compressive strength of the mortar was enhanced, practically at early ages. It is concluded that the nano-TiO₂ acted as a catalyst in the cement hydration reactions.     

Immobilization of low and intermediate level of organic radioactive wastes in cement matrices

The adequacy of cement-clay composite, for solidification/stabilization of organic radioactive spent liquid scintillator wastes and its resistance to frost attack were determined by a freezing/thawing (F/T) test. Frost resistance is assessed for the candidate cement-clay composite after 75 cycles of freezing and thawing by evaluating their mass durability index, compressive strength, apparent porosity, volume of open pores, water absorption, and bulk density. Infrared (IR), X-ray diffraction (XRD), differential thermal analysis (DTA), thermal gravimetric analysis (TGA) and scanning electron microscopy (SEM) were performed for the final waste form (FWF) before and after the F/T treatment to follow the changes that may take place in its microstructure during the hydration regime. The results were obtained indicate that the candidate composite exhibits acceptable resistance to freeze/thaw treatment and has adequate suitability to solidify and stabilize organic radioactive spent liquid scintillator wastes even at very exaggerating conditions (-50°C and +60°C).     

Properties of binary and ternary blended cement mortars containing palm oil fuel ash and metakaolin

Abstract

This paper has investigated the properties of mortars made from binary and ternary blends of metakaolin (MK), palm oil fuel ash (POFA), and ordinary Portland cement (OPC). A total of 17 different mortar mixtures were produced. The OPC in the mixtures was partially replaced by MK, POFA, or a combination of MK and POFA at different replacement levels of (0–30%) by weight of the binder. At the fresh state, the flow (workability) of mortar mixtures was determined, while at the hardened state, the compressive strength and porosity at the ages of 7, 28, and 90 days were evaluated. The results showed that the flow of mortar is boosted with the combined use of MK and POFA compared to when MK is separately used. Besides, improvement in low early compressive strength development and reduction in high porosity from use of POFA occurred with the addition of up to 10% MK content. Therefore, the combination of POFA and MK could be used as a supplementary cementitious material to produce cement-based material of higher quality than OPC.     

Flash-calcined dredging sediment blended cements: effect on cement hydration and properties

Dredging of docks and waterways generates a large and continuous supply of sediments currently destined for disposal. Transforming this currently wasted materials into new resources still requires meeting technical challenges. One of the options is to process the sediments into a supplementary cementitious material by flash-calcination. This paper describes the effect of cement replacement by flash-calcined dredged sediments on cement hydration and key properties. The hydration kinetics, products and microstructure are studied to explain changes in cement properties such as compressive strength development and workability. The flash-calcined dredging sediments show clear pozzolanic activity which surpasses that of typical coal combustion siliceous fly ash (V, EN 197-1). This is manifested in (1) the rate of compressive strength development, (2) reduced portlandite and (3) increased ettringite and bound water contents. The results show that calcination can transform wasted dredging sediments into a new supplementary cementitious resource for producing large volumes of low-CO₂ blended cements.     

Characterization of green composites from biobased epoxy matrices and bio-fillers derived from seashell wastes

The seashells, a serious environmental hazard, are composed mainly by calcium carbonate, which can be used as filler in polymer matrix. The main objective of this work is the use of calcium carbonate from seashells as a bio-filler in combination with eco-friendly epoxy matrices thus leading to high renewable contents materials. Previously obtaining calcium carbonate, the seashells were washed and grinded. The powder obtained and the resin was characterized by DSC, TGA, X-ray diffraction (XRD), X-ray fluorescence spectroscopy (XRF), and rheology plate-plate. The results show that addition of 30 wt.% of seashell bio-filler increase mechanical properties as flexural modulus (over 50%) and hardness Shore D (over 6%) and thermal properties as an increase around 13% in glass transitions temperature. The results show that the addition of calcium carbonate from seashells is an effective method to increase mechanical properties of bio-composite and to reduce the residue of seashells from industrial production.     

Properties of self-compacting portland pozzolana and limestone blended cement concretes containing different replacement levels of slag

In order to reduce energy consumption and CO₂ emission, and increase production, cement manufacturers are blending or inter-grinding mineral additives such as slag, natural pozzolana, and limestone. This paper reports on the results of an experimental study on the production of self-compacting concrete (SCC) produced with portland cement (PC), portland pozzolana (PPC) and portland limestone (PLC) blended cements. Moreover, the effect of different replacement levels (0–45%) of ground granulated blast furnace slag (GGBFS) with the PPC, PLC, and PC cements on fresh properties (such as slump flow diameter, T ₅₀₀ slump flow time, V-funnel flow time, L-box height ratio, setting time, and viscosity) and hardened properties (such as compressive strength and ultrasonic pulse velocity) of self-compacting concretes are investigated. From the test results, it was found that it was possible to manufacture self-compacting concretes with PPC or PLC cements with comparable or superior performance to that of PC cement. Furthermore, the use of GGBFS in plain and especially blended cement self-compacting concrete production considerably enhanced the fresh characteristics of SCCs.     

Sulfate resistance of plain and blended cement

This paper presents a laboratory study on the sulfate resistance of blended cement combination of reference Portland cement with high volume ground granulated blast-furnace slag (GGBS) and natural pozzolan (NP). The exposure solutions were tap water containing 5% magnesium sulfate solution and 5% sodium sulfate solution. Two types of grinding method (separately grinding and intergrinding, two finenesses (250 m²/kg and 500 m²/kg) and three different proportions (10%, 20%, and 30% by weight of mixture)) of each of two different additives (GGBS and NP) in equal amounts were employed. In addition to these blends, plain Portland cements without additives were prepared as references specimens. Standard Rilem sample size (40 mm × 40 mm × 160 mm) was used for the experimental study.It was observed that the sulfate resistances of blended cements were significantly higher both against sodium sulfate and magnesium sulfate attacks than references cement. Final strength reductions for finer mixes attacked by magnesium sulfate were marginally lower than those attacked by sodium sulfate. On the other hand, no particular relation was found between the sulfate resistance of the mortars and the grinding methods.     

The influence of superabsorbent polymers on strength and durability properties of blended cement mortars

The effect of different quantities of admixed superabsorbent polymers (SAP) on durability and strength properties of normal strength mortars containing various binary cement blends was investigated. Addition of SAP did not significantly affect compressive strength, although a slight retardation of strength development was observed in mortars with higher w/b ratio. Tensile strength values were generally slightly improved with the use of SAP. Durability was assessed by measuring porosity, oxygen permeability, chloride conductivity, accelerated carbonation, and bulk diffusion. The generally improved durability properties, especially for mortars containing silica fume, indicates the potential to use SAP to design high quality concrete repair mortars.     

Micro-structural development of gap-graded blended cement pastes containing a high amount of supplementary cementitious materials

To clarify the strength improvement mechanism of gap-graded blended cements with a high amount of supplementary cementitious materials, phase composition of hardened gap-graded blended cement pastes was quantified, and compared with those of Portland cement paste and reference blended cement (prepared by co-grinding) paste. The results show that the gap-graded blended cement pastes containing only 25% cement clinker by mass have comparable amount of gel products and porosity with Portland cement paste at all tested ages. For gap-graded blended cement pastes, about 40% of the total gel products can be attributed to the hydration of fine blast furnace slag, and the main un-hydrated component is coarse fly ash, corresponding to un-hydrated cement clinker in Portland cement paste. Further, pore size refinement is much more pronounced in gap-graded blended cement pastes, attributing to high initial packing density of cement paste (grain size refinement) and significant hydration of BFS.     

Influence of key cement chemical parameters on the properties of metakaolin blended cements

The use of metakaolin (MK) as a mineral admixture for cement and concrete is a well-documented practice. The properties of cement pastes and mortars containing MK have been investigated as a function of key cement chemical parameters recognized as potential activators of the MK. Rheological behavior, initial setting time and compressive strength development have been compared by varying the total sulfate content, the nature of the added calcium sulfate and the free lime content (in the form of portlandite) in the cement. The results obtained indicate that it exists a compromise for the ratio performance/consistency in term of sulfate content and nature. Concurrently, a small addition of portlandite improves the consistency of the properties investigated.     

Susceptibility of Portland cement and blended cement concretes to plastic shrinkage cracking

The market share of different types of blended cements is increasing year by year. Generally, blended cements are ground to higher fineness and exhibit a slower development of mechanical properties compared to Ordinary Portland Cement (OPC), which might affect the concrete performance in terms of shrinkage cracking at early ages.In this paper, the performance of concretes made with different cement types is compared according to the ASTM C1579-13 standard for plastic shrinkage cracking. The cracking behavior was further correlated to the deformations of both unrestrained and restrained specimens measured by a 3D image correlation system. The main factors influencing the cracking behavior were discussed based on poromechanics. It is concluded that the bulk modulus evolution has a dominant effect on controlling the plastic shrinkage cracking. Concretes made of more reactive cements, in particular with higher clinker content, are less susceptible to plastic shrinkage cracking. For cements with the same clinker content, increasing the cement fineness reduces the risk of plastic shrinkage cracking.     

Solidification/stabilization of arsenic containing solid wastes using portland cement, fly ash and polymeric materials

Stabilization/solidification (S/S) is used as a pre-landfill waste treatment technology that aims to make hazardous industrial wastes safe for disposal. Cement-based solidification/stabilization technology is widely used because it offer assurance of chemical stabilization of many contaminants and produce a stable form of waste. The leaching behavior of arsenic from a solidified/stabilized waste was studied to obtain information about their potential environmental risk. Activated alumina (AA) contaminated with arsenic was used as a waste, which was stabilized/solidified (S/S) using ordinary portland cement (C), fly ash (FA), calcium hydroxide (CH) and various polymeric materials such as polystyrene and polymethyl methacrylate (PMMA). Toxicity characteristics leaching procedure (TCLP) and semi-dynamic leach tests were conducted to evaluate the leaching behavior of arsenic. Formations of calcite along with precipitate formation of calcium arsenite were found to be responsible for low leaching of arsenic from the stabilized/solidified samples. Effective diffusivity of arsenic ion from the matrix and leachablity index was also estimated. Minimum leaching of the contaminant was observed in matrix having AA+C+FA+CH due to the formation of calcite.     

Simulation of silica fume blended cement hydration

A model is proposed in this paper to simulate silica fume (SF) blended cement hydration based on the kinetics, stoichiometry and physical chemistry of cement hydration and pozzolanic reaction. The pozzolanic reaction degree, volume fraction of hydration products, capillary porosity and gel porosity can be obtained from model simulation. By using proper amount of silica fume replacement, the microstructure of silica fume blended cement paste is improved since the volume fraction of C-S-H gel is increased, Ca(OH)₂ content and capillary porosity are decreased due to pozzolanic reaction compared with ordinary Portland cement (OPC) paste. The effects of silica fume particle size, glass phase content and the percentage of silica fume replacement on pozzolanic reaction degree, volume fraction of hydration products, and capillary porosity are simulated. The simulation results show that finer silica fume particles with higher glass phase content (GP) are of higher reactivity. There is an optimum silica fume replacement; extra silica fume only acts as inert filler because there is no enough Ca(OH)₂ from cement hydration to react with it pozzolanically.

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Résumé Le modèle proposé dans cet article simule l'hydratation de ciment mélangé à de la fumée de silice et est basé sur la cinétique, la stoichiométrie et la physico-chimie de l'hydratation du ciment et la réaction pozzolanique. Le degré de réaction pozzolanique, la fraction volumique des produits de l'hydratation, la porosité capillaire et la porosité de gel peuvent être obtenues par un modèle de simulation. En utilisant la bonne quantité de remplacement de fumée de silice, la microstructure de la fumée de silice mélangée à la pate de ciment est améliorée étant donné que la fraction volumique du gel C-S-H augmente, que le taux de Ca(OH)₂ et la porosité capillaire décroissent en raison de la réaction pozzolanique lorsque l'on compare avec une pate de ciment à base de Portland ordinaire (OPC). Les effets de la taille des particules de fumée de silice, le contenu de la phase de verre et le pourcentage de remplacement de fumée de silice sur le degré de réaction pozzolanique, la fraction volumique des produits d'hydratation et la porosité capillaire sont simulés. Les résultats de cette simulation montrent que de plus fines particules de fumée de silice avec une plus grande quantité de phase de verre (GP) sont de forte réactivité. Il existe un remplacement de fumée de silice optimal; de la fumée de silice en plus ne sert que de filler inerte car il n'y a pas assez de Ca(OH)₂ à partir de l'hydratation du ciment pour provoquer une réaction pozzolanique

     

Enhancement of durability of concrete composites containing natural pozzolans blended cement through the use of Polypropylene fibers

A parametric experimental study of the effects of Polypropylene fibers (PPF) on early cracking due to drying shrinkage in concretes with Natural Pozzolan Cement (NPC) and its influence on its durability is presented.Concrete composites containing natural pozzolan (toba trachite), point shaped crushed aggregates and different fiber volume fractions of PPF (0.03%, 0.06%, 0.09%, and 0.12%) were studied. This mixture is characterized by high permeability and carbonation ranges.Early age cracking control ability and drying shrinkage of PPF in NPC concretes were measured under dry setting conditions. The cracked area due to drying shrinkage was measured to establish the positive effect of the different PPF volume fractions in concretes. Besides, bulk density and water permeability depth were determined. Finally these specimens were stored for two years and tested afterwards, measuring the natural carbonation depth. Then the cracking area was again measured to assess the control ability of PPF on this parameter after long time.Finally a relationship of these indicators is analyzed to understand future lifespan of these concrete composites.The results indicate that a volume fraction of 0.07% of PPF reduces cracking area due to drying shrinkage of NPC a 66%, but larger volume fractions did not increased linearly this effect, and even worse results were obtained. The increment of PPF volume fraction reduces the water permeability depth and even the carbonation depth. A reduction of the cracked area, due to early shrinkage, of a 66% in NPC concretes may reach in these concretes a 32% lower water permeability indicators (enclosed wet area) and a 43% shorter minimum carbonation depth attending to the results obtained.So it can be considered that the cracking control ability of fibers on the exposed concrete surface reduced water permeability and CO₂ diffusion. However the use of fiber increased porosity and reduced bulk density and ultrasonic modulus of NPC concretes.In conclusion NPC concretes with low amounts of PP fibers (upper to 0.07% volume fraction) are less permeable and the CO₂ diffusion is slower in time due to early age cracking control, producing more durable concretes.     

Tensile properties of a bone cement containing non-ionic contrast media

The addition of contrast media such as BaSO4 or ZrO2 to bone cement has adverse effects in joint replacements, including third body wear and particle-induced bone resorption. Ground PMMA containing particles of the non-ionic water-soluble iodine-based X-ray contrast media, iohexol (IHX) and iodixanol (IDX), has, in bone tissue culture, shown less bone resorption than commercial cements. These water-soluble non-ceramic contrast media may change the mechanical properties of acrylic bone cement. The static mechanical properties of bone cement containing either IHX or IDX have been investigated. There was no significant difference in ultimate stress between Palacos R (with 15.0 wt % of ZrO2) and plain cement with 8.0 wt % of IHX or IDX with mass median diameter (MMD) of 15.0 or 16.0 microm, while strain to failure was higher for the latter (p < 0.02). The larger particles (15.0 or 16.0 microm) gave significantly higher (p < 0.001) ultimate tensile strengths and strains to failure than smaller sizes (2.4 or 3.6 microm). Decreasing the amount of IHX from 10.0 wt % to 6.0 wt % gave a higher ultimate tensile strength (p < 0.001) and strain to failure (p < 0.02). Scanning electron microscopy (SEM) showed the smaller contrast media particles attached to the surface of the polymer beads, which may prevent areas of the acrylate bead surface from participating in the polymerization. In conclusion, the mechanical properties of bone cement were influenced by the size and amount of contrast medium particles. By choosing the appropriate amount and size of particles of water-soluble non-ionic contrast media the mechanical properties of the new radio-opaque bone cement can be optimized, thus reaching and surpassing given regulatory standards.     

Mechanical properties and durability of mortar and concrete containing natural pozzolana and limestone blended cements

The benefits of limestone filler (LF) and natural pozzolana (NP) as partial replacement of Portland cement are well established. Economic and environmental advantages by reducing CO₂ emission are well known. However, both supplementary materials have certain shortfalls. LF addition to Portland cement causes an increase of hydration at early ages inducing a high early strength, but it can reduce the later strength due to the dilution effect. On the other hand, NP contributes to hydration after 28 days improving the strength at medium and later ages. Hence, ternary blended cement (OPC–LF–NP) with better performance could be produced. In this paper, mortar prisms in which Portland cement was replaced by up to 20%LF and 30%NP were tested in flexure and compressive strength at 2, 7, 28 and 90 days. Some samples were tested under sulfate and acid solutions and for chloride ions permeability. Results show that the use of ternary blended cement improves the early age and the long-term compressive and flexural strengths. Durability was also enhanced as better sulfate, acid and chloride ions penetration resistances were proved.     

Characterization of carbonation behavior of fly ash blended cement materials by the electrochemical impedance spectroscopy method

The carbonation behavior of fly ash blended cement materials is studied by the electrochemical impedance spectroscopy (EIS) method, and a novel equivalent circuit model R_s(Q₁(R_ct1W₁)) (Q₂(R_ct2W₂)) is proposed to investigate the influence of fly ash on the carbonation process in the cementitious materials. The experimental results demonstrate that the diameter of the impedance arc in high frequency region increases as carbonation progresses. Increasing the amount of fly ash incorporated in the cement paste is also found to enlarge the high frequency arc. The carbonation process can be quantified by the parameter R_ct2 extracted from the equivalent circuit model R_s(Q₁(R_ct1W₁)) (Q₂(R_ct2W₂)). It is found that the R_ct2 value increases with increase in fly ash content. A linear relationship between the R_ct2 value and the carbonation time is also observed. As a consequence, prediction of the carbonation depth of fly ash bended cement materials can be achieved through knowledge of the R_ct2 value.     

Physico-mechanical properties of aerated cement composites containing shredded rubber waste

The study reported in this paper was undertaken to investigate the physico-mechanical properties of aerated cement composite with rubber waste particles, in order to produce usable materials in cellular concrete applications. The material, containing different amounts of rubber particles as replacement to cement by volume, was aerated by artificially entrapping air voids by means of a new proteinic air-entraining agent. Results from tests performed on fresh composite have shown many attractive properties, such as improvement in workability and air-entrained with high stability of air-bubbles in the matrix. A study conducted on hardened composite properties has indicated a significant reduction in sample unit weight, thereby resulting in a level of compressive strength compatible with a load-bearing wall. The reduction in flexural strength was lower than that in compressive strength. The results have shown that the presence of air voids and rubber particles in the matrix reduces the elasticity dynamic modulus, which indicates a high level of sound insulation of the composite. This study has also highlighted the effect of the proteinic air-entraining agent on the cement matrix/rubber interaction system, as regards the composite’s mechanical strength.