Mortars with nano-SiO2 and micro-SiO2 investigated by experimental design

This paper reports the effects of nanosilica (nS) and silica fume (SF) on rheology, spread on flow table, compressive strength, water absorption, apparent porosity, unrestrained shrinkage and weight loss of mortars up to 28 days. Samples with nS (0–7 wt.%), SF (0–20 wt.%) and water/binder ratio (0.35–0.59), were investigated through factorial design experiments. Nanosilica with 7 wt.% showed a faster formation of structures during the rheological measurements. The structure formation influences more yield stress than plastic viscosity and the yield stress relates well with the spread on table. Compressive strength, water absorption and apparent porosity showed a lack of fit of second order of the model for the range interval studied. In addition, the variation of the unrestrained shrinkage and weight loss of mortars do not follow a linear regression model. The maximum unrestrained shrinkage increased 80% for nS mortars (7 days) and 54% (28 days) when compared to SF mortars in the same periods.     

Use of natural and thermally activated porphyrite in cement production

The aim of the present study was to investigate the use of porphyrite in the production of Portland cement. Natural and thermally activated porphyrites were used as a clay raw material and an activator, respectively, at 0, 10, 20, 30, 40 and 50 wt% in order to assess their effects on the cement properties. According to the test results, the compressive strength of the specimens decreased with increasing natural porphyrite content in various curing periods. However, the compressive strength of cement produced with 10 wt% porphyrite (activator) activated at 650 °C for 30 min showed a higher value (56 MPa in TPC-6) than cement without activator (51 MPa in RPC-2). Due to thermal activation, porphyrite activator containing a glass phase possesses an enhanced reactivity during clinker hydration that intensifies the synthesis of hydrosilicates and improves compressive strength accordingly. The X-ray diffraction analysis confirmed an intensive formation of Portland cement minerals such as C₃S, β-C₂S, C₃A and C₄AF. The addition of thermally activated porphyrite has also led to an improvement of the rheological behavior, stability to expansion, increase in setting time and decrease in specific surface area of cement. As prepared cement composites and concretes with improved properties meet the requirements of State Standards 310-86 and 10181-81 for Portland cement and concrete, respectively. The findings in this report indicate that porphyrite can be utilized both as a raw material and an activator in the production of cement.     

Utilization of bagasse ash as a pozzolanic material in concrete

The physical properties of concrete containing ground bagasse ash (BA) including compressive strength, water permeability, and heat evolution, were investigated. Bagasse ash from a sugar factory was ground using a ball mill until the particles retained on a No. 325 sieve were less than 5wt%. They were then used as a replacement for Type I Portland cement at 10, 20, and 30wt% of binder. The water to binder (W/B) ratio and binder content of the concrete were held constant at 0.50 and 350 kg/m³, respectively.The results showed that, at the age of 28 days, the concrete samples containing 10–30% ground bagasse ash by weight of binder had greater compressive strengths than the control concrete (concrete without ground bagasse ash), while the water permeability was lower than the control concrete. Concrete containing 20% ground bagasse ash had the highest compressive strength at 113% of the control concrete. The water permeability of concrete decreased as the fractional replacement of ground bagasse ash was increased. For the heat evolution, the maximum temperature rise of concrete containing ground bagasse ash was lower than the control concrete. It was also found that the maximum temperature rise of the concrete was reduced 13, 23, and 33% as compared with the control concrete when the cement was replaced by ground bagasse ash at 10, 20, and 30wt% of binder, respectively. The results indicate that ground bagasse ash can be used as a pozzolanic material in concrete with an acceptable strength, lower heat evolution, and reduced water permeability with respect to the control concrete.     

Hybrid effect of carbon nanotube and nano-clay on physico-mechanical properties of cement mortar

In this work, several nanomaterials have been used in cementitious matrices: multi wall carbon nanotubes (MWCNTs) and nano-clays. The physico-mechanical behavior of these nanomaterials and ordinary Portland cement (OPC) was studied. The nano-clay used in this investigation was nano-kaolin. The metakaolin was prepared by thermal activation of nano-kaolin clay at 750 °C for 2 h. The organic ammonium chloride was used to aid in the exfoliation of the clay platelets. The blended cement used in this investigation consists of ordinary Portland cement, carbon nanotubes and exfoliated nano metakaolin. The OPC was substituted by 6 wt.% of cement by nano metakaolin (NMK) and the carbon nanotube was added by ratios of 0.005, 0.02, 0.05 and 0.1 wt.% of cement. The blended cement: sand ratio used in this investigation was 1:2 wt.%. The blended cement mortar was prepared using water/binder ratio of 0.5 wt.% of cement. The fresh mortar pastes were first cured at 100% relative humidity for 24 h and then cured in water for 28 days. Compressive strength, phase composition and microstructure of blended cement were investigated. The results showed that, the replacement of OPC by 6 wt.% NMK increases the compressive strength of blended mortar by 18% compared to control mix and the combination of 6 wt.% NMK and 0.02 wt.% CNTs increased the compressive strength by 29% than control.     

Damage to cement concrete pavements due to exposure to organic compounds in a cold region

Pop-out and disaggregation of aggregate in a 1-year old cement concrete pavement originally mixed with air-entraining (AE) water-reducing agent was observed after the pavement had been exposed to ethylene glycol based snow-melting agent on the surface in the winter. The study used: gas chromatography–mass spectrometry (GC–MS) tests, ¹H Nuclear Magnetic Resonance (NMR) tests, X-ray fluorescence analysis, emission spectral analysis (ICP), elution tests in anion type surfactant solution conducted for mortar and aggregate taken from the cement concrete where pop-out had occurred, as well as samples made by cement paste in the laboratory. Tests of the tensile strength, thermal-stress, and three-dimensional crack analysis by micro-focus computerized tomography (CT) scanner were conducted for specimens (2.5 × 2.5 × 10 cm) taken from the cement concrete where pop-out had occurred and with cement concrete samples made in the laboratory. Microscope observations and Electron Probe Micro Analyzer (EPMA) analysis were conducted for thin samples (2.5 × 2.5 cm and 20 μm thick) taken from the cement concrete where pop-out had occurred. The tests results showed that organic compounds contained in the cement reacted with the cement during the hardening process, generating cracks and gel in the cement paste. It was established that these caused the pop-out of the aggregate, together with the effects of the ethylene glycol based snow-melting agent that the cement concrete had been exposed to. No pop-out or disaggregation of aggregate were found in cement concrete at a repaired section, at the same location, with aggregate of low absorbing water ratio in this cold region and in place for 2 years.     

Strength and toughness improvement of cement binders using expandable thermoplastic microspheres

The effect of Expandable Thermoplastic Microspheres (ETM) loading on the fracture resistance and indirect tensile strength of cement binders is studied. Portland white cement (PWC) was used as the matrix in the current study. Loadings of 0.1%, 0.35%, 0.5%, 0.75% and 1%, by weight, of ETM were added to the dry cement. Semi-circular bend specimens, 152 mm in diameter and 27 mm thickness with different notch depths were fabricated to study the crack resistance of the compounds, J_c. For the indirect tensile tests, circular specimens, 50 mm in diameter and 12.7 mm thickness were used. All specimens were left to cure under water for 7 days. A 2.5-fold increase in the indirect tensile strength was achieved at an ETM loading of 0.35% by weight. A nearly threefold increase in the fracture resistance occurred at the 0.1% ETM loading. The thermal resistivity of the compounds increased by 30% for a 1% Expancel loading. Fracture surface examination revealed that the ETM facilitated the permeation of water by creating pores. Thus, an optimum strength and fracture resistance was achieved between 0.1% and 0.4%.     

Effect of fly ash addition on the mechanical properties of tile adhesive

Statistical relationship between various strengths of tile adhesives in which cement or sand was partially replaced with fly ash was studied. A low-lime fly ash was used in five different replacement levels from 5% to 30% by weight of either cement or sand. The tensile adhesion, flexural and compressive strengths of adhesives were determined at 2, 7 and 28 days. In small substitution levels, sand replacement increased the tensile adhesion strength. No strong relationship was found between tensile adhesion strength and flexural or compressive strength of the specimens in which the fly ash was used as sand replacement (r < 0.659). Strong relationship was observed between the same properties when fly ash was used as cement replacement (r > 0.896). Flexural and compressive strength values showed quite strong relationship (r > 0.949). This may be due to the fact that both of these strength values were obtained on the same specimens.     

Durability of gamma irradiated polymer-impregnated blended cement pastes

This study is focusing on durability of the neat blended cement paste as well as those of the polymer-impregnated paste towards seawater and various concentrations of magnesium sulfate solutions up to 6 months of curing. The neat blended cement paste was prepared by a partial substitution of ordinary Portland cement with 5% of active rice husk ash (RHA). These samples were cured under tap water for 7 days. A similar paste was impregnated with unsaturated polyester resin (UPE) followed by gamma rays ranging from 10 to 50 kGy. The obtained data indicated that the polymer-impregnated specimens higher values of compressive strength than those of the neat blended cement paste. In addition, the polymer-impregnated blended cement specimens irradiated at a dose of 30 kGy and neat blended cement specimens were immersed in seawater and different concentrations of magnesium sulfate solutions namely, 1%, 3% and 5% up to 6 months. The results showed that the polymer-impregnated blended cement (OPC–RHA–UPE) paste irradiated at a dose of 30 kGy has a good resistance towards sulfate and seawater attack as compared to the neat blended cement (OPC–RHA) paste. These results were confirmed by scanning electron microscopy (SEM) and mercury intrusion porosimetry (MIP) studies.     

Modeling mechanical performance of lightweight concrete containing silica fume exposed to high temperature using genetic programming

In this study, the mechanical performance of lightweight concrete exposed to high temperature has been modeled using genetic programming. The mixes incorporating 0%, 10%, 20% and 30% silica fumes were prepared. Two different cement contents (400 and 500 kg/m³) were used in this study. After being heated to temperatures of 20 °C, 200 °C, 400 °C and 800 °C, respectively, the compressive and splitting tensile strength of lightweight concrete was tested. Empirical genetic programming based equations for compressive and splitting tensile strength were obtained in terms of temperature (T), cement content (C), silica fume content (SF), pumice aggregate content (A), water/cement ratio (W/C) and super plasticizer content (SP). Proposed genetic programming based equations are observed to be quite accurate as compared to experimental results.     

Lightweight properties and pore structure of foamed material made from sewage sludge ash

Pore structure significantly affects the lightweight characteristics and thermal performance of materials. Therefore, in this study, sewage sludge ash (SSA) was used to make lightweight materials. Physical and chemical properties, and how the mixing proportions affected the foaming behavior were investigated, including the lightweight characteristics and pore structure of the materials produced. The experiments showed that the minimum required cement amount was determined by the compressive strength of the sewage sludge ash foamed material (SSAFM), not its alkali content. The hydration of cement and SSA mainly generated pores with diameters of less than 0.1  μm, but cement added with metallic aluminum powder produced pores with diameters larger than 10  μm. The addition of SSA increased the volume of pores smaller than 10  μm. The thermal conductivity of SSAFM was between 0.084 and 0.102 W/m K. Therefore, SSA could be used as the lightweight filler and heat-insulating material.     

Study on the graphite and carbon fiber modified asphalt concrete

The mechanical and electrical properties of graphite and carbon fiber modified asphalt concrete were measured in this paper through the indirect tensile test. The experimental results indicate that the mechanical properties of asphalt mixture are influenced by the addition of conductive component like graphite and carbon fiber, When the graphite content increased from 0 to 22 vol.%, Marshall stability decreased from 12.8 kN to 9.43 kN and residual stability from 91.1% to 87.2%. Rutting dynamic stability decreased from 3318 times/mm to 2619 times/mm. After adding the carbon fiber, when the carbon fiber content increased from 0 to 2 vol.%, their Marshall stability and residual stability increased from 12.8 kN to 13.5 kN and residual stability from 91.1% to 92.7%. Rutting dynamic stability increased from 3318 times/mm to 3403 times/mm. When modified through combination effect of graphite and carbon fiber mixed fillers, the mechanical performance and electrical property were improved greatly, their Marshall stability and residual stability has increased from 9.43 kN to 12.1 kN and residual stability from 87.2% to 89.2%. Rutting dynamic stability increased from 2619 times/mm to 3292 times/mm. Furthermore, the resilient modulus is influenced by the addition of graphite, the value of resilient modulus is as much as that of the original, it is 90% when graphite is 30 vol.% and is 70% when graphite is 45 vol.%. The electrical resistance increases reversibly with increasing tensile strain either under dynamic indirect tensile testing or static indirect tensile testing, graphite and carbon fiber modified asphalt concretes are effective for the self-monitoring of strain. It is foreseen that the strain–stress self monitoring is valuable for weighing, traffic monitoring, border monitoring and structural vibration control.     

Study of the reactivity of cement/metakaolin binders at early age for specific use in steam cured precast concrete

The paper presents the results of a hydration study performed in order to explain the significant increase in compressive strength at one day of age observed on steam cured mortars when 25% by mass of cement was replaced with a metakaolin. Two CEM I 52.5R cements, differing in reactivity, and a metakaolin (MK) were used. By means of XRD and thermal analysis carried out on cement pastes, blended or not with MK, the main results showed that the improvement in strength at one day of age could be explained by the occurrence of a pozzolanic reaction due to MK, thermo-activated by the high curing temperature (55 °C). The pozzolanic reaction was observed through the consumption of calcium hydroxide and an increase in the amount of C–S–H and C–S–A–H hydrated phases. This change in the hydration product nature and amount was more pronounced when MK was combined with the less reactive cement, in agreement with the mechanical results on mortars. These results are of great importance for the concrete industry where the current trend is to decrease the clinker content in cements (1 ton of clinker = 1 ton of CO₂ released). In particular, the interesting mechanical performance at early ages can be helpful for precast concrete manufacturing.     

Effect of micro-silica loading on the mechanical and acoustic properties of cement pastes

This study aimed at investigating the role of ultra fine sand (UFS) in enhancing the mechanical and acoustic properties of cementitious pastes. The microstructural origin of these properties was also identified and compared to the conventional materials. The maximum particle size of the UFS used was 100 μm (100% passing) while 50% of the UFS had less than 20 μm in diameter. Ordinary Portland cement (OPC) was partially substituted by UFS at 1%, 2%, 3%, 4%, 5%, 7.5% and 10% by weight of binder. The blended compounds were prepared using the standard water of consistency. Test samples with dimension of 20 × 20 × 20 mm and 40 × 40 × 160 mm were cast for compression and bending strengths tests, respectively. Circular samples with diameters of about 100 and 29 mm and average thickness of about 30 mm were used for sound absorption tests. All samples were kept in molds for 24 h, and then de-molded and allowed to cure in water for 28 days. The specimens were dried at a temperature of 105 °C for 24 h in an oven before testing. It was found that as the loading of UFS increases both the compressive and bending strength increase up to about 5% UFS loading, then a decrease in these properties was observed. This can be attributed to the pozzolanic effect of UFS resulting in enhancing the chemical reaction between free lime in cement and silica producing more hydration products that makes the paste more homogeneous and dense. In addition, the dispersed UFS has improved the filling effect allowing denser packing of the paste. These dense microstructural features were captured by scanning electron microscope (SEM) examination of the 5% UFS modified compound. The results also showed that, the sound absorption and noise reduction coefficient (NRC) for modified cement paste decreases with the increase of UFS up to 5% and this may be due to the decrease in porosity. However, the NRC began to increase at UFS loadings of 7.5% and 10% due to the increase in the porosity of the compounds.     

A study of the workability and compressive strength characteristics of corn cob ash blended cement concrete

The study investigated the workability and compressive strength characteristics of corn cob ash (CCA) blended cement concrete. Nine classes of CCA-blended cements were employed with the CCA content ranging from 0% to 25%. The 0% CCA replacement involved the use of normal ordinary Portland cement and it served as the control. The mix proportions of cement:sand:granite used were 1:1½:3, 1:2:4 and 1:3:6 with 0.5, 0.6 and 0.7 water-to-cement ratios, respectively. The concrete cubes were tested at the curing ages of 3, 7, 28, 60, 120, and 180 days. Slump and compacting factor tests were carried out to check the effect of CCA on the workability of concrete. The results showed that the concrete slump and compacting factor decreased as the CCA content increased indicating that concrete becomes less workable (stiff) as the CCA percentage increases. The compressive strength of CCA-blended cement concrete was lower than the control at early ages, but improves significantly, and outperforms the control at later ages (120 days and above). The optimum compressive strength of 57.10 N/mm², 40.30 N/mm² and 28.07 N/mm² for 1:11/2:3, 1:2:4 and 1:3:6 mix proportions, respectively at 180 days were obtained at 8% CCA replacement level. It was concluded that only up to 8% CCA substitution is adequate where the blended cement is to be used for structural concrete.     

Mix proportion of high-strength,roller-compacted,latex-modified rapid-set concrete for rapid road repair

In this study, we optimized a blend of high-strength, roller-compacted, latex-modified rapid-set concrete (RCLMC) that can be re-opened to traffic after 4 h. To this end, we tested several variables in laboratory experiments, including hardening acceleration agents, cement type, latex addition, and CSA admixture ratios. The target compressive strength was 21 MPa after 4 h. A mixture of Type III cement to CSA admixture at 235:165 kg/m³ (400 kg/m³ total binder) and 23.5 kg/m³ latex (10% of the cement weight) achieved the target compressive strength and was the most economically efficient.     

Hydration heat kinetics of concrete with silica fume

The objective of this study was to evaluate the influence of silica fume on the hydration heat of concrete. Portland cement was replaced by silica fume in amounts from 10 % to 30 % by mass in concrete with w/(c+sf) ratios varying between 0.25 and 0.45. A superplasticizer was used to maintain a fluid consistency. The heat of hydration was monitored continuously by a semi-adiabatic calorimetric method for 10 days at 20 °C. The calorimetric study indicated that the hydration was modified by the presence of silica fume. In the early stages, the silica fume showed a high activity and accelerated the hydration rate as compared to that of the reference concrete. The fine silica fume particled provided nucleation sites for hydrates growth. Then the pozzolanic activity took over and increased both strength and the hydration heat. A substitution of Portland cement by 10% with silica fume produced greater strength and cumulative heat of hydration as compared to that of the reference concrete.     

Recycling of the product of thermal inertization of cement–asbestos for the production of concrete

A novel field of research in materials science is the recycling of secondary raw materials for construction and building materials such as concrete. This paper describes the successful recycling of as much as 20 wt% of the product of thermal transformation of cement–asbestos for the formulation of concrete. The main mineralogical phases present in the product of transformation of cement–asbestos are C2S, ferrite, and Al-, Ca-, Mg-rich silicates such as akermanite (ideally Ca₂MgSi₂O₇) and merwinite (ideally Ca₃Mg₂Si₂O₈). The behavior of this secondary raw material, termed KRY·AS, in commercial concrete was investigated using five different mixtures in which various portions (0, 5, 10, 15 and 20 wt%) of cement were substituted by KRY·AS. The results of preliminary technological tests (slump test, compressive strength, flexural strength after 28 days, and depth of penetration of water under pressure after 28 days) were discussed and interpreted with the aid of chemical, mineralogical and SEM analyses.One of the major results is that after 28 days, although all the concrete samples are invariably classified as “ordinary concrete” according to the UNI 6132 tests, those diluted with KRY·AS display a lower resistance to compression with respect to the standard. On the other hand, they recover compressive strength and display values identical to that of the standard after 90 days. The addition of the secondary raw material has the effect to slow down the kinetics of setting/hardening because the main cement phase present in KRY·AS is C2S which has a slower rate of hydration with respect to C3S.     

Utilization of separator bag filter dust for high early strength cement production

This paper presents the feasibility of incorporating ultra-fine particles collected in the separator bag filter during the process of manufacturing cement (SBFC) as an substitution material for cement. Approximately 2.5% of SBFC is produced during OPC manufacturing process. Also, the average size of SBFC particles is about 5 μm, the average size of OPC particles is about 14 μm. This method does not require additional processes needed in the existing processes to manufacture high early strength cement such as modifying mineral components and adjusting the firing temperature. Moreover, it can also solve the issue of efficiency decrease resulted from the increase of the grinding time applied in the existing process of manufacturing microcement. In order to investigate the characteristic properties of this cement mixture, cement blends have been produced by using different amounts of SBFC. While the blaine value of 100% SBFC was significantly higher (6953 cm²/g) than that of Ordinary Portland Cement (OPC), its chemical composition showed no significant difference. Cement paste, mortar mixtures have been prepared by using cement blends incorporating 0, 50 and 100% SBFC by weight. Flowability, setting time and compressive strength tests has been performed. Test results showed that substitution of SBFC negatively affect the flowability of cement paste and mortar mixtures. Moreover, setting times shortened, compressive and flexural strength values increased by the substitution of SBFC. Finally, microstructure analysis of cement paste samples showed that incorporation of SBFC reduced the internal porosity by 9% as determined by the proposed method. The internal porosity of paste was measured by mercury intrusion porosimetry (MIP). The compressive strength and bending strength of mortar were higher in the order of 100, 50 and 0% SBFC mixed.     

Effects of crushed glass cullet sizes,casting methods and pozzolanic materials on ASR of concrete blocks

The aim of this study is to investigate the influence of using different particle sizes of recycled glass, casting methods and pozzolanic materials in reducing the expansion due to alkali-silica reaction (ASR) of concrete blocks prepared with the use of crushed glass as fine aggregate. In this work, 25 × 25 × 285 mm mortar bar specimens were prepared using conventional wet-mixed and dry-mixed methods. Except for the control mortar bar, all the specimens were prepared by completely replacing river sand with different particle sizes of recycled glass. In addition, the influence of fly ash (PFA) and metakaolin (MK) content on the reduction of ASR expansion was also investigated. The flexural strength of the mortar bar specimens before and after they had been exposed to 1N NaOH solution was determined to complement the results of ASR expansion test. SEM was performed to examine the microstructure as well as nature of the cement binder-glass interfacial zone. The results reveal that ASR expansion reduced with reducing particle size of glass used. For the same given mix proportion, the dry-mixed method resulted in 44% less expansion when compared with the wet-mixed method. Both PFA and MK were demonstrated to be able to significantly reduce ASR expansion of the concrete glass blocks.     

Properties of cement mortars containing clinoptilolite as a supplementary cementitious material

This paper presents a study of the properties and behavior of cement mortar with clinoptilolite which is one of the most common zeolite minerals found in nature. Six mortar mixtures were prepared by replacing the Portland cement with 0%, 5%, 10%, 15%, 20% and 30% clinoptilolite by weight. Test results showed that water demand, soundness and setting times of the cement pastes increased with the increase of clinoptilolite content. Compressive and flexural strength of the mortars containing clinoptilolite were higher than the control mixture. Dry unit weight of the mortars with clinoptilolite was lower than the control mortar. Clinoptilolite replacement decreased water absorption and porosity of the mortars. The control mortar showed less durability to carbonation compared to the mortars made with clinoptilolite at the end of carbonation tests. Freeze–thaw resistance of the mortars containing 5% clinoptilolite was higher than control mortar. The effect of clinoptilolite incorporation on high-temperature resistance seemed to be dependent on amount of clinoptilolite, temperature level, and the cooling method.