Concrete building blocks made with recycled demolition aggregate

A study undertaken at the University of Liverpool has investigated the potential for using recycled demolition aggregate in the manufacture of precast concrete building blocks. Recycled aggregates derived from construction and demolition waste (C&DW) can be used to replace quarried limestone aggregate, usually used in coarse (6 mm) and fine (4 mm-to-dust) gradings. The manufacturing process used in factories, for large-scale production, involves a “vibro-compaction” casting procedure, using a relatively dry concrete mix with low cement content (≈100 kg/m³). Trials in the laboratory successfully replicated the manufacturing process using a specially modified electric hammer drill to compact the concrete mix into oversize steel moulds to produce blocks of the same physical and mechanical properties as the commercial blocks. This enabled investigations of the effect of partially replacing newly quarried with recycled demolition aggregate on the compressive strength of building blocks to be carried out in the laboratory. Levels of replacement of newly quarried with recycled demolition aggregate have been determined that will not have significant detrimental effect on the mechanical properties. Factory trials showed that there were no practical problems with the use of recycled demolition aggregate in the manufacture of building blocks. The factory strengths obtained confirmed that the replacement levels selected, based on the laboratory work, did not cause any significant strength reduction, i.e. there was no requirement to increase the cement content to maintain the required strength, and therefore there would be no additional cost to the manufacturers if they were to use recycled demolition aggregate for their routine concrete building block production.     

Strength,durability, and micro-structural properties of concrete made with used-foundry sand (UFS)

This paper presents the design of concrete mixes made with used-foundry (UFS) sand as partial replacement of fine aggregates. Various mechanical properties are evaluated (compressive strength, and split-tensile strength). Durability of the concrete regarding resistance to chloride penetration, and carbonation is also evaluated. Test results indicate that industrial by-products can produce concrete with sufficient strength and durability to replace normal concrete. Compressive strength, and split-tensile strength, was determined at 28, 90 and 365 days along with carbonation and rapid chloride penetration resistance at 90 and 365 days. Comparative strength development of foundry sand mixes in relation to the control mix i.e. mix without foundry sand was observed. The maximum carbonation depth in natural environment, for mixes containing foundry sand never exceeded 2.5 mm at 90 days and 5 mm at 365 days. The RCPT values, as per ASTM C 1202-97, were less than 750 coulombs at 90 days and 500 coulombs at 365 days which comes under very low category. Thereby, indicating effective use of foundry sand as an alternate material, as partial replacement of fine aggregates in concrete. Micro-structural investigations of control mix and mixes with various percentages of foundry sand were also performed using XRD and SEM techniques. The micro-structural investigations shed some light on the nature of variation in strength at the different replacements of fine aggregates with foundry sand, in concrete.     

Characterization of concrete blocks containing petroleum-contaminated soils

This paper presents the results of a study on the potential use of petroleum-contaminated soil (PCS) in the manufacturing of concrete blocks. PCS was obtained from Fahud asset area in northern Oman, where contaminated soils are typically transported for treatment. Hollow blocks of size 400 × 200 ×200 mm, widely used in Oman, were manufactured with a mix proportion of 1:2:4:0.8 for cement, coarse aggregate, sand, and water, respectively. The coarse aggregate had a 10 mm maximum aggregate size. PCS was subjected to the toxicity characteristic leaching procedure (TCLP). The chemical analysis of the extract indicated that the concentrations of metals and organic compounds did not exceed the maximum contaminant levels set by USEPA for TCLP extracts. Different mixes were prepared by replacing the sand with PCS with percentages up to 80% by sand weight in the mix. Five different tests were conducted on the concrete blocks: density, compressive strength, absorption, compressive strength of a masonry column, and thermal conductivity. The compressive strength test was conducted after 14 and 28 days of curing. The other tests were performed after 28 days of curing. Results indicated that PCS can be used with a replacement percentage up to 60% to produce concrete blocks meeting the Omani Standard specifications. The results also indicate potential deterioration when more than 60% PCS are used.     

Effect of aggregate properties on asphalt mixtures stripping and creep behavior

The purpose of this paper is to look at some aspects of the effects of aggregate chemical and physical properties on the creep and stripping behavior of hot-mix asphalt (HMA). Two types of aggregates evaluated in this study were limestone and basalt. The effects of the aggregates type were evaluated on three different aggregate gradations and two types of asphalt used in preparing the HMA. The percent of increase in static creep strain of HMA due to conditioning was utilized in this study to assess the stripping.Test results indicated that unconditioned HMA specimens prepared using basalt aggregate resist creep better than those prepared using limestone. However, after conditioning, mixes prepared using basalt were less resistant to creep strain than those prepared using limestone aggregate. Percent absorbed asphalt was found to be directly related to stripping resistant. Also, mixes prepared using aggregate following ASTM upper limit of dense aggregate gradation presented the highest resistance to stripping. The results of the calculated adhesion work were able to detect the effect of stripping on creep behavior for mixes prepared.     

Experimental behaviour of RACFST stub columns after exposed to high temperatures

The experimental studies on the behaviour of recycled aggregate concrete-filled steel tube (RACFST) stub columns after exposed to high temperatures are reported in this paper. Forty specimens, including 32 RACFST stub columns and 8 normal concrete-filled steel tube (CFST) stub columns as reference, were tested, and the failure pattern, load versus strain relation and ultimate strength of the specimens were presented and analysed. Five types of concrete were produced: one reference concrete with natural aggregates, two concrete mixes with recycled coarse aggregate (RCA) replacement ratios of 50% and 100%, and two concrete mixes with recycled fine aggregate (RFA) replacement ratios of 50% and 100%. The specimens were exposed to 300 °C, 600 °C and 800 °C for 3 h. The test results showed that, due to the existence of the recycled aggregates, the post-fire performance of RACFST stub columns was lower than the corresponding normal CFST specimens under the same maximum temperature suffered, and the RACFST specimens with RCA had a better behaviour than those with RFA under the same recycled aggregate replacement ratio.     

Post-fire residual mechanical properties of concrete made with recycled rubber aggregate

This study investigates the effects of elevated temperatures on the residual mechanical performance of concrete produced with recycled rubber aggregate (RRA). Four different concrete compositions were prepared: a reference concrete (RC) made with natural coarse aggregate and three concrete mixes with replacement rates of 5%, 10% and 15% of natural fine and coarse aggregate by RRA from used tyres. Specimens were exposed for a period of 1 h to temperatures of 400 °C, 600 °C and 800 °C, after being heated in accordance with ISO 834 time–temperature curve. After cooling down to ambient temperature, the compressive strength and the splitting tensile strength were evaluated and compared with reference values obtained prior to fire exposure. For the replacement rates used in the present experiments, the obtained results show that concrete made with recycled rubber aggregate (CRRA) present a thermal response that is roughly similar to that of RC; in addition, although residual mechanical properties of CRRA are noticeably more affected than those of RC, particularly for higher exposure temperatures, the relative reduction should not prevent it from being used in structural applications.     

Use of recycled demolition aggregate in precast products,phase II: Concrete paving blocks

A study undertaken at the University of Liverpool has investigated the potential for using construction and demolition waste (C&DW) as aggregate in the manufacture of a range of precast concrete products, i.e. building and paving blocks and pavement flags. Phase II, which is reported here, investigated concrete paving blocks. Recycled demolition aggregate can be used to replace newly quarried limestone aggregate, usually used in coarse (6 mm) and fine (4 mm-to-dust) gradings. The first objective, as was the case with concrete building blocks, was to replicate the process used by industry in fabricating concrete paving blocks in the laboratory. The compaction technique used involved vibration and pressure at the same time, i.e. a vibro-compaction technique. An electric hammer used previously for building blocks was not sufficient for adequate compaction of paving blocks. Adequate compaction could only be achieved by using the electric hammer while the specimens were on a vibrating table. The experimental work involved two main series of tests, i.e. paving blocks made with concrete- and masonry-derived aggregate. Variables that were investigated were level of replacement of (a) coarse aggregate only, (b) fine aggregate only, and (c) both coarse and fine aggregate. Investigation of mechanical properties, i.e. compressive and tensile splitting strength, of paving blocks made with recycled demolition aggregate determined levels of replacement which produced similar mechanical properties to paving blocks made with newly quarried aggregates. This had to be achieved without an increase in the cement content. The results from this research programme indicate that recycled demolition aggregate can be used for this new higher value market and therefore may encourage demolition contractors to develop crushing and screening facilities for this.     

The role of industrial by-products in self-compacting concrete

The development of self-compacting concrete is considered as a milestone achievement in concrete technology due to several advantages. In order to be self-compactable the fresh concrete must show high fluidity besides good cohesiveness. For the purpose of evaluating these properties, several concrete mixtures were prepared with a water to cement ratio of 0.45 in the presence of an acrylic-based superplasticizer at a dosage ranging from 1% to 2% by weight of very fine material fraction (maximum 150 μm). Either limestone powder or fly ash or recycled aggregate powder (that is a powder obtained from the rubble recycling process) were used as mineral addition, in order to assure adequate rheological properties, in terms of cohesiveness, in the self-compacting concretes. Preliminary rheological tests were carried out on cement pastes containing these mineral additions. In some cases, recycled instead of natural aggregate was used by substituting either the coarse or the fine aggregate fraction. The fresh concrete properties were evaluated through slump flow, L-box test and segregation resistance. Compressive strength of concrete was determined at 1, 3, 7 and 28 days of wet curing. Results obtained showed that an optimization of self-compacting concrete mixture seems to be achievable by the simultaneous use of rubble powder and coarse recycled aggregate with improved fresh concrete performance and unchanged concrete mechanical strength.     

Mechanical and elastic behaviour of concretes made of recycled-concrete coarse aggregates

In this paper an investigation of mechanical behaviour and elastic properties of recycled-aggregate concretes is presented. These concretes were prepared by alternatively using two different (coarse and finer coarse) recycled-aggregate fractions both made of recycled concrete coming from a recycling plant in which rubble from demolition is collected and suitably treated. Several concrete mixtures were prepared by using only virgin aggregates (as reference), 30% finer coarse recycled aggregate replacing fine gravel and 30% coarse recycled aggregate replacing gravel. Five different water to cement ratios were adopted as: 0.40, 0.45, 0.50, 0.55 and 0.60. Concrete workability was in the slump range of 190–200 mm. Compression tests were carried out after 28 days of wet curing. In addition, concrete elastic modulus and drying shrinkage were evaluated. Results obtained showed that structural concrete up to C32/40 strength class can be manufactured by replacing 30% virgin aggregate with recycled-concrete aggregate. Moreover, a correlation between elastic modulus and compressive strength of recycled-aggregate concrete was found and compared to those reported in the literature. Finally, on the basis of drying shrinkage results, particularly if finer coarse recycled-concrete aggregate is added to the mixture, lower strains could be detected especially for earlier curing time.     

Influence of mineral additions on the performance of 100% recycled aggregate concrete

A judicious use of resources, by using by-products and waste materials, and a lower environmental impact, by reducing carbon dioxide emission and virgin aggregate extraction, allow to approach sustainable building development. Recycled aggregate concrete (RAC) containing supplementary cementitious materials (SCM), if satisfactory concrete properties are achieved, can be an example of such sustainable construction materials.In this work concrete specimens were manufactured by completely replacing fine and coarse aggregates with recycled aggregates from a rubble recycling plant. Also RAC with fly ash (RA + FA) or silica fume (RA + SF) were studied.Concrete properties were evaluated by means of compressive strength and modulus of elasticity in the first experimental part. In the second experimental part, compressive and tensile splitting strength, dynamic modulus of elasticity, drying shrinkage, reinforcing bond strength, carbonation, chloride penetration were studied. Satisfactory concrete properties can be developed with recycled fine and coarse aggregates with proper selection and proportioning of the concrete materials.     

Utilization of Rice Husk Ash as viscosity modifying agent in Self Compacting Concrete

Self Compacting Concrete (SCC) is defined by two primary properties: Deformability and Segregation resistance. Deformability or flowability is the ability of SCC to flow or deform under its own weight (with or without obstructions). Segregation resistance or stability is the ability to remain homogeneous while doing so. High range water reducing admixtures are utilized to develop sufficient deformability. At the same time, segregation resistance is ensured, which is accomplished either by introducing a chemical viscosity modifying admixture (VMA) or by increasing the amount of fines in the concrete. These viscosity modifying admixtures are very expensive and the main cause of increase in the cost of SCC. Therefore, for producing low cost SCC, it is prudent to look at the alternates to help reducing the SSC cost. This research is aimed at evaluating the usage of Rice Husk Ash (RHA) as viscosity modifying agent in SCC, and to study the relative costs of the materials used in SCC.In this research, the main variables are the proportion of RHA, dosage of superplasticizer for flowability and water/binder ratio. The parameters kept constant are the amount of cement, water, fine and coarse aggregate contents.Test results substantiate the feasibility to develop low cost SCC using RHA. In the fresh state of concrete, the different mixes of concrete have slump flow in the range of 595–795 mm, L-box ratio ranging from 0 (stucked) to 1 and flow time ranging from 2.2 to 29.3 s. Out of nine mixes, four mixes were found to satisfy the requirements suggested by European federation of national trade associations representing producers and applicators of specialist building products (EFNARC) guide for making SCC. The compressive strengths developed by the SCC mixes with RHA were comparable to the control concrete. Cost analysis showed that the cost of ingredients of specific SCC mix is 42.47% less than that of control concrete.     

Investigating on possible use of Diyarbakir basalt waste in Stone Mastic Asphalt

Stone Mastic Asphalt (SMA) improved for road construction which has been utilized in Europe and America for 40 years is a rather new process in Turkey. SMA basically consists of 93–94% aggregate and mineral fillers, 6–7% bitumen and additives. Road and construction industry consume stone in large amounts. Stone used are obtained from nearby quarries and carried to the location where they are to be used, destroying the nature and causing large costs. The constantly increasing demand on quarries harms the general structure of the earth thus causing the emergence of large scale environmental problems. The use of basalt waste from stone processing plants as aggregates and mineral filler in SMA might help to meet this increasing demand thus solving environmental problems. In this study, primarily some important material properties of fine and coarse basalt waste, taken from basalt processing plants in Diyarbakir, such as sieve analysis, chemical analysis, specific gravity, water absorption, Los Angeles abrasion loss value, soundness of aggregate by Na₂SO₄, flakiness index and stripping strength were determined. Then by using this waste material, a SMA was designed according to Turkish Highway Technical Specifications. Marshall stability and flow tests have been carried out on designed SMA specimens. Test results indicate that properties of the basalt waste and the SMA produced were within the specified limits and that these waste materials can be used as aggregates and mineral filler in SMA.     

Influence of fly ash on strength and sorption characteristics of cold-bonded fly ash aggregate concrete

Cold-bonded fly ash aggregate concrete with fly ash as part of binder or fine aggregate facilitates high volume utilization of fly ash in concrete with minimum energy consumption. This paper investigates the influence of fly ash on strength and sorption behaviour of cold-bonded fly ash aggregate concrete due to partial replacement of cement and also as replacement material for sand. While cement replacement must be restricted based on the compressive strength requirement at desired age, replacement of sand with fly ash appears to be advantageous from early days onwards with higher enhancement in strength and higher utilization of fly ash in mixes of lower cement content. Microstructure of concrete was examined under BSEI mode. Replacement of sand with fly ash is effective in reducing water absorption and sorptivity attributable to the densification of both matrix and matrix–aggregate interfacial bond. Cold-bonded fly ash aggregate concrete with a cement content of 250 kg/m³, results in compressive strength of about 45 MPa, with a total inclusion of around 0.6 m³ of fly ash in unit volume of concrete.     

Influence of high temperature on the properties of concretes made with industrial by-products as fine aggregate replacement

Influence of high temperature on the properties of concrete containing non-ground granulated blast-furnace slag (GBFS) and coal bottom ash (BA) as fine aggregate was presented. Six series of concrete mixtures were prepared by partially replacing fine aggregate separately with GBFS and BA. Replacement percentages were between 10 and 50% with an increment of 10% by dry weight of fine aggregate. Then 0.2% polypropylene fibres (PP) were added to last three mixtures that has the same mixture with the first three series. The first series is control concrete, the second series contained GBFS and the third series contained BA. All the concrete specimens were exposed to 800 °C temperature at the age of 90 days. Tests were conducted to determine loss in weight, compressive strength, and dynamic modulus of elasticity. Also surface crack observations were conducted with microscope. Test results showed that it is possible to partially replace fine aggregate with GBFS or BA even if such concretes were to be subjected to high temperature response. Performance of BA concrete was found to be better than GBFS as replacement material.     

Behaviour of recycled aggregate concrete under drop weight impact load

This paper presents the experimental results of recycled aggregate concrete (RAC) beams prepared with different amount of recycled coarse aggregate (RCA) subjected to low velocity impact. The recycled coarse aggregates are obtained from a demolished RCC culvert. Four concrete mixes with 0%, 25%, 50% and 100% RCA respectively are prepared. With each mix three beam specimens of size 1.15 × 0.1 × 0.15 m are prepared and tested under drop weight impact load. The behavior of the RAC beams are studied in terms of acceleration, strains and support reaction histories under impact load in addition to the physical and mechanical characteristics of RCA and RAC. It is observed that 25% RCA does not influence the strength of concrete. In addition, it is found that for a given impact energy (the energy imparted by the hammer per blow) the reactions and strains of RAC with 50% and 100% RCA are significantly lower and higher respectively than those of normal concrete and RAC with 25% RCA.     

Properties of EPS RHA lightweight concrete bricks under different curing conditions

The depletion of non-renewable resources has become an alarming issue nowadays. Many environmentalists and researchers have been investigating the use of waste materials as a renewable resource for use especially as raw materials in construction. This paper reports on the potential use of waste rice husk ash (RHA) and expanded polystyrene (EPS) beads in producing lightweight concrete bricks. The RHA was used as a cementitious material since it is a lightweight reactive pozzolanic material. RHA was used as partial cement replacement, while the EPS was used as partial aggregate replacement in the mixes. Bricks of 215 mm × 102.5 mm × 65 mm in size were prepared in this study. The engineering properties of the bricks were investigated. Among the properties studied were hardened concrete density, compressive strength and water absorption of the EPS RHA concrete bricks. Scanning electron microscopy (SEM) analysis was also performed on the brick samples. Four types of curing conditions were employed in this study. These include full water curing, air dry curing, 3-day curing and 7-day curing. It was found that the properties of the bricks are mainly influenced by the content of EPS and RHA in the mix and also the curing condition used.     

Use of low CaO unprocessed steel slag in concrete as fine aggregate

Steel slag, which is produced locally in great amounts, has a negative impact on the environment when disposed. Local steel slag has a low CaO content and has no pozzolanic activity.In this research, local unprocessed steel slag is introduced in concrete mixes. Various mixes with compressive strength ranging from 25 to 45 MPa are studied. The slag is used as fine aggregate replacing the sand in the mixes, partly or totally. Ratios of 0%, 15%, 30%, 50% and 100% are used.Depending on the grade of concrete, the compressive strength is improved when steel slag is used for low sand replacement ratios (up to 30%).When optimum values are used, the 28-day tensile strength of concrete is improved by 1.4–2.4 times and the compressive strength is improved by 1.1–1.3 times depending on the replacement ratio and the grade of concrete. The best results are obtained for replacement ratios of 30–50% for tensile strength and 15–30% for compressive strength.Therefore, the use of steel slag in concrete would enhance the strength of concrete, especially tensile strength, provided the correct ratio is used.     

High-strength rice husk ash concrete incorporating quarry dust as a partial substitute for sand

Quarry dust is a by-product from the granite crushing process in quarrying activities. This paper presents the findings from experimental work undertaken to evaluate the suitability of quarry dust as a partial substitute for sand in high-strength concrete (HSC) containing rice husk ash (RHA). Two grades of HSC mixes, to achieve 60 MPa and 70 MPa at 28 days, were designed with and without the incorporation of RHA. Quarry dust was then used in the mixes containing RHA as a partial substitute for sand, in quantities ranging from 10% to 40%. The slump of the fresh concrete and the compressive strength development were monitored up to 28 days. Based on the results obtained, the mixes containing 20% quarry dust were chosen as the optimum mix design for both grades of concrete, which would then undergo further evaluation of their strength and mechanical properties up to one year. The results obtained in the next stage suggest that even though the use of quarry dust as a partial substitute for sand results in some minor negative effects in the compressive strength and other mechanical properties of concrete, these outcomes can easily be compensated by a good mix design and by the incorporation of RHA. The findings of the research assert that quarry dust can be used as a viable replacement material to sand to produce high-strength RHA concrete.     

Strength reduction factors for structural rubbercrete

Many researches have been carried out to study the fresh and hardened properties of concrete containing crumb rubber as replacement to fine aggregate by volume, yet there is no specific guideline has been developed on the mix design of the rubbercrete. The experimental program, which has been developed and reported in this paper, is designed and executed to provide such mix design guidelines. A total of 45 concrete mixes with three different water to cement ratio (0.41, 0.57 and 0.68) were cast and tested for fresh and mechanical properties of rubbercrete such as slump, air content, unit weight, compressive strength, flexural strength, splitting tensile strength and modulus of elasticity. Influence of mix design parameters such as percentage of crumb rubber replacement, cement content, water content, fine aggregate content, and coarse aggregate content were investigated. Three levels of slump value (for conventional concrete mixes) has been selected; low, medium and high slump. In each slump level, water content was kept constant. Equations for the reduction factors (RFs) for compressive strength, flexural strength, splitting tensile strength and modulus of elasticity have been developed. These RFs can be used to design rubbercrete mixes based on the conventional mix (0% crumb rubber content)     

Properties of self-compacting concrete mixtures containing metakaolin and blast furnace slag

Rheological, mechanical and durability properties of self-compacting concrete (SCC) mixes produced using blended binders containing metakaolin and blast furnace slag are studied. The rheological properties of SCC mix with metakaolin are characterized by significant yield stress and relatively low viscosity, while the mix with blast furnace slag shows zero yield stress and higher viscosity. The compressive strength of SCC with metakaolin grows very fast during the initial hardening period and remains significantly higher, as compared with the mix with blast furnace slag, up to 90 days. Durability properties of the mix containing metakaolin are excellent. Water absorption coefficient and water penetration depths are very low. The freeze resistance tests show zero mass loss after 56 cycles in deicing salt solution.