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.     

Modeling of some properties of the crushed tile concretes exposed to elevated temperatures

In this study, artificial neural network (ANN) and fuzzy logic (FL) models have been developed for predicting the compressive strength (f_c) and dynamic modulus of elasticity (E_d) of the crushed tile concretes (CTC) exposed to elevated temperatures. Some relationships are established between chosen inputs and outputs by developing and testing a multi-layered feed forward ANN and FL trained with the back-propagation algorithm. First of these relationships is established between the outputs as f_c of CTC after being exposed to elevated temperatures and the inputs as exposed temperature (T), crushed tile aggregate (CT) and crushed stone II (CSII) contents of concrete. The second one is the relationship between E_d of concretes and the same inputs. In this aim, concrete specimens are produced by CT replacing 16–31.5 mm coarse aggregate at the ratios of 0%, 10%, 25%, 50%, 75% and 100%. Concrete specimens are exposed to 20, 150, 300, 400, 600, 900 and 1200 °C high temperatures corresponding TS EN 1363-1 after an initial 28 day curing period. After heating, the specimens are slowly air-cooled to the room temperature and then E_d and f_c of concretes were determined. Experimental results are also predicted by constructing models in ANN and FL methods. In the models, the training and testing results have shown that ANN and FL methods have strong potential for predicting the f_c and E_d of crushed tile concretes exposed to elevated temperatures.     

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.     

Effects of curing regimes and cement fineness on the compressive strength of ordinary Portland cement mortars

Curing techniques and curing duration have crucial effects on the strength and other mechanical properties of mortars. Proper curing can protect against moisture loss from fresh mixes. The objective of this experimental work is to examine the compressive strength of ordinary Portland cement mortars (OMs) under various curing regimes and cement fineness. Six different curing methods including water, air, water heated, oven heated, air–water, and water–air were applied to the specimens and also six groups of mortars were used. The results showed that the highest and lowest compressive strengths are attributed to the specimens of OPC mortar water cured using grounded OPC for duration of 6 h (OM–G6–wc) and OPC mortar air cured under room temperature with oven heated after demoulding of the specimens at 60 °C for duration of 20 h (OM–OH–ac), respectively. The maximum levels obtained of compressive strengths at 7, 28, and 90 days are 57.5, 70.3, and 76.0 MPa, respectively.     

Effects of steam curing on strength and porous structure of concrete with low water/binder ratio

A research program was carried out to investigate the effects of duration of initial steam curing at atmosphere pressure on compressive strength of concrete with low water/binder ratio. The results showed that the compressive strength of samples steam cured for 5, 10, 14 h increased, while it decreased distinctively for sample steam cured for 24 h. Mercury intrusion porosimetry (MIP) method and scanning electron microscope-backscattered electron (SEM-BSE) image analysis technique were adopted to measure the corresponding variation of porous characteristics caused by the increasing duration of steam curing. The changes in coarse porosity and total porosity calculated by SEM-BSE image analysis and MIP method respectively could indicate the relationship between porosity and mechanical properties of the concrete subjected to different duration of steam curing. Compared with total porosity obtained by MIP method, the coarse porosity by SEM-BSE image analysis was in better accord with the compressive strength because the coarse pores measured by SEM-BSE image analysis were larger than 0.5 μm and included not only the interconnected pores but also the closed ones. An empirical model was developed to evaluate the influence of duration of initial steam curing on the compressive strength of concrete. By comparison, the measured compressive strength was in great accordance with the compressive strength calculated by the proposed model.     

Metakaolin,a solution for the precast industry to limit the clinker content in concrete: Mechanical aspects

The current trend to decrease the clinker content in cements through the use of mineral additions in order to limit CO₂ emissions into the atmosphere is of major concern for the precast industry as the resulting binders are generally not very reactive at early ages. Here, composed cements (clinker + slag) or combinations between clinker and mineral admixtures are studied with a view to investigating the compressive strength of cement-based materials at both early (1 day) and later (28 days) ages under steam curing conditions. Limestone and siliceous fillers, silica fume and four metakaolins differing in their production process and impurity content were investigated. Considering performance, economic and environmental criteria, results in the laboratory showed that metakaolin (MK) is a very promising solution at a clinker replacement rate of 12.5–25% by mass. Compressive strength was significantly increased (1-day age) or practically the same as for reference mortars incorporating cement only (28-day age). Thus, in comparison with a reference concrete containing no MK and for an identical granular skeleton, the combination clinker/MK was validated in the precast factory in full-scale trials for slip-forming (25% replacement) and self-compacting (17.5% replacement) concrete applications: compressive strength and porosity were not affected.     

Effect of metakaolin and foundry sand on the near surface characteristics of concrete

This paper deals with the effect of foundry sand (FS) and metakaolin (MK) on the near surface characteristics of concrete. A control concrete having cement content 450 kg/m³ and w/c of 0.45 was designed. Cement was replaced with three percentages (5%, 10%, and 15%) of metakaolin weight, and fine aggregates were replaced with 20% foundry sand. Tests were conducted for initial surface absorption, sorptivity, water absorption and compressive strength at the ages of 35, 56, and 84 days.Test results indicated that with the increase in MK content from 5% to 15%, there was a decrease in the initial surface absorption, decrease in the sorptivity till 10% metakaolin replacement. But at 15% MK replacement an increase in sorptivity was observed. All mixtures showed low water absorption characteristic i.e. less than 10%. Compressive strength shared an inverse relation with sorptivity. Higher MK replacements of 15% are not helpful in improving inner core durability, even though it helps in improving surface durability characteristics. Inclusion of foundry sand resulted in reduction in compressive strength. This aspect cements the findings that addition of FS causes permeability of concrete to increase causing in an increase in sorptivity and water absorption of concrete.     

Effect of concrete mixing parameters on propagation of ultrasonic waves

An experimental study was conducted to evaluate the effect of concrete aggregate gradation, water–cement ratio, and curing time on measured ultrasonic wave velocity (UPV). 30 × 30 × 10 cm Portland cement concrete slabs were cast for ultrasonic evaluation, while 10 cm diameter by 20 cm height cylinders were cast for compressive strength evaluation The slabs and cylinders were prepared using Portland cement and limestone aggregate. Two slabs were cast from each combination of coarse aggregate gradations and water cement ratio (0.40, 0.45, 0.50, and 0.55). Four ASTM gradations were considered, ASTM No: 8, 67, 56, and 4. These gradations have nominal maximum aggregate size 25, 4.75, 19.3, and 12.5 mm, respectively.The ultrasonic equipment used in this study was the portable ultrasonic non-destructive digital indicating tester (PUNDIT) with a generator having an amplitude of 500 V producing 54 kHz waves. The time needed to transfer the signal between the transducers was recorded and used to calculate the signal velocity, which was used as a parameter in the evaluation. Ultrasonic measurements were performed at 3, 7, 28, and 90 days after concrete casting.The results of the analysis indicated that water–cement ratio was found to have a significant effect on UPV. The UPV was found to decrease with the increase of water cement ratio. Aggregate gradation was also found to have significant effect on UPV. In general, the larger the aggregate size used in preparing Portland cement concrete, the higher the measured velocity of ultrasonic waves. Also, UPV was found to be increased as concrete curing time increased. Concrete compressive strength was found to be significantly affected by water–cement ratio and coarse aggregate gradation. Lower water–cement ratio produced higher concrete strength. Also, the concrete compressive strength increased as maximum aggregate size decreased.     

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.     

Coarse blast furnace slag as a cementitious material,comparative study as a partial replacement of Portland cement and as an alkali activated cement

The cementitious performance of a coarse granulated blast furnace slag, 2900 cm²/g, was investigated in concretes of 230, 280 and 330 kg binder/m³. First, the slag partially replaced 30%, 50% and 70% of Portland cement, the strength reduced as the amount of slag increased; however, for high binder contents, similar strengths were attained for lower Portland cement contents. Second, the slag was alkali activated with sodium silicate (moduli 1.7 and 2) at 4%, 6% and 8% %Na₂O, the strength increased with the amount of slag in the concrete and developed faster as %Na₂O increased. The microstructures of both type of concretes were dense; however, the strengths of activated slag were superior at similar binder loads, indicating that the hydration products of activated slag are of higher intrinsic strength.     

Experimental study of shotcrete and concrete strength development in a hot spring environment

To determine the influence of hot spring water on mechanical characteristics of tunnel supports made from Portland cement, this study investigates strength development and associated temporal variations of shotcrete and concrete specimens cast in situ and cured in water from a hot spring. Experimental results reveal that weakly-base hot spring water with a curing temperature of 40 °C does not adversely affect strength development for shotcrete and concrete; however, the hot spring curing environment may benefit early stage strength development and subsequent integrity. Chloride and sulfate ions in hot spring water do not enhance the alkali–aggregate or alkali–carbonate reaction significantly. Concrete specimens with high uniaxial compressive strength have high surface hardness, high electrical resistance and low permeability, implying excellent short-term durability.     

Parameter optimization on compressive strength of steel fiber reinforced high strength concrete

This paper illustrates parameter optimization of compressive strength of steel fiber reinforced high strength concrete (SFRHSC) by statistical design and analysis of experiments. Among several factors affecting the compressive strength, five parameters that maximize all of the responses have been chosen as the most important ones as age of testing, binder type, binder amount, curing type and steel fiber volume fraction. Taguchi analysis techniques have been used to evaluate L₂₇ (3¹³) Taguchi’s orthogonal array experimental design results. Signal to noise ratio transformation and ANOVA have been applied to the results of experiments in Taguchi analysis. The confirmation runs were conducted for the optimal parameter level combination, which is obtained from the results of the above methodologies. The maximum compressive strength has been observed as around 124 MPa. By using the optimal parameter level combination, the direct tensile strength and flexural strength tests have been conducted. The mean values at the age of 28 days are obtained as 7.5 MPa and 13 MPa respectively. In this study, it is clearly demonstrated that all main factors except steel fiber significantly contribute to the compressive strength of steel fiber reinforced high strength concrete, yet age and binder type are the most significant contributors.     

Effect of mineral admixtures and curing periods on shrinkage and cracking age under restrained condition

This paper presents the test results on cracking behavior at medium age of uniaxially restrained specimens containing different types of mineral admixture, namely fly ash and limestone powder. In this study, the uniaxially restrained shrinkage, free shrinkage and strength tests were conducted to study the potential of cracking of concrete under restrained shrinkage condition. The influences of water to binder ratio, mineral admixtures and curing period of concrete on cracking behavior were investigated in this study. The investigation showed that cracking age and cracking strain of restrained specimens vary with mix proportion, mineral admixture and curing period. The potential of shrinkage cracking is not influenced only by cracking strain and amount of shrinkage but also on shrinkage rate and tensile creep. Mixture with lower water to binder ratio (w/b = 0.35) shows shorter cracking age than the mixture with higher water to binder ratio (w/b = 0.55). Fly ash and limestone powder significantly increase cracking age of concrete. The cracking age increases with the increase of the replacement ratio of fly ash. The higher shrinkage rate, when exposed to drying, of mixture with longer curing period leads to shorter cracking age.     

Improving hydraulic properties of lime–rice husk ash (RHA) binders with metakaolin (MK)

To improve long-term hydraulic properties of binders from RHA and lime, 25–75% MK was added to RHA. Binders were formulated and properties were compared to that containing RHA or MK as only pozzolans. The lime–pozzolan ratio was 1:3. The properties tested after 7, 28 and 56 days were: absolute density and fineness of the binders, initial setting time, chemical and mineralogical composition of hydrated binders, flexural and compressive strengths and water absorption of mortars. The micrographs of the hardened binder pastes at 56 days permitted to evaluate the densification of different matrixes and the development of pores. From the results obtained, it was concluded that, MK increased the density of mixtures and decreased their grindability. The presence of MK decreased the SiO₂ content of binders and increases their Al₂O₃ and Fe₂O₃ contents. Calcium-silicate hydrates (CSH) gel and gehlenite (C₂ASH₈) were the main phases formed during the pozzolanic reaction in the presence of MK. No reduction in flexural and compressive strengths was observed after 28 days for binders containing MK. The mixture of 25% MK and 75% RHA which is recommended gave flexural and compressive strengths higher than binder with RHA or MK as the only pozzolan. Water absorption of mortars was less than 20%.     

Effect of elevated temperature on physico-mechanical properties of blended cement concrete

Pozzolanas are readily available for use in concrete in the local markets for strength and/or durability enhancement. Although safety and security against disasters are not new, they still presuming a challenge. For instance, the fire resistive properties of concrete are of prime interest.Through this work, the effect of different kinds of pozzolana on the fire resistive properties of concrete was studied. Four types of pozzolana were incorporated into the concrete mixtures, i.e. metakaolin (MK), silica fume (SF), fly ash (FA), and ground granulated blast furnace slag (GGBS). Each of the employed pozzolana was used in two ratios: 10% and 20%, either in the form of cement replacement or as an addition without affecting the cement content. A total of 17 mixes were cast.For all mixtures, compressive strength is evaluated after 28 days of water curing. The mixtures’ compressive strengths were also evaluated after exposure to elevated temperatures: 200 °C, 400 °C, 600 °C, and 800 °C. The residual compressive strengths after heat exposure are evaluated. The formed cementitious phases after incorporation of pozzolana and the heat-induced transformations are investigated via the X-ray diffraction technique (XRD).Test results demonstrate the impact of each type of the employed pozzolana on the heat resistive properties of concrete in addition to their influence on the strength development of the investigated mixes. Therefore, a decision could be made regarding optimizing the benefits specific to each type of pozzolana and their employment method.     

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.     

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 concretes of activated metakaolin-fly ash binders,with blast furnace slag aggregates

This work investigated geopolymeric lightweight concretes based on binders composed of metakaolin with 0% and 25% fly ash, activated with 15.2% of Na₂O using sodium silicate of modulus SiO₂/Na₂O = 1.2. Concretes of densities of 1200, 900 and 600 kg/m³ were obtained by aeration by adding aluminium powder, in some formulations lightweight aggregate of blast furnace slag was added at a ratio binder:aggregate 1:1; curing was carried out at 20 and 75 °C. The compressive and flexural strength development was monitored for up to 180 days. The strength diminished with the reduction of the density and high temperature curing accelerated strength development. The use of the slag had a positive effect on strength for 1200 kg/m³ concretes; reducing the amount of binder used. The thermal conductivity diminished from 1.65 to 0.47 W/mK for densities from 1800 to 600 kg/m³. The microstructures revealed dense cementitious matrices conformed of reaction products and unreacted metakaolin and fly ash. Energy dispersive spectroscopy and X-ray diffraction showed the formation of amorphous silicoaluminate reaction products.     

Development of alpha plaster from phosphogypsum for cementitious binders

Efforts have been made to make high strength alpha plaster from phosphogypsum, a by-product of phosphoric acid industry. Phosphogypsum was autoclaved in slurry form (phosphogypsum 50% + water 50%, by wt.) in the laboratory at different steam pressures for different durations in presence of chemical admixtures. It was found that with small quantity of chemical admixture (sodium succinate/potassium citrate/sodium sulphate), alpha plaster of high strength can be produced. The optimum pressure and duration of autoclaving was found to be as 35 psi and 2.0 h, respectively. The alpha plaster was examined for making cementitious binders by admixing hydrated lime, fly ash, granulated blast furnace slag, marble dust and chemical additives with alpha plaster. Data showed that cementitious binder of compressive strength of 22.0 and 30 MPa (at 28 days of curing at 40° and 50 °C) and low water absorption was produced. DTA and SEM studies of the binder showed formation of CSH, ettringite and C₄AH₁₃ as main cementitious products to give strength.     

Effect of Granulated Blast Furnace Slag and fly ash addition on the strength properties of lightweight mortars containing waste PET aggregates

In this work, the effect of Granulated Blast Furnace Slag (GBFS) and fly ash (FA) addition on the strength properties of lightweight mortars containing waste Poly-ethylene Terephthalate (PET) bottle aggregates was investigated. Investigation was carried out on three groups of mortar specimens. One made with only Normal Portland cement (NPC) as binder, second made with NPC and GBFS together and, third made with NPC and FA together. The industrial wastes mentioned above were used as the replacement of cement on mass basis at the replacement ratio of 50%. The size of shredded PET granules used as aggregate for the preparation of mortar mixtures were between 0 and 4 mm. The waste lightweight PET aggregate (WPLA)–binder ratio (WPLA/b) was 0.60; the water–binder (w/b) ratios were determined as 0.45 and 0.50. The dry unit weight, compressive and flexural–tensile strengths, carbonation depths and drying shrinkage values were measured and presented. The results have shown that modifying GBFS had positive effects on the compressive strength and drying shrinkage values (after 90 days) of the WPLA mortars. However, FA substitution decreased compressive and flexural–tensile strengths and increased carbonation depths. Nevertheless a visible reduction occurred on the drying shrinkage values of FA modifying specimens more than cement specimens and GBFS modified specimens. The test results indicated that, GBFS has a potential of using as the replacement of cement on the WPLA mortars by taking into consideration the characteristics. But using FA as a binder at the replacement ratio of 50% did not improve the overall strength properties. Although it was thought that, using FA as binder at the replacement ratio of 50% for the aim of production WPLA concrete which has a specific strength, would provide advantages of economical and ecological aspects.