Alkali-silica reactivity of large silica fume-derived particles

Pozzolanic materials, including silica fume, are commonly added to concrete to reduce expansion due to alkali-silica reaction (ASR). It has been noted, however, that commercial silica fume is not always adequately dispersed, and large agglomerates may be present. These large particles have been hypothesized to act as amorphous silica aggregates, thereby participating in an expansive reaction with the alkalis present in cement paste pore solution. If such were the case, some silica fume particles would actually aggravate expansion due to ASR rather than suppress it. The present investigation characterizes the microstructure and morphology of agglomerated and sintered silica fume particles and compares their effects on alkali-silica-related expansion. While a 5% replacement of moderately reactive sand with sintered silica fume aggregates caused significant expansion under accelerated testing conditions (modified ASTM C1260), the replacement with large agglomerates of densified silica fume decreased expansion compared with control mortar bars containing only sand. Both the sintered aggregates and the agglomerates reacted with the pore solution; one reaction was expansive, while the other was not.     

Fibre reinforced lightweight aggregates

Carbon steel fibre reinforced lightweight aggregates (LWA) were produced in a pilot scale rotary kiln. Narrow size fractions as well as not-sieved (as received) material were investigated according to European standards with a main focus on strength and density and compared to a reference material without fibres. Depending on the size of the pellets a fraction of the fibres oxidized during firing. A strength increase proportional to the amount of non-oxidized fibres within the pellet was observed. The crushing resistance for as received fibre reinforced pellets (bulk density 452 kg/m³) was 3.0 MPa corresponding to an increase in strength of 140%. The enhanced strength was also confirmed by the single pellet compression test.     

Mechanical properties of lightweight aggregates

Lightweight aggregates (LWAs) were successfully produced both in a pilot-scale rotary kiln and in a laboratory chamber furnace. The mechanical properties of LWA were investigated in detail applying the European standard crushing resistance test (CR-test) as well as the single pellet compression test (spc-test). The spc-test showed that LWA pellets with porosities <82% behave similar to solid brittle spheres under compression when considering only the solid fraction of the pellet and the strength may be calculated according to σ_crit = F_crit/d² where σ_crit is a porosity independent strength, F_crit is the measured load at failure and d the solid diameter (assuming zero porosity). It was reasoned that catastrophic failure was due to tensile stresses in the centre of the pellet and the strength was observed to increase exponentially with decreasing sample size. The relationship between the CR- and spc-test has been established facilitating “translation” of strength data between the two different test methods.     

Neapolitan Yellow Tuff as raw material for lightweight aggregates in lightweight structural concrete production

The possibility of using Italian zeolitized volcanoclastites for the production of lightweight aggregates in the building industry has been tested.The present paper definitely demonstrates the good attitude of the Neapolitan Yellow Tuff (NYT) for the production of lightweight expanded aggregates (LEA) with bulk densities ranging between 0.9 and 1.1 g/cm³. LEAs showing these features, usually manufactured with clays, are mainly used in the production of lightweight structural concretes (LSC). The physical characterization of LEAs was carried out by means of: grain size analysis, loose weight, mean density of the single grain, water absorption after 30 min and 24 h, and strength of particles (UNI-7549). Afterwards, LEAs were mixed with sand, cement and water to prepare cubic concrete blocks following the UNI specifications (UNI-7549-12). On these specimens, the unit weight and uniaxial compressive strength after 28 days were determined.The investigated parameters measured both on LEAs and concretes, are comparable with those measured on materials commonly traded in Italy.The obtained results foresee interesting potential applications of a raw material characterized by a low exploitation cost and a widespread availability on the Italian territory.     

Performance of glass-ceramic-based lightweight aggregates manufactured from waste glass and muck

Lightweight aggregates (LWAs) with microcrystalline diopside as the main constituent were prepared in this study. Waste glass and waste muck were used as the main raw materials, and the formula was designed according to the chemical composition of diopside, rather than using the Riley scheme. The effects of the glass content and nucleating agent on the mechanical properties, mineral composition, and microstructure of LWAs were studied. The results indicated that the presence of diopside crystallites can significantly improve the mechanical properties of LWAs. With an increase in the glass content from 0 wt % to 70 wt %, the strength of the LWAs increased from 12.21 MPa to 19.31 MPa with similar densities in the range of 1.667–1.687 g/cm³. The addition of a nucleating agent has a fluxing effect and promotes the formation and growth of diopside, which provides aggregates with high strength and low density. For example, the addition of CaF₂ decreased the density of the LWAs from 1.687 g/cm³ to 1.461 g/cm³ and increased the strength from 17.59 MPa to 20.81 MPa under the same calcination regime. The effect of the pore structure on the mechanical properties of the LWA in this experiment was far less than that of the crystal phase composition. With the addition of a nucleating agent, the diopside was co-precipitated from both the muck and glass. If no nucleating agent is added, diopside mainly precipitates from glass, and muck mainly forms a glass phase.     

Compatibility between ecocement produced from incinerator ash and reactive aggregates in ASR expansion of mortars

Recently, in Japan, two new-type hydraulic cements, high early strength type ecocement (HEC) and normal type ecocement (NEC), have been developed using incinerator ashes up to 50% of the raw materials. In this study, the compatibility of these ecocements with various types of reactive aggregates with respect to alkali-silica reaction (ASR) was studied. Ordinary Portland cement (OPC) and blast furnace slag cement (BFSC) were also used for a comparative study. Two types of the accelerated mortar bar expansion test, the JIS A1146 and the Danish methods, were used to clarify the expansion behavior of mortars made with the above cements. The influence of a combination of the chemical and mineralogical compositions of cement and the reactive components of aggregate on both the amount of ASR gel and the expansion rate of the mortar was also investigated. From the results, it was found that the expansion behaviors of mortars due to ASR varied significantly depending on a combination of both the mineralogical composition of cement and the reactive component of aggregate.     

Crystallized alkali-silica gel in concrete from the late 1890s

The Elon Farnsworth Battery, a concrete structure completed in 1898, is in an advanced state of disrepair. To investigate the potential for rehabilitation, cores were extracted from the battery. Petrographic examination revealed abundant deposits of alkali silica reaction products in cracks associated with the quartz rich metasedimentary coarse aggregate. The products of the alkali silica reaction are variable in composition and morphology, including both amorphous and crystalline phases. The crystalline alkali silica reaction products are characterized by quantitative X-ray energy dispersive spectrometry (EDX) and X-ray diffraction (XRD). The broad extent of the reactivity is likely due to elevated alkali levels in the cements used.     

Summary of research on the effect of LiNO3 on alkali-silica reaction in new concrete

This paper summarizes findings from a research study conducted at the University of New Brunswick in collaboration with the University of Texas at Austin, and CANMET-MTL, on the effect of LiNO₃ on ASR in new concrete. The studies included expansion testing, silica dissolution measurements and microstructural examinations of cement systems containing glass and two different reactive aggregates (NB and NS). Only a small proportion of the data are presented here for the purpose of highlighting the principal findings of this investigation.Based on these findings, it is proposed that the inhibiting effect of LiNO₃ against ASR in new concrete is attributed to the formation of two reaction products in the presence of lithium, these being a crystalline lithium silicate compound (Li₂SiO₃) crystal and a Li-bearing, low Ca silica gel. These two phases could serve as a diffusion barrier and protective layer to prevent the reactive silica from further attack by alkalis.It was found that the reason the two reactive aggregates selected responded differently to LiNO₃ was due to the difference in their textural features. The NB aggregate contained reactive volcanic glass particles, the surface of which was immediately and equally available to sodium, potassium and lithium, and thus a Li-Si barrier was able to form quickly. The reactive phase in the NS aggregate was microcrystalline and strained quartz, which was embedded in a dense matrix of a non-reactive predominantly alumino-silicate phase and was not easily accessible to lithium.     

The effect of heat treatment and cooling rate on the properties of lightweight aggregates

Lightweight aggregates (LWA) were produced from clay in the laboratory. After firing different heat treatments and cooling rates were applied and the resulting material was investigated with respect to strength and microstructure. Fast cooling led to the formation of micro cracks and weakened the material whereas slow cooling enhanced the strength of LWA. The residence time at temperatures between 700 °C and 900 °C led to differences in average oxidation state of iron in the matrix phase leading to substantial changes in thermal behaviour of the matrix phase. The combination of a highly oxidized shell and a reduced core proved to enhance the strength of LWA. A two hour heat treatment at 800 °C in air combined with a subsequent slow cooling rate (0.7 °C/min) applied to LWA produced in an industrial rotary kiln led to a strength increase of 114% compared to material of the normal production without changing any other property.     

Pozzolanic reactivity of lightweight aggregates

Over recent years more attention has been given to the influence of the aggregate-cement paste interfacial zone on the various properties of concrete. For the lightweight aggregate - cement paste interface, it is believed that the interface is characterized by a mechanical interlocking in combination with a chemical interaction in the form of pozzolanic reaction. In the literature, however, not too much information on the effect of the pozzolanic reactivity of lightweight aggregates is available. Therefore, an investigation on the pozzolanic reactivity of some lightweight aggregates based on expanded clay and sintered fly ash was carried out. A certain degree of pozzolanic reaction between cement paste and lightweight aggregate was observed, but the effect was not very pronounced. The low degree of pozzolanic reactivity may be the result of a recrystallization of the mineral compounds during the manufacturing process of the aggregate.     

Alkali silica reactivity of agglomerated silica fume

It is commonly accepted that replacement of a portion of cement in mortar or concrete with well-dispersed silica fume reduces expansion caused by alkali silica reaction. Recently there has been much discussion that large, agglomerated particles of silica fume may actually act as alkali silica reactive aggregates, thereby increasing expansion rather than reducing it. The data in the literature, from both field and laboratory studies, are inconsistent. This prompted an extensive laboratory investigation into the alkali silica reactivity of silica fume. Results from accelerated expansion testing and microscopic investigations are presented. It was seen that some agglomerated silica fumes participate in ASR while others do not. Factors determining the reactivity of silica fume agglomerates are suggested.     

Lightweight aggregate based on waste glass and its alkali-silica reactivity

The possible use of waste glass for the production of lightweight aggregate has been studied. The aggregate, in the form of highly porous granules, was produced by mixing together finely ground waste glass and an expansive agent and firing this mixture at a selected temperature. The expansive agent was chosen on the basis of the results of DTA/TGA experiments, which were carried out on some selected agents and confirmed by using a hot-stage microscope, where the temperature interval of the expansion was also determined. Pilot production of about 0.5 m³ of the aggregate was performed in a rotary kiln, and the water absorption and bulk density of the aggregate so obtained were determined. Special emphasis was placed on the determination of the alkali-silica reactivity of the aggregate, and the results of initial tests for alkali-aggregate reaction were encouraging, given the high potential reactivity of the material. However, before such aggregate can be considered safe for general use in concrete, longer-term concrete prism tests need to be carried out, which would cover the range of mixes in which the aggregate is likely to be used.     

Laboratory assessment of alkali contribution by aggregates to concrete and application to concrete structures affected by alkali-silica reactivity

In Phase I, particles from 17 different aggregates, 1.25-5 mm in size, were immersed in continuously agitated solutions at 38 °C: distilled water, Ca(OH)₂-saturated solution, 0.7 M NaOH (measurement of K supply), and 0.7 M KOH (measurement of Na supply). These solutions were periodically analysed for K and/or Na up to 578 days. More alkalies were released in alkaline solutions than in lime-saturated solution, with lower values in water. After 578 days, the aggregates released between <0.01% and 0.19% Na₂O_e, excluding the nepheline-rich aggregate tested (0.68%). This would correspond to a contribution to concrete from <0.1 to 3.4 kg/m³ Na₂O_e (12.7 for the phonolite), based on an aggregate content of 1850 kg/m³. In general, the feldspar-rich aggregates released significantly more alkalies. In Phase II, the water-soluble alkali content of mass concrete elements from many dams was measured using a hot water extraction method. The values obtained often largely exceed the soluble alkali content expected to be released by the cement used. These results thus also suggest that large amounts of alkalies were supplied with time by the aggregates, particularly by feldspar-rich ones.     

Alkali-silica reaction: A method to quantify the reaction degree

We propose a new chemical method for quantitative measurement of the reaction degrees of the alkali-silica reaction (ASR). We apply this method to a crushed natural reactive aggregate kept in contact with an alkaline solution, lime saturated by an appropriate amount of portlandite. This chemical system is designed to model the concrete capillary pores alkaline solution, in contact with reactive aggregates. Two reaction steps are taken into account in the mechanism: formation of Q₃ sites made by breaking up siloxane bonds of the reactive silica and dissolution of these Q₃ sites. The dissolution degree is measured by a selective acid treatment, and the nature of silica into solution is characterised by liquid NMR spectroscopy. The remaining silica is composed of Q₄ tetrahedrons and Q₃ protonated sites identified by solid NMR spectroscopy. These Q₃ protonated sites are measured by thermogravimetry analysis. We show that the formation Q₃ sites prevails on dissolution as the reaction progresses and contributes to an internal silica gel generation. The limiting step is the siloxane breaking up. Petrographic observations show that the reaction front penetrates in the aggregate through its porosity.     

Rapid evaluation of alkali-silica reactivity of aggregates using a nonlinear resonance spectroscopy technique

A new nonlinear acoustic technique — Nonlinear Impact Resonance Acoustic Spectroscopy (NIRAS) — is developed and used to characterize the alkali-reactivity of different aggregates. Cementitious materials such as mortar and concrete exhibit a hysteretic and nonlinear elastic behavior in their constitutive relations. This hysteretic nonlinearity is associated with interfacial debonding between the different constituents, and it changes with the progress of damage such as that induced by the alkali-silica reaction (ASR). One of the consequences of the hysteretic nonlinear property of these materials is the decrease in resonance frequencies, with increased excitation amplitude. This shift in the resonance frequency as a function of the material nonlinearity parameter can be used to directly characterize the damage state of the material. This research tracks the variation of the nonlinearity parameter during a standard accelerated mortar bar test (AMBT) to assess the potential for alkali-reactivity of aggregates. The results show that the NIRAS technique is more sensitive than conventional linear acoustic methods and is capable of accurately characterizing the reactivity of the aggregates examined. Furthermore, the results show advantages over standard expansion measurements for differentiating various aggregates having similar levels of reactivity, particularly at early test ages. These changes in the nonlinearity parameter are benchmarked against results from a petrographic analysis. Thus, the proposed NIRAS is a promising technique for the rapid identification of alkali-reactive aggregates.     

The effects of gradation and admixture on the pumice lightweight aggregate concrete

The usage of lightweight concrete, which has some advantage over ordinary concrete, has increased to a remarkable level in recent years. Many researchers have investigated the possible uses of lightweight concrete in terms of its strength, density and other mechanical and physical properties. The desired quality for lightweight concrete can be obtained through the proper selection of admixtures and proper grading of the lightweight aggregate.In this article, an experimental investigation on the production of moderate-strength lightweight concrete with pumice, according to the ACI standard, is presented. The gradation curves' (which fall within A16-C16 gradation curves, Turkish Standard Code, TS706) performances were investigated in terms of strength and density. The addition of superplasticizer and air-entraining admixtures improved the strength-to-density ratio of the hardened concrete and the workability of fresh concrete. As a result of this study, lightweight concrete blocks having a minimum compressive strength of 6.56 N/mm² and a density of 1300 kg/m³ were obtained.     

The effects of air content on permeability of lightweight concrete

Air entraining agent is used to control the floatation of lightweight aggregate (LWA) in lightweight aggregate concrete (LWAC), therefore reducing the segregation of LWAC. At the same time, using an air entraining agent will affect the water sorption of the concrete. In this paper, two lightweight concrete mixes of density 1000 kg/m³ and air content of 13.5% and 31.9% were compared and the effects of entrained air on the strength, surface sorptivity, and chloride permeability of LWAC are presented. Results show that the use of porous LWA would not lower the permeability resistance of concrete. Entrained air had little effect on sorptivity but a major effect on chloride permeability. The weaker pores' network in the cement paste is the basic cause for the high chloride permeability of concrete than the use of porous LWA. Although chloride permeability of low density LWAC concrete decreased with age of concrete, it was found that the concrete was not dense enough to stop the chloride ion to penetrate through the concrete before the concrete mature at 90 days.     

Shrinkage cracking of lightweight concrete made with cold-bonded fly ash aggregates

Shrinkage cracking performance of lightweight concrete (LWC) has been investigated experimentally on ring-type specimens. LWCs with and without silica fume were produced at water-cementitious material ratios (w/cm) of 0.32 to 0.55 with cold-bonded fly ash coarse aggregates and natural sand. Coarse aggregate volume ratios were 30%, 45%, and 60% of the total aggregate volume in the mixtures. A total of 12 lightweight aggregate concrete mixtures was cast and tested for compressive strength, static elastic modulus, split-tensile strength, free shrinkage, weight loss, creep, and restrained shrinkage. It was found that the crack opening on ring specimens was wider than 2 mm for all concretes. Free shrinkage, weight loss, and maximum crack width increased, while compressive and split-tensile strengths, static elastic modulus, and specific creep decreased with increasing coarse aggregate content. The use of silica fume improved the mechanical properties but negatively affected the shrinkage performance of LWCs. Shrinkage cracking performance of LWCs was significantly poorer than normal weight concrete (NWC).     

Effect of sintering temperature on lightweight aggregates manufacturing from copper contaminated soil

Manufacturing lightweight aggregate (LWA) at high temperature is an effective way to immobilize heavy metals in solid waste. This work investigated the performance and solidification mechanism of LWA prepared from copper contaminated soil. The volume expansion of LWA could reach a maximum of 28%, and its lowest density accounted of 1.5 g/cm³, which met the standard requirements. Optical microscope and micro-CT test illustrated that the addition of Cu leaded to obvious phase separation in LWA. The Cu leaching result of LWA first increased and then dropped with the temperature. The XRD test found that the main formation phase of Cu in LWA were t-CuFe₂O₄ and amorphous phase that they had different acid resistance ability. XPS revealed that the main cause of the agglomeration of liquid phase in LWA was the chain broken reaction between Cu and Si–O tetrahedron. SEM-EDS results showed that the distribution of Cu and Si had a strong correlation, which meant that Cu mostly formed amorphous phase. This work showed the uniqueness of Cu in the high temperature immobilization and pointed out the best immobilization target phase.