Influence of steam curing on the properties of concretes incorporating metakaolin and silica fume

In this paper, influence of steam curing on the compressive strength, ultrasonic pulse velocity, water sorptivity, chloride ion permeability, and electrical resistivity of metakaolin and silica fume blended concretes were investigated. A total of seven mixtures containing various combinations of Portland cement (PC), silica fume (SF), and metakaolin (MK) were produced with 400 kg/m³ of total cementitious materials content and with a constant water/binder ratio of 0.44. For each mixture, concrete samples were either standard-cured in water at 23°C or steam-cured at 70°C maximum temperature over 17 h curing period. Test results revealed that steam curing enhanced the 1-day compressive strength and ultrasonic pulse velocity while leading to reduced long term strength in line with earlier findings. At the end of the water sorptivity, chloride ion permeability, and electrical resistivity tests, it was found that the steam-cured concretes had higher water sorptivity and chloride ion permeability, and lower electrical resistivity values compared to the standard cured specimens. Use of SF and MK as cementitious materials remarkably decreased the water sorptivity and chloride ion permeability of concretes, irrespective of the curing condition.     

Optimization of concrete mixture with hybrid blends of metakaolin and fly ash using response surface method

This paper presents the experimental results of a research carried out on the strength and permeability related properties of high performance concretes made with binary and ternary cementitious blends of fly ash (FA) and metakaolin (MK). The replacement ratios for FA were 10% and 20% by weight of Portland cement and those for MK were 5% and 10%. Compressive strength, chloride permeability, water sorptivity, and water absorption properties of concretes were obtained in this study for different testing ages up to 90 days. The influences of fly ash, metakaolin, and testing age on the properties of concretes have been identified using the analysis of variance. The statistical based regression models and the response surface method with the backward stepwise techniques were employed in the multi-objective optimization analysis. That is carried out by maximizing compressive strength while minimizing chloride permeability, water sorptivity, and water absorption. It was observed that fly ash and especially metakaolin were very effective on the aforementioned properties of the concretes, depending mainly on replacement levels and duration of curing. The results indicated that the ternary use of fly ash and metakaolin with the approximate cement replacement values of 13.3% and 10% respectively has provided the best results for the testing age of 90 days, when the optimized strength and permeability based durability properties of the concretes are concerned.     

Efficiency,skin strength and sorptivity of fly ash concretes

Four grades of concrete with and without fly ash were devised and tested for compressive strength. The concretes were cured in three different curing regimes. The skin strength of concretes under inadequate curing was calculated by assuming a linear model for the variation of strength, and the strength difference between cement and fly ash concretes has been worked out. The skin strength of cement concretes was found to be higher than that of fly ash concretes. The test results were found to be affected by the size of the test specimen, when proper curing was not provided. The difference in sorptivity of fly ash and cement concretes cured for four days and not provided with any initial curing has been included. For all grades of concrete, the sorptivity of fly ash concrete was found to be marginally higher. The difference in sorptivity between fly ash and cement concretes was observed to increase as the strength of the mix decreased. The effect of initial curing was found to be highly significant. The sorptivity of samples with no curing was twice as much as those with four days initial curing. Besides the material properties, the age and strength of a fly ash concrete were also found to be important factors in determining the cementing efficiency of the fly ash.     

Moisture and ionic transport in concretes containing coarse limestone powder

Concretes containing a coarse limestone powder (median particle size of 72 μm) as a partial cement replacement material are proportioned so as to attain similar 7-day compressive strengths as a 0.40 water-to-cement ratio (w/c) control concrete. The moisture and chloride ion transport behavior of the concretes containing limestone powder with and without small amounts of silica fume are evaluated in this paper. It is shown that a 15% cement replacement with coarse limestone powder at a water-to-powder ratio (w/p) of 0.34 results in concretes of better or comparable compressive strengths, porosities, moisture transport parameters (overall moisture intake, and sorptivity), and rapid chloride permeability (RCP) as that of a 0.37 w/c plain concrete. However, the non-steady state migration coefficients (D_nssm) of concretes containing limestone powder are found to be higher than those of plain concretes of even higher w/c. A microstructural parameter (?β – product of porosity and pore connectivity) is used to relate the pore structure to the moisture and ionic transport. Relationships between ?β and the moisture and ionic transport parameters are provided, which shed light on the combined influence of w/p and a highly reactive cement replacement material such as silica fume on the different transport properties of concretes containing a coarse limestone powder.     

Permeability properties of concretes with high reactivity metakaolin and calcined impure kaolin

This study reports the findings of an experimental study carried out on transport properties of the concretes modified with different calcined non purified kaolins (CK) and commercially available high reactivity metakaolin (MK). CK used in this study were obtained by calcining impure ground kaolins from four different quarries located on kaolin beds of different morphological and geological formations in Turkey. However, commercially available MK produced by thermal treatment of high purity kaolin from Czech Republic was used as reference material. In concrete mix design, the cement was replaced with 5, 10, 15, and 20 % by weight of CK or MK. The gas permeability, water permeability, water sorptivity, and chloride permeability tests were performed at the end of 28 and 90 days of curing periods. The results indicated that the concretes incorporated with different types of calcined kaolins had comparable performance in permeability with MK modified concrete, depending mainly on the type and amount of the mineral admixture used. Moreover, all of the concretes incorporation MK or CK had considerably better permeability than plain concrete regardless of the replacement level.     

Durability aspect of concretes composed of cold bonded and sintered fly ash lightweight aggregates

This study reports the finding of an experimental study carried out on the durability related properties of the lightweight concretes (LWCs) including either cold bonded (CB) or sintered (S) fly ash aggregates. CB aggregate was produced with cold bonding pelletization of class F fly ash (FA) and Portland cement (PC) while S aggregate was produced by sintering the fresh aggregate pellets manufactured from FA and bentonite (BN). Two concrete series with water-to-binder (w/b) ratios of 0.35 and 0.55 were designed. Moreover, silica fume (SF) with 10% replacement level was also utilized for the purpose of comparing the performances of LWCs with and without ultrafine SF. The durability properties of concretes composed of CB and S aggregates were evaluated in terms of water sorptivity, rapid chloride ion permeability, gas permeability, and accelerated corrosion testing after 28 days of water curing period. The compressive strength test was also applied to observe the strength level at the same age. The results revealed that S aggregate containing LWCs had relatively better performance than LWCs with CB aggregates. Moreover, the incorporation of SF provided further enhancement in permeability and corrosion resistance of the concretes.     

A study on reinforcement corrosion and related properties of plain and blended cement concretes under different curing conditions

This paper presents the results of an experimental investigation on the steel reinforcement corrosion, electrical resistivity, and compressive strength of concretes. Concretes having two different water–cement ratios (0.65 and 0.45) and two different cement contents (300 and 400 kg/m³) were produced by using a plain and four different blended portland cements. Concrete specimens were subjected to three different curing procedures (uncontrolled, controlled, and wet curing). The effect of using plain or blended cements on the resistance of concrete against damage caused by corrosion of the embedded reinforcement has been investigated using an accelerated impressed voltage setup. The resistivity of the cover concrete has been measured non-destructively by placing electrodes on concrete surface. The compressive strength, electrical resistivity, and corrosion resistance of the concretes were determined at different ages up to 180 days. The results of the tests indicated that the wet curing was essential to achieve higher strength and durability characteristics for both plain and especially blended cement concretes. The concretes, which received inadequate (uncontrolled) curing, exhibited poor performance in terms of strength and corrosion resistance.     

Durability assessment of alkali activated slag (AAS) concrete

The environmental impact from the production of cement has prompted research into the development of concretes using 100% replacement materials activated by alkali solutions. This paper reports research into the durability of AAS concrete. The durability properties of AAS have been studied for a range of sodium oxide dosages and activator modulus. Properties investigated have included measurements of workability, compressive strength, water sorptivity, depth of carbonation and rapid chloride permeability. Microstructure studies have been conducted using scanning electron microscopy and energy dispersive X-ray spectroscopy. It was concluded that an activator modulus of between 1.0 and 1.25 was identified as providing the optimum performance for a sodium oxide dosage of 5% and that AAS concretes can exhibit comparable strength to concrete currently produced using Portland cement (PC) and blended cements. However, with regards to the durability properties such as water sorptivity, chloride and carbonation resistance; the AAS concretes exhibited lower durability properties than PC and blended concretes. This, in part, can be attributed to surface microcracking in the AAS concretes.     

Effect of metakaolin on the near surface characteristics of concrete

Results on an investigation dealing with the effect of metakaolin (MK) on the near surface characteristics of concrete are presented in this paper. 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. 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.     

Improving strength, drying shrinkage, and pore structure of concrete using metakaolin

This paper presents the results of an investigation on the use of metakaolin (MK) as a supplementary cementing material to improve the performance of concrete. Two MK replacement levels were employed in the study: 10% and 20% by weight of the Portland cement used. Plain and PC-MK concretes were designed at two water–cementitious materials (w/cm) ratios of 0.35 and 0.55. The performance characteristics of the concretes were evaluated by measuring compressive and splitting tensile strengths, water absorption, drying shrinkage, and weight loss due to the corresponding drying. The porosity and pore size distribution of the concretes were also examined by using mercury intrusion porosimetry (MIP). Tests were conducted at different ages up to 120 days. The results revealed that the inclusion of MK remarkably reduced the drying shrinkage strain, but increased the strengths of the concretes in varying magnitudes, depending mainly on the replacement level of MK, w/cm ratio, and age of testing. It was also found that the ultrafine MK enhanced substantially the pore structure of the concretes and reduced the content of the harmful large pores, hence made concrete more impervious, especially at a replacement level of 20%.     

Influence of a fine glass powder on the durability characteristics of concrete and its comparison to fly ash

A detailed investigation carried out to ascertain the durability characteristics of fine glass powder modified concretes is reported in this paper. Tests were designed to facilitate comparisons between concretes modified with either glass powder or fly ash at the same cement replacement level. The optimal replacement level of cement by glass powder is determined from strength and hydration tests as 10%. The later age compressive strengths of glass powder and fly ash modified concretes are seen to differ by only 5%. The durability characteristics are ascertained using tests for rapid chloride permeability, alkali–silica reactivity, and moisture transport parameters. The chloride penetrability values indicate some amount of pore refinement. The potential of glass powder to reduce the expansion due to alkali–silica reaction is established from tests conducted in accordance with ASTM C 1260, but fly ash is found to perform better at similar replacement levels. Glass powder–fly ash blends that make up a 20% cement replacement level are found to be as efficient as 20% fly ash in reducing expansion. The control concrete is seen to exhibit the lowest overall moisture intake after 14 days of curing, and fly ash concrete the highest, with the glass powder concrete in between. The trend is reversed at later ages, demonstrating that both the replacement materials contribute to improved durability characteristics. The sorptivity and moisture diffusion coefficient values calculated from the moisture intake-time data also demonstrate a similar trend. These studies show that fine glass powder has the potential to improve the durability of concretes.     

Transport and mechanical properties of self consolidating concrete with high volume fly ash

This paper presents the transport and mechanical properties of self consolidating concrete that contain high percentages of low-lime and high-lime fly ash (FA). Self consolidating concretes (SCC) containing five different contents of high-lime FA and low-lime FA as a replacement of cement (30, 40, 50, 60 and 70 by weight of total cementitious material) are examined. For comparison, a control SCC mixture without any FA was also produced. The fresh properties of the SCCs were observed through, slump flow time and diameter, V-funnel flow time, L-box height ratio, and segregation ratio. The hardened properties included the compressive strength, split tensile strength, drying shrinkage and transport properties (absorption, sorptivity and rapid chloride permeability tests) up to 365 days. Test results confirm that it is possible to produce SCC with a 70% of cement replacement by both types of FA. The use of high volumes of FA in SCC not only improved the workability and transport properties but also made it possible to produce concretes between 33 and 40 MPa compressive strength at 28 days, which exceeds the nominal compressive strength for normal concrete (30 MPa).     

Study on water sorptivity of the surface layer of concrete

This paper presents the results from a study of water sorptivity of concrete surface layer. The sorptivity is characterized by a surface sorptivity index as measured by Autoclam. In this study, different types of concrete were immersed in ultrapure water and NaCl solution prior to the sorptivity test. The influences of several factors on the value and evolution of concrete surface sorptivity index are discussed. It is found that: concrete surface sorptivity is a function of the pore structure, higher porosity and lower tortuosity lead to higher surface sorptivity; as cured in moist condition for 1 month, the surface sorptivity is an increasing function of w/c in plain cement concretes, and an increasing function of fly ash replacement if w/b is kept constant; surface sorptivity increases as immersed in ultrapure water in the first month of immersion due to leaching, and decreases thereafter as the continuous hydration of cementitious materials makes the pore structure finer and finer; the immersion in NaCl solution limits the effect of leaching because of the formation of calcium oxychloride compounds, and results in lower long-term surface sorptivity index as compared with the ultrapure water immersion, due to the formation of Friedel’s salt which reduces the pore volume and blocks the pore network.     

Influence of various amounts of limestone powder on performance of Portland limestone cement concretes

The benefits of limestone as a partial replacement for Portland Cement (PC) are well established. Economic and environmental advantages by reducing CO₂ emissions are well known. The paper describes the effect of various amounts of limestone on compressive strength, water penetration, sorptivity, electrical resistivity and rapid chloride permeability on concretes produced by using a combination of PC and limestone at 28, 90 and 180 days. The percentages of limestone that replace PC in this research are 0%, 5%, 10%, 15% and 20% by mass. The water/(clinker + limestone) or (w/b) ratios are 0.37, 0.45 and 0.55 having a constant total binder content of 350 kg/m³. Generally, results show that the Portland limestone cement (PLC) concretes having up to 10% limestone provide competitive properties with PC concretes.     

Performance of metakaolin concrete at elevated temperatures

An experimental investigation was conducted to evaluate the performance of metakaolin (MK) concrete at elevated temperatures up to 800 °C. Eight normal and high strength concrete (HSC) mixes incorporating 0%, 5%, 10% and 20% MK were prepared. The residual compressive strength, chloride-ion penetration, porosity and average pore sizes were measured and compared with silica fume (SF), fly ash (FA) and pure ordinary Portland cement (OPC) concretes. It was found that after an increase in compressive strength at 200 °C, the MK concrete suffered a more severe loss of compressive strength and permeability-related durability than the corresponding SF, FA and OPC concretes at higher temperatures. Explosive spalling was observed in both normal and high strength MK concretes and the frequency increased with higher MK contents.     

Strength development and chloride penetration in rubberized concretes with and without silica fume

The study presented herein has been carried out in order to investigate the strength development and chloride permeability characteristics of plain and rubberized concretes with and without silica fume. For this purpose, two types of tire rubber, namely crumb rubber and tire chips, were used as fine and coarse aggregate, respectively, in the production of rubberized concrete mixtures which were obtained by partially replacing the aggregate with rubber. Two water-cementitious material (w/cm) ratios (0.60 and 0.40), three moist curing periods (3, 7, and 28 days), four designated rubber contents (0, 5, 15, and 25 by total aggregate volume), two silica fume content (0 and 10% by weight of cement), and five different testing ages (3, 7, 28, 56, and 90 days) were considered as experimental parameters. The results indicated that for a given w/cm ratio and moist curing period, the use of rubber significantly aggravated the chloride ion penetration through concrete but the degree of the rate of the increment of the chloride permeability depended on the amount of the rubber used. When the curing period was extended from 3 to 28 days, the reduction in the magnitude of chloride penetration depth was notably higher for the rubberized concretes, even at a rubber content of as high as 25%. It was also observed that silica fume may be considered as a remedy to enhance the chloride penetration resistance of the rubberized concretes.     

Evaluation of Portland limestone cements for use in concrete construction

The paper describes a study carried out to examine the performance of concrete produced using combinations of Portland cement (PC) and limestone (LS), covering compositions for Portland limestone cement (PLC) conforming to BS EN 197-1: 2000, and up to 45% LS. In particular, key engineering (mechanical) and durability properties of concrete were studied. The results indicate only minor differences in performance between PC and 15% PLC concretes of the same cement content and water/cement (w/c) ratio (cement = Portland cement + addition). However, there was an adverse effect with increasing LS content beyond 15% of the cement content for many properties. It is shown that for 35 N/mm² cube strength concrete the adjustment to w/c ratio to match the compressive strength of PC concrete was in the region of 0.08 for each 10% LS added (water curing at 20°C) above this level. Studies of permeation and concrete durability performance, including, initial surface absorption, carbonation resistance, chloride diffusion, freeze/thaw scaling and abrasion resistance, indicate that in general the test concretes followed single relationships with strength for most properties. Consideration is given to the practical implications of the main outcomes of the study.     

Correlation between compressive strength and certain durability indices of plain and blended cement concretes

In this study, plain, silica fume and fly ash cement concrete specimens prepared with varying water to cementitious materials ratio and cementitious materials content were tested for compressive strength, water permeability, chloride permeability, and coefficient of chloride diffusion after 28 days of water curing. The data so developed were statistically analyzed to develop correlations between the compressive strength and the selected durability indices of concrete. Very good correlations were noted between the compressive strength and the selected durability indices, particularly chloride permeability and coefficient of chloride diffusion, irrespective of the mix design parameters. However, these correlations were observed to be dependent on the type of cement.     

Durability performance potential and strength of blended Portland limestone cement concrete

This paper describes a study on the durability potential and strength of composite Portland-limestone cement (PLC) concrete mixtures blended with ground granulated blast furnace slag (GGBS) and/or fly ash (FA). Their performance was compared against ordinary Portland cement, plain PLC and Portland-slag cement concrete mixtures. Using the South African Durability Index approach, results indicate reductions in the penetrability of the composite PLC blends compared to the other mixtures. The durability indicators are chloride conductivity, gas (oxygen) permeability and water sorptivity. Compressive strength of the composite PLC mixtures containing both GGBS and FA showed competitive performance with the comparative mixtures, but FA blended PLC mixtures had diminished compressive strength values. The paper also presents considerations on the practical implications of using blended PLC concrete mixtures.     

The permeability of fly ash concrete

Oxygen permeability tests were carried out on plain ordinary Portland cement (OPC) and fly ash concretes at three nominal strength grades. Prior to testing the concretes were subjected to a wide range of curing and exposure conditions. The results emphasize the importance of adequate curing to achieve concrete of low permeability, especially when the ambient relative humidity is low. In addition, the results demonstrate the considerable benefit that can be achieved by the use of fly ash in concrete. Even under conditions of poor curing, fly ash concrete is significantly less permeable than equal-grade OPC concrete, the differences being more marked for higher-grade concretes. Attempts were made to correlate strength parameters with permeability but it is concluded that neither the strength at the end of curing nor the 28-day strength provides a reliable indicator of concrete permeability. A reliable correlation was established between the water to total cementitious material ratio [w/(c+f)] and the permeability of concretes subjected to a given curing and exposure regime.