Linking fresh and durability properties of paste to SCC mortar

In the last years many approaches to design SCC have been developed, but it remains a very complex process since it is necessary to manipulate several variables and understand their effects on concrete behaviour (fresh and hardened state). The prediction of concrete or mortar behaviour based on paste properties will be a significant contribution to simplify SCC design. With this purpose, two statistical experimental designs were carried out, one at paste level and the other at mortar level, to mathematically model the influence of mixture parameters on fresh and durability properties. The derived numerical models were used to define an area, labelled by self-compacting zone at paste level (SCZ), where fresh properties of the paste enable the design of SCC mortar. Furthermore, in order to extend this link to durability properties, the effect of including aggregate in cement paste was evaluated by means of the electrical resistivity test.     

Metakaolin and calcined clays as pozzolans for concrete: a review

The utilisation of calcined clay, in the form of metakaolin (MK), as a pozzolanic material for mortar and concrete has received considerable attention in recent years. This interest is part of the widely spread attention directed towards the utilisation of wastes and industrial by-products in order to minimise Portland cement (PC) consumption, the manufacture of which being environmentally damaging. Another reason is that mortar and concrete, which contain pozzolanic materials, exhibit considerable enhancement in durability properties. This paper reviews work carried out on the use of MK as a partial pozzolanic replacement for cement in mortar and concrete and in the containment of hazardous wastes. The literature demonstrates that MK is an effective pozzolan which causes great improvement in the pore structure and hence the resistance of the concrete to the action of harmful solutions.     

Investigation on micronized biomass silica as a sustainable material

Micronized biomass silica (MBS) is an agricultural waste obtained from controlled burning of rice husk and grind in jar mill. This paper investigates the optimum percentage of MBS for the replacement of cement by conducting several experiments with the blended cement paste and mortar with MBS percentages varying from 0, 4, 8 and 12. In addition, hydration products were also investigated in the blended cement paste through X-ray diffraction. Due to the pozzolanic reaction of MBS with cement hydrates, secondary calcium silicate hydrates (CSH) were formed and also MBS which has a potential to reduce the intensity of Ca(OH)₂ exhibited improved properties. The experimental results showed that the optimum percentage of MBS for the replacement of cement was 8% for the materials used in this study. The mechanical and durability properties of recycled aggregate concrete by replacing cement with 8% MBS were also carried out and it was found that the concrete exhibited improved properties. There by, using MBS one can overcome the drawbacks of recycled aggregate concrete as it acts as a supplementary cementitious material. Thus, by combining recycled concrete aggregate with MBS will achieve sustainable development.     

Investigation on the scattering-filling coarse aggregate self-consolidating concrete

To secure good flowability and workability of SCC, the volume fraction of coarse aggregate keep at an extremely low level. A new kind of SCC pouring method named scattering-filling coarse aggregate process was invented: it was method to scatter 20% (volume fraction to the finished concrete) of extra coarse aggregate into the fresh SCC mixture to replace the fresh concrete mixture while the concrete was pouring. A high strength (82 MPa) SCC just composing 360 kg/m³ cement and 120 kg/m³ class F fly ash was prepared with this process. With an increase of the extra coarse aggregate replacing ratio from 0 to 30%, the compressive strength of SCC increased steadily and reached a peak value when this ratio is 20%, then the strength dropped sharply. The drying shrinkage ratio and the chloride ion permeability decreased with the increase of that ratio. The scattering-filling coarse aggregate process can cast high strength SCC with lower cementitious materials content and produce concrete with better performance than the ordinary process.     

Effect of pozzolans on the performance of fiber-reinforced mortars

Randomly oriented short fibers have been shown to increase tensile strength and retard crack propagation of cement based materials such as fiber-reinforced mortars for diverse applications, especially in aggressive environments. In the case of reinforced concrete, it is very important to produce a “high quality” cover in order to prevent corrosion of the rebars. In order to obtain a high performance material the use of a pozzolan is advisable because low permeability is achieved. The objective of this research was to determine the effect of pozzolans such as silica fume (SF), fly ash (FA), and metakaolin (MK) on the properties of fiber-reinforced mortars. Different types of natural and synthetic fibers were used. A superplasticizer was used to keep the same workability as that of the control mortar. Results of the mechanical and durability properties of the fiber-reinforced mortars are reported. The results show that a loss of resistance due to embedding fibers in mortar is compensated for by the increase in strength caused by silica fume or metakaolin additions to the mortar. The addition of 15% of SF or MK produces an improvement of up to 20% and 68%, respectively, when compared with those mortars without addition. There is a significant decrease in the coefficient of capillary absorption and chloride penetration when a highly pozzolanic material is incorporated into the matrix. In general, these materials, especially SF and MK, improve the mechanical performance and the durability of fiber-reinforced materials, especially those reinforced with steel, glass or sisal fibers. The fly ash addition had a different performance, which could be attributed to its low degree of pozzolanicity.     

Durability of recycled aggregate concrete designed with equivalent mortar volume method

Results of a comprehensive investigation about the durability of structural-grade concrete made with recycled concrete aggregate (RCA) are presented. The RCA-concrete mixes were proportioned using a new concrete mix design method, termed the equivalent mortar volume (EMV) method. The EMV method is based on the hypothesis that RCA is a composite material comprising mortar and natural aggregate; therefore, when proportioning a concrete mixture containing RCA, one must account for the relative amount and properties of each the two components and adjust both the fresh coarse aggregate and fresh paste content of the mix accordingly. Tests were conducted to study the freeze–thaw, chloride penetration and carbonation resistances of the mixes proportioned by the EMV method and by the conventional method. Results of the test showed that RCA-concrete mixes proportioned by the EMV method have higher resistance to freeze–thaw action, chloride penetration and carbonation than those designed with the conventional method, and they satisfy the current requirements for concrete exposed to severe environments.     

Properties of self-compacting concrete prepared with coarse and fine recycled concrete aggregates

In this study, the fresh and hardened properties of self-compacting concrete (SCC) using recycled concrete aggregate as both coarse and fine aggregates were evaluated. Three series of SCC mixtures were prepared with 100% coarse recycled aggregates, and different levels of fine recycled aggregates were used to replace river sand. The cement content was kept constant for all concrete mixtures. The SCC mixtures were prepared with 0, 25, 50, 75 and 100% fine recycled aggregates, the corresponding water-to-binder ratios (W/B) were 0.53 and 0.44 for the SCC mixtures in Series I and II, respectively. The SCC mixtures in Series III were prepared with 100% recycled concrete aggregates (both coarse and fine) but three different W/B ratios of 0.44, 0.40 and 0.35 were used. Different tests covering fresh, hardened and durability properties of these SCC mixtures were executed. The results indicate that the properties of the SCCs made from river sand and crushed fine recycled aggregates showed only slight differences. The feasibility of utilizing fine and coarse recycled aggregates with rejected fly ash and Class F fly ash for self-compacting concrete has been demonstrated.     

Performance evaluation of structural concrete using controlled quality coarse and fine recycled concrete aggregate

This paper presents the fresh, mechanical, and durability performance, of a structural concrete mix classified as C-1, by the Canadian Standards Association (CSA) made with controlled quality Recycled Concrete Aggregate (RCA). Five mixes with water-to-cementing material (w/cm) ratio of 0.40 were produced with various RCA contents and tested against two 0% RCA control mixes made with General Use (GU) cement, and General Use Limestone cement (GUL). The RCA contents in the mixes were 10%, 20%, and 30% by coarse aggregate volume replacement, as well as 10% and 20% fine and coarse (granular) aggregate volume replacement. All evaluated mixes met the specifications from the CSA for fresh, mechanical, and durability properties. The coarse RCA mixes performed better than the granular RCA mixes in terms of flexural and splitting tensile strengths, linear drying shrinkage, water sorptivity, and rapid chloride-ion permeability, where the test results were significantly affected by the ultra fines present in the granular RCA.     

Effect of composition,environmental factors and cement-lime mortar coating on concrete carbonation

The paper describes the physicochemical processes of concrete carbonation and presents a simple mathematical model for the evolution of carbonation in time, applicable under constant relative humidity higher than 50%. The model is based on fundamental principles of chemical reaction engineering, and uses as parameters the ambient concentration of CO₂, the molar concentratrations of the carbonatable constituents, Ca(OH)₂ and CSH, in the concrete volume, and the effective diffusivity of CO₂ in carbonated concrete. The latter is given by an empirical function of the porosity of hardened cement paste and of relative humidity, derived from laboratory diffusion tests. The validity of the model for OPC or pozzolanic cement concretes and mortars is demonstrated by comparison of its predictions with accelerated carbonation test results obtained in an environment of controlled CO₂ concentration, humidity and temperature. The mathematical model is extended to cover the case of carbonation of the coating-concrete system, for concrete coated with a cement-lime mortar finish, applied either almost immediately after the end of concrete curing or with a delay of a certain time. Parametric studies are performed to show how the evolution of carbonation depth with time is affected by cement and concrete composition (water/cement or aggregate/cement ratio, percentage OPC or aggregate replacement by a pozzolan), environmental factors (relative humidity, ambient concentration of CO₂), the presence and the time of application of a lime-cement mortar coating and its composition (water/cement, aggregate/cement and lime/cement ratios of the mortar, percentage OPC or aggregate replacement by a pozzolan).     

Packing optimization of paste and aggregate phases for sustainability and performance improvement of concrete

Previous research demonstrated that the packing density, water film thickness and paste film thickness have great effects on the performance of a concrete mix. On this basis, it is herein proposed a strategy of adding a powder waste as both paste and aggregate replacements to reduce the cement and aggregate consumptions for sustainable development and to improve the packing densities of both the paste phase and aggregate phase for performance improvement. To evaluate such strategy, 25 concrete mixes incorporating granite polishing waste (GPW) as paste and aggregate replacements were tested. The results revealed that the addition of GPW as paste replacement up to 7.5% and as aggregate replacement up to 10% would most effectively increase the packing densities of the paste phase, aggregate phase and whole concrete mix, and thereby increasing the strength of the concrete, despite reduction in cement content. Such increases in packing density would also increase the excess water and excess paste to avoid excessive reductions in the water and paste film thicknesses, which are needed to maintain workability. Last but not least, separate optimization of the paste phase and aggregate phase is an effective way of optimizing the concrete mix design.     

A comprehensive investigation into the effect of aging and coarse aggregate size and volume on mechanical properties of self-compacting concrete

The popularity of self-compacting concrete (SCC), as an innovative construction materials in concrete industry, has increased all over the world in recent decades. SCC offers a safer construction process and durable concrete structure due to its typical fresh concrete behavior which is achieved by SCC’s significantly different mixture composition. This modification of mix composition may have significant effect on the hardened mechanical properties of SCC as compared to normal vibrated concrete (NVC). Therefore, it is necessary to know whether the use of all rules and relations that have been formulated for NVC in current design codes based on years of experience are also valid for SCC. Furthermore, this study represents an extensive evaluation and comparison between mechanical properties of SCC using current international codes and prediction equations proposed by other researchers. Thus, in this experimental study, major mechanical properties of SCC are investigated for twelve SCC mixes with wide spectrum of different variables i.e. maximum coarse aggregate size, coarse aggregate volume and aging. In the present study, an extensive body of data reported by many researchers for SCC and NVC has been used to validate the obtained results.     

Experimental study of the interfacial transition zone (ITZ) of model rock-filled concrete (RFC)

Rock-filled concrete (RFC), a new type of concrete that was developed mainly for large scale concrete construction, has a different casting process than conventional concrete: large rocks are piled into the formwork first, then self-compacting concrete (SCC) is poured in and fill the voids of the rock skeleton under gravity due to its high flowability. One of the key issues about RFC lies in its large interfaces between the SCC and rocks. In this paper, laboratory-scale model RFC consisting of coarse aggregates (simulating rocks) and cement grout (simulating SCC) was cast to simulate RFC in construction. The effects of different factors (aggregate size, rheology of cement grout, etc.) on the properties of the interfacial transition zone (ITZ) between cement paste and aggregates of model RFC were investigated using Backscatter Electron (BSE) and nanoindentation techniques. Furthermore, by comparing the results of BSE and nanoindentation at identical regions, the relationship between porosity and elastic modulus was found to agree well with empirical formulas, bridging the microstructure with the mechanical properties of concrete.     

Effect of metakaolin and silica fume on the durability of self-consolidating concrete

Metakaolin (MK) is a valuable admixture for concrete/cement applications that can enhance the performance of cementitious composites through high pozzolanic reactivity, much like silica fume (SF). While SF concrete is characterized by superior mechanical and durability performance, concrete containing MK achieves comparable properties at a lower price and with better workability. The objective of this study is to investigate the effect of cement replacement by MK on the durability of self-consolidating concrete (SCC); the effect of SF at similar levels of MK replacement has also been included for comparison. The durability performance of SCC was evaluated based on the results of drying shrinkage, freezing and thawing, salt scaling, and rapid chloride permeability tests. The results of these tests indicate that highly durable SCC mixtures can be produced using a high MK content with an optimum percentage of around 20%. The results also show that the durability of SCC, especially with high MK content, is higher than that of SCC containing SF.     

Mix design for self-compacting palm oil clinker concrete based on particle packing

The consumption of waste materials in self-compacting concrete (SCC) in the construction industry will not only help to conserve the natural resources but also promote sustainability in preserving the environment. Palm oil clinker (POC) is a waste by-product from the incineration process of oil palm shells and fibres. They are porous and lightweight in nature, which makes them suitable for use as a lightweight aggregate (LWA). In this study, a new procedure was employed to obtain the mix design based on the particle packing (PP) concept to ensure the fresh and hardened properties of SCC are achieved. The actual packing level of aggregate and paste volume is integrated into the proportioning method to obtain the final mix design. The proposed procedure was verified by evaluating the SCC formed for self-compactability and mechanical properties. Based on the overall performance of fresh and hardened properties, it can be deduced that the procedure satisfied the requirements for SCC. The satisfactory results indicate that the mix design can be employed not only for POC but also for a variety of combinations of aggregate.     

The effect of metakaolin on the corrosion behavior of cement mortars

In this paper the effect of metakaolin addition on the corrosion resistance of cement mortar is studied. A poor Greek kaolin with a low kaolinite content was thermally treated and the produced metakaolin (MK) was ground to the appropriate fineness. In addition, a commercial metakaolin (MKC) of high purity was used. Several mixture proportions were used to produce mortar specimens, where metakaolin replaced either sand or cement. Mortar specimens were then exposed to the corrosive environment of either partial or total immersion in 3.5% w/w NaCl solution. For the evaluation of the performance of metakaolin, the following methods were used: compressive strength, corrosion potential, mass loss, electrochemical measurements of the corrosion rate by the Linear Polarization method, carbonation depth and porosity. It is concluded that metakaolin improves the compressive strength and the 10% w/w addition shows the optimum contribution to the strength development. In addition, the use of metakaolin, either as a sand replacement up to 20% w/w, or as a cement replacement up to 10% w/w, improves the corrosion behavior of mortar specimens, while when metakaolin is added in greater percentages there is no positive effect.     

Properties of self-compacting mortars with binary and ternary cementitious blends of fly ash and metakaolin

The link between flow properties and the formulation is actually one of the key-issues for the design of self-compacting concretes (SCC). As an integral part of a SCC, self-compacting mortars (SCMs) may serve as a basis for the design of concrete since the measurement of the rheological properties of SCCs is often impractical due to the need for complex equipment. This paper discusses the properties of SCMs with mineral admixtures. Portland cement (PC), metakaolin (MK), and fly ash (FA) were used in binary (two-component) and ternary (three-component) cementititios blends. Within the frame work of this experimental study, a total of 16 SCMs were prepared having a constant water-binder (w/b) ratio of 0.40 and total cementitious materials content of 550 kg/m³. Then, the fresh properties of the mortars were tested for mini-slump flow diameter, mini-V-funnel flow time, setting time, and viscosity. Moreover, development in the compressive strength and ultrasonic pulse velocity (UPV) of the hardened mortars were determined at 1, 3, 7, 14, and 28 days. Test results have shown that using of FA and MK in the ternary blends improved the fresh properties and rheology of the mixtures when compared to those containing binary blends of FA or MK.     

Self compacting concrete from uncontrolled burning of rice husk and blended fine aggregate

This paper presents an experimental study on the development of normal strength Self compacting concrete (SCC) from uncontrolled burning of rice husk ash (RHA) as a partial replacement to cement and blended fine aggregate whilst maintaining satisfactory properties of SCC. Experiments on the fresh and hardened state properties have been carried out on RHA based SCC from uncontrolled burning. The dosages of RHA are limited to 0%, 20%, 30% and 40% by mass of the total cementitious material in the concrete. The experiments on fresh state properties investigate the filling ability, the passing ability and the segregation resistance of concrete. The experiments on hardened state properties investigate the compressive and the splitting tensile strengths. The water absorption level of the concrete with changing RHA levels has also been monitored. The experimental studies indicate that RHA based SCC developed from uncontrolled burning has a significant potential for use when normal strength is desired.     

Influence of field recycled coarse aggregate on properties of concrete

This paper investigates the influence of different amounts of recycled coarse aggregates obtained from a demolished RCC culvert 15 years old on the properties of recycled aggregate concrete (RAC). A new term called “coarse aggregate replacement ratio (CRR)” is introduced and is defined as the ratio of weight of recycled coarse aggregate to the total weight of coarse aggregate in a concrete mix. To analyze the behaviour of concrete in both the fresh and hardened state, a coarse aggregate replacement ratio of 0, 0.25, 0.50 and 1.0 are adopted in the concrete mixes. The properties namely compressive and indirect tensile strengths, modulus of elasticity, water absorption, volume of voids, density of hardened concrete and depth of chloride penetration are studied. From the experimental results it is observed that the concrete cured in air after 7 days of wet curing shows better strength than concrete cured completely under water for 28 days for all coarse aggregate replacement ratios. The volume of voids and water absorption of recycled aggregate concrete are 2.61 and 1.82% higher than those of normal concrete due to the high absorption capacity of old mortar adhered to recycled aggregates. The relationships among compressive strength, tensile strengths and modulus of elasticity are developed and verified with the models reported in the literature for both normal and recycled aggregate concrete. In addition, the non-destructive testing parameters such as rebound number and UPV (Ultrasonic pulse velocity) are reported. The study demonstrates the potential use of field recycled coarse aggregates (RCA) in concrete.     

Combined effects of water film thickness and paste film thickness on rheology of mortar

In the mortar portion of a concrete mix, the water must be more than sufficient to fill the voids between the solid particles of cement and fine aggregate whereas the paste volume must be more than sufficient to fill the voids between the solid particles of fine aggregate so that there will be excess water to form water films coating all the solid particles and excess paste to form paste films coating the fine aggregate particles. Hence, it may be postulated that the water film thickness (WFT) and the paste film thickness (PFT) have major effects on the rheology of mortar. In this study, the combined effects of WFT and PFT on the rheology, cohesiveness and adhesiveness of mortar were investigated by testing mortar samples with varying water, cement and aggregate contents. It was found that whilst the WFT is the single most important factor governing the rheology of mortar, the PFT also has significant effects. Particularly, the PFT has certain interesting effects on the cohesiveness and adhesiveness of mortar, which should be duly considered in mortar design.