Dispersion and optimization of a calcium sulfoaluminate mortar prepared with superplasticizer

Calcium sulfoaluminate (CSA) cements/mortars are receiving increasing attention since their manufacture produces less CO2 than ordinary Portland cement (OPC) (up to 22% of decrease depending on its composition). These systems are complex and there are many parameters affecting their hydration mechanism, such as water-to-cement (w/c) ratio, type and amount of sulfate source, and so on. Low w/c ratios, within certain limits, may reduce the porosity and consequently, improve the mechanical strengths. However, it is accompanied by an increasing of viscosity and lack of both workability and homogeneity, with the consequent negative effect on the mechanical properties. The dispersion of the particles through the adsorption of the right amount and type of additives, such as superplasticizers, is a key point to improve the workability of mortars allowing both the preparation of homogeneous mixtures and the reduction of the amount of mixing water. This work deals with the preparation and optimization of homogeneous CSA-mortars with improved mechanical strengths. The optimum amount of superplasticizer was optimized through rheological measurements. The effect of different amounts of the superplasticizer on the viscosity of the mortars, its hydration mechanism and corresponding mechanical properties has been studied and will be discussed.

Synthesis of active Belite-Alite-Ye'elimite clinker (BAY)

Ordinary Portland cement (OPC) is an environmentally contentious material, as for every ton of OPC produced, on average, 0.97 tons of CO2 are released. Ye'elimite-rich cements are considered as eco-cements because their manufacturing process releases less CO2 into the atmosphere than OPC; this is due to the low calcite demand. Belite-Alite-Ye’elimite (BAY) cements are promising eco-friendly building materials as OPC substitutes at a large scale. The reaction of alite and ye´elimite with water should develop cements with high mechanical strengths at early ages, while belite will contribute to later curing times. However, they develop lower mechanical strengths at early-medium ages than OPC. It is known that the presence of different polymorphs of ye'elimite and belite affects the hydration due to the different reactivity of those phases. Thus, a solution to this problem may be well the activation of BAY clinkers by preparing them with 'H-belite and pseudo-cubic-ye'elimite, jointly with alite. The aim of this work is the preparation and characterization of active-BAY clinkers which contain high percentages of coexisting 'H-belite and pseudo-cubic-ye'elimite, jointly with alite to develop, in a future step, comparable mechanical strengths to OPC. The parameters evolved in the preparation of the clinker have been optimized, including the selection of raw materials (mineralizers and activators) and clinkering conditions. Finally, the clinker was characterized through laboratory X-ray powder diffraction, in combination with the Rietveld methodology, and scanning electron microscopy.

Synthesis and behavior of Belite-Alite-Ye’elimite (BAY) cement

Ye’elimite based cements have been studied since 70’s years in China, due to the irrelevant characteristics from a hydraulic and environmental point of view. One of them is the reduced fuel consumption, related to the lower temperature reaction required for this kind of cement production as compared to Ordinary Portland Cement (OPC), another characteristic is the reduced requirement of carbonates as a typical raw material, compared to OPC, with the consequent reduction in CO2 releases (~22%)from combustion. Thus, Belite-Ye’elimite-Ferrite (BYF) cements have been developed as potential OPC substitutes. BYF cements contain belite as main phase (>50 wt%) and ye´elimite as the second content phase (~30 wt%). However, an important technological problem is associated to them, related to the low mechanical strengths developed at intermediate hydration ages (3, 7 and 28 days). One of the proposed solutions to this problem is the activation of BYF clinkers by preparing clinkers with high percentage of coexisting alite and ye'elimite. These clinkers are known Belite-Alite-Ye’elimite (BAY) cements. Their manufacture would produce ~15% less CO2 than OPC. Alite is the main component of OPC and is responsible for early mechanical strengths. The reaction of alite and ye´elimite with water will develop cements with high mechanical strengths at early ages, while belite will contribute to later curing times. Moreover, the high alkalinity of BAY cement pastes/mortars/concretes may facilitate the use of supplementary cementitious materials with pozzolanic activity which also contributes to decrease the CO2 footprint of these ecocements. The main objective of this work was the design and optimization of all the parameters evolved in the preparation of a BAY eco-cement that develop higher mechanical strengths than BYF cements. These parameters include the selection of the raw materials (lime, gypsum, kaolin and sand), milling, clinkering conditions (temperature, and holding time), and clinker characterization The addition of fly ash has also been studied. All BAY clinker and pastes (at different hydration ages) were mineralogically characterized through laboratory X-ray powder diffraction (LXRPD) in combination with the Rietveld methodology to obtain the full phase assemblage including Amorphous and Crystalline non-quantified, ACn, contents. The pastes were also characterized through rheological measurements, thermal analyses (TA), scanning electronic microscopy (SEM) and nuclear magnetic resonance (NMR). The compressive strengths were also measured at different hydration times and compared to BYF.