Properties of high-strength concrete mixes containing PFA and ggbs

The effects of incorporating pulverized fuel ash (PFA) and ground granulated blastfurnace slag (ggbs) on the workability (slump), adiabatic temperature rise during hydration and long-term (up to 570 days) strength of high-strength concretes have been measured. Binary (PFA/ggbs and Portland cement) and ternary (PFA/ggbs plus microsilica and Portland cement) blends at water-binder ratios from 0.38 to 0.20 have been tested. The results show broadly similar effects to those in lower strength concrete, although of differing magnitude in some cases. Some potential advantages of ternary blends for optimization of properties have been demonstrated.

Exposure of mortars to cyclic chloride ingress and carbonation

The presence of chloride ions is one of the primary factors causing the degradation of reinforced concrete structures. An investigation to monitor ingress of chlorides during a 24-week wetting and drying exposure regime to simulate conditions in which multiple-mode transport mechanisms are active was conducted on a variety of binders. Penetration was evaluated using free and total chloride profiles. Acid extraction of chlorides is quantitatively reliable and practical for assessing penetration. X-ray diffraction was used to determine the presence of bound chlorides and carbonation. The ability of the cement blends to resist chloride penetration was, from best to worst, ground granulated blast-furnace slag, microsilica, pulverised-fuel ash, Portland cement. The effect of carbonation on binding capability was observed and the relative quantity of chlorides also showed a correlation with the amount of chlorides bound in the form of Friedel’s salt.

Influence of the type of coarse lightweight aggregate on properties of Semi-Lightweight Self-Consolidating Concrete

This paper presents studies on the properties of fresh and hardened semilightweight self-consolidating concrete (SLWSCC) mixtures, produced with two types of manufactured coarse lightweight aggregates (LWA) and normal weight sand. The first type, a sintered pulverized fuel ash, was made from an industrial by-product, fly ash, whereas the second one, an expanded clay, was produced from a naturally sourced clay. For all mixtures, normal weight sand was used as a fine fraction of aggregates, and the portland cement was partially replaced with a limestone powder. The SLWSCC was produced with different water presaturation regimes of the LWAs. The desired initial slump-flow spread was set between 700 and 800 mm. The effect of three superplasticizers was evaluated by testing properties of SLWSCC, normal weight SCC, and paste mixtures. Three SCC fresh properties were measured: the slump-flow, the V-funnel flow time, and the J-ring blocking step. Moreover, the slump-flow loss was evaluated. The degree of segregation was assessed in both fresh and hardened states. Additionally, the hardened density and the compressive strengths were tested. All SLWSCC mixtures were produced with a desired range of slump-flow spread and with satisfactory passing ability assessed with the J-ring test. SLWSCCs prepared with the expanded clay LWA were less sensitive to the variation of water presaturation levels and showed lower viscosity than those made with the sintered pulverized fuel ash LWA. Only mixtures containing SP-3 superplasticizer showed acceptable workability loss resistance. The saturated surface-dry density of all of the mixtures varied in a range of 2,025–2,125??kg/m 3 . Mixtures containing 29% of coarse LWAs and 71% of sand (by mass) had 24-h and 28-day compressive strengths above 20 and 40 MPa, respectively, but the mixtures made with the expanded clay were slightly weaker.

Hydration and properties of sodium sulfate activated slag

Interest in alkali-activated slag as a construction material is increasing, primarily due to its environmentally friendly nature. Although strong alkaline activators, such as sodium hydroxide and sodium silicate solution, are preferred for high strength, none of them exists naturally and their manufacturing process is quite energy intensive. Whilst sodium sulfate (NaSO ) can be obtained from natural resources, the early strength of NaSO activated slag is usually low. In this paper, the effects of slag fineness and NaSO dosage on strength, pH, hydration and microstructure were investigated and compared with those of a pure Portland cement (PC). Test results indicated that increasing the slag fineness is a more effective approach than increasing NaSO dosage for increasing both the early and long-term strength of NaSO activated slags. In addition, increasing the slag fineness can also increase the strength without increasing the pH of the hardened matrix, which is beneficial for immobilizing certain types of nuclear waste containing reactive metals and resins.© 2012 Elsevier Ltd. All rights reserved.

Characterization of physio-chemical processes and hydration kinetics in concretes containing supplementary cementitious materials using electrical property measurements

The current study monitors both the short- and long-term hydration characteristics of concrete using discretized conductivity measurements from initial gauging, through setting and hardening, the latter comprising both the curing and post-curing periods. In particular, attention is directed to the near-surface concrete as it is this zone which protects the steel from the external environment and has a major influence on durability, performance and service-life. A wide range of concrete mixes is studied comprising both plain Portland cement concretes and concretes containing fly-ash and ground granulated blast furnace slag. The parameter normalised conductivity was used to identify four distinct stages in the hydration process and highlight the influence of supplementary cementitious materials (SCM) on hydration and hydration kinetics. A relationship has been presented to account for the temporal decrease in conductivity, post 10-days hydration. The testing procedure and methodology presented lend itself to in-situ monitoring of reinforced concrete structures. (c) 2013 Elsevier Ltd. All rights reserved.

Alkali Activated Fuel Ash and Slag Mixes:Optimization Study from Mortars to Concrete Building Blocks

Alkali activated binders, based on ash and slag, also known as geopolymers, can play a key role in reducing the carbon footprint of the construction sector by replacing ordinary Portland cement in some concretes. Since 1970s, research effort has been ongoing in many research institutions. In this study, pulverized fuel ash (PFA) from a UK power plant, ground granulated blast furnace slag (GGBS) and combinations of the two have been investigated as geopolymer binders for concrete applications. Activators used were sodium hydroxide and sodium silicate solutions. Mortars with sand/binder ratio of 2.75 with several PFA and GGBS combinations have been mixed and tested. The optimization of alkali dosage (defined as the Na2O/binder mass ratio) and modulus (defined as the Na2O/SiO2 mass ratio) resulted in strengths in excess of 70 MPa for tested mortars. Setting time and workability have been considered for the identification of the best combination of PFA/GGBS and alkali activator dosage for different precast concrete products. Geopolymer concrete building blocks have been replicated in laboratory and a real scale factory trial has been successfully carried out. Ongoing microstructural characterization is aiming to identify reaction products arising from PFA/GGBS combinations.

Influence of micro and macro cracks due to sustained loading on chloride-induced corrosion of reinforced concrete beams

Chloride-induced corrosion of steel is one of the most commonly found problems affecting the durability of reinforced concrete structures in both marine environment and where de-icing salt is used in winter. As the significance of micro-cracks on chloride induced corrosion is not well documented, 24 reinforced concrete beams (4 different mixes - one containing Portland cement and another containing 35% ground granulated blastfurnace slag at 0.45 and 0.65 water-binder ratios) were subjected to three levels of sustained lateral loading (0%, 50% and 100% of the load that can induce 0.1 mm wide cracks on the tension surface of beam - F_0.1) in this work. The beams were then subjected to weekly cycles of wetting with 10% NaCl solution for 1 day followed by 6 days of drying at 20 (±1) °C up to an exposure period of 60 weeks. The progress of corrosion of steel was monitored using half-cell potential apparatus and linear polarisation resistance (LPR) test. These results have shown that macro-cracks (at load F_0.1) and micro-cracks (at 50% of F_0.1) greatly accelerated both the initiation and propagation stages of the corrosion of steel in the concrete beams. Lager crack widths for the F_0.1 load cases caused higher corrosion rates initially, but after about 38 weeks of exposure, there was a decrease in the rate of corrosion. However, such trends could not be found in 50% F _0.1 group of beams. The extent of chloride ingress also was influenced by the load level. These findings suggest that the effect of micro-cracking at lower loads are very important for deciding the service life of reinforced concrete structures in chloride exposure environments. © 2014 4th International Conference on the Durability of Concrete Structures.

Chloride induced corrosion of steel in alkali activated slag concretes

Alkali activated slag (AAS) is an alternative cementitious material. Sodium silicate solution is usually used to activate ground granulated blast furnace slag to produce AAS. As a consequence, the pore solution chemistry of AAS differs from that of Portland cement (PC). Although AAS offers many advantages over PC, such as higher strength, superior resistance to acid and sulphate environments and lower embodied carbon due to 100% PC replacement, there is a need to assess its performance against chloride induced corrosion duo to its different pore solution chemistry. For PC systems, resistivity measurement, as a type of nondestructive test, is usually used to evaluate its chloride diffusivity and the corrosion rate of the embedded steel. However, due to the different pore solution chemistry present in the different AAS systems, the application of this test in AAS concretes would be questionable as the resistivity of concrete is highly dependent on its conductivity of the pore solution. Therefore, a study was carried out using twelve AAS concretes mixes, the results of which are reported in this paper. The AAS mixes were designed with alkali concentration of 4%, 6% and 8% (Na₂O% of the mass of slag) and modulus (Ms) of sodium silicate solution of 0.75, 1.00, 1.50 and 2.00. A PC concrete with the same binder content as the AAS concretes was also studied as a reference. The chloride diffusion coefficient was determined using a non-steady state chloride diffusion test (NT BUILD 443). The resistivity of the concretes before the diffusion test was also measured. Macrocell corrosion current (corrosion rate) for steel rods embedded in the concretes was measured whilst subjecting the concretes to a cyclic chloride ponding regime (1 day ponded with salt solution and 6 days drying). The results showed that the AAS concretes had lower chloride diffusivity with associated higher resistivity than the PC concrete. The measured corrosion rate was also lower for the AAS concretes. However, unlike the PC, in which a higher resistivity yields a lower diffusivity and corrosion rate, there was no relationship apparent between the resistivity and either the diffusivity or the corrosion rate of steel for the AAS concretes. This is assigned to the variation of the pore solution composition of the AAS concretes. This also means that resistivity measurements cannot be depended on for assessing the chloride induced corrosion resistance of AAS concretes.

Chloride ingress through alkali activated slag concretes

Alkali activated slag (AAS) is a credible alternative to Portland cement (PC) based binder systems. The superior strength gain and low embodied carbon make it a potential binder for next generation concretes. However there is little known about the long term durability of AAS systems, especially the chloride transport and subsequent corrosion of reinforcing steel.
In this study, chloride transport through 12 AAS concretes with different alkali concentrations (Na2O% of mass of slag) and different modulus (Ms) of sodium silicate solution activator was investigated. A non-steady state chloride diffusion test was used for this study due to its similarity to the real exposure environment in terms of chloride transport through concrete. The results showed that the chloride concentration at the surface (Cs) of AAS concretes was higher than that for PC concrete.
However, lower non-steady state chloride diffusion coefficient (Dnssd) was obtained for the AAS concretes. The Dnssd of the AAS concretes decreased with the increase of Na2O% and Ms of 1.50 gave the lowest Dnssd. The results are encouraging and it can be concluded that AAS concrete offers a superior performance in terms of chloride transport.

The Role of Water Content and Paste Proportion on Physico-mechanical Properties of Alkali Activated Fly Ash–Ggbs Concrete

The growth of the construction industry worldwide poses a serious concern on the sustainability of the building material production chain, mainly due to the carbon emissions related to the production of Portland cement. On the other hand, valuable materials from waste streams, particularly from the metallurgical industry, are not used at their full potential. Alkali activated concrete (AAC) has emerged in the last years as a promising alternative to traditional Portland cement based concrete for some applications. However, despite showing remarkable strength and durability potential, its utilisation is not widespread, mainly due to the lack of broadly accepted standards for the selection of suitable mix recipes fulfilling design requirements, in particular workability, setting time and strength. In this paper, a contribution towards the design development of AAC synthetized from pulverised fuel ash (60%) and ground granulated blast furnace slag (40%) activated with a solution of sodium hydroxide and sodium silicate is proposed. Results from a first batch of mixes indicated that water content influences the setting time and that paste content is a key parameter for controlling strength development and workability. The investigation indicated that, for the given raw materials and activator compositions, a minimum water to solid (w/s) ratio of 0.37 was needed for an initial setting time of about 1 hour. Further work with paste content in the range of 30% to 33% determined the relationship between workability and strength development and w/s ratio and paste content. Strengths in the range of 50 - 60 MPa were achieved.

Sustainable binders for concrete: a structured approach from waste screening to binder composition development

Worldwide, the building sector requires the production of 4 billion tonnes of cement annually, consuming more than 40% of global energy. Alkali activated “cementless” binders have recently emerged as a novel eco-friendly construction material with a promising potential to replace ordinary Portland cement. These binders consist of a class of inorganic polymer formed mainly by the reaction between an alkaline solution and an aluminosilicate source. Precursor materials for this reaction can be found in secondary material streams from different industrial sectors, from energy to agro-alimentary. However, the suitability of these materials in developing the polymerisation reaction must be assessed through a detailed chemical and physical characterisation, ensuring the availability of required chemical species in the appropriate quantity and physical state. Furthermore, the binder composition needs to be defined in terms of proper alkali activation dosages, water content in the mix, and curing conditions. The mix design must satisfy mechanical requirements and compliance to desired engineering properties (workability, setting time) for ensuring the suitability of the binder in replacing Portland cement in concrete applications. This paper offers a structured approach for the development of secondary material-based binders, from their identification to mix design and production procedure development. Essential features of precursor material can be determined through chemical and physical characterisation methods and advanced microscope techniques. Important mixing parameters and binder properties requirements are examined and some examples of developed binders are reported.

Alkali activated fuel ash and slag mixes:optimization study from paste to concrete building blocks

Alkali activated binders, based on ash and slag, also known as geopolymers, can play a key role in reducing the carbon footprint of the construction sector by replacing ordinary Portland cement in some concretes. Since 1970s, research effort has been ongoing in many research institutions. In this study, pulverized fuel ash (pfa) from a UK power plant, ground granulated blast furnace slag (ggbs) and combinations of the two have been investigated as geopolymer binders for concrete applications. Activators used were sodium hydroxide and sodium silicate solutions. Mortars with sand/binder ratio of 2.75 with several pfa and ggbs combinations have been mixed and tested. The optimization of alkali dosage (defined as the Na2O/binder mass ratio) and modulus (defined as the Na2O/SiO2 mass ratio) resulted in strengths in excess of 70 MPa for tested mortars. Setting time and workability have been considered for the identification of the best combination of pfa/ggbs and alkali activator dosage for different precast concrete products. Geopolymer concrete building blocks have been replicated in laboratory and a real scale factory trial has been successfully carried out. Ongoing microstructural characterization is aiming to identify reaction products arising from pfa/ggbs combinations.

Chloride transport and the resulting corrosion of steel bars in alkali activated slag concretes

As the relative performance of alkali activated slag (AAS) concretes in comparison to Portland cement (PC) counterparts for chloride transport and resulting corrosion of steel bars is not clear, an investigation was carried out and the results are reported in this paper. The effect of alkali concentration and modulus of sodium silicate solution used in AAS was studied. Chloride transport and corrosion properties were assessed with the help of electrical resistivity, non-steady state chloride diffusivity, onset of corrosion, rate of corrosion and pore solution chemistry. It was found that: (i) although chloride content at surface was higher for the AAS concretes, they had lower chloride diffusivity than PC concrete; (ii) pore structure, ionic exchange and interaction effect of hydrates strongly influenced the chloride transport in the AAS concretes; (iii) steel corrosion resistance of the AAS concretes was comparable to that of PC concrete under intermittent chloride ponding regime, with the exception of 6% Na2O and Ms of 1.5; (iv) the corrosion behaviour of the AAS concretes was significantly influenced by ionic exchange, carbonation and sulphide concentration; (v) the increase of alkali concentration of the activator generally increased the resistance of AAS concretes to chloride transport and reduced its resulting corrosion, and a value of 1.5 was found to be an optimum modulus for the activator for improving the chloride transport and the corrosion resistance.

Chloride induced corrosion of steel bars in alkali activated slag concretes

The studies on chloride induced corrosion of steel bars in alkali activated slag (AAS) concretes are scarcely reported in the past. In order to make this issue clearer and compare the corrosion performance of AAS with Portland cement (PC) counterpart, an investigation was carried out and the results are reported in this paper. Corrosion properties were assessed with the help of rate of corrosion, electrical resistivity and pore solution chemistry. It was found that: (i) steel corrosion resistance of the AAS concretes was comparable or in some cases even worse than that of Portland cement (PC) concrete under intermittent chloride ponding regime; (ii) the corrosion behaviour of the AAS concretes was significantly influenced by ionic exchange, carbonation and sulphide concentration; (iii) the increase of alkali concentration of the activator generally reduced chloride resulting corrosion, and a value of 1.5 was found to be an optimum modulus for the activator for improving the corrosion resistance.

Influence of service loading and the resulting micro-cracks on chloride resistance of concrete

Chloride-induced corrosion of steel in reinforced concrete structures is one of the main problems affecting their durability, but most previous research projects and case studies have focused on concretes without cracks or not subjected to any structural load. Although it has been recognised that structural cracks do influence the chloride transport and chloride induced corrosion in reinforced concrete structures, there is little published work on the influence of micro-cracks due to service loads on these properties. Therefore the effect of micro-cracks caused by loading on chloride transport into concrete was studied. Four different stress levels (0%, 25%, 50% and 75% of the stress at ultimate load – fu) were applied to 100 mm diameter concrete discs and chloride migration was measured using a bespoke test setup based on the NT BUILD 492 test. The effects of replacing Portland cement CEMI by ground granulated blast-furnace slag (GGBS), pulverised fuel ash (PFA) and silica fume (SF) on chloride transport in concrete under sustained loading were studied. The results have indicated that chloride migration coefficients changed little when the stress level was below 50% of the fu; however, it is desirable to keep concrete stress less than 25% fu if this is practical. The effect of removing the load on the change of chloride migration coefficient was also studied. A recovery of around 50% of the increased chloride migration coefficient was found in the case of concretes subjected to 75% of the fu when the load was removed.