Oxygen and Chloride Permeability of Alkali-Activated Natural Pozzolan Concrete

One of the important factors in the use of portland cement concrete is its durability, and most of the situations where durability is lacking have been identifi ed and strategies to manage durability have been implemented. Geopolymer concrete, made from an alkali-activated natural pozzolan (AANP), provides an important opportunity for the reduction of carbon dioxide (CO2) emissions associated with the manufacture of concrete but has a limited history of durability studies. Until its different properties are well understood there is no desire to adopt this new technology of unknown provenance by the concrete industry. This paper presents an experimental study of oxygen and chloride permeability of AANP concrete prepared by activating Taftan andesite and Shahindej dacite (Iranian natural pozzolans), with and without calcining, and the correlations between these properties and compressive strength. The results show that compared to ordinary portland cement (OPC) concrete, AANP concrete has lower oxygen permeability at later ages; but it shows moderate to high chloride ion penetrability.

Simplified model for prediction of compressive strength of alkali-activated natural pozzolans

The assessment of pozzolanic activity is essential for estimating the reaction of a material as pozzolan. Natural pozzolans can be activated and condensed with sodium silicate in an alkaline environment to synthesize high performance cementitious construction materials with low environmental impact. In this paper, the pozzolanic activities of five natural pozzolans are studied. The correlation between type and chemical composition of natural pozzolan, which affects the formation of the geopolymer gel phase, both for the calcined and untreated natural pozzolans, have been reviewed. The improvement in pozzolanic properties was studied following heat treatment including calcinations and/or elevated curing temperature by using alkali solubility, and compressive strength tests. A model was developed to allow prediction of the alkali-activated pozzolan strength versus their chemical compositions, alkali solubility, and crystallinity.

Mechanical behaviour at high temperature of alkali-activated aluminosilicates (geopolymers)

This study was designed to determine the effect of temperature on the mechanical strength (in both in vivo and post-exposure trials) of two alkaline cements (without OPC): (a) 100% fly ash (FA) and (b) 85% FA + 15% bauxite, the activated alkaline solution used was 85% 10-M NaOH + 15% sodium silicate. A Type I 42.5 R Portland cement was used as a control. Two series of trials were conducted: (i) in vivo trials in which bending and compressive strength, fracture toughness and modulus of elasticity were determined at different temperatures; and (ii) post-firing trials, assessing residual bending and compres-sive strength after a 1-h exposure to high temperatures and subsequent cooling. The findings showed that from 25 to 600 C, irrespective of the type of test (in vivo or post-firing), compressive mechanical strength rose, with the specimens exhibiting elastic behaviour and consequently brittle failure. At tem-peratures of over 600 C, behaviour differed depending on the type of test: (i) in the in vivo trials the high temperature induced pseudo-plastic strain and a decline in mechanical strength that did not necessarily entail specimen failure; (ii) in the post-firing trials, compressive strength rose.

Factors influencing the compressive strengths of fly ash based geopolymers

Several factors affecting the reactivity of pulverised fuel ash (pfa) as a precursor for geopolymer concrete have been investigated. These include physical and chemical properties of various pfa sources, inclusion of ground granulated blast furnace slag (ggbs), chemical activator dosages and curing temperature. Alkali-activated pfa was found to require elevated curing temperatures and high alkali concentrations. A mixture of sodium hydroxide and sodium silicate was used and this was shown to result in high strengths, as high as 70 MPa at 28-days. The presence of silicates in solution was found to be a key factor. Detailed physical and chemical characterisation was carried out on thirteen pfa sources from the UK. The most important factor affecting the reactivity was found to be the particle size of pfa. The loss on ignition (LOI) and the amorphous content are also important parameters that need to be considered for the selection of pfa for use in geopolymer concrete. The partial replacement of pfa by ground granulated blast furnace slag (ggbs) was found to be beneficial in not only avoiding the need for elevated curing temperatures but also in improving compressive strengths. Microstructural characterisation with scanning electron microscope (SEM) coupled with energy dispersive X-ray spectroscopy (EDS) was performed on pfa/ggbs pastes. The reaction product of pfa and ggbs in these binary systems was calcium aluminium silicate hydrate gel (C-A-S-H) with inclusion of Na in the structure.

Estudo de geopolímeros utilizando cinzas residuais do bagaço de cana-de-açúcar

Pós-graduação em Engenharia Civil - FEIS

Análise da viabilidade da utilização da cinza do bagaço de cana-de-açúcar como aglomerante para a produção de matrizes cimentantes

Pós-graduação em Engenharia Civil - FEIS

Mechanical behavior of alkali-cement as function of the temperature.

This investigation reports on a comparative study of the mechanical behavior at different temperatures of three different alkali-activated fly ash pastes chemically activated using sodium silicate. A control Portland cement (OPC) was used as a reference. In an attempt to simulate the conditions prevailing in the event of accidental fire, post-thermal mechanical tests were performed to determine the residual strength. It has therefore been established that FA based cements can be fabricated for construction purposes and these materials have great potential for fire resistance applications.

Sustainable solutions for the construction sector: integration of secondary raw materials in the production cycle of concrete

The construction industry is one of the largest consumers of raw materials and energy and one of the highest contributor to green-houses gases emissions. In order to become more sustainable it needs to reduce the use of both raw materials and energy, thus lim-iting its environmental impact. Developing novel technologies to integrate secondary raw materials (i.e. lightweight recycled aggre-gates and alkali activated “cementless” binders - geopolymers) in the production cycle of concrete is an all-inclusive solution to im-prove both sustainability and cost-efficiency of construction industry. SUS-CON “SUStainable, Innovative and Energy-Efficiency CONcrete, based on the integration of all-waste materials” is an European project (duration 2012-2015), which aim was the inte-gration of secondary raw materials in the production cycle of concrete, thus resulting in innovative, sustainable and cost-effective building solutions. This paper presents the main outcomes related to the successful scaling-up of SUS-CON concrete solutions in traditional production plants. Two European industrial concrete producers have been involved, to design and produce both pre-cast components (blocks and panels) and ready-mixed concrete. Recycled polyurethane foams and mixed plastics were used as aggre-gates, PFA (Pulverized Fuel Ash, a by-product of coal fuelled power plants) and GGBS (Ground Granulated Blast furnace Slag, a by-product of iron and steel industries) as binders. Eventually, the installation of SUS-CON concrete solutions on real buildings has been demonstrated, with the construction of three mock-ups located in Europe (Spain, Turkey and Romania)

Optimization of wastepaper sludge ash (WSA) in robust cementitious systems

Abstract : Wastepaper sludge ash (WSA) is generated by a cogeneration station by burning wastepaper sludge. It mainly consists of amorphous aluminosilicate phase, anhydrite, gehlenite, calcite, lime, C2S, C3A, quartz, anorthite, traces of mayenite. Because of its free lime content (~10%), WSA suspension has a high pH (13). Previous researchers have found that the WSA composition has poor robustness and the variations lead to some unsoundness for Portland cement (PC) blended WSA concrete. This thesis focused on the use of WSA in different types of concrete mixes to avoid the deleterious effect of the expansion due to the WSA hydration. As a result, WSA were used in making alkali-activated materials (AAMs) as a precursor source and as a potential activator in consideration of its amorphous content and the high alkaline nature. Moreover, the autogenous shrinkage behavior of PC concrete at low w/b ratio was used in order to compensate the expansion effect due to WSA. The concrete properties as well as the volume change were investigated for the modified WSA blended concrete. The reaction mechanism and microstructure of newly formed binder were evaluated by X-ray diffraction (XRD), calorimetry, thermogravimetric analysis (TGA), scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDX). When WSA was used as precursor, the results showed incompatible reaction between WSA and alkaline solution. The mixtures were not workable and provided very low compressive strength no matter what kinds of chemical activators were used. This was due to the metallic aluminum in WSA, which releases abundant hydrogen gas when WSA reacts with strong alkaline solution. Besides, the results of this thesis showed that WSA can activate the glassy phase contained in slag, glass powder (GP) and class F fly ash (FFA) with an optimum blended ratio of 50:50. The WSA/slag (mass ratio of 50:50) mortar (w/b of 0.47) attained 46 MPa at 28 days without heat curing assistance. A significant fast setting was noticed for the WSA-activated binder due to the C3A phase, free lime and metallic aluminum contained in the WSA. Adding 5% of gypsum can delay the fast setting, but this greatly increased the potential risk of intern sulfate attack. The XRD, TGA and calorimetry analyses demonstrated the formation of ettringite, C-S-H, portlandite, hydrogarnet and calcium carboaluminate in the hydrated binder. The mechanical performance of different binder was closely related to the microstructure of corresponding binder which was proved by the SEM observation. The hydrated WSA/slag and WSA/FFA binder formed a C-A-S-H type of gel with lower Ca/Si ratio (0.47~1.6). A hybrid gel (i.e. C-N-A-S-H) was observed for the WSA/GP binder with a very low Ca/Si ratio (0.26) and Na/Si ratio (0.03). The SEM/EDX analyses displayed the formation of expansive gel (ettringite and thaumasite) in the gypsum added WSA/slag concrete. The gradual emission of hydrogen gas due to the reaction of WSA with alkaline environment significantly increased the porosity and degraded the microstructure of hydrated matrix after the setting. In the last phase of this research WSA-PC blended binder was tailored to form a high autogenous shrinkage concrete in order to compensate the initial expansion. Different binders were proportioned with PC, WSA, silica fume or slag. The microstructure and mechanical properties of concrete can be improved by decreasing w/b ratios and by incorporating silica fume or slag. The 28-day compressive strength of WSA-blended concrete was above 22 MPa and reached 45 MPa when silica fume was added. The PC concrete incorporating silica fume or slag tended to develop higher autogenous shrinkage at low w/b ratios, and thus the ternary binder with the addition of WSA inhibited the long term shrinkage due to the initial expansion property to WSA. In the restrained shrinkage test, the concrete ring incorporating the ternary binder (PC/WSA/slag) revealed negligible potential to cracking up to 96 days as a result of the offset effect by WSA expansion. The WSA blended regular concrete could be produced for potential applications with reduced expansion, good mechanical property and lower permeability.

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.

Biomass fly ash incorporation in cement based materials

In recent years, pressures on global environment and energy security have led to an increasing demand on renewable energy sources, and diversification of Europe’s energy supply. Among these resources the biomass could exert an important role, since it is considered a renewable and CO2 neutral energy resource once the consumption rate is lower than the growth rate, and can potentially provide energy for heat, power and transports from the same installation. Currently, most of the biomass ash produced in industrial plants is either disposed of in landfill or recycled on agricultural fields or forest, and most times this goes on without any form of control. However, considering that the disposal cost of biomass ashes are raising, and that biomass ash volumes are increasing worldwide, a sustainable ash management has to be established. The main objective of the present study is the effect of biomass fly ashes in cement mortars and concretes in order to be used as a supplementary cementitious material. The wastes analyzed in the study were collected from the fluidized bed boilers and grate boilers available in the thermal power plants and paper pulp plants situated in Portugal. The physical as well as chemical characterisations of the biomass fly ashes were investigated. The cement was replaced by the biomass fly ashes in 10, 20 and 30% (weight %) in order to investigate the fresh properties as well as the hardened properties of biomass fly ash incorporated cement mortar and concrete formulations. Expansion reactions such as alkali silica reaction (ASR), sulphate attack (external and internal) were conducted in order to check the durability of the biomass fly ash incorporated cement mortars and concretes. Alternative applications such as incorporation in lime mortars and alkali activation of the biomass fly ashes were also attempted. The biomass fly ash particles were irregular in shape and fine in nature. The chemical characterization revealed that the biomass fly ashes were similar to a class C fly ash. The mortar results showed a good scope for biomass fly ashes as supplementary cementitious materials in lower dosages (<20%). The poor workability, concerns about the organic content, alkalis, chlorides and sulphates stand as the reasons for preventing the use of biomass fly ash in high content in the cement mortars. The results obtained from the durability tests have shown a clear reduction in expansion for the biomass fly ash mortars/concretes and the binder blend made with biomass fly ash (20%) and metakaolin (10%) inhibited the ASR reaction effectively. The biomass fly ash incorporation in lime mortars did not improve the mortar properties significantly though the carbonation was enhanced in the 15-20% incorporation. The biomass fly ash metakaolin blend worked well in the alkali activated complex binder application also. Portland cement free binders (with 30-40 MPa compressive strength) were obtained on the alkali activation of biomass fly ashes (60-80%) blended with metakaolin (20-40%).

Argamassas e betões geopoliméricos: estado da arte e potencial de industrialização em Portugal

Dissertação para obtenção do grau de Mestre em Engenharia Civil

New geopolymeric binder based on fluid catalytic cracking catalyst residue (FCC)

This paper provides information about the synthesis and mechanical properties of geopolymers based on fluid catalytic cracking catalyst residue (FCC). FCC was alkali activated with solutions containing different SiO2/Na2O ratios. The microstructure and mechanical properties were analysed by using several instrumental techniques. FCC geopolymers are mechanically stable, yielding compressive strength about 68 MPa when mortars are cured at 65 degrees C during 3 days. The results confirm the viability of producing geopolymers based on FCC. (C) 2012 Elsevier B.V. All rights reserved.

Sistemi tecnologici innovativi di involucro per il recupero del patrimonio edilizio recente. L'edilizia scolastica nel Comune di Bologna

La ricerca è volta a presentare un nuovo approccio integrato, a supporto di operatori e progettisti, per la gestione dell’intero processo progettuale di interventi di riqualificazione energetica e architettonica del patrimonio edilizio recente, mediante l’impiego di soluzioni tecnologiche innovative di involucro edilizio. Lo studio richiede necessariamente l’acquisizione di un repertorio selezionato di sistemi costruttivi di involucro, come base di partenza per l’elaborazione di soluzioni progettuali di recupero delle scuole appartenenti al secondo dopoguerra, in conglomerato cementizio armato, prevalentemente prefabbricate. Il progetto individua procedimenti costruttivi ecocompatibili per la progettazione di componenti prefabbricati di involucro “attivo”, adattabile ed efficiente, da assemblare a secco, nel rispetto dei requisiti prestazionali richiesti dalle attuali normative. La ricerca è finalizzata alla gestione dell’intero processo, supportato da sistemi di rilevazione geometrica, collegati a software di programmazione parametrica per la modellazione di superfici adattabili alla morfologia dei fabbricati oggetto di intervento. Tali strumenti informatizzati CAD-CAM sono connessi a macchine a controllo numerico CNC per la produzione industrializzata degli elementi costruttivi “su misura”. A titolo esemplificativo dell’approccio innovativo proposto, si formulano due possibili soluzioni di involucro in linea con i paradigmi della ricerca, nel rispetto dei principi di sostenibilità, intesa come modularità, rapidità di posa, reversibilità, recupero e riciclo di materiali. In particolare, le soluzioni innovative sono accomunate dall’applicazione di una tecnica basata sull’assemblaggio di elementi prefabbricati, dall’adozione di una trama esagonale per la tassellazione della nuova superficie di facciata, e dall’utilizzo del medesimo materiale termico isolante, plastico e inorganico, riciclato ed ecosostenibile, a basso impatto ambientale (AAM - Alkali Activated Materials). Le soluzioni progettuali proposte, sviluppate presso le due sedi coinvolte nella cotutela (Università di Bologna, Université Paris-Est) sono affrontate secondo un protocollo scientifico che prevede: progettazione del sistema costruttivo, analisi meccanica e termica, sperimentazione costruttiva, verifica delle tecniche di messa in opera e dei requisiti prestazionali.

Desarrollo de conglomerantes basados en hipótesis constructivas de pirámides egipcias del Reino Antiguo

En la presente tesis doctoral se revisan las principales hipótesis que intentan aclarar los procesos constructivos llevados a cabo para edificar las pirámides egipcias de las Dinastías III y IV, organizándose dichas teorías desde el punto de vista de los posibles materiales constituyentes. La investigación se ha centrado en la hipótesis heterodoxa que propone, como medio para ejecutar estas construcciones, la manufactura completa de la pirámide con piedra caliza conglomerada. Con este fin, se profundiza en artículos que tienen por objeto el análisis de muestras de material de estos monumentos, de piedras calizas naturales y de piedras calizas geopoliméricas, con objeto de determinar si la hipótesis constructiva mencionada es viable. Tomando como referencia la hipótesis constructiva estudiada, se adicionan morteros de cal aérea con carbonato de sodio (natrón) y metacaolín, analizando posteriormente las nuevas características de estos conglomerantes. El cementante descrito en la teoría constructiva se enmarca dentro de la química y tecnología de los polímeros sintéticos inorgánicos activados alcalinamente, también denominados geopolímeros. Se desarrolla una primera mezcla basada en los datos extraídos de la investigación precedente. Posteriormente, se realizan varios grupos de mezclas, en las que se parte de unas proporciones iniciales correspondientes al geopolímero teórico de la hipótesis constructiva. Sobre dichas proporciones se realizan incrementos en la cantidad de cal, y los productos obtenidos son ensayados, tomando datos de: dureza Shore C, velocidad de ultrasonidos, densidades, resistencia a compresión y a flexión, difracción de rayos X, análisis térmicos y microscopía electrónica de barrido. Los resultados derivados de introducir las adiciones, en las proporciones estudiadas, mejoran notablemente algunas características de los morteros de cal convencionales. ABSTRACT In the present PhD thesis the main hypotheses about the construction processes to build the Egyptian pyramids of Dynasties III and IV are reviewed. These theories are addressed from the point of view of their possible constituent materials. The research focuses on the heterodox hypothesis that proposes, as a means to perform these constructions, the complete manufacturing of the pyramid with limestone conglomerate. In this regard, a state of the art is set on the analysis of samples of material of these monuments, natural limestone and limestone geopolymeric, to determine if the constructive hypothesis is viable. Using this constructive hypothesis as a reference, aerial lime mortars are added with sodium carbonate (natron) and metakaolin, and the new characteristics of these resulting binders are then analyzed. The cementing described in the constructive theory belongs to the chemistry and the technology of synthetic inorganic alkali-activated polymers, also called geopolymer. Based on data obtained from previous research, a first mix is prepared. Subsequently, several groups of mixes are made, starting from theoretical initial ratios corresponding to the geopolymer that was presumably used in the constructive hypothesis. Increments in the amount of lime are made upon such proportion, and the resulting products are tested for data collection about: Shore C hardness, ultrasound velocity, densities, compressive and flexural strength, X-ray diffraction, thermal analysis and scanning electron microscopy. The results allow to conclude that, if in the studied proportions, additions improve significantly some of the characteristics of conventional lime mortars.