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.

Cement As a Waste Form for Nuclear Fission Products: The Case of 90Sr and Its Daughters

One of the main challenges faced by the nuclear industry is the long-term confinement of nuclear waste. Because it is inexpensive and easy to manufacture, cement is the material of choice to store large volumes of radioactive materials, in particular the low-level medium-lived fission products. It is therefore of utmost importance to assess the chemical and structural stability of cement containing radioactive species. Here, we use ab initio calculations based on density functional theory (DFT) to study the effects of ⁹⁰Sr insertion and decay in C-S-H (calcium-silicate-hydrate) in order to test the ability of cement to trap and hold this radioactive fission product and to investigate the consequences of its β-decay on the cement paste structure. We show that ⁹⁰Sr is stable when it substitutes the Ca²⁺ ions in C-S-H, and so is its daughter nucleus ⁹⁰Y after β-decay. Interestingly, ⁹⁰Zr, daughter of ⁹⁰Y and final product in the decay sequence, is found to be unstable compared to the bulk phase of the element at zero K but stable when compared to the solvated ion in water. Therefore, cement appears as a suitable waste form for ⁹⁰Sr storage.

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.

Cimentos de fosfato de magnésio: consolidação e caracterização

A reação entre o óxido de magnésio (MgO) e o fosfato de monoamónio (MAP), à temperatura ambiente, origina os cimentos de fosfato de magnésio, materiais caracterizados pela sua presa rápida e pelas excelentes propriedades mecânicas adquiridas precocemente. As propriedades finais são dependentes, essencialmente, da composição do cimento (razão molar magnésia:fosfato e utilização de retardantes de presa) mas também são influenciadas pela reatividade da magnésia utilizada. Neste trabalho, a reação foi caracterizada através do estudo da influência da razão molar MgO:MAP (variando de 1:1 até 8:1), da presença e teor de aditivos retardantes (ácido bórico, ácido cítrico e tripolifosfato de sódio) e da variação da área superficial específica da magnésia (conseguida por calcinação do óxido), no tempo de presa, na temperatura máxima atingida e nas fases cristalinas finais formadas. A reação de presa pode ser comparada à hidratação do cimento Portland, com a existência de 4 estágios (reação inicial, indução, aceleração e desaceleração), com a diferença que estes estágios ocorrem a velocidade muito mais alta nos cimentos de fosfato de magnésio. Este estudo foi realizado utilizando a espetroscopia de impedâncias, acompanhada pela monitorização da evolução de temperatura ao longo do tempo de reação e, por paragem de reação, identificando as fases cristalinas formadas. A investigação do mecanismo de reação foi complementada com a observação da microestrutura dos cimentos formados e permitiu concluir que a origem da magnésia usada não afeta a reação nem as propriedades do cimento final. A metodologia de superfície de resposta foi utilizada para o estudo e otimização das características finais do produto, tendo-se mostrado um método muito eficaz. Para o estudo da variação da área superficial específica da magnésia com as condições de calcinação (temperatura e tempo de patamar) usou-se o planeamento fatorial de experiências tendo sido obtido um modelo matemático que relaciona a resposta da área superficial específica da magnésia com as condições de calcinação. As propriedades finais dos cimentos (resistência mecânica à compressão e absorção de água) foram estudadas utilizando o planeamento simplex de experiências, que permitiu encontrar modelos que relacionam a propriedade em estudo com os valores das variáveis (razão molar MgO:MAP, área superficial específica da magnésia e quantidade de ácido bórico). Estes modelos podem ser usados para formular composições e produzir cimentos com propriedades finais específicas.

Low-Carbon Cement with Waste Oil-Cracking Catalyst Incorporation

The present paper shows preliminary results of an ongoing project which one of the goals is to investigate the viability of using waste FCC catalyst (wFCC), originated from Portuguese oil refinery, to produce low carbon blended cements. For this purpose, four blended cements were produced by substituting cement CEM I 42.5R up to 20% (w/w) by waste FCC catalyst. Initial and final setting times, consistency of standard paste, soundness and compressive strengths after 2, 7 and 28 days were measured. It was observed that the wFCC blended cements developed similar strength, at 28 days, compared to the reference cement, CEM I 42.5R. Moreover, cements with waste FCC catalyst incorporation up to 15% w/w meet European Standard EN 197-1 specifications for CEM II/A type cement, in the 42.5R strength class.

Contribuição para o conhecimento das propriedades pozolânicas da fracção fina resultante da produção de areia de origem granítica

O presente estudo diz respeito a um trabalho de pesquisa no âmbito de uma Tese de Mestrado incluída no segundo ciclo de estudos do curso de Engenharia Geotécnica e Geoambiente, realizado sobre as condições de desidroxilação para a obtenção de metacaulino com propriedades cimentíceas, a partir da fracção argilosa proveniente dos finos residuais da produção de areias de natureza granítica. O produto resultante da alteração e desintegração dos feldspatos constituintes dos granitos são ricos em caulinite. Na natureza e em particular no Norte de Portugal, existem significativos depósitos cauliníticos com características potenciadoras para a produção de metacaulino. O metacaulino utilizado neste estudo foi obtido de uma amostra de argila submetida a 750oC, por um período de tempo de 30 minutos, processo que permitiu a desidroxilação quase total da matéria-prima, transformando esta numa fase amorfa e irreversível, com propriedades pozolânicas. Os metacaulinos, também conhecidos por geopolímeros, são produtos de fácil produção utilizando uma matéria-prima abundante e proporcionam a obtenção de novos produtos que permitem a substituição parcial do cimento Portland normal na composição das pastas de betão, com vantagens significativas no comportamento mecânico e na resistência aos agentes atmosféricos. Neste estudo são apresentados os resultados dos ensaios de caracterização da matéria-prima, das condições de calcinação e do produto resultante da desidroxilação, nomeadamente a determinação da pozolanicidade e das características fundamentais para a aplicabilidade do produto. No âmbito da especialidade de Georrecursos, consideramos que este trabalho está perfeitamente adequado, já que, para além do estudo para o conhecimento das propriedades da matéria-prima, foi possível, através das alterações introduzidas com o tratamento térmico, obter um novo produto, cuja utilização terá importantes reflexos na sustentabilidade dos recursos naturais e sua utilização.

Contribuição para o conhecimento sobre o efeito da utilização de material pozolânico no fabrico de betão

O presente trabalho, realizado no âmbito da Tese de Mestrado, tem como principal objectivo estudar as características pozolânicas dos materiais da zona de Arganil para substituição parcial do cimento Portland com o objectivo de intensificar certas qualidades devido à diminuição da porosidade do betão. Estas qualidades são interessantes quando se procura maior durabilidade. Para tal, foram realizados diversos ensaios para a caracterização física, química e mineralógica dos produtos. Os metacaulinos utilizados foram obtidos de amostras de argila submetidas a calcinação (750oC, durante uma hora), processo que permitiu a desidroxilação quase total da matéria-prima, transformando esta numa fase amorfa e irreversível, com propriedades pozolânicas. São apresentados os resultados dos ensaios de caracterização da matéria-prima, das condições de calcinação e do produto resultante da desidroxilação, nomeadamente a determinação da pozolanicidade e superfície específica e das características fundamentais para a aplicabilidade do produto. Descreve ainda o emprego do metacaulino em betões de resistência convencional. Estudou-se a influência do emprego do metacaulino (15% de substituição de cimento, em massa) na resistência à flexão e à compressão (aos 28 dias) em argamassas e o emprego de metacaulino (10%, 15% e 20% de substituição de cimento, em massa) na resistência à compressão (3, 7 e 28 dias) no betão.

Current mortars in conservation: an overview

Renders are an important item in historical buildings and the need for their periodical re-application is a basic conservation procedure. In modern times there has been a trend towards the replacement of traditional pure lime mortars by new formulations including Portland cement or hydraulic lime. Apart from those interventions on specific and very important monuments, in which the use oftraditional non-hydraulic mortars can be enforced, in most of the projects involving less than first order magnitude heritage the use of some sort of hydraulic components is becoming the rule rather than the exception. The present paper describes and analyses the results of an experimental study with ten formulations of current mortars - including some that can hardly be considered as adequate conservation procedures - allowing a direct comparison in terms of some of the most relevant characteristics.

Low-carbon cement with waste oil-craking catalyst incorporation

The present paper shows preliminary results of an ongoing project which one of the goals is to investigate the viability of using waste FCC catalyst (wFCC), originated from Portuguese oil refinery, to produce low carbon blended cements. For this purpose, four blended cements were produced by substituting cement CEM I 42.5R up to 20% (w/w) by waste FCC catalyst. Initial and final setting times, consistency of standard paste, soundness and compressive strengths after 2, 7 and 28 days were measured. It was observed that the wFCC blended cements developed similar strength, at 28 days, compared to the reference cement, CEM I 42.5R. Moreover, cements with waste FCC catalyst incorporation up to 15% w/w meet European Standard EN 197-1 specifications for CEM II/A type cement, in the 42.5R strength class.

Experimental study on polyester based concretes filled with glass fibre reinforced plastic recyclates – a contribution to composite materials sustainability

The development and applications of thermoset polymeric composites, namely fibre reinforced plastics (FRP), have shifted in the last decades more and more into the mass market [1]. Despite of all advantages associated to FRP based products, the increasing production and consume also lead to an increasing amount of FRP wastes, either end-of-lifecycle products, or scrap and by-products generated by the manufacturing process itself. Whereas thermoplastic FRPs can be easily recycled, by remelting and remoulding, recyclability of thermosetting FRPs constitutes a more difficult task due to cross-linked nature of resin matrix. To date, most of the thermoset based FRP waste is being incinerated or landfilled, leading to negative environmental impacts and supplementary added costs to FRP producers and suppliers. This actual framework is putting increasing pressure on the industry to address the options available for FRP waste management, being an important driver for applied research undertaken cost efficient recycling methods. [1-2]. In spite of this, research on recycling solutions for thermoset composites is still at an elementary stage. Thermal and/or chemical recycling processes, with partial fibre recovering, have been investigated mostly for carbon fibre reinforced plastics (CFRP) due to inherent value of carbon fibre reinforcement; whereas for glass fibre reinforced plastics (GFRP), mechanical recycling, by means of milling and grinding processes, has been considered a more viable recycling method [1-2]. Though, at the moment, few solutions in the reuse of mechanically-recycled GFRP composites into valueadded products are being explored. Aiming filling this gap, in this study, a new waste management solution for thermoset GFRP based products was assessed. The mechanical recycling approach, with reduction of GFRP waste to powdered and fibrous materials was applied, and the potential added value of obtained recyclates was experimentally investigated as raw material for polyester based mortars. The use of a cementless concrete as host material for GFRP recyclates, instead of a conventional Portland cement based concrete, presents an important asset in avoiding the eventual incompatibility problems arisen from alkalis silica reaction between glass fibres and cementious binder matrix. Additionally, due to hermetic nature of resin binder, polymer based concretes present greater ability for incorporating recycled waste products [3]. Under this scope, different GFRP waste admixed polymer mortar (PM) formulations were analyzed varying the size grading and content of GFRP powder and fibre mix waste. Added value of potential recycling solution was assessed by means of flexural and compressive loading capacities of modified mortars with regard to waste-free polymer mortars.

Estudo de Argamassas com Cinza de Casca de Amêndoa

Perante o elevado consumo de materiais naturais no processo e produtos na área da construção civil, o reaproveitamento de resíduos é uma das soluções a ser estudada. As cinzas agroindustriais têm lugar de destaque entre estes resíduos, pois têm a possibilidade de aplicação em materiais cimentícios, reduzindo assim o consumo de cimento de Portland. O presente estudo debruça-se sobre a substituição parcial (1,5% e 5%) de cimento de Portland por cinzas de casca de amêndoa. Realizaram-se provetes com diferentes tipos de argamassas: (i) uma de controlo sem substituição de cimento (ARF); (ii) uma com 1,5% de substituição parcial de cimento por cinzas de casca de amêndoa (CCA 1,5%); (iii) e uma com 5% de substituição parcial de cimento por cinza de casca de amêndoa (CCA 5%). Executaram-se ensaios para resistências mecânicas aos 3, 7, 14, 28 e 41 dias de idade. A nível químico pode-se concluir que esta cinza de casca de amêndoa não apresentou qualquer potencial pozolânico. A trabalhabilidade na generalidade diminui ligeiramente, contendo cinza de casca de amêndoa, mas ainda assim considerando-se de fácil manuseamento. Em relação às resistências mecânicas, pode-se concluir que o ideal é a substituição parcial de cimento com 1,5%, pois as resistências diminuem com o uso de uma maior percentagem de substituição, ou seja, o ideal é substituir em pequenas percentagens. Com os dados obtidos, conclui-se que as cinzas testadas não apresentam características necessárias para serem consideradas pozolanas e se será viável a sua utilização mesmo como filer.