The encore project: sustainable solutions for cementitious materials

Since concrete is the most widely utilized construction material, several solutions are currently being developed and investigated for enhancing the sustainability of cementitious materials. One of these solutions is based on producing Recycled Concrete Aggregates (RCA) from existing concrete members resulting by either industrial processes or demolitions of existing structures as a whole. Moreover, waste resulting from industrial processes other than the building construction (i.e., tire recycling, production of steel, powders resulting from other depuration processes) are also being considered as possible low-impact constituents for producing structural concrete and Fiber-Reinforced Cementitious Composites (FRCC). Furthermore, the use of natural fibers is another option for producing environmentally-friendly and cost-effective materials, depending on the local availability of raw materials. To promote the use of concretes partially composed of recycled constituents, their influence on the mechanical and durability performance of these concretes have to be deeply investigated and correlated. This was the main goal of the EnCoRe Project (www.encore-fp7.unisa.it), a EU-funded initiative, whose activities and main findings are summarized in this paper.

Adhesion as a tool for in-built nanotechnology design in cementitious materials

Confined water, such as those molecules in nanolayers of 2-3 nm in length, plays an important role in the adhesion of hydrophilic materials, mainly in cementitious ones. In this study, the effects of water containing kosmotropic substances on adhesion, known for their ability of enhancing the hydrogen bond (H-bond) network of confined water, were evaluated using mechanical strength tests. Indeed, to link adhesion provided by water confined in nanolayers to a macro-response of the cementitious samples, such as the bending strength, requires the evaluation of local water H-bond network configuration in the presence of kosmotropes, considering their influences on the extent and the strength of H-bonds. Among the kosmotropes, trimethylamine and sucrose provided a 50% increase in bending strength compared to the reference samples, the latter just using water as an adhesive, whereas trehalose was responsible for reducing the bending strength to a value close to the samples without any adhesive. The results attained opened up perspectives regarding exploring the confined water behavior which naturally occurs throughout the hydration process in cement-based materials.

Integration of computational models and experimental characterization to study internal frost damage in cementitious materials

The objective of this doctoral research is to investigate the internal frost damage due to crystallization pore pressure in porous cement-based materials by developing computational and experimental characterization tools. As an essential component of the U.S. infrastructure system, the durability of concrete has significant impact on maintenance costs. In cold climates, freeze-thaw damage is a major issue affecting the durability of concrete. The deleterious effects of the freeze-thaw cycle depend on the microscale characteristics of concrete such as the pore sizes and the pore distribution, as well as the environmental conditions. Recent theories attribute internal frost damage of concrete is caused by crystallization pore pressure in the cold environment. The pore structures have significant impact on freeze-thaw durability of cement/concrete samples. The scanning electron microscope (SEM) and transmission X-ray microscopy (TXM) techniques were applied to characterize freeze-thaw damage within pore structure. In the microscale pore system, the crystallization pressures at sub-cooling temperatures were calculated using interface energy balance with thermodynamic analysis. The multi-phase Extended Finite Element Modeling (XFEM) and bilinear Cohesive Zone Modeling (CZM) were developed to simulate the internal frost damage of heterogeneous cement-based material samples. The fracture simulation with these two techniques were validated by comparing the predicted fracture behavior with the captured damage from compact tension (CT) and single-edge notched beam (SEB) bending tests. The study applied the developed computational tools to simulate the internal frost damage caused by ice crystallization with the two dimensional (2-D) SEM and three dimensional (3-D) reconstructed SEM and TXM digital samples. The pore pressure calculated from thermodynamic analysis was input for model simulation. The 2-D and 3-D bilinear CZM predicted the crack initiation and propagation within cement paste microstructure. The favorably predicted crack paths in concrete/cement samples indicate the developed bilinear CZM techniques have the ability to capture crack nucleation and propagation in cement-based material samples with multiphase and associated interface. By comparing the computational prediction with the actual damaged samples, it also indicates that the ice crystallization pressure is the main mechanism for the internal frost damage in cementitious materials.

In-situ X-ray micro-diffraction studies of heterogeneous interfaces between cementitious materials and geological formations

In the present study the challenge of analyzing complex micro X-ray diffraction (microXRD) patterns from cement–clay interfaces has been addressed. In order to extract the maximum information concerning both the spatial distribution and the crystal structure type associated with each of the many diffracting grains in heterogeneous, polycrystalline samples, an approach has been developed in which microXRD was applied to thin sections which were rotated in the X-ray beam. The data analysis, performed on microXRD patterns collected from a filled vein of a cement–clay interface from the natural analogue in Maqarin (Jordan), and a sample from a two-year-old altered interface between cement and argillaceous rock, demonstrate the potential of this method.

Ionic and molecular diffusion in cementitious materials

The work described in this thesis is an attempt to provide improved understanding of the effects of several factors affecting diffusion in hydrated cement pastes and to aid the prediction of ionic diffusion processes in cement-based materials. Effect of pore structure on diffusion was examined by means of comparative diffusion studies of quaternary ammonium ions with different ionic radii. Diffusivities of these ions in hydrated pastes of ordinary portland cement with or without addition of fly ash were determined by a quasi-steady state technique. The restriction of the pore geometry on diffusion was evaluated from the change of diffusivity in response to the change of ionic radius. The pastes were prepared at three water-cement ratios, 0.35, 0.50 and 0.65. Attempts were made to study the effect of surface charge or the electrochemical double layer at the pore/solution interface on ionic diffusion. An approach was to evaluate the zeta potentials of hydrated cement pastes through streaming potential measurements. Another approach was the comparative studies of the diffusion kinetics of chloride and dissolved oxygen in hydrated pastes of ordinary portland cement with addition of 0 and 20% fly ash. An electrochemical technique for the determination of oxygen diffusivity was also developed. Non-steady state diffusion of sodium potassium, chloride and hydroxyl ions in hydrated ordinary portland cement paste of water-cement ratio 0.5 was studied with the aid of computer-modelling. The kinetics of both diffusion and ionic binding were considered for the characterization of the concentration profiles by Fick's first and second laws. The effect of the electrostatic interactions between ions on the overall diffusion rates was also considered. A general model concerning the prediction of ionic diffusion processes in cement-based materials has been proposed.

An energy based nanomechnical properties evaluation method for cementitious materials

Advances in multiscale material modeling of structural concrete have created an upsurge of interest in the accurate evaluation of mechanical properties and volume fractions of its nano constituents. The task is accomplished by analyzing the response of a material to indentation, obtained as an outcome of a nanoindentation experiment, using a procedure called the Oliver and Pharr (OP) method. Despite its widespread use, the accuracy of this method is often questioned when it is applied to the data from heterogeneous materials or from the materials that show pile-up and sink-in during indentation, which necessitates the development of an alternative method. ^ In this study, a model is developed within the framework defined by contact mechanics to compute the nanomechanical properties of a material from its indentation response. Unlike the OP method, indentation energies are employed in the form of dimensionless constants to evaluate model parameters. Analysis of the load-displacement data pertaining to a wide range of materials revealed that the energy constants may be used to determine the indenter tip bluntness, hardness and initial unloading stiffness of the material. The proposed model has two main advantages: (1) it does not require the computation of the contact area, a source of error in the existing method; and (2) it incorporates the effect of peak indentation load, dwelling period and indenter tip bluntness on the measured mechanical properties explicitly. ^ Indentation tests are also carried out on samples from cement paste to validate the energy based model developed herein by determining the elastic modulus and hardness of different phases of the paste. As a consequence, it has been found that the model computes the mechanical properties in close agreement with that obtained by the OP method; a discrepancy, though insignificant, is observed more in the case of C-S-H than in the anhydrous phase. Nevertheless, the proposed method is computationally efficient, and thus it is highly suitable when the grid indentation technique is required to be performed. In addition, several empirical relations are developed that are found to be crucial in understanding the nanomechanical behavior of cementitious materials.^

Materials and Mix Optimization Procedures for PCC Pavements, March 2006

Severe environmental conditions, coupled with the routine use of deicing chemicals and increasing traffic volume, tend to place extreme demands on portland cement concrete (PCC) pavements. In most instances, engineers have been able to specify and build PCC pavements that met these challenges. However, there have also been reports of premature deterioration that could not be specifically attributed to a single cause. Modern concrete mixtures have evolved to become very complex chemical systems. The complexity can be attributed to both the number of ingredients used in any given mixture and the various types and sources of the ingredients supplied to any given project. Local environmental conditions can also influence the outcome of paving projects. This research project investigated important variables that impact the homogeneity and rheology of concrete mixtures. The project consisted of a field study and a laboratory study. The field study collected information from six different projects in Iowa. The information that was collected during the field study documented cementitious material properties, plastic concrete properties, and hardened concrete properties. The laboratory study was used to develop baseline mixture variability information for the field study. It also investigated plastic concrete properties using various new devices to evaluate rheology and mixing efficiency. In addition, the lab study evaluated a strategy for the optimization of mortar and concrete mixtures containing supplementary cementitious materials. The results of the field studies indicated that the quality management concrete (QMC) mixtures being placed in the state generally exhibited good uniformity and good to excellent workability. Hardened concrete properties (compressive strength and hardened air content) were also satisfactory. The uniformity of the raw cementitious materials that were used on the projects could not be monitored as closely as was desired by the investigators; however, the information that was gathered indicated that the bulk chemical composition of most materials streams was reasonably uniform. Specific minerals phases in the cementitious materials were less uniform than the bulk chemical composition. The results of the laboratory study indicated that ternary mixtures show significant promise for improving the performance of concrete mixtures. The lab study also verified the results from prior projects that have indicated that bassanite is typically the major sulfate phase that is present in Iowa cements. This causes the cements to exhibit premature stiffening problems (false set) in laboratory testing. Fly ash helps to reduce the impact of premature stiffening because it behaves like a low-range water reducer in most instances. The premature stiffening problem can also be alleviated by increasing the water–cement ratio of the mixture and providing a remix cycle for the mixture.

Alkali activated materials based on fluid catalytic cracking catalyst residue (FCC): Influence of SiO2/Na2O and H 2O/FCC ratio on mechanical strength and microstructure

Reuse of industrial and agricultural wastes as supplementary cementitious materials (SCMs) in concrete and mortar productions contribute to sustainable development. In this context, fluid catalytic cracking catalyst residue (spent FCC), a byproduct from the petroleum industry and petrol refineries, have been studied as SCM in blended Portland cement in the last years. Nevertheless, another environmental friendly alternative has been conducted in order to produce alternative binders with low CO2 emissions. The use of aluminosilicate materials in the production of alkali-activated materials (AAMs) is an ongoing research topic which can present low CO2 emissions associated. Hence, this paper studies some variables that can influence the production of AAM based on spent FCC. Specifically, the influence of SiO 2/Na2O molar ratio and the H2O/spent FCC mass ratio on the mechanical strength and microstructure are assessed. Some instrumental techniques, such as SEM, XRD, pH and electrical conductivity measurements, and MIP are performed in order to assess the microstructure of formed alkali-activated binder. Alkali activated mortars with compressive strength up to 80 MPa can be formed after curing for 3 days at 65°C. The research demonstrates the potential of spent FCC to produce alkali-activated cements and the importance of SiO2/Na2O molar ratio and the H2O/spent FCC mass ratio in optimising properties and microstructure. © 2013 Elsevier Ltd. All rights reserved.

In-situ Molibdenum X-ray powder diffraction study of the early hydration of cementitious systems on a humidity chamber

The durability of cement-based construction materials depends on the environmental conditions during their service life. A further factor is the microstructure of the cement bulk, established by formation of cement hydrates. The development of the phases and microstructure under given conditions is responsible of the high strength of cementitious materials. The investigation on the early hydration behavior of cements and cementing systems has been for a long time a very important area of research: understanding the chemical reactions that lead to hardening is fundamental for the prediction of performances and durability of the materials. The production of 1 ton of Ordinary Portland Cement, OPC, releases into the atmosphere ~0.97 tons of CO2. This implies that the overall CO2 emissions from the cement industry are 6% of all anthropogenic carbon dioxide. An alternative to reduce the CO2 footprint consists on the development of eco-cements composed by less calcite demanding phases, such as belite and ye'elimite. That is the case of Belite-Ye’elimite cements (BY). Since the reactivity of belite is not quick enough, these materials develop low mechanical strengths at intermediate hydration ages. A possible solution to this problem goes through the production of cements which jointly contain alite with the two previously mentioned phases, named as Belite-Alite-Ye’elimite (BAY) cements. 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 values. The final goal is to understand the hydration mechanisms of a variety of cementing systems (OPC, BAY and pure phases) as a function of water content, superplasticizer additives and type and content of sulfate source. In order to do so, in-situ laboratory humidity chambers with Molybdenum X-ray Powder diffraction are employed. In the first 2h of hydration, reaction degree (α) of ye'elimite had been decreased for superplasticizer.

Sources of Variations When Comparing Concrete Carbonation Results

Carbonation is one of the main concerns for concrete service life in tropical countries. The mechanism and materials that produce it have been widely studied as well as natural and accelerated methods to report and analyze it. In spite of reported investigations, there is a need for information that could allow an adequate interpretation of the results of the standardization process. This lack of information can produce variations not only in the interpretation but also in the predictions of service life. The purpose of this paper is to analyze and discuss variables that could be sources of error, especially when performing accelerated tests. As a result, a methodologies to minimize variations when interpreting and comparing results is proposed, such as specimen geometry and preconditioning, spacing, relative humidity, and CO(2) concentration.

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.

NHL 3.5 mortars with scrap tire rubber

The use of wastes and industrial by-products as building materials is an important issue in order to decrease costs with waste management and the embodied energy of building products. Scrap tire rubber has been studied as aggregate for cementitious materials. Natural hydraulic limes are natural binders with particular characteristics of both air and hydraulic binders. Their specifications became stricter with the last version of EN 459-1:2010. In this study scrap tire rubber was used as additional aggregate of mortars, based on NHL3.5 and natural sand. Different particle size fractions and proportions of scrap tire rubber were used: a mix obtained almost directly from industry (only after sieving for preparation of particle sizes similar to mortar aggregate) and separated fine, medium and coarse fractions; 0%, 18%, 36% and 54% weight of binder, corresponding to 2.5%, 5% and 7.5% weight of sand. The influence of the rubbers´ additions on the mortars´ fresh state, mechanical and physical performance is presented, namely by flow table consistency, water retention, fresh bulk density, dynamic elasticity modulus, flexural and compressive strength, open porosity and bulk density, capillary absorption, drying and thermal conductivity. The use of the rubber mix coming from the waste tire industry seems advantageous and may open possibilities for use as raw material by the mortars industry.

Development of ductile cementitiuos composites using carbon nanotubes

Concrete is the primary construction material for civil infrastructures and generally consists of cement, coarse aggregates, sand, admixtures and water. Cementitious materials are characterized by quasi-brittle behaviour and susceptible to cracking [1]. The cracking process within concrete begins with isolated nano-cracks, which then conjoin to form micro-cracks and in turn macro-cracks. Formation and growth of cracks lead to loss of mechanical performance with time and also make concrete accessible to water and other degrading agents such as CO2, chlorides, sulfates, etc. leading to strength loss and corrosion of steel rebars. To improve brittleness of concrete, reinforcements such as polymeric as well as glass and carbon fibers have been used and microfibers improved the mechanical properties significantly by delaying (but could not stop) the transformation of micro-cracks into macro forms [2]. This fact encouraged the use of nano-sized fillers in concrete to prevent the growth of nano-cracks transforming in to micro and macro forms. Nanoparticles like SiO2, Fe2O3, and TiO2 led to considerable improvement in mechanical performance and moreover, nano-TiO2 helped to remove organic pollutants from concrete surfaces [3].