Study on binary and ternary systems with cement, hydrated lime and fly ash: thermogravimetric analysis, mechanical analysis and durability behaviour

The use of high percentages of substitution of Portland cement by pozzolans can provoke the total consumption of portlandite. The present research proposes the study of ternary systems of Portland cement (PC), fly ash (FA), and hydrated lime (CH). After 180 days of curing, the mortar with 50% substitution of PC by FA obtained 65.9 MPa versus the mortars with an addition of 20% of CH and control mortar (100 PC) that obtained 69.9 MPa and 76.7 MPa respectively: this behavior is very positive value considering that tested FA containing mortars had a 50% of Portland cement. Regarding the effect of the amount of extra hydrated lime on durability issues, the evolution against carbonation of PC-FA and PC-CH-FA mortars was studied: the reduction of carbonation velocity was around a 37% for the mortar with CH respect the PC-FA mortar

Mineralogical evolution of Portland cement blended with silica nanoparticles and its effect on mechanical strength

Mineralogical analysis on pastes of Spanish Portland cement Type I, blended with nanosilica was carried out by conventional and high-resolution thermogravimetric analysis (TG-HRTG) and X-ray diffraction (XRD) in order to determine the quantity of the different mineralogical phases obtained during the hydration process. Simultaneously, mortars with the same materials and replacement ratio were made in order to assess their compressive strength for up to 28 days of curing time. In this paper, the rate and quantity of each one of the main constituent phases of the cement during its hydration process (CSH, portlandite, stratlingite, etc.) were determined. A correlation between the quantity of CSH and the development of compressive strength was established. Additionally, the pozzolanic activity of nanosilica was evaluated by quantifying the fixation of calcium hydroxide and its impact on the development of the compressive strength. © 2012 Elsevier Ltd. All rights reserved.The authors express their thanks to Cementos Argos S.A. and to COLCIENCIAS (Project 20201007768) of Colombia for their financial support in the execution of this research.Tobón, JI.; Paya Bernabeu, JJ.; Borrachero Rosado, MV.; Restrepo Baena, OJ. (2012). Mineralogical evolution of Portland cement blended with silica nanoparticles and its effect on mechanical strength. Construction and Building Materials. 36:736-742. https://doi.org/10.1016/j.conbuildmat.2012.06.043S7367423

Refluxed rice husk ash/NaOH suspension for preparing alkali activated binders

Geopolymers simultaneously containing two waste materials have been developed: fluid catalytic cracking catalyst (FCC) as mineral admixture and rice husk ash (RHA) for preparing an alkaline activator. Alkaline activators were prepared by refluxing aqueous mixtures of ground or original RHA with NaOH. All mortars with alkaline activator containing RHA show compressive strength (cured at 65 °C for 1 day) in the range of 31 41 MPa, which is similar to control mortar prepared using an equivalent mixture of NaOH and water glass. Refluxing times between 30 and 240 min yielded good performance mortars. This new way of valorisation would imply economic and environmental benefits in geopolymer production.GEOCEDEM Project BIA 2011-26947 was financed by Spanish Government, Project 3018/2009 was financed by Generalitat Valenciana, Project AP/35235/11 was financed by AECID, COMBURES Project was financed by Centro de Cooperacion al Desarrollo de la Universitat Politecnica de Valencia ADSIDEO COOPERACIO and OMYA Clariana S.A. and Maicerias Espanolas DACSA S.A. supplied FCC and RHA samples respectively.Bouzón, N.; Paya Bernabeu, JJ.; Borrachero Rosado, MV.; Soriano Martínez, L.; Mitsuuchi Tashima, M.; Monzó Balbuena, JM. (2014). Refluxed rice husk ash/NaOH suspension for preparing alkali activated binders. Materials Letters. 115:72-74. https://doi.org/10.1016/j.matlet.2013.10.001S727411

A new geopolymeric binder from hydrated-carbonated cement

This paper evaluates the use of hydrated Portland cement as the raw material in the production of geopolymers. The silicon and aluminium oxides needed for the geopolymerization process were produced by the carbonation of hydrated Portland cement, which transforms CSH and CAH (Portland cement hydrates) into silica and alumina gels. Hydrated-carbonated Portland cement was alkali activated with a NaOH/waterglass solution. Pastes and mortars were prepared, and micro-structural and mechanical properties were analyzed. It has been noted that geopolymers are mechanically stable and yield compressive strength higher than 10 MPa when mortars are cured at 65 °C for 3 days. The results have shown that there are interesting possibilities for re-using the cement-rich fraction of construction and demolition waste. Alkaline activation of hydrated-carbonated Portland cement could be considered a low CO 2-emission binder. © 2012 Elsevier B.V. All rights reserved.Paya Bernabeu, JJ.; Borrachero Rosado, MV.; Monzó Balbuena, JM.; Soriano Martinez, L.; Mitsuuchi Tashima, M. (2012). A new geopolymeric binder from hydrated-carbonated cement. Materials Letters. 74:223-225. doi:10.1016/j.matlet.2012.01.132S2232257

Cement equivalence factor evaluations for fluid catalytic cracking catalyst residue

Fluid catalytic cracking catalyst residue (FC3R) is a waste material that can be used as a Portland cement replacement in pastes, mortars, and concrete. The flow table results show that FC3R is a water demanding addition; nevertheless, this effect can be compensated with the use of superplasticizers. The pozzolanic activity of FC3R was studied observing the mechanical strength evolution with time. Pastes and mortars with FC3R incorporated show higher mechanical strengths than control specimens, indicating the pozzolanic activity of the waste. Cement equivalence factor (k-factor) evaluations were carried out. The k-factor values for the FC3R pastes and mortars were always greater than one, indicating that in order to maintain the same compressive mechanical strength of the control specimen it is sufficient to replace cement with a smaller amount of catalyst residue, due to the high pozzolanic activity of FC3R. There is a strong agreement between the k-factor values obtained in pastes and mortars.This work was supported by Ministerio de Ciencia y Tecnologia, Spain (Project MAT 2001-2694).Paya Bernabeu, JJ.; Monzó Balbuena, JM.; Borrachero Rosado, MV.; Velazquez Rodriguez, S. (2013). Cement equivalence factor evaluations for fluid catalytic cracking catalyst residue. Cement and Concrete Composites. 39:12-17. https://doi.org/10.1016/j.cemconcomp.2013.03.011S12173

Multimodal analysis of GRC ageing process using Nonlinear Impact Resonance acoustic Spectroscopy

Glass fibre Reinforced Cement (GRC) is a composite material composed of Portland cement mortar with low w/c (water/cement) ratio and high proportion of glass fibres. This material suffers from the ageing process by losing its strength with time because of its exposure to severe weather conditions. Ageing process damages the fibre surface and decreases the mechanical properties of the structural components made of this material. It reduces the elastic modulus and toughness of GRC. Fracture toughness is traditionally measured by four point bending tests. In a previous study by the authors it was observed that ageing related deterioration or damage of GRC could be monitored by Non Destructive Testing (NDT) techniques such as Non-linear Impact Resonance Acoustic Spectroscopy (NIRAS) and other ultrasonic techniques. The scope of this paper is to corroborate previous investigations and offer early damage detection capability by generating more experimental data points by optimizing location of the point of strike and thus generating more resonance vibration modes in NIRAS tests.The authors acknowledge the financial support of the Ministerio de Ciencia e Innovacion MICINN, Spain, and FEDER funding (Ondacem Project: BIA 2010-19933).Genovés Gómez, V.; Riestra García-San Miguel, C.; Borrachero Rosado, MV.; Eiras Fernández, JN.; Kundu, T.; Paya Bernabeu, JJ. (2015). Multimodal analysis of GRC ageing process using Nonlinear Impact Resonance acoustic Spectroscopy. Composites Part B: Engineering. 76:105-111. https://doi.org/10.1016/j.compositesb.2015.02.020S1051117

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 SiO 2/Na 2O 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°C during 3 days. The results confirm the viability of producing geopolymers based on FCC. © 2012 Elsevier B.V. All rights reserved.We acknowledge the Ministerio de Ciencia e Innovacion (MICINN) of the Spanish Government and FEDER funds (MAT-2011-19934 project) and the PROPG-UNESP "Universidade Estadual Paulista Julio de Mesquita Filho", Brazil.Mitsuuchi Tashima, M.; Akasaki, JL.; Castaldelli, V.; Soriano Martínez, L.; Monzó Balbuena, JM.; Paya Bernabeu, JJ.; Borrachero Rosado, MV. (2012). New geopolymeric binder based on fluid catalytic cracking catalyst residue (FCC). Materials Letters. 80:50-52. https://doi.org/10.1016/j.matlet.2012.04.051S50528

Behavior of metakaolin-based geopolymers incorporating sewage sludge ash (SSA)

[EN] In recent years, geopolymers have become a widely researched binding material. There are technological and environmental advantages tousing this type of binder instead of Portland cement. In this study, binary systems of geopolymers were produced by using mixtures of metakaolin (MK) ,a well-known aluminosilicate raw material, and a residue from sewage sludge incineration: sewage sludge ash (SSA). This ash was used to partially replace the metakaolin in proportions of 0 20%. The mixtures were activated with alkaline solutions and they were cured by using two different conditions: at room temperature (25 °C) and in a thermal bath (65 °C). The samples were assessed by X-ray diffraction, scanning electron microscopy (pastes) and compressive strength (mortars). The results from these studies showed zeolite formation (faujasite) in geopolymers cured in the thermal bath, which caused a decrease in the compressive strength of the alkali-activated mortars.Replacement of MK with SSA caused a lower reduction in the compressive strength of mortars cured at 65 °C. However, at room temperature, similar mechanical strength was observed for the MK and MK-SSA systems. These results demonstrated that SSA is a suitable mineral precursor for partial replacement of MK in geopolymer production.The authors acknowledge Santander Universidades for the grant to Lucia Reig (program: Becas lberoamerica Jovenes Profesores Investigadores Espana 2014), CAPES (CAPES/DGU no 266/12), CNPq (no. 14/2013 processo 478057/2013-0) Scanning electron microscopy service of FEIS/UNESP and CNPq (processo 309015/2015-4).Istuque, D.; Reig Cerdá, L.; Moraes, J.; Akasaki, JL.; Borrachero Rosado, MV.; Soriano Martínez, L.; Paya Bernabeu, JJ.... (2016). Behavior of metakaolin-based geopolymers incorporating sewage sludge ash (SSA). Materials Letters. 180:192-195. https://doi.org/10.1016/j.matlet.2016.05.137S19219518

Salt slag recycled by-products in high insulation geopolymer cellular concrete manufacturing

[EN] This investigation presents an important contribution to the understanding of the ¿zero discharge in the aluminium cycle¿ goal. The salt slag recycled by-product was reused as alternative aerating agent in the manufacture of cellular concretes: fluid catalytic cracking catalyst (FCC) ¿ based geopolymer (GCC) and blast furnace (BFS) ¿ based alkali-activated (AACC). The hydrogen emission test was used to evaluate the gas releasing properties because of the presence of metallic aluminium in the salt slag. Density (kg/cm3), compressive strength (MPa) and thermal conductivity (W/mK) for GCC were 75, 6.9 and 0.31 and for AACC were 602, 7.5 and 0.16.The authors give special grateful to Befesa Aluminio S.L (Valladolid, Spain) for the granulated paval supply. The authors would also thanks to Cementval and BPOil for precursors supplying. Thanks are given to the Electron Microscopy Service of the Universitat Politècnica de València (Spain).Font-Pérez, A.; Soriano Martinez, L.; Monzó Balbuena, JM.; Moraes, J.; Borrachero Rosado, MV.; Paya Bernabeu, JJ. (2020). Salt slag recycled by-products in high insulation geopolymer cellular concrete manufacturing. Construction and Building Materials. 231:1-13. https://doi.org/10.1016/j.conbuildmat.2019.117114S113231Meyer, C. (2009). The greening of the concrete industry. Cement and Concrete Composites, 31(8), 601-605. doi:10.1016/j.cemconcomp.2008.12.010Petek Gursel, A., Masanet, E., Horvath, A., & Stadel, A. (2014). Life-cycle inventory analysis of concrete production: A critical review. Cement and Concrete Composites, 51, 38-48. doi:10.1016/j.cemconcomp.2014.03.005Panesar, D. K. (2013). Cellular concrete properties and the effect of synthetic and protein foaming agents. Construction and Building Materials, 44, 575-584. doi:10.1016/j.conbuildmat.2013.03.024B. Dolton, C. Hannah, Cellular Concrete : Engineering and Technological Advancement for Construction in Cold Climates, (2006) 1–11.Narayanan, N., & Ramamurthy, K. (2000). Structure and properties of aerated concrete: a review. Cement and Concrete Composites, 22(5), 321-329. doi:10.1016/s0958-9465(00)00016-0Holt, E., & Raivio, P. (2005). Use of gasification residues in aerated autoclaved concrete. Cement and Concrete Research, 35(4), 796-802. doi:10.1016/j.cemconres.2004.05.005Mo, K. H., Alengaram, U. J., Jumaat, M. Z., Yap, S. P., & Lee, S. C. (2016). Green concrete partially comprised of farming waste residues: a review. Journal of Cleaner Production, 117, 122-138. doi:10.1016/j.jclepro.2016.01.022Luukkonen, T., Abdollahnejad, Z., Yliniemi, J., Kinnunen, P., & Illikainen, M. (2018). One-part alkali-activated materials: A review. Cement and Concrete Research, 103, 21-34. doi:10.1016/j.cemconres.2017.10.001Duxson, P., Provis, J. L., Lukey, G. C., & van Deventer, J. S. J. (2007). The role of inorganic polymer technology in the development of ‘green concrete’. Cement and Concrete Research, 37(12), 1590-1597. doi:10.1016/j.cemconres.2007.08.018Ducman, V., & Korat, L. (2016). Characterization of geopolymer fly-ash based foams obtained with the addition of Al powder or H2O2 as foaming agents. Materials Characterization, 113, 207-213. doi:10.1016/j.matchar.2016.01.019Esmaily, H., & Nuranian, H. (2012). Non-autoclaved high strength cellular concrete from alkali activated slag. Construction and Building Materials, 26(1), 200-206. doi:10.1016/j.conbuildmat.2011.06.010Font, A., Borrachero, M. V., Soriano, L., Monzó, J., & Payá, J. (2017). Geopolymer eco-cellular concrete (GECC) based on fluid catalytic cracking catalyst residue (FCC) with addition of recycled aluminium foil powder. Journal of Cleaner Production, 168, 1120-1131. doi:10.1016/j.jclepro.2017.09.110Font, A., Borrachero, M. V., Soriano, L., Monzó, J., Mellado, A., & Payá, J. (2018). 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Physical and mechanical properties of foamed Portland cement composite containing crumb rubber from worn tires

The management of worn tires is a concern in industrialized countries. The application of crumb rubber as lightweight aggregate in cement based materials is a green alternative for reusing this material. High replacements of natural sand by crumb rubber were studied and an air-entraining agent was employed to ensure a cellular structure in the cement-based composite. The obtained results from tests in fresh state reveal an improvement in workability. The tests conducted on hardened composite show promise for constructive applications where thermal and acoustic properties are required. The minimum requirement of mechanical strength for masonry units was achieved, since compressive strengths varied between 1 and 10 MPa. Finally, potential applications as a construction material have been highlightedEiras Fernández, JN.; Segovia Rueda, F.; Borrachero Rosado, MV.; Monzó Balbuena, JM.; Bonilla Salvador, MM.; Paya Bernabeu, JJ. (2014). Physical and mechanical properties of foamed Portland cement composite containing crumb rubber from worn tires. Materials and Design. 59:550-557. doi:10.1016/j.matdes.2014.03.021S5505575