Nuevas aportaciones en el desarrollo de materiales cementantes con residuo de catalizador de craqueo catalítico (fcc)

La industria de la Construcción es un campo muy dinámico, donde continuamente se consiguen avances y mejoras en los materiales utilizados con el fin de ofrecer mejores prestaciones y mayor seguridad. Dentro de dichos avances se encuentra la utilización de materiales puzolánicos que mejoran el comportamiento de los conglomerantes que los incorporan. En el presente trabajo se estudia los posibles beneficios obtenidos al incorporar el catalizador de craqueo catalítico del petróleo (FCC) en pastas, morteros y hormigones. El trabajo se divide en dos bloques principales, en el primero de ellos se realiza un estudio completo sobre la caracterización fisicoquímica del catalizador, y el segundo trata de su utilización e interacciones producidas al cinorporarlo junto al cemento o la cal en pastas, morteros y hormigones. El estudio de muestras de FCC de diversa procedencia, ha permitido comprobar la similitud entre los residuos y permite afirmar que es posible su utilización en cualquiera de los casos. Se ha estudiado la incorporación del FCC tanto como sustitución de parte de cemento como de la fracción árido; en ambos casos, se ha comprobado que el FCC actúa como una puzolana muy activa desde las primeras edades de curado. Este comportamiento se ha corroborado con estudios de fijación de cal, por medio de técnicas termogravimétricas. El FCC es una excelente puzolana para utilizar en hormigones autocompactables, tradicionales y de alta resistencia, tanto para hormigones con cemento Pórtland ordinario como hormigones blancos.Soriano Martínez, L. (2007). Nuevas aportaciones en el desarrollo de materiales cementantes con residuo de catalizador de craqueo catalítico (fcc) [Tesis doctoral no publicada]. Universitat Politècnica de València. https://doi.org/10.4995/Thesis/10251/2542Palanci

Determining corrosion levels in the reinforcement rebars of buildings in coastal areas. A case study in the Mediterranean coastline

This paper describes a study of the damage caused by corrosion to the reinforcement rebars of a 40-year old building used as a car park at a distance of 20 m from the sea. The corrosion levels of the building s structural elements, including beams, joists and columns were analyzed by optical and electron microscopy. Carbonation depths and chloride contents (Volhard method) of the concrete cover were measured in situ. EDX was used to analyze the condition of the reinforcement surfaces and the morpholog and composition of the oxides. A high degree of corrosion was observed in all the above elements, carbonation had reached the depth of the reinforcement in all the samples studied, and the concrete chloride levels were far in excess of the recommended maximums. The study of the reinforcement rebars revealed different types of oxides of varying morphologies, compaction and coloring according to chloride content. A comparison with previous studies allowed us to verify the presence of crystals of at least akaganeite, lepidocrocite and goethite.Moreno, JD.; Bonilla Salvador, MM.; Adam Martínez, JM.; Borrachero Rosado, MV.; Soriano Martinez, L. (2015). Determining corrosion levels in the reinforcement rebars of buildings in coastal areas. A case study in the Mediterranean coastline. Construction and Building Materials. 100:11-21. doi:10.1016/j.conbuildmat.2015.09.059112110

Microconcrete with partial replacement of Portland cement by fly ash and hydrated lime addition

[EN] The reduction in Portland cement consumption means lower CO2 emissions. Partial replacement of Portland cement by pozzolans sucha as fly ash has its limitations due to the quantity of calcium hydroxide generated in the mix. In this work we have studied the contribution of the addition of hydrated lime to Portland cement + fly ash systems. We have also studied several levels of cement replacement, ranging from the 15% to 75%. The best mechanical results were obtained replacing 50% of Portland cement by the same amount of fly ash plus the addition of hydrated lime (20% respect to the amount of fly ash). In these systems, an acide-base self-neutralization of the matrix has occurred through a pozzolanic reaction of fly ash with portlandite liberated in the hydration of Portland cement and the added hydrated lime. It has been identified for these mixtures a significant amount of hydrated gehlenite, typical reaction product from rich-alumina pozzolans.Lorca, P.; Calabuig Pastor, R.; Benlloch Marco, J.; Soriano Martinez, L.; Paya Bernabeu, JJ. (2014). Microconcrete with partial replacement of Portland cement by fly ash and hydrated lime addition. Materials and Design. 64:535-541. doi:10.1016/jmatdes.2014.08.022S5355416

Increase of the reactivity of densified silica fume by sonication treatment

Five silica fumes from different manufacturers were subjected to ultrasonic treatment in order to decrease particle agglomeration and improve particle dispersion. The effectiveness of the sonication was observed as a reduction in particle size distribution of sonicated silica fume (SSF) compared to non-sonicated silica fume. SSF was added to Portland cement, and then the hydrated paste was analysed by thermogravimetric analyses (TGA/DTG) and scanning electron microscopy (SEM/EDX). The results were compared with those of control pastes made with untreated densified silica fume (DSF), as well as a reference cement paste of ordinary Portland cement (OPC). A maximum grade of de-agglomeration by the sonication was obtained, with a high volume of particles of diameter less than 1 mu m. Images obtained by transmission electron microscopy (TEM) of the SSF showed sintered particles that could not be fragmented by the treatment. Micro-structural characterisation results showed an increase in the reactivity of the silica fume after the treatment. (C) 2012 Elsevier B.V. All rights reserved.Acknowledgments to Ministerio de Ciencia e Innovacion (Project BIA-2007-63252 and research scholarship BES-2008-002440 and EEBB-2011-43847) of Spain, European regional development fund (FEDER), and Ferroatlantica I + D for the support on the development of this research. A special acknowledgement is also due to the Centre of Electron Microscopy of the Universitat Politecnica de Valencia.Rodríguez Martínez, ED.; Soriano Martinez, L.; Paya Bernabeu, JJ.; Borrachero Rosado, MV.; Monzó Balbuena, JM. (2012). Increase of the reactivity of densified silica fume by sonication treatment. Ultrasonics Sonochemistry. 19(5):1099-1107. doi:10.1016/j.ultsonch.2012.01.011S1099110719

Geopolymer eco-cellular concrete (GECC) based on fluid catalytic cracking catalyst residue (FCC) with addition of recycled aluminium foil powder

[EN] This study presents a new cellular concrete design focused on the energy eco-efficiency and the sustainability concept: geopolymer eco-cellular concrete (GECC). Geopolymer systems made from alkali-activated fluid cracking catalyst residue (FCC) aerated by recycled aluminium foil powders (R) were designed. Commercial aluminium powder (A) was also used as an aerating agent in GECC matrix and its effect was compared with traditional cellular concrete (TCC) made with ordinary Portland cement (OPC). The more alkaline medium of the GECC system improved the hydrogen reaction rate and consequently a higher efficiency in the pore matrix development can be found. Aluminium powder addition of 0.2% by mass of the precursor (FCC) was enough to yield cellular concrete with a natural density significantly lower than that found for TCC. The replacement of A by R made it possible to produce an alternative GECC in which the recycling of the waste aluminium has an important eco-efficiency role because its low cost and its energy saving function. Ground R has less aeration effectiveness than A. However, when comilling of FCC þ R was carried out, advantageous performance GECC was attained. Very interesting properties were obtained for this material: good pore size and its proper distribution in the matrix, low natural density (600e700 kg/m3), relatively high compressive strength (2.5e3.5 MPa), low open/closed porosity ratio (1.15) and the lowest thermal conductivity (0.581 W/mK). This opens an interesting way of reusing both FCC as precursor and aluminium foil waste as an aerating agent in the preparation of new geopolymer eco-cellular concrete (GECC).This work was developed within the scope of the project Geocelplus (internal project, Universitat Politècnica de València).The authors give special grateful to Dra. Mrs. Josefa L. Roselló Caselles for kindly support and recycled aluminium foil supply. The authors also thank the Electron Microscopy Service of the Universitat Politècnica de València (Spain).Font-Pérez, A.; Borrachero Rosado, MV.; Soriano Martinez, L.; Monzó Balbuena, JM.; Paya Bernabeu, JJ. (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.2017.09.110S1120113116

Stabilization of soil by means alternative alkali-activated cement prepared with spent FCC catalyst

[EN] Alkali-activated cements are widely studied as alternative and sustainable binder in soil stabilization. In this research work, a mold was designed and constructed, which allowed small cubic specimens to be made (40 x 40 x 40 mm(3)). With the newly designed mold, cubic samples of soil stabilized with portland cement (OPC) and alternative AAC (based on spent fluid catalytic cracking catalyst FCC) were prepared from which compressive strength was obtained. Cylindrical specimens were also prepared using the same binders as in the previous case to obtain their compressive strength. The results obtained in both cases were compared. Greater resistances for cubic samples were achieved. The cubic specimens were selected for being better in terms of standard deviation of compressive strength for AAC stabilized soil. The obtained compressive strength and standard deviation results were compared between the soil specimens stabilized with different stabilizers cured at 7, 14, 28, and 90 days. The method allows small-sized cubic specimens to be prepared. It improves ergonomics. It also facilitates a large number of specimens being obtained with a small amount of sample. Soil stabilized with AAC yielded higher compressive strength after 90 days compared to that with OPC.Spanish Ministry of Economy and Competitiveness, Grant/Award Number: BIA2015 70107-R.Cosa-Martínez, J.; Soriano Martinez, L.; Borrachero Rosado, MV.; Paya Bernabeu, JJ.; Monzó Balbuena, JM. (2020). Stabilization of soil by means alternative alkali-activated cement prepared with spent FCC catalyst. International Journal of Applied Ceramic Technology. 17(1):190-196. https://doi.org/10.1111/ijac.13377S190196171UNE‐EN 12390‐1.Testing hardened concrete ‐ Part 1: Shape dimensions and other requirements for specimens and moulds.2013.UNE‐EN 41410.Compressed earth blocs for walls and partitions. Definitions specifications and test Methods.2008.ASTM D‐18C. ed. STP479‐EB Special Procedures for Testing Soil and Rock for Engineering Purposes: 5th ed. West Conshohocken PA: ASTM International.1970.https://doi.org/10.1520/STP479-EBUNE‐EN 196–1.Methods of testing cement ‐ Part 1: Determination of strength.2005.Auroville Earth Institute Earthen architecture for sustainable habitat and compressed stabilized earth block technology [cited 2019 Sep 2]. Available fromhttp://www.ada.gov.sa/idc/groups/public/documents/AR_ADA_Researches/004568.pdfNLT‐310 90.Vibrating hammer compaction of treated granular. materials.1990.UNE‐EN 13286‐2.Unbound and hydraulically bound mixtures ‐ Part 2: Test methods for laboratory reference density and water content ‐. Proctor compaction.2011.Khadka, B., & Shakya, M. (2015). Comparative compressive strength of stabilized and un-stabilized rammed earth. Materials and Structures, 49(9), 3945-3955. doi:10.1617/s11527-015-0765-5Alrubaye, A. J., Hasan, M., & Fattah, M. Y. (2016). Stabilization of soft kaolin clay with silica fume and lime. International Journal of Geotechnical Engineering, 11(1), 90-96. doi:10.1080/19386362.2016.1187884Zhang, M., Guo, H., El-Korchi, T., Zhang, G., & Tao, M. (2013). Experimental feasibility study of geopolymer as the next-generation soil stabilizer. Construction and Building Materials, 47, 1468-1478. doi:10.1016/j.conbuildmat.2013.06.017Zhang, M., Zhao, M., Zhang, G., Nowak, P., Coen, A., & Tao, M. (2015). Calcium-free geopolymer as a stabilizer for sulfate-rich soils. Applied Clay Science, 108, 199-207. doi:10.1016/j.clay.2015.02.029Bouzón, N., Payá, J., Borrachero, M. V., Soriano, L., Tashima, M. M., & Monzó, J. (2014). Refluxed rice husk ash/NaOH suspension for preparing alkali activated binders. Materials Letters, 115, 72-74. doi:10.1016/j.matlet.2013.10.001Mejía, J. M., Mejía de Gutiérrez, R., & Montes, C. (2016). Rice husk ash and spent diatomaceous earth as a source of silica to fabricate a geopolymeric binary binder. Journal of Cleaner Production, 118, 133-139. doi:10.1016/j.jclepro.2016.01.057Puertas, F., & Torres-Carrasco, M. (2014). Use of glass waste as an activator in the preparation of alkali-activated slag. Mechanical strength and paste characterisation. Cement and Concrete Research, 57, 95-104. doi:10.1016/j.cemconres.2013.12.005CosaJ SorianoL BorracheroMV PayáJ MonzóJ.Use ofAlkaline Activated Cements from Residues for Soil Stabilization. NOCMAT 2017. Proceeding Paper Published. In: Ghavami K Herrera PJ eds. Materials Research Proceedings. 2018. 7:257–64.http://dx.doi.org/10.21741/9781945291838-23Tashima, M. M., Akasaki, J. L., Castaldelli, V. N., Soriano, L., Monzó, J., Payá, J., & Borrachero, M. V. (2012). New geopolymeric binder based on fluid catalytic cracking catalyst residue (FCC). Materials Letters, 80, 50-52. doi:10.1016/j.matlet.2012.04.051Mellado, A., Catalán, C., Bouzón, N., Borrachero, M. V., Monzó, J. M., & Payá, J. (2014). Carbon footprint of geopolymeric mortar: study of the contribution of the alkaline activating solution and assessment of an alternative route. RSC Adv., 4(45), 23846-23852. doi:10.1039/c4ra03375bUNE‐EN 103 501.Geotechnics. Compactation test. Modified proctor.1994.ASTMD1557–12e1 Standard Test Methods for Laboratory Compaction Characteristics of Soil Using Modified Effort (56 000 ft‐lbf/ft3 (2 700 kN‐m/m3)).West Conshohocken PA:ASTM. International.2012.https://doi.org/10.1520/D1557-12E01UNE‐EN 772–1.Methods of test for masonry units.2011.UNE‐EN 197–1.Cement ‐ Part 1: composition specifications and conformity criteria for common cements.2011

Determination of the optimum parameters in the high resolution thermogravimetric analysis (HRTG) for cementitious materials

In this article, the methodology to implementation of high resolution thermogravimetric analysis (HRTG) for construction materials like Portland cement pastes is presented. The aim of this technique is to make easier the identification of the decomposition reactions that frequently are overlapping on conventional thermogravimetric analysis (TG) like is the case of some mineral phases in the cement pastes. The optimum parameters related to sample mass and purge flow gas were established. It is necessary carried out the analysis with high quantity of sample (60 mg in this case) and without purge gas in order to get better results and excellent reproducibility. The tests have average heating rate higher than 3 °C min -1 in the temperature range studied (35-300 °C), showing that the HRTG is not time-expensive technique. © 2010 Akadémiai Kiadó, Budapest, Hungary.Ivan Tobón, J.; Paya Bernabeu, JJ.; Borrachero Rosado, MV.; Soriano Martinez, L.; Restrepo Baena, OJ. (2012). Determination of the optimum parameters in the high resolution thermogravimetric analysis (HRTG) for cementitious materials. Journal of Thermal Analysis and Calorimetry. 107:233-239. doi:10.1007/s10973-010-0997-0S233239107Borrachero MV, Payá J, Bonilla M, Monzó J. The use of thermogravimetric analysis technique for the characterization of construction materials: the gypsum case. J Therm Anal Calorim. 2008;91–92:503–9.Ramachandran VS, Paroli RM, Beaudoin JJ, Delgado AH. Thermal analysis of construction materials. Building materials series. New York: Noyes Publications; 2003.Ramachandran VS. Application of differential thermal analysis in cement chemistry. New York: Chemical Publishing Co., Inc.; 1969.Vechio S, La Ginestra A, Frezza A, Ferragine C. The use thermoanalytical techniques in the characterization of ancient mortars. Thermochim Acta. 1993;227:215–23.Anastiasiou M, Hasapis Yh, Zorba T, Pavlidou E, Chfissafis K, Parasakevopoulos KM. TGA-DTA and FTIR analyses of plasters form byzantine monuments in Balkan region. J Therm Anal Calorim. 2006;84:27–32.Brown ME. Introduction to thermal analysis technique and applications. London: Chapman and Hall; 1998.Riesen R. Adjustment of heating rate for maximum resolution in TG and TMA (MaxRes). J Therm Anal Calorim. 1998;53:365–74.Haines PJ. Thermal methods of analysis. London: Blackie Academic Professional; 1995.Dweck J, Büchler PM, Celho ACV, Cartledge FK. Hydration of cement bended with calcium carbonate. Thermochim Acta. 2000;346:105–13.Pacewska JB, Wilinska I, Bukowska M, Blonkowski G, Nocun-Wczelik WJ. An attempt to improve the pozzolanic activity of waste aluminosilicate catalyst. J Therm Anal Calorim. 2004;77:133–42.Payá J, Monzó J, Borrachero MV, Velazquez S. Evaluation of the pozzolanic activity of fluid catalytic cracking catalyst residue (FC3R) thermogravimetric analysis studies of FC3R-Portland cement pastes. Cem Concr Res. 2003;33:603–9.Pinto CA, Büchler PM, Dweck JJ. Pozzolanic properties of a residual FCC catalyst during the early stages of cement hydration. J Therm Anal Calorim. 2007;87:715–20.Rojas MF, Cabrera J. The effect of temperature on the hydration rate and stability of the hydration phases of metakaolin-lime water systems. Cem Concr Res. 2002;32:133–8.Dweck J, Ferreira Da Silva PF, Silva Aderne R, Büchler PM, Cartledge Fk. Evaluating cement hydration by non-conventional DTA: an application to waste solidification. J Therm Anal Calorim. 2003;71:821–7.Criado JM, Pérez-Maqueda LA, Diánez MJ, Sánchez-Jiménez PE. Development of a universal constant rate thermal analysis system for being used with any thermoanalytical instrument. J Therm Anal Calorim. 2007;87:297–300.Gill PS, Sauerbrunn SR, Crowe BS. High resolution thermogravimetry. J Therm Anal Calorim. 1992;38:255–66.Frost RL, Martens W, Ding Z, Kloprogge JT. DSC and high-resolution TG of synthesized hydrotalcites of Mg and Zn. J Therm Anal Calorim. 2003;71:429–38.Ozawa T. Controlled rate thermogravimetry new usefulness of controlled rate thermogravimetry revealed by decomposition of polyimide. J Therm Anal Calorim. 2000;59:375–84.Zanier A. High resolution TG for characterization of diesel fuel additives. J Therm Anal Calorim. 2001;64:377–84.Mojundar SC, Sain M, Prasad RC, Sun L, Venart ES. Selected thermoanalytical methods and their applications from medicine to construction. Part I. J Therm Anal Calorim. 2007;90:653–62

Compressive strength and microstructure of alkali-activated mortars with high ceramic waste content

[EN] The present work investigated alkali-activated mortars with high ceramic waste contents. Tile ceramic waste (TCW) was used as both a recycled aggregate (TCWA) and a precursor (TCWP) to obtain a binding matrix by the alkali-activation process. Mortars with natural siliceous (quartz) and calcareous (limestone) aggregates, and with other ceramic waste materials (red clay brick RCB and ceramic sanitaryware CSW waste), were also prepared for comparison purposes. Given the lower density and higher water absorption values of the ceramic aggregates, compared to the natural ones, it was necessary to adapt the preparation process of the recycled mortars by presaturating the aggregate with water before mixing with the TCWP alkali-activated paste. Aggregate type considerably determined the mechanical behaviour of the samples cured at 65 °C for 3 days. The mortars prepared with the siliceous aggregate presented poor mechanical properties, even when cured at 65 °C. The behaviour of the limestone aggregate mortars depended heavily on the applied curing temperature and, although they presented the best mechanical properties of all those cured at room temperature, their compressive strength reached a maximum when cured at 65 °C, and then decreased. The mechanical properties of the mortars prepared with TCWA progressively increased with curing time (53 MPa at 65 °C for 28 days). An optimum 50 wt% proportion was observed for the limestone/TCWA mortars (¿43 MPa, 3 days at 65 °C), whereas the mechanical properties of that prepared with siliceous particles (10 MPa) progressively increased with the TCWA content, up to 100 wt% substitution (23 MPa). Limestone particles interacted with the binding matrix, and played an interesting beneficial role at the 20 °C curing temperature, with a slight reduction when cured long term (28 days) at 65 °C. The results demonstrated a potential added value for these ceramic waste materials.The authors would like to thank the Spanish Ministry of Science and Innovation and the Spanish Ministry of Economy and Competitiveness for supporting this study through Projects GEOCEDEM BIA 2011-26947 and BIA2015 70107-R, respectively. They also thank FEDER funding.Reig, L.; Sanz, M.; Borrachero Rosado, MV.; Monzó Balbuena, JM.; Soriano Martínez, L.; Paya Bernabeu, JJ. (2017). Compressive strength and microstructure of alkali-activated mortars with high ceramic waste content. Ceramics International. 43(16):16322-16334. https://doi.org/10.1016/j.ceramint.2017.07.072S1632216334431

Spent FCC catalyst for improving early strength Portland cement

[EN] Spent fluid catalytic cracking (FCC) catalyst from the petrol industry has proven to be a very active pozzolanic material. This behavior leads to an additional increase in the strength of the mortar that contains this catalyst. Pozzolanic effects tend to be considered for periods above three days, whereas in shorter times, the influence of pozzolan is usually negligible. The reactivity of FCC is so high, however, that both pozzolanic effects and acceleration of cement hydration are evident in short curing times. This paper presents a study of the effect of the presence of FCC on cement hydration and the reaction products in the first 48 hours of curing time, carried out by determining flexural and compressive strength of mortars in three different tests (substitution, addition, and with accelerator). For the FCC behavior comparison, limestone, mullite, and andalusite were used. Finally, the characterization of hydrates was performed by thermogravimetry.Borrachero Rosado, MV.; Monzó Balbuena, JM.; Paya Bernabeu, JJ.; Vunda, C.; Velázquez Rodríguez, S.; Soriano Martinez, L. (2014). Spent FCC catalyst for improving early strength Portland cement. Materials Journal. 111(1):59-66. http://hdl.handle.net/10251/51723S5966111