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Construction and Building Materials 95 (2015) 164170

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Construction and Building Materials


journal homepage: www.elsevier.com/locate/conbuildmat

The potential of ground clay brick to mitigate AlkaliSilica Reaction


in mortar prepared with highly reactive aggregate
Kaveh Afshinnia , Amir Poursaee
Glenn Department of Civil Engineering, Clemson University, Clemson, SC 29634, USA

h i g h l i g h t s

 A brief study has been done to evaluate the pozzolanic reactivity and ASR mitigation performance of ground crushed brick.
 A brief study has been done to evaluate the effect of ground crushed brick neness on ASR mitigation performance.
 Microscopic analysis has been conducted to evaluate the microstructure of the mortar containing ground crushed brick.
 A comparison has been made to investigate the pozzolanic reactivity of ground crushed brick using XRD analysis.

a r t i c l e i n f o a b s t r a c t

Article history: The objective of this work was to study the effect of ground clay brick on mitigating the Alkali Silica
Received 1 March 2015 Reaction (ASR) in mortar bars prepared with highly reactive aggregates. To evaluate the potential of
Received in revised form 9 July 2015 ground crushed clay brick to mitigate ASR distress in mortar, mortar bars and mortar cubes were cast
Accepted 15 July 2015
with combination of different dosages of ground clay brick (partial replacement of portland cement).
The pozzolanic reactivity of ground clay brick was also evaluated using strength activity index test. In
addition, the Scanning Electron Microscopy (SEM) and the Energy-Dispersive X-ray Spectroscopy (EDS)
Keywords:
were conducted to evaluate the microstructure and location of the ASR gel and its chemical composition.
Ground crushed brick (GCB)
AlkaliSilica Reaction (ASR)
The results from this study indicated satisfactory level of pozzolanic reactivity when cement was partially
Pozzolanic reactivity replacement by the ground clay brick. Also, it was found that replacing 25% of cement with ground clay
Concrete expansion brick (by weight) could signicantly decrease the ASR expansion by 67% at the age of 14 days. However,
Cementitious material this study suggested that the compressive strength values of the specimens containing higher dosages of
XRD ground crushed brick (i.e. 50% replacement level) were signicantly lower than that of the control
specimens.
2015 Elsevier Ltd. All rights reserved.

1. Introduction [1519] have been used successfully to mitigate the ASR distress in
concrete. Depletion of alkali loading in concrete mixture due to the
Alkali Silica Reaction (ASR) is a chemical reaction occurs replacement of portland cement (dilution effect), better alkali
between the specic source of silica from aggregate and the binding provided by modied CSH (CalciumSilicateHydrate)
hydroxyl ions that are usually available in the alkaline environ- gel (particularly, where the calcium to silica ratio are low), higher
ment of the pore solution. The product of this reaction is a strength provided by pozzolanic reaction of SCMs and decreasing
hygroscopic ASR gel, which by itself does not cause any problem the rate of silica dissolution from aggregate surface [20] are some
for the concrete. However, at the presence of moisture, the ASR of the main causes by which the SCMs can mitigate ASR distress in
gel swells and consequently causes signicant pressure through concrete mixtures. Moreover, the SCMs may rene the pores dis-
the surrounding concrete matrix. tribution in concrete paste; therefore, the reactive aggregates have
Typically, Supplementary Cementitious Materials (SCMs) such less access to the external moisture compared to the conventional
as y ashes [15], slag [68], meta-kaolin [912], silica fume concrete (without SCMs) [21,22]. Even though the benecial inu-
[13,14] and other SCMs derived from waste materials such as glass ence of typical SCMs such as y ash, meta-kaolin, slag and silica
fume have been well investigated in different studies, the use of
Corresponding author. pozzolans derived from waste materials such as ground clay brick
E-mail addresses: kafshin@clemson.edu (K. Afshinnia), amire@clemson.edu needs further investigations. In addition, due to the different envi-
(A. Poursaee). ronmental agency reports, alternative methods of recycling waste

http://dx.doi.org/10.1016/j.conbuildmat.2015.07.155
0950-0618/ 2015 Elsevier Ltd. All rights reserved.
K. Afshinnia, A. Poursaee / Construction and Building Materials 95 (2015) 164170 165

materials such as using them in construction materials must be and concrete prisms containing crushed brick aggregate indicated
considered to reduce the high volume of waste disposed of in signicant amount of ASR distress [30]. In addition, both ASR gel
landlls. and ettringite from delayed ettringite formation (DEF) were seen
Typically, the main components of the clay bricks are kaolin and within the mortar or concrete specimens. Another study by
shale. However, small amount of magnesium and/or barium are Bektas et al. was carried out to investigate the ASR distress in mor-
added to modify its color. Based on the chemical composition of tar bars containing 10% and 20% crushed brick aggregate as a ne
clay brick, this material typically contains approximately 70% silica aggregate replacement using the accelerated mortar bar test
and 1520% alumina. It has been reported that the presence of sol- (AMBT) [31]. It was found that the crushed brick aggregate was
uble alumina in SCM may improve the ASR mitigation performance susceptible to ASR attack.
by formation of CASH (Aluminum containing CalciumSilicate This study was aimed to evaluate the impact of ground clay
Hydrate) gel instead of the CSH gel, which has more potential to brick as both cement and aggregates partial replacements on mit-
bind the alkalis and consequently deplete the alkalinity of the pore igating the ASR in mortar bars prepared with highly reactive aggre-
solution [23]. Several studies were conducted to assess the bene- gates. Moreover, the pozzolanic reactivity of ground brick as a
cial inuence of ground clay brick when used as a portland cement cement replacement was evaluated. The microscopic analysis
replacement on the fresh properties as well as mechanical proper- was also conducted to study the ASR gel in the specimens.
ties of mortar or concrete mixtures [2428]. Wild et al. evaluated
the pozzolanic reactivity of ground clay brick with a maximum
particle size of 250 lm collected from four European countries 2. Materials and experimental procedures
[24]. They found that the ground clay brick could be replaced up
to 30% of the portland cement by weight without signicant reduc- 2.1. Materials
tion in mechanical properties of concrete. Other study by Naceri
2.1.1. Cement
et al. was carried out to evaluate the inuence of using waste brick
Type I high alkali cement (Na2Oeq = 0.88%), with the chemical composition
powder as a cement replacement at 5%, 10%, 15% and 20% dosage shown in Table 1, was used in this study.
levels on the mechanical properties of mortars [25]. It was found
that the 28-day compressive strength of the mortar cubes gradu-
ally decreased with increasing waste brick powder content. Lin
2.1.2. Clay brick as an aggregate material
et al. evaluated the fresh and mechanical properties of paste spec- Clay brick with chemical composition shown in Table 1, was used in this study.
imens containing 050% waste brick powder [26]. They found that The clay bricks were rst crushed using laboratory jaw crusher. Then, crushed brick
the use of waste brick powder increased the initial and nal setting with the specic size gradation in accordance with ASTM C1260 was used as ne
time of the paste. Also, the compressive strength of the paste spec- aggregates in mortar bars [32].

imens with brick powder developed slowly in the early ages, and
increased at the later ages. OFarrel et al. showed that at early ages,
the pore volume of the mortar mixtures containing brick was 2.1.3. Ground crushed brick (GCB) as a cementitious material
A laboratory ball mill crusher was used to prepare the ground crushed brick
higher than that of the control [27]. Therefore, the compressive
with an average particle size of 40 lm. Fine crushed brick was grounded in a labo-
strength of such mixtures was less than the control mixtures. ratory ball mill for 10 min with the speed of 250 rpm.
However, at later ages, the pore volume and the compressive
strength of the mortar specimens were comparable with control
mixtures. A study by Gonalves et al. was carried out to compare
2.1.4. Reactive ne aggregate
the compressive strength, modulus of elasticity and pore size dis- Rhyolitic gravel from Las Placitas Pit in Bernalillo County, New Mexico with
tribution of mortar mixtures containing waste clay brick powder oven-dry specic gravity (SGOD) of 2.6, saturate-surface-dry specic gravity
with mortar mixture containing meta-kaolin [28]. It was found (SGSSD) of 2.63, absorption of 1.09%, and dry rodded unit weight (DRUW) of
that the use of clay brick powder as a cement replacement reduced 1585.3 kg m3 was used as the reactive sand in all mixtures. Previous study showed
considerable 14-day expansion value of mortar bars containing Rhyolitic gravel,
the proportion of macro pores and modulus of elasticity of the thus, it is used in this investigation as reactive aggregate [3].
mortar specimens. As aforementioned studies, the majority of the
studies showed that the pozzolanic reactivity of ground brick
was more profound at later ages compared to that in early ages.
2.2. Mixture proportion
A limited number of studies conducted to assess the mitigation
ability of the ground brick powders to suppress the Alkali Silica Mortar bars containing 10%, 25% and 50% ground crushed brick as portland
Reaction in mortars or concrete [29,16]. A study by Turanli et al. cement replacement by weight were cast. To consider the inuence of cement dilu-
on mortar bars containing 0%, 10%, 20% and 30% ground crushed tion effect (reducing the proportion of alkali loading), two more mortar mixtures
wherein 10% and 25% of the cement in the mixture proportion were replaced by
brick as cement replacement using accelerated mortar bar test
inert non-reactive material, were cast. In order to evaluate the effect of crushed
(AMBT) showed that the ASR distress was properly mitigated in brick neness on the ASR mitigation, a mortar mixture containing 100% portland
mortar bars containing 20% or 30% ground crushed brick [29]. cement and 25% crushed brick as an aggregate replacement was prepared.
Other study by Bektas et al. on the ASR mitigation performance Table 2 shows the mixture proportions of the mortar mixtures used in this study.
of ground clay brick combined with other conventional SCMs such
as y ash and natural pozzolan indicated that the ground clay brick
Table 1
was not as effective as y ash while a similar mitigation Chemical compositions of portland cement and ground crushed brick.
performance of ground clay brick compared to that of the natural
Chemical analysis (%) Portland cement Clay brick
pozzolans was observed. Nevertheless, the ASR mitigation perfor-
mance of ternary blend of ground clay brick and y ash SiO2 19.45 69.43
out-performed the mitigation performance of binary blend con- Al2O3 4.85 17.29
Fe2O3 3.79 6.4
taining just ground clay brick, but underperformed the mitigation CaO 61.37 0.51
performance of binary blend containing y ash [16]. SO3 3.3 2.54
Some studies were carried out to assess the ASR reactivity in MgO 2.92 1.14
specimens containing crushed brick as their aggregates replace- Na2Oeq 0.88 1.72
Loss on ignition 2.54 0.17
ment [30,31]. A study by Bektas showed that both mortar bars
166 K. Afshinnia, A. Poursaee / Construction and Building Materials 95 (2015) 164170

Table 2 125
Mixture proportions used to prepare the samples. 7 Days 28 Days 90 Days

Strength Activity Index (%)


Mixtures Cementitious material (%-mass) Fine aggregate 100
(%-mass)
Inert non- Portland Ground New Crushed 75
reactive cement crushed Mexico brick
material brick
50
1 0 100 0 100 0
2 0 90 10 100 0
25
3 0 75 25 100 0
4 0 50 50 100 0
5 0 100 0 75 25 0
6 10 90 0 100 0 10% 25% 50%
7 25 75 0 100 0 Ground crushed brick dosage (%)

Fig. 1. Strength activity index of the mortar specimens containing ground crushed
brick.
2.3. Test procedures

2.3.1. X-ray Diffraction (XRD)


The mineralogical compositions of the ground clay brick were examined by
respectively, which indicated the pozzolanic reactivity of ground
X-ray Diffraction (XRD) technique. For this purpose, the powder was mounted on crushed brick at later ages. However, the improvement in strength
an aluminum slide for XRD analysis and scanned from 5 to 80 2h with a scan rate activity index values by time was not observed in the mortar mix-
of 0.1 steps per minute. tures containing 10% ground crushed brick. For instance, the 7-day
and 90-day strength activity index values of the mortar mixtures
2.3.2. Strength activity index (SAI) containing 10% ground crushed brick were very similar.
50 mm  50 mm  50 mm (2.00 in.  2.00 in.  2.00 in.) mortar cubes contain-
ing 0%, 10%, 25% and 50% ground crushed brick were cast to evaluate the pozzolanic
Higher dosage of ground-crushed brick (i.e. 50% replacement)
reactivity of mortar mixtures containing ground crushed brick as portland cement did not show the acceptable pozzolanic reactivity.
replacement. After demolding, the mortar cubes were wet cured at the curing room
at 23 C and 100% relative humidity. The compressive strength of the mortar cubes 3.2. Accelerated mortar bar test (AMBT)
were measured at 7, 28 and 90 days using ASTM C109 [34]. The strength activity
index (SAI) which is a number based on the compressive strength of the cubes,
was calculated using the ASTM C311 as following [35]: As shown in Fig. 2, the expansion values of mortar bars contain-
ing the inert material (10% and 25% inert non-reactive material) as
Strength Activity Index SAI A=B  100 1
cement replacement were less than that of the mortar bars contain-
where, A is an average compressive strength of three mortar specimens containing ing 100% portland cement (i.e. control mortar bars) and more than
pozzolan and B is an average compressive strength of reference sample (without that of the mortar bars containing the same dosages of ground
pozzolan). The higher strength activity index represents the higher pozzolanic
crushed brick. Therefore, it can be concluded that the incorporation
reactivity of the pozzolan.
of ground crushed brick as cement replacement mitigated ASR, par-
2.3.3. Accelerated mortar bar test (AMBT)
ticularly at higher dosage levels (i.e. 25% replacement level). For
For each mixture, three 25 mm  25 mm  285 mm (1 in  1 in  11.25 in) instance, the 14-day expansion values of mortar bars containing
mortar bars were cast and wet cured for 24 h. Then, bars were demolded and imme- 10%, 25% and 50% ground crushed brick reduced approximately
diately immersed in water and kept in an oven at 80 C for 24 h. The measured 31%, 67% and 95% compared to that of the control specimens,
length of each bar (after 24 h immersion in water) was recorded as the initial length
respectively. In addition, the 14-day expansion values of the mortar
(zero reading). Then, all bars were transferred into the 1 N NaOH solution and kept
at 80 C during the test period. The bars expansions were measured during 28 days bars containing 10% and 25% ground crushed brick as cement
of the experiment. The mixture with the 14-day expansion value less than 0.1% is replacement in mortar mixtures showed 22% and 47% reduction
considered as a mixture that will not experience the ASR distress, while the mixture compared to that of the mortar bars containing the same dosages
with the 14-day expansion value more than 0.2% is considered a mixture that will of inert material, indicating the benecial mitigation inuence of
experience the ASR distress.
ground crushed brick. The 14-day expansion value of the mortar
bars containing 50% ground crushed brick was 0.04%, which was
2.3.4. Scanning Electron Microscopy (SEM) and Energy Disperse X-ray Spectroscopy
(EDS) signicantly lower than 0.1%, the expansion threshold suggested
The microstructural examination of polished sections from mortar bars sub- by the ASTM C33 [33]. However, due to the low strength activity
jected to the ASTM C1260 method, containing ground crushed brick as a portland index values of the mortar mixtures containing 50% ground crushed
cement replacement was conducted to identify the location of ASR gel after 28 days brick (as shown in Fig. 1), by employing this level of replacement,
immersion in 1 N NaOH soak solution. A lapidary saw was used to section samples
from the mortar bar specimens. The SEM test was conducted in back-scatter mode
the satisfactory level of the compressive strength will not be
using Hitachi TM-3400 microscope. Also, the EDS equipment was used to evaluate achieved. Considering the high reactivity of the natural aggregates
the chemical composition of paste and ASR gel in mixtures prepared with or used in this study, the results from this study suggested that by
without ground crushed brick. employing moderate or low reactive aggregate, even 25% ground
crushed brick could be sufcient to mitigate the ASR distress.
3. Results and discussion To evaluate the effect of crushed brick particle size on the mit-
igation performance of ASR distress in mortar bars, mortar bars
3.1. Strength activity index containing ne crushed brick as partial replacement of ne aggre-
gates were used in this study as well. The crushed brick was
As shown in Fig. 1, the 28-day strength activity index values of replaced as an aggregate material with the specic size fraction
the mortar specimens containing 10%, 25% and 50% ground in accordance with ASTM C1260. As shown in Fig. 3, the use of ne
crushed brick were 92%, 86% and 59%, respectively. In addition, crushed brick as an aggregate material did not have any positive
the strength activity index values of the mortar mixtures were impact on the ASR mitigation. For instance, the 14-day expansion
gradually increased by time. For instance, the 7-day, 28-day and value of the mortar bars containing 25% ne crushed brick as an
90-day strength activity index values of the mortar mixtures aggregate replacement was 0.71%, while the 14-day expansion
containing 25% ground crushed brick were 79%, 86% and 91%, value of the mortar bars containing 25% ground crushed brick as
K. Afshinnia, A. Poursaee / Construction and Building Materials 95 (2015) 164170 167

1.30 10% groung crushed brick


1.20 10% inert material
25% ground crushed brick
1.10 25% inert material
1.00 50% ground crushed brick
Control (100% portland cement) 0.88
0.90
0.78

Expansion (%)
0.80
0.70 0.61
0.60
0.50 0.55
0.40
0.29
0.30
0.20
0.10 0.04
0.00
0 7 14 21 28
Age (day)s

Fig. 2. Expansion behavior of mortar bars containing 0%, 10%, 25% and 50% ground crushed brick or inert non-reactive material.

1.30
1.20 25% ground crushed brick (cement replacement)
25% crushed brick (aggregate replacement)
1.10
Control (0% ground or crushed brick)
1.00
0.90
0.88
Expansion (%)

0.80
0.70
0.71
0.60
0.50
0.40
0.30
0.29
0.20
0.10
0.00
0 7 14 21 28
Age (Days)

Fig. 3. Expansion behavior of mortar bars containing 0% and 25% ground crushed brick and ne crushed brick.

cement replacement was 0.29%. Thus, the neness of crushed brick examined to identify the location and chemical composition of
plays an important role in the ASR mitigation. ASR gel after 28 days immersion in 1 N NaOH solution.
It seems that the higher surface area of the ground brick power The SEM images of the aforementioned specimens are shown in
compared to that of the crushed brick, enhanced the mitigation Fig. 5. As shown in Fig. 5(a), signicant amount of ASR gel was
performance of the ground crushed brick. observed within the cement paste and aggregate particles of the
Fig. 4(a)(c) show the images were taken from control mortar control specimen. These results are in agreement with the
bar (without brick), the mortar bars containing 25% ground 28-day expansion values of the control mortar bars (as shown in
crushed brick (cement replacement) and the mortar bar containing Fig. 2, the 28-day expansion value of the control mortar bar was
25% ne crushed brick (ne aggregate replacement), respectively, 1.21%). However, as shown in Fig. 5(b), less ASR gel was observed
after 28 days of immersion in 1 N NaOH solution. As can be seen, in the microstructure of the mortar section containing 25% ground
signicant amount of cracks were observed on the surface of the crushed brick. Nevertheless, the ASR gel in the mortar section of
control mortar bar. Furthermore, considerable deformation along specimen containing ground crushed brick was mostly found in
its longitudinal axis was observed in the control specimen. While the air voids (as shown in Fig. 5(b)).
the deformation and cracks were decreased, using the ne crushed The EDS test was conducted to evaluate the chemical composi-
brick as aggregate replacement, there is no visible deformation or tion of the ASR gel in the specimens. Results from the EDS analysis
surface cracks of the bar made with ground crushed brick as it par- showed distinctive chemical compositions for the ASR gels formed
tial cement replacement. in the specimen containing ground crushed brick compared to that
in the control specimen. The chemical compositions of the ASR gel
3.3. Scanning Electron Microscopy (SEM) and Energy Disperse X-ray obtained from at least three locations as indicated in Fig. 5 (by
Spectroscopy (EDS) average) are given in Table 3. As it is apparent from Table 3, the
alkali content of ASR gel in control specimen is much higher than
Microstructure of polished sections from mortar bars subjected that of the specimen containing ground crushed brick (i.e. Na + K
to AMBT test, containing 0% and 25% ground crushed brick was content). Less alkali content in the ASR gel from specimen with
168 K. Afshinnia, A. Poursaee / Construction and Building Materials 95 (2015) 164170

(a) Control (0% crumb rubber)

(b) 25% ground crushed brick (cement replacement)

(c) 25% fine crushed brick (aggregate replacement)


Fig. 4. Images from mortar bars after immersion in 1 N NaOH for 28 days.

ASR Gel (Point 1) ASR Gel (Point 2)

Fig. 5. SEM Images from mortar bar sections after immersion in 1 N NaOH for 28 days: (a) Control (0% ground crushed brick) and (b) 25% ground crushed brick.

Table 3 rigid without signicant swelling [37]. In addition, the EDS results
Chemical compositions ASR gel obtained from EDX analysis. in this study suggested that the ASR gel in the specimen containing
Sample Location Chemical composition (%) ground crushed brick could exchange its alkali ions with calcium
Ca Si Na K Al Ca/Si
ions from the surrounding cement paste. The resulting gel was
more stable than the initial alkali-rich gel. In addition, the gels
Control ASR gel 21.3 48.9 24.5 3.1 1.4 0.44
(Point 1)
were accumulated in the void (Fig. 5(b)), which indicated lower
25% Ground ASR gel 28.4 45.0 16.1 4.2 4.4 0.63 viscosity of the gel.
crushed brick (Point 2)

3.4. X-ray Diffraction (XRD)

ground crushed brick was attributed to the higher potential of Fig. 6 shows the XRD pattern of the mortar specimens with dif-
alkali binding provided by the modied CASH gel in the speci- ferent percentage of ground crushed brick as cement replacement,
men containing ground crushed brick [23]. Considering that the 1 year after casting. Results showed that the peaks corresponding
ground crushed brick was rich in alumina, the CASH gel had to the portlandite decreased or disappeared by replacing the
a potential to x the alkali ions in the pore solution; therefore, less cement with brick powder. This can be attributed to consumption
alkali ions were available in the pore solution to react with sili- of the portlandite phase due to pozzolanic activity of the brick
cates. The calcium content of the ASR gel in the specimen contain- powers. However, at 10% replacement level, the level of portlandite
ing ground-crushed brick was noticeably higher than that in the was comparable with that of the control.
control specimen. It was shown that the ASR gel with higher cal- Fig. 7 compares the XRD pattern of a mortar specimen contain-
cium content, was more viscous and less mobile compared to the ing 25% ground crushed brick as cement replacement with a mor-
ASR gel with lower level of calcium content (lower calcium to silica tar specimen containing 25% crushed brick as ne aggregate
ratio-C/S) [36]. Although, the mobile gel was more capable of dif- replacement. As can be seen, the portlandite peaks were either
fusing through cement matrix and could move through the paste weaker or disappeared when the brick powder was used as cement
and did not apply a localized pressure to the surrounding matrix, replacement. This observation can be characterized as more poz-
the stiff ASR gel (which contains high level of calcium) was more zolanic activity of ground crushed brick with smaller size and more
K. Afshinnia, A. Poursaee / Construction and Building Materials 95 (2015) 164170 169

3. The particle size of crushed brick plays an important role in its


potential to mitigate ASR distress in mortars. Thus, the ner
crushed brick provides higher level of mitigation due to the
ASR distress.
4. The presence of ground crushed brick in the mortar mixtures
can signicantly alter the chemical composition of the ASR gel
in mortar specimens prepared with highly reactive aggregate.
It was found that the ASR gel in the mortar specimens contain-
Intensity (a.u.)

ing ground crushed brick has lower viscosity; decreasing the


pressure on the surrounding matrix.
5. The XRD tests conrmed that brick powders indeed have poz-
zolanic behavior. Smaller size (more surface area) showed more
pozzolanic activity.

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