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Sustainable Construction Materials and Technologies

The construction materials industry is a major user of the world’s resources.


While enormous progress has been made towards sustainability, the scope and
opportunities for improvements are significant.

To further the effort for sustainable development, a conference on


Sustainable Construction Materials and Technologies was held at Coventry
University, Coventry, U.K., from June 11th - 13th, 2007, to highlight case
studies and research on new and innovative ways of achieving sustainability of
construction materials and technologies. This book presents selected, important
contributions made at the conference. Over 190 papers from over 45 countries
were accepted for presentation at the conference, of which approximately 100
selected papers are published in this book. The rest of the papers are published
in two supplementary books.

Topics covered in this book include: sustainable alternatives to natural sand,


stone, and portland cement in concrete; sustainable use of recyclable
resources such as fly ash, ground municipal waste slag, pozzolan, rice-husk ash,
silica fume, gypsum plasterboard (drywall), and lime in construction; sustainable
mortar, concrete, bricks, blocks, and backfill; the economics and environmental
impact of sustainable materials and structures; use of construction and demolition
wastes, and organic materials (straw bale, hemp, etc.) in construction; sustainable
use of soil, timber, and wood products; and related sustainable construction
and rehabilitation technologies.

Chun
Claisse
Naik
Ganjian
Editors Sustainable Construction Materials and Technologies

Y.-M. Chun, P. Claisse, T.R. Naik & E. Ganjian - Editors

an informa business
SUSTAINABLE CONSTRUCTION MATERIALS AND TECHNOLOGIES
BALKEMA – Proceedings and Monographs
in Engineering, Water and Earth Sciences
INTERNATIONAL CONFERENCE ON SUSTAINABLE CONSTRUCTION MATERIALS AND
TECHNOLOGIES, 11–13 JUNE, 2007, COVENTRY, UK

Sustainable Construction
Materials and Technologies
Editors

Yoon-moon Chun
Research Associate, UWM Center for By-Products Utilization,
University of Wisconsin – Milwaukee, Milwaukee, Wisconsin, USA

Peter Claisse
Professor of Construction Materials, Faculty of Engineering and Computing,
Coventry University, Coventry, UK

Tarun R. Naik
Research Professor and Academic Program Director, UWM Center for
By-Products Utilization, University of Wisconsin – Milwaukee, Milwaukee,
Wisconsin, USA

Eshmaiel Ganjian
Senior Lecturer in Civil Engineering, Faculty of Engineering and Computing,
Coventry University, Coventry, UK

LONDON / LEIDEN / NEW YORK / PHILADELPHIA / SINGAPORE


Cover photo: Milwaukee Art Museum, USA, courtesy of Tarun R. Naik

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© 2007 Taylor & Francis Group, London, UK

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ISBN 13: 978-0-415-44689-1


Sustainable Construction Materials and Technologies – Chun, Claisse, Naik & Ganjian (eds)
© 2007 Taylor & Francis Group, London, ISBN 978-0-415-44689-1

Table of contents

Preface XI

Contributions of the concrete industry toward sustainable development 1


K. Sakai
Site trials of concrete with a very low carbon footprint 11
P.A. Claisse, E. Ganjian & H. Sadeghi-Pouya
Sustainability of the cement and concrete industries 19
T.R. Naik
Closed Cycle Construction – A process for the separation and reuse of the total C&D waste stream 27
E. Mulder, L. Feenstra & T.P.R. de Jong
Effect of GRP industrial waste on durability of cement mortars 35
F. Tittarelli & G. Moriconi
Engineering properties of oil palm shell (ops) hybrid concrete for lightweight precast floor slab 41
C.H. Ng, Z. Ideris, S.P. Narayanan, M.A. Mannan & V.J. Kurian
Durability of concrete mixed with fine recycled aggregates 45
S. Levy & P. Helene
An experimental investigation on the viability of using fine concrete recycled
aggregate in concrete production 53
S.R. Sarhat
Effect of different recycled aggregates on mortar performance 59
V. Corinaldesi, S. Monosi & G. Moriconi
Researching recycled aggregate structural concrete for buildings 63
N. Morohashi & T. Sakurada
Recycling of concrete in precast concrete production 69
V. Corinaldesi & G. Moriconi
Concrete paving products made with recycled demolition aggregates 77
K. Tang, M.N. Soutsos & S.G. Millard
Using tires rubber waste for modification of concrete properties 85
G. Skripkiu-nas, A. Grinys & M. Dauksys
Employment of waste sand to compose fibre reinforced cement composites 91
J. Katzer
Portland cement concrete using high levels of microfines 101
P.N. Quiroga & D.W. Fowler
Utilization of organo-modified reservoir sludge as fine aggregates in cement mortars 107
W.Y. Kuo, J.S. Huang, T.E. Tan & C.Y. Chou
Study on fly ash-saturation in cementitious materials 115
L. Guangcheng, L. Yunhua & X. Youjun

V
Ultra fine fly ash concrete 121
B.K.T. Kandie & E.A. Byars
Achieving sustainable construction through use of fly ash in concrete – An Indian experience 131
M. Mokal
“Eco-pad” in-situ mixed concrete pavement with a 93–100% total recycled content 137
B.W. Ramme, T. Jansen, A. Tawil & D.B. Anderson
Properties of shotcrete with highly functional fly ash used as dust-reducing agent 147
K. Sasaki, M. Ishii, Y. Butou & K. Yuno
The use of fly ash for enhancing durability and sustainability 155
L.K.A. Sear
Cracking behavior of concrete containing fly ash due to drying shrinkage 165
T. Seo, Y. Ohno & T. Nakagawa
Potential uses for coal combustion by-products for sustainable construction materials 171
T.F. Vandivort & P.F. Ziemkiewicz
Properties of calcium enriched fly ash and its utilization in concrete 183
X. Ma, Y. Gong & X. Gong
Production of gypsum products from waste battery acid 189
G.M. Cann, P.A. Claisse & J.P. Lorimer
Use of waste gypsum as construction low strength materials 203
S. Karami, P.A. Claisse, E. Ganjian, H.S. Pouya & R. Greaves
Development of novel cementitious binders using plasterboard waste and pozzolanic
materials for road bases 209
H.S. Pouya, E. Ganjian, P.A. Claisse & S. Karami
Investigation into the use of cement stabilised gypsum waste as a backfill material 215
W. Rahman, G. Ghataora & D.N. Chapman
The importance of mixture proportioning in sustainable construction 223
N.G. Maldonado & P. Helene
Research and development of new building materials on the basis of industrial
waste materials in the field of rehabilitation of concrete structures 231
V. Petranek, P. Matulova & G. Michalcova
Development of an optimal high-performance concrete mixture for Tennessee bridge decks 237
R.M. Salem, E.G. Burdette & J.H. Deatherage
Establishing optimum mixture proportions for concrete durability using recyclable by-products 243
D.M. Vruno
Effects of cement and mineral admixture on migration of chloride ions and
generation of hydration heat in concrete 255
J. Yoo, S. Park & B. Oh
Hemp as a filler of cement-bonded particleboards 265
J. Bydzovský & F. Khestl
Chemical and physical characterization of coarse bauxite residue (red sand) for concrete making 271
M.G. Davoodi, H. Nikraz & E. Jamieson
Effect of ground perlite incorporation on the performance of blended cements 279
T.K. Erdem, Ç. Meral, M. Tokyay & T.Y. Erdogan
Use of Magnesium Oxide-cement binders for the production of blocks with lightweight aggregates 287
N. Vlasopoulos & C.R. Cheeseman

VI
Leaching behavior and environmental impact of concrete manufactured with biomass ashes 295
G. Fava, M.L. Ruello & D. Sani
The application of paper sludge ash to extremely stiff consistency concrete product 303
H. Fujiwara, M. Maruoka, K. Koibuchi & K. Fujita
Alkali-activation of natural pozzolan for geopolymer cement production 313
D. Bondar, C.J. Lynsdale, A.A. Ramezanianpour & N.B. Milestone
Effect of spent catalyst, obtained from the catalytic cracking of petroleum, on the
compressive strength of concrete 319
K.O. Ampadu, K. Torri & J.J. Vordoagu
Sulfate resistance of mortars with and without silica fume and natural pozzolan 325
F. Canpolat, M.A. Yurdusev, S. Targan & K. Yilmaz
Strength of mortar and concrete using fine powder of molten slag made from municipal
waste as a cementitious material 333
K. Fukuzawa, D. Kwak, O. Abe, H. Ojima & H. Yoshida
Use of supplementary cementing materials for cost-effective repair of marine
corrosion damage 339
D.V. Reddy, J.C. Bolivar, V. Gutierrez & Z.A. Saleh
Change of concrete properties due to impressed current of cathodic protection 353
T. Suginoue & H. Seki
Advanced calcareous ceramics via novel green processing and supercritical carbonation 359
E. Farahi, P. Purnell & N.R. Short
Supercritical carbonation of Casamic 367
S.J. Shaw, C.L. Page, A.R. Brough, J.P. Forth, M.M. Page, T.R. Jones & M. Carsana
Investigations on the efficiency of Enhanced Porosity Concrete in Containing vehicular oil spills 375
B.V. Bhayani, T.M. Holsen & N. Neithalath
CO2 uptake by concrete hardened in a simulated flue gas 381
Y. Shao & X. Zhou
Early hydration of calcium sulfoaluminate-based cements for structural applications 389
M. Marroccoli, M. Nobili, A. Telesca & G.L. Valenti
Reactive magnesium oxide cements: properties and applications 397
L.J. Vandeperre, M. Liska & A. Al-Tabbaa
Bacterial carbonate precipitation reduces the permeability of cementitious materials 411
W.D. Muynck, K. Cox, N.D. Belie & W. Verstraete
Sustainable, ‘green’ solutions for concrete pavement rehabilitation. A feasibility (pilot) study 417
J.N. Karadelis, K. Koutselas, A. Khan, Z. Jiebin, K. Moscicka & A. Plachta
Effect of loading level, cooling regime, polypropylene fibers, and coating type on the
behavior of high strength concrete columns in fire 427
H.I. El Sayad, M.M. Abdel-Razek & H.S. Haddad
Effect of simulated desert climate and sustained moderate temperature on some
properties of concrete with and without polypropylene fibers 437
H.I. El Sayad
Rheological and engineering properties of SCLC 447
A.A. Maghsoudi & S.M. Pour
Coefficient of moisture contraction – A new concrete material parameter 457
M.H. Baluch, M.K. Rahman, A.H. Al-Gadhib & A. Raza

VII
Thaumasite sulphate attack on self-compacting concrete with limestone filler 461
B. Persson
Effect of polypropylene fiber addition on restrained plastic shrinkage cracking of SCC 471
A.A. Maghsoudi, R. Rahgozar & M. Motavaselian
High performance grout connection for pre-cast concrete structures 479
M.M.A. Kharazi
Sustainable concrete arch bridges 487
J. Radic, Z. Savor & J. Bleiziffer
Determination of the amount of hydrated cement in hardened concrete and
mortar by gravimetric thermal analysis on macro and semi-micro scales 493
F. Gomà
Assessment of the fracture of three-point bending concrete specimens 503
A. Ziliukas & A. Augonis
The economics of recycling in the US construction industry 509
C. Meyer
An analysis of environmental and fiscal impacts of recycling during Kern Center construction 515
M.U. Christiansen
Impact of regulations on fly ash marketing in the United States 521
G.C. Plunk & D.C. Goss
Quantifying VOCs in products off-gassed during the construction of
MSOE’s Kern Center and proposed strategies for reducing employee exposure 527
S. Botic & C. Diggelman
Relative thermal performance of three test buildings – thermal mass v insulation 541
K.A. Heathcote & G. Moor
LEED-NC version 2.2 rating system applications of common structural materials 549
J.E. Maher & K.W. Kramer
A life cycle perspective on recycling construction materials (The most sustainable
materials may be the ones we already have) 563
T.R. Napier, D.T. McKay & N.D. Mowry
Demonstrating how plasterboard can be collected more efficiently on construction and
demolition sites in the UK 575
S.B. Emery, D.N. Smith, S. Johansson & J. Cope
Extending experimental data to investigate phosphogypsume use in light brick by
Artificial Neural Networks 589
M.A. Yurdusev, A.A. Kumanlioglu, Y. Abali, M.S. Zeybek & F. Canpolat
Opportunities for wealth generation through small scale sustainable building materials production 593
S.N. Mclean, A. Williams & D.R. Moore
Electrokinetic treatment for freezing and thawing damage mitigation within limestone 603
H.E. Cardenas, P. Paturi & P. Dubasi
Carbonation and hydration of mortars with calcium hydroxide and calcium silicate binders 611
O. Cizer, K. Van Balen, D. Van Gemert & J. Elsen
Biostore: towards sustainable composite waste reuse 623
B.K.C. Chan & A.W.L. Dudeney
Review of composting and anaerobic digestion of municipal solid waste and
a methodological proposal for a mid-size city 631
M.R.Q. Silva & T.R. Naik

VIII
Innovative use of clay backfill at the new Wembley Stadium, UK 645
S.W. Carley, A.S. O’Brien, F.A. Loveridge & Y.S. Hsu
A rationale for the production of Devon Cob to ensure performance 657
K.A. Coventry & J. Griffiths
Mixture proportioning and strength prediction technique for soil mortar made using
soil generated at construction sites 665
T. Yoshida & Y. Kitamoto
Utilization of olive oil liquid waste as an additive to roadway construction 675
O.A. Abaza
Investigation into the use of cement stabilised sand and silty sand in
road pavement construction in Bangladesh 685
W. Rahman, R. Freer-Hewish & G. Ghataora
Monitoring of strawbale and non-food-crop based walling systems 697
S. Goodhew, R. Griffiths, P. de Wilde & T. Simmons
Development of sustainable forms of construction 705
A.E. Long, S.E. Taylor, R.K. Venables & J. Kirkpatrick
Sustain the chapel building – a demonstration of sustainable materials renovation 717
E.A. Chien, T.S. Tolman, R.G. Lampo, T.R. Napier, N.D. Mowry & K.J. Smith
Environmental science in building construction: new course development
for undergraduate students 725
C. Diggelman
Cardboard: An innovative construction material 731
J. Schönwälder & J.G. Rots
Improvement mechanism of bondability in uf-bonded reed board by pf 741
J.Torkaman
Sustainable construction in Yellowstone Park: A case study 745
A.S. Denzer & K.E. Hedges
Ultrasound assisted crystallisation of synthetic gypsum from used battery acid 753
H. Abdul-Jabbar, H. Al-Daffaee, P.A. Claisse & J.P. Lorimer
Manufactured aggregate from waste materials 763
R. Lupo, M. Tyrer, C.R. Cheeseman & S. Donatello
Evaluation and minimization of life cycle environmental risk of concrete structures 769
T. Noguchi & S. Fujimoto
Comparison between mechanical properties of SCC containing Rice-Husk Ash and normal concrete 779
A.S. Momtazi, M.A. Mehrdad, K.A. Nia & A. Azhari
Comparative study between properties of SCC containing lime-stone powder and NC 785
A.S. Momtazi, A.H. Modaraei, A. Azhari & K.A. Nia
Compressive response of plastered straw bale wall panels 789
S. Vardy & C. MacDougall

Author index 801

IX
Sustainable Construction Materials and Technologies – Chun, Claisse, Naik & Ganjian (eds)
© 2007 Taylor & Francis Group, London, ISBN 978-0-415-44689-1

Preface

The construction materials industry is a major user of the world’s resources. While enormous progress has been
made towards sustainability, the scope and opportunities for further improvements are significant. This conference
was held at Coventry University, Coventry, U.K., from June 11th – 13th, 2007, to highlight case studies and
research that show new and innovative ways of achieving sustainability of construction materials and technologies.
In 2006, papers were invited on all the different materials that are used in construction including cementi-
tious materials (fly ash, wood ash, slag, silica fume, natural pozzolans, and other similar materials), aggregates,
concrete, timber, masonry, metals, plastics, glass, bitumen, lime, and gypsum. Papers on paints, adhesives,
preservatives, and preservation processes were also invited.
Over 190 papers from 45 countries were accepted for publication, following review. The papers covered a
wide range of topics including sustainable alternatives for aggregates and cementitious materials in concrete;
making concrete sustainable; the economics and environmental impact of sustainable materials; sustainable use
of gypsum, lime, soil, natural fibers, wood, and other organic materials; and sustainable construction methods
and technologies. The accepted papers are published in three volumes: Main, Special Sessions, and
Supplementary. Wherever possible, papers were grouped by their subject matter for the convenience of readers.
Conference organizers would like to thank Committee members and others who worked hard to prepare
and distribute call for papers and program, to review manuscripts, and to publish proceedings. We greatly appre-
ciate the cooperation of the authors in considering and incorporating review comments for revision of their
manuscripts.
It is our sincere hope that the proceedings will be useful to civil engineers, architects, construction managers,
researchers, and all other professions related to the construction industry, for achieving sustainable development.
We are considering holding the next conference in 2010 at a venue yet to be decided.

Yoon-moon Chun
Peter Claisse
Tarun R. Naik
Eshmaiel Ganjian
Editors, International Conference on
Sustainable Construction Materials and Technologies

XI
Sponsors
Sustainable Construction Materials and Technologies – Chun, Claisse, Naik & Ganjian (eds)
© 2007 Taylor & Francis Group, London, ISBN 978-0-415-44689-1

Contributions of the concrete industry toward sustainable development

K. Sakai
Department of the Safety Systems Construction Engineering, Kagawa University, Takamatsu, Japan

ABSTRACT: Sustainable development has become more and more important in the 21st century. The human
race is steadily transitioning its socioeconomic system in an effort to solve its resource, energy and environ-
mental problems. The concrete industry is certainly no exception. This paper discusses the latest trends in envi-
ronmental aspects of concrete and related environmental technologies, as well as presents the “JSCE
Recommendation of Environmental Performance Verification for Concrete Structures (Draft).” It also proposes
a method for the assessment of environmental benefits of constructing concrete structures as a means for the
concrete industry to contribute toward sustainable development.

1 INTRODUCTION Environment Programme (UNEP) was established. In


1987, the UN World Commission on Environment and
Only a mere 200 some years had passed since the end Development published the Brundtland Report [The
of the Industrial Revolution. The human race found World Commission on Environment and Development
itself faced with two extremely serious problems: 1987], which presented the following well-known
resource/energy depletion and global warming. These concept of sustainable development:
problems arose as a result of the human race’s enjoy- “Sustainable development is development that meets
ment of convenient and comfortable lifestyles. the needs of the present without compromising the abil-
A sense of crisis arising from these circumstances ity of future generations to meet their own needs.”
has led to various movements over the past several In 1992, 20 years after the Stockholm Conference,
decades. The first warning came in the form of a report the Rio Declaration was adopted at the UN Conference
to the Club of Rome entitled “Limits of Growth” on Environment and Development (Earth Summit) held
[Meadows D.H., Meadows D.I., Randers & Behren III in Rio de Janeiro. At this conference, the importance of
1971] Despite its devastating content, the report was not sustainable development to maintain balance between
taken very seriously at the time of its publication. The environmental conservation and economic growth was
“Declaration of the Human Environment” was adopted once again clarified, and participating nations signed
at the UN Conference on the Human Environment held the United Nations Framework Convention on Climate
in Stockholm in 1972, presenting the following princi- Change, which went into effect in 1994. The Kyoto
ple concerning the environment-related rights and Protocol for reduction in greenhouse gases was adopted
responsibilities of the human race: at the Third Conference of the Parties to the United
“Man has the fundamental right to freedom, equality Nations Framework Convention on Climate Change
and adequate conditions of life, in an environment of a (COP3) held in Kyoto in 1997, and entered into force in
quality that permits a life of dignity and well-being, and February 2005. The Protocol defines greenhouse gas
he bears solemn responsibility to protect and improve emission reduction targets for 2008/2012 for individual
the environment for present and future generations.” advanced countries, with the levels of 1990 set as the
In other words, the Declaration of the Human standard. The so-called “Kyoto Mechanism,” including
Environment was the first clear statement of the the clean development mechanism, emissions trading
human race’s responsibility to protect and improve the and other mechanisms for promoting the reduction of
environment, in addition to its fundamental right, and greenhouse gas emissions in developing countries and
the Declaration greatly influenced subsequent interna- regions, was also introduced under the Protocol.
tional trends in environmental conservation. As the Although the US government withdrew from the
implementing agency of this Declaration, the UN Kyoto Protocol, a new path was set for reduction of

1
greenhouse gases at the COP11 held in Montreal in was 8,191 in 2005, it is expected to increase to 63,494
2005, where an agreement was reached on the com- by 2025 [Ministry of Land, Infrastructure and Transport
mencement of post-COP3 discussions including the 2005]. Reconstruction of structures is also increasing
United States. in urban areas. According to an estimate by the
While the rise of global-scale resource, energy and Development Bank of Japan [Development Bank of
warming issues has been recognized as important by Japan 2002], the total amount of concrete masses to
the concrete industry and various research activities be generated in 2025 is estimated to be 210 million
have been promoted, such activities are still in their tons, which is a twofold increase of the 112 million
infancy and environmental aspects have not actually tons generated in 2005. These amounts are extremely
been included in the design of concrete structures. As high, considering that the total concrete production for
mentioned above, however, it is obvious that the consid- Japan in 2005 was approximately 285 million tons.
eration of resource, energy and warming issues is While most concrete masses have been used as base
essential to all future socioeconomic activities, and the course materials, their demand is expected to decrease
concrete industry is certainly no exception. Fortunately, dramatically. Since the use of these as recycled aggre-
international concrete conventions focused on “sustain- gate is crucial considering the pressure on waste dis-
ability” have been held in recent years. This proves the posal sites and the preservation of aggregate resources,
recognition of the importance of the environment in the the development of technologies for recycled aggregate
field of concrete technologies. production is being promoted.
This paper discusses the latest trends in environmen- Technologies for recycled aggregate production in
tal aspects of concrete and related environmental tech- Japan include the heating and rubbing [Tateyashiki,
nologies, as well as presents the “Recommendation of Okamoto, Nishimura & Kuroda 2000], eccentric-shaft
Environmental Performance Verification for Concrete rotor [Yanagibashi, Yonezawa, Kamiyama & Inoue
Structures (Draft),” which was recently published by 1999] and mechanical grinding [Yoda, Shintani,
JSCE. It also proposes a method for the assessment of Takahashi & Yanagase 2004] methods. In the heating
environmental benefits of constructing concrete struc- and rubbing method, concrete masses are heated at
tures as a means for the concrete industry to contribute 300°C and the cement paste content is weakened to
toward sustainable development. remove mortar and cement paste from the aggregate.
Figure 1 shows an overview of a recycled aggregate
production system using this method. Figure 2 illus-
trates the recycled coarse and fine aggregate produced
2 ENVIRONMENTAL ASPECTS OF
by the system. While the production of recycled aggre-
CONCRETE AND ENVIRONMENTAL
gate generated a large amount of fine powder, it also
TECHNOLOGIES
indicated the possibility of using fine powder like
this as a substitute solidification material for the deep
2.1 Aggregate
mixing stabilization method (soil cement walls)
It is said that, of the approximately 26 billion tons of [Uchiyama, Kuroda & Hashida 2003]. In the eccentric-
annual material flow throughout the world, aggregate shaft rotor method, crushed concrete lumps are passed
used as a construction material accounts for some 20 downward between an outer cylinder and an inner
billion tons [Brown 2001]. In other words, natural sand, cylinder that eccentrically rotates at a high speed to
gravel and crushed stone exist most abundantly in the separate it into coarse aggregate and mortar through a
natural world, thus these materials are most frequently grinding effect. Figure 3 presents an overview of a
used for infrastructure development. Although the recycled aggregate production system using this
aggregate situation varies by country and region, the method. Mechanical grinding is a method used to pro-
replacement of natural aggregate with crushed stone duce coarse and fine aggregate by separating a drum
aggregate has progressed in recent years due to envi- into small sections with partitions, loading the drum
ronmental restrictions. It is believed that this has also with iron balls for grinding and rotating the partitions.
led to changes in the quality of aggregate, which greatly Figure 4 shows an overview of the recycled aggregate
affects the quality and durability of concrete. Crushed production system using this method. The coarse
stone aggregate usually has sharp edges, thereby aggregate produced by these methods has been used
increasing the water content of concrete, and the energy for actual construction projects.
used for the production of crushed stone has an adverse In Japan, JIS A 5021 [Japanese Standards Associa-
impact on the environment. Moreover, the development tion 2005] was established in 2005 as a standard for
of quarries is also causing environmental problems. high-quality recycled aggregate H for concrete, which
In recent years it has been said that infrastructure is produced through advanced processing, including
development has matured in Japan. While the number crushing, grinding and classifying, of concrete masses
of national highways and bridges 50 years or older generated in the demolition of structures. Recycled
managed by nation and local governments in Japan aggregate H must have physical properties satisfying

2
Figure 1. Production technology of recycled aggregate (heating and rubbing method).

Recycled External
Charge aggregate diameter:
Steel ball inlet discharge 1500mm

Drum Passing
Partition hole
4000mm
Plate
Figure 2. Recycled aggregates by heating and rubbing
method. Figure 4. Production technology of recycled aggregate
(mechanical grinding method).

for recycled concrete using low-quality recycled aggre-


gate L. This type of concrete includes backfilling,
filling and leveling concrete, and the use of Type B
blended cement and admixture is required as a meas-
ure against alkali-silica reactivity.
Production of recycled aggregate usually involves
greater energy use compared with that of virgin aggre-
gate, thus leading to greater environmental impacts.
While finding ways to deal with these environmental
impacts as an external cost is a major issue, it would be
ideal to absorb this cost in the entire production/use
system of recycled aggregate. As shown in Figure 5,
Kuroda et al. [2004] established an on-site concrete
resource recycling system from this standpoint, and
proved that CO2 emissions from the system were lower
than those in which it was used as a conventional base
course material. This was achieved by reducing the
Figure 3. Production technology of recycled aggregate
amount of transported material and the use of fine
(eccentric-shaft rotor method). powder as a substitute solidification material for
ground improvement. Yanagibashi [2004] studied CO2
the requirements listed in Table 1. There are also emissions in the cases of use of recycled aggregate for
upper limits for the amounts of deleterious substances base course material made of concrete masses, use of
contained in recycled aggregate H, as shown in Table 2. recycled coarse aggregate for concrete and recycled
JIS A 5023 has also been established as a standard sand for base course and backfill materials, and use of

3
Table 1. Physical properties requirements for recycled aggregate H.

Items Coarse aggregate Fine aggregate

Oven-dry density, g/cm3 not less than 2.5 not less than 2.5
Water absorption, % not more than 3.0 not more than 3.0
Abrasion, % not more than 35 NA
Solid volume percentage for shape determination, % not less than 55 not less than 53
Amount of material passing test sieve 75 µm, % not more than 1.0 not more than 7.0
Chloride ion content not more than 0.04

Table 2. Limits of amount of deleterious substances for P1 P2 P3 P4


recycled aggregate.

Limits Usual 1,010 19,183 3,580


Category Deleterious substances (mass %) case
1,042
A Tile, Brick, Ceramics, 2.0
Asphalt Closed-loop 2,530 17,852 2,349
B Glass 0.5 concrete
C Plaster 0.1 system
D Inorganic substances other 0.5 0 5,000 10,000 15,000 20,000 25,000
than plaster
E Plastics 0.5 (P1: Road sub-bases production, P2: Recycled aggregate
recovering, P3: Concrete mixing and delivery, P4:
F Wood, Paper, Asphalt 0.1 Ground improvement)
Total 3.0
Figure 5. CO2 emission in usual and closed-looped con-
recycled coarse aggregate for concrete and the remain- crete recycle systems.
ing amount for cement clinker. The paper concluded
that the use of recycled aggregate was an environmen- illegally dumped industrial waste in Teshima, Kagawa
tally friendly method that could contribute to the preser- Prefecture [Takatsuki 2003]. Approximately 300,000
vation of natural aggregate since CO2 emissions were tons of molten slag is to be produced for 10 years, and
nearly identical. the prefecture government has decided to use the entire
Iron and steel slag is also used as aggregate. In amount as aggregate for concrete. Basic studies on the
2005, 25,747,000 tons of blast-furnace slag and application of municipal solid waste and Teshima
14,897,000 tons of steelmaking (converter and electric- molten slag to concrete have been conducted [Matsuka,
furnace) slag were generated in Japan [Nippon Slag Sakai, Nakamura & Kusanagi 2006a], [Matsuka, Sakai,
Association 2005]. Of these, blast-furnace slag was Nishigori, Yokoyama, Nishimoto & Onodera 2006b].
primarily used as aggregate for concrete, and its Molten slag is characterized by low water-retentivity
amount was 3,158,000 tons. since it is vitreous. When it is used in large amounts,
While fly ash has been used as a substitute admix- bleeding increases and leads to a decrease of the
ture for cement, the idea of using this as fine aggre- strength of concrete and, in the case of reinforced con-
gate has emerged in recent years [Shikoku Chapter of crete, a decrease in the bond of reinforcing bars to con-
Japan Society of Civil Engineers 2003]. Considering crete. The permissible replacement ratio of molten slag
the worldwide increase in fly ash production expected for fine aggregate thus varies according to the perform-
in the future, it is desirable to design a mix that inte- ance required for concrete. It is also necessary to pay
grates substitutes for cement and fine aggregate. attention to aluminum, which is a metal contained in
In recent years, melting treatment of waste and molten slag, since it may cause expansion and deterio-
sewage sludge has become common in Japan due to ration of concrete as it reacts with the alkali of cement
pressures on waste disposal site and problems related and generates hydrogen. In Japan, JIS A 5031 [Japanese
to dioxin and heavy metals. Molten slag is generated Standards Association 2006] was established for molten
as a residue after melting treatment. In 2004, 144 slag aggregate for concrete. Table 3 lists the physical
waste and 18 sewage sludge melting treatment facili- properties of molten slag required by this standard.
ties were in operation throughout Japan, producing
480,000 and 44,000 tons of molten slag, respectively. 2.2 Cement
Waste molten slag production is estimated to reach as
high as 2.7 million tons in the future. Melting treatment Cement is the most important basic material for infra-
was also commenced in 2005 for 600,000 tons of structure development. There are two aspects of

4
Table 3. Physical properties requirements for molten slag aggregates.

Molten slag

Items Coarse aggregate Fine aggregate


3
Oven-dry density, g/cm not less than 2.5 not less than 2.5
Water absorption, % not more than 3.0 not more than 3.0
Soundness, % not less than 12 not less than 10
Solid volume percentage for shape determination, % not less than 55 not less than 53
Amount of material passing test sieve 75 µm, % not more than 1.0 not more than 7.0

10000 Cement production


Cement demand (million tons)

(million t) Wastes utilization (kg/t-cement)


Scenario A1 12,000 450
8000 Scenario A2 Amount of wastes utilization per 1 ton of cement
Scenario B1 400
10,000
Scenario B2 350
6000
8,000 300

4000 250
6,000
200
2000 4,000 150
100
0 2,000
50
’90 ’05 ’20 ’35 ’50 ’65 ’80 ’95
0 0
90 91 92 93 94 95 96 97 98 99 00 01 02 03 04 05
Figure 6. Estimated cement demand.
Figure 8. Amount of wastes utilization for cement produc-
tion in Japan.
Unit-based CO2 emissions (kg-CO2/kg-cement)

1.2

1
each country/region. Based on the mean value 0.87(kg-
0.8
CO2/kg-Cement) of these, CO2 emissions from cement
0.6 production totaling 4 billion tons is estimated to be
approximately 3.5 billion tons, which is 2.7 times as
0.4 high as Japan’s current total CO2 emissions (approx.
0.2 1.3 billion tons). Also, based on the lowest CO2 emis-
sion unit of Japan (0.73), the world’s CO2 emissions are
0 expected to reach approximately 2.9 billion tons 30
Japan
USA
Canada
W. Europe
Australia & NZ
China
SE. Asia
Rep. of Korea
India
Former USSR

S. and L. America
E. Europe

Africa
Middle East

years from now. This means that the world’s cement-


originated CO2 emissions can be reduced by approxi-
mately 8% through the use of Japan’s cement production
technology.
Nearly 30 million tons of waste and byproducts are
currently used as raw materials and fuels for cement
Figure 7. Unit-based CO2 emission in cement manufactures. production in Japan. Such raw materials include blast-
furnace slag, fly ash and sewage sludge, and fuels
cement production and its relation to the environment – include waste tires and plastic. Figure 8 illustrates the
CO2 emissions and the use of waste as a raw material changes in cement production and use of waste and
and fuel. Japan’s cement production, including blended byproducts in Japan. It can be seen that the use of waste
cement and export, has amounted to more than 800 and byproducts is steadily increasing while cement pro-
million tons in the last 10 years. The world’s cement duction is decreasing. The cement industry is setting a
production is thought to be approximately 2 billion target value of 400 kg/t-cement for 2010. Figure 9
tons at present. Figure 6 shows the cement demand pre- shows an international comparison of energy consump-
dicted by Humphreys et al. [2002] According to this tion per ton of cement clinker, in which Japan displays
prediction, production is expected to reach approxi- incomparably high energy efficiency. It can be seen
mately 4 billion tons 30 years from now. Figure 7 dis- from this that Japan has exceptional cement production
plays the CO2 emission unit of cement production in technology. This means that CO2 emissions associated

5
180 Agriculture, Forestry
and Fisheries 2.2% Other
160
Building 3.8% 12.1%
140
120 Public Works
Cement
11.7%
100 70.2%
80
60
40
20
Figure 11. Utilization of fly ash in Japan.
Japan
USA
Canada
W. Europe
Australia & NZ
China
SE. Asia
Rep. of Korea
India
Former USSR
E. Europe
S. and L. America
Africa
Middle East
Oceania
11

Europe Former
270 USSR
Figure 9. International comparison of energy consumption 65
in cement-clinker production. Asia America
1,060 215
Public Works 3.5% Other 1.8%
Africa
Concrete 12.7% 75

Year 2002
Road Cement Oceania
14.7% 67.3% 13

Europe Former
290 USSR
154
Asia
Figure 10. Utilization of blast furnace slag in Japan. America
1,317
259

with the construction of concrete structures is being Africa


reduced as a consequence. 99

Year 2020 (million tons)


2.3 Admixtures
Figure 12. Estimated world admixture minerals production.
It can be said that basic technologies have already been
established for the use of admixtures in concrete [Japan
Society of Civil Engineers 1996] [Japan Society of cement production. Although the amount of fly ash that
Civil Engineers 1999]. Admixtures have been used for can be used for concrete is approximately 20% of the
concrete for the effective use of industrial byproducts total production of coal ash, its use as an admixture for
and improvement in concrete properties through their concrete is only about 1%. This situation is not appro-
utilization. In recent years, however, their importance priate considering the excellent performance of fly ash
in the reduction of environmental impacts has also as an admixture. Approximately 10% of the coal ash
attracted attention. produced in Japan is currently disposed of in landfills.
As shown in Figure 10, approximately 67% of Figure 12 shows the estimated volumes of admix-
blast-furnace slag was used for blast-furnace cement ture production in the world in 2002 and 2020 [Jahren
in Japan in 2005. This means that the performance of 2003]. In particular, the production volumes of fly ash
blast-furnace slag is used in the most rational manner. and blast-furnace slag are expected to increase 1.7
Figure 11 presents the breakdown of the use of coal and 3 times, respectively. By effectively using these
ash (9,792,000 tons) in Japan in 2004 [Japan Coal increased volumes of admixtures, it will become pos-
Energy Center 2006]. Of the 70% used in the field of sible to reduce environmental impacts caused by the
cement, the majority was used as a raw material for future increase in concrete demand.

6
3 JSCE RECOMMENDATION OF on the reduction rate from the standard value). In the
ENVIRONMENTAL PERFORMANCE case of the use of a byproduct, the minimum amount
VERIFICATION FOR CONCRETE that must be used is set as the performance requirement,
STRUCTURES which is satisfied if the amount used for a structure is
larger than this value. While environmental perform-
The Japan Society of Civil Engineers (JSCE) published ance requirements may include legal regulations,
the Recommendation of Environmental Performance demands of the owners and intentions of the designer,
Verification for Concrete Structures (draft) [Japan they are referred to as the regulation value, limit value
Society of Civil Engineers 2006] in 2005. This and target value, respectively, in the Recommendation
Recommendation (draft) provides general principles (draft).
of consideration concerning environmentality when When considering the environmental performance
conducting design, construction, use, maintenance/ by comparative design, the designer is not necessarily
management, dismantling, disposal and reuse after required to set a target value, and “verification” will
dismantling of a concrete structure. Its purpose is to become unnecessary if the decision-maker selects an
extend the application of performance verification con- appropriate one from the environmental performance
cept on safety, serviceability and durability of concrete evaluation results of several designs.
structures to the “environment.” The Recommendation As for environment-related international standards,
(draft) consists of chapters on general rules, environ- there is the ISO 14000 series. In ISO 14040, the princi-
mentality, evaluation and verification of environmental ple and framework of environmental management (life
performance, inspection and records. The followings cycle assessment) are provided. This standard is for
are listed as items that must be taken into account when general products, and its life cycle assessment is com-
considering the environmental aspects of concrete posed of the purpose, definition of the scope, inventory
structures: analysis, impact assessment and interpretation. A stan-
dard for buildings and civil engineering structures is
(1) Greenhouse gas, air contaminants, resources/
ISO 15686-6 [2004]. This standard is for the considera-
energy, waste
tion of environmental impacts in service life planning
(2) Water and soil contaminants
of structures, and provides general procedures for envi-
(3) Noise/vibration
ronmental impact assessment of design options. Also,
(4) Others
ISO/TC59/SC17/WG3 is currently examining the
The followings are also provided as methods to be draft of environmental product declaration standards
used for evaluation of environmental performance: for buildings and civil engineering structures [ISO/
DIS21930 2006]. The purpose of this draft is to make
(1) LCA method for evaluation of the emission of
environmental product declarations (EPD) on environ-
greenhouse gasses and air contaminants, consump-
mental impacts, resource use, discharge of waste and
tion of resources/energy, waste generation, etc.
other matters by looking at buildings and civil engi-
(2) Appropriate testing and measurement methods for
neering structures as “products.” Although the objects
identification and quantitative evaluation of the
of these two ISO standards (drafts) are identical, their
substances causing water and soil contamination
ideas and methods are different.
(3) Direct measurements, reliable prediction methods
In the design of concrete structures, safety, servicea-
or a combination of both for evaluation of noise,
bility and durability have been verified. In the future,
vibration, etc.
the consideration of environmentality will become nec-
(4) Others
essary in addition to these. It is, however, obvious that
The Recommendation (draft) also gives examples of environmentality is essentially different from safety etc.
basic environmental impact units and integration fac- This means that, in the case of design for safety, a struc-
tors necessary for evaluation of environmental perform- ture is required not to cause direct damage to people or
ance related to design, construction and other aspects of society by its destruction. As for environmentality, no
concrete structures. systems have been established for the control of green-
The verification of environmental performance is house gases, air contaminants, resources/energy and
the act of confirming that the value of performance waste, although direct contamination and noise have
retained by a structure (R) is larger (or smaller) than been taken into account under legal regulations. This is
the set value (S) based on the performance require- because the final damage of global environment issues
ments for the structure concerning the environmental has yet to be clarified. Although it is easy to imagine
aspect subject to the verification. For example, verifi- that various substances generated as a result of human
cation of CO2 emissions can be passed if the calcu- activities will eventually cause damage to humans, soci-
lated value of CO2 associated with an actual structure ety and ecosystems, the problem is that it is difficult to
is smaller than the absolute value of CO2 emissions evaluate these damages quantitatively. It is, however,
set as the performance requirement (or the value based necessary to prevent further aggravation of the situation

7
Roadway Roadway

Underpass 7500 5300 7200


Underpass

176000 (mm)
Figure 13. Plan view of intersection.
Figure 14. Cross-section of reinforced concrete underpass.

Construction Construction Construction


1107.43 1107.43 12.02
Materials
Materials Materials manufacture
Transport manufacture manufacture 7.83
296.18 3459.02 1.83

Transport
3.66 Transport
1.06
(a) CO2 Emission (b) SOx Emission (c) NOx Emission

Figure 15. CO2, SOx and NOx emissions due to materials manufacture, transport and construction (unit: t).

by not taking any measures merely because of the lack civil engineering structures contributes to social and
of clarity regarding these damages. environmental benefits as a means of fulfilling social
The Recommendation of Environmental Perform- accountability, few comprehensive studies have been
ance Verification for Concrete Structures (draft) pre- conducted, especially concerning the latter.
sented here was developed based on the idea that With these circumstances in the background, the
systems to enable reduction of environmental impacts author studied the direct environmental impact due to
should be established in a variety of concrete-related the construction of a reinforced concrete underpass at
activities. While this Recommendation (draft) is based an intersection with chronic traffic congestion and the
on the performance verification system of the JSCE indirect reduction effect by the clearance of the traffic
Standard Specifications for Concrete structures, it congestion, for comprehensive evaluation of the envi-
can also be used for comparative design related to ronmental benefits of the construction. The one-lane
environmental performance or environmental labels/ underpass used for this study was actually con-
declarations of ISO. This Recommendation (draft) structed at an intersection of six-lane national road,
can therefore be considered as the concrete version of where traffic flows between the suburbs and center of
ISO environmental standards. a local city are concentrated. Figures 13 and 14 show
the plan view of the intersection and cross section of
the underpass, respectively. Approximately 150,000
4 ENVIRONMENTAL BENEFITS FROM THE automobiles pass through this intersection daily.
CONSTRUCTION OF CONCRETE To evaluate the environmental benefits of the con-
STRUCTURES struction of this underpass, its environmental impacts
by the construction itself were calculated. Figure 15
Civil engineering structures are the foundation of shows the CO2, SOx and NOx emissions from mate-
socioeconomic activities, and have contributed greatly rials manufacture, transport and construction. While
to the establishment of a pleasant and efficient living CO2 emissions from materials manufacture were high,
environment. While there is an unfortunate aspect the percentage of construction and transport increased
where construction of civil engineering structures is for SOx and NOx. Next, the environmental impacts
seen as a symbol of environmental destruction, this is due to automobile traffic were calculated based on the
thought to be due to insufficient evaluation of envi- traveling speed of automobiles before and after con-
ronmental impacts caused by construction of civil struction of the underpass. Following the construc-
engineering structures. In other words, although it is tion, daily CO2 emissions and oil use were reduced by
extremely important to evaluate how construction of 1.434 and 0.557 tons, respectively. The reduction of

8
Table 4. Years until counterbalance of construction impact and traffic impact reduction.

Impact due to Traffic impact reduction Years until


Items construction (kg) per day (kg/day) counterbalance

CO2 4862629 1434.3 9.3


NOx 23503 8.5 7.6
SOx 3660 0.8 12.2
Oil 745898 556.7 3.7

Impact reduction by easing traffic congestion necessary to evaluate the benefits of construction by
Impact due to construction of underpass considering all these factors. In any case, it is obvious
10
from the above example that the environment is an ele-
Integrated impact (x107)

8 ment that must be taken into account in infrastructure


development.
6

2 5 CONCLUDING REMARKS
0
0 5 10 15 20 25 30 35 40 45 50 For the concrete industry to contribute to the sustain-
Service able development of mankind, it is necessary to pro-
mote technical development for further reduction of
Figure 16. Environmental-benefit evaluation by the con- environmental impacts. To promote this, it will be
struction of underpass. necessary to introduce environmental design systems
based on environmental performance, develop envi-
ronmental performance evaluation tools and construct
daily SOx and NOx emissions was 9 and 1 kg, respec- systems for their actual application.
tively. The relationship between the impact generated Since environmental consideration could lead to an
by the construction of the underpass and the reduc- increase in cost and the reduction of environmental
tion of impact by improvements in traffic can be stud- impacts was not a design requirement, environmental
ied for individual emission substances. Table 4 shows impacts have been thought of as negative externality.
the calculated result of years until the counterbalance The comprehensive evaluation bidding system is cur-
of construction impact and traffic impact reduction. rently attracting attention in Japan as a system for
However, since nonmetals, iron and wood was also enabling internalization of negative externality. The
used as resource consumption for the construction of bidding system enable absorption of the cost increases
the underpass, integration by the method of LIME resulting from environmental consideration. It is desir-
[Itsubo & Inaba 2005] was conducted to evaluate these able to actively use this system in the future.
comprehensively. Figure 16 shows the environmental- Since the industrial revolution, the system of human
benefit evaluation by the construction of underpass. society has been formed with a focus on the economy.
The integrated impact on the vertical axis represents In other words, the cost of “things” is the most impor-
the integrated index calculated by considering weight tant factor in mass production and mass consumption,
to the respective impacts of greenhouse gases, acidifi- and environmental, cultural and social aspects have
cation substances, air contaminants and resource con- been controlled by the viewpoints of economic aspects.
sumption. This result shows that the environmental Fortunately, however, the human race has finally begun
impacts generated at the time of construction of the to realize that policies that put the economy ahead of
underpass will be offset by the reduction of environ- all else may even jeopardize their survival. In the
mental impacts of automobile traffic in approximately future, the human race must balance these economic,
9 years. In general, the time it takes until such an offset environmental, cultural and social aspects. One major
becomes shorter and the significance of the construc- problem is the regional economic disparity that cur-
tion of an underpass becomes higher when the traffic rently exists in the world. It is necessary to eliminate
volume is larger and the degree of congestion is higher. this regional economic disparity by taking the above
While this paper discussed an evaluation method for aspects into account. But if this cannot be done suc-
environmental benefits by construction of a concrete cessfully, a new negative externality may emerge in the
structure as an example, the construction of structures world. One of the keys is the CDM established by the
has many aspects, such as economic benefits and Kyoto Protocol. An enormous amount of concrete will
social benefits as a lifeline. It will eventually become be consumed throughout the world in the future as an

9
important material for infrastructure development. site, Technical Research Report of Shimizu Corporation
And since the sustainable development of the world is 79: 1–10 (in Japanese).
directly connected to the survival of the human race, it Matsuka, T., Sakai, K., Nakamura, T., & Kusanagi, S. 2006a.
is the duty of advanced countries to develop technolo- Flexure and shear behavior of reinforced concrete beams
using molten slag from industrial waste. Journal of
gies and systems for environmental impact reduction Materials, Concrete structures and Pavements, No.809 V-
related to concrete, enlighten other advanced countries 70: 131–145 (in Japanese).
that are not environmentally conscious and transfer Matsuka, T., Sakai, K., Nishigori, W., Yokoyama, T.,
technologies to developing countries. Nishimoto, Y., & Onodera, S. 2006b. Effect of rubbing-
reformation in application of various molten slag to con-
crete, Journal of Materials, Concrete structures and
REFERENCES Pavements, No.809 V-70: 147–158 (in Japanese).
Meadows, D.H., Meadows D.I., Randers J., & Behren III,
Brown, L.R. 2001. Eco-economy. Earth Policy Institute W.W. 1971. Limit of growth. The Club of Rome.
Development Bank of Japan 2002. Urban renewal and Ministry of Land, Infrastructure and Transport 2005. White
resource recycling: For the creation of a resource recy- paper on land, infrastructure and transport in Japan.
cling society, Research Report No.28. Nippon Slag Association 2005. Annual Statistics Report of
Humphreys, K. & Mahasenan, M. 2002. Toward a sustain- Iron and Steel Slag, http://www.slag.jp/e/index.htm.
able cement industry, Climatic change sub-study 8, Shikoku Chapter of Japan Society of Civil Engineers 2003.
World Business Council for Sustainable Development. Recommendation on execution of concrete using fly ash
ISO 15686-6 2004. Buildings and constructed assets – as a fine aggregate substitute (draft) (in Japanese).
Service life planning – Part 6: Procedures for considering Takatsuki, H. 2003. The Teshima Island industrial waste
environmental impact. case and its process towards resolution. Special feature:
ISO/DIS21930 2006. Environmental Declarations of Building Conference Report, Journal of Material Cycles and
Products. Waste Management, 5: 26–30.
Itsubo, T. & Inaba, A. (Editors) 2005. Life-Cycle environmen- Tateyashiki, H., Okamoto, M., Nishimura, Y., & Kuroda, Y.
tal assessment method. Japan Environmental Management 2000. Experimental studies on production of high quality
Association for Industry. recycle aggregate from demolished concrete, Proc. of the
Jahren, P. 2003. What are the options? The CO2 case. Japan Concrete Institute, Vol.22 No.2: 1099–1104 (in
STF22A03610 Report, SINTEF. Japanese).
Japan Coal Energy Center 2006. Annual Report 2005/06. The World Commission on Environment and Development
http://www.jcoal.or.jp/news_en/news_en.html#061005-1 1987. Our common future. Oxford University Press.
Japan Society of Civil Engineers 1996. Recommendation on Uchiyama, S., Kuroda, Y., & Hashida, H. 2003. Deep mixing
execution of concrete using blast furnace slag. Concrete stabilization using concrete powder from recycled aggre-
Library 86 (in Japanese). gate production by heating and rubbing, The Foundation
Japan Society of Civil Engineers 1999. Recommendation on Engineering & Equipment, July: 62–65 (in Japanese).
execution of concrete using fly ash (draft). Concrete Yanagibashi, K. 2004. Inventory and analysis on a process of
Library 94 (in Japanese). recycling aggregate for concrete, Construction Materials,
Japan Society of Civil Engineers 2006. Recommendation of Vol.13 No.1: 38–45 (in Japanese). ttp://www.slg.jp/e/
environmental performance verification for concrete index.htm.
structures (draft). JSCE Guidelines for Concrete No.7. Yanagibashi, K., Yonezawa, T., Kamiyama, Y., & Inoue, T.
Japan Standards Association (JIS A 5021) 2005. Recycled 1999. Study on high quality recycle aggregates, Proc. of
aggregate for concrete-class H (in Japanese). the Japan Concrete Institute, Vol.21 No.2: 205–210 (in
Japanese Standards Association (JIS A 5031) 2006. Melt- Japanese).
solidified slag aggregate for concrete derived from Yoda, K., Shintani, A., Takahashi, I., & Yanagase, S. 2004.
municipal solid waste and sewage sludge (in Japanese). Quality of recycles coarse and fine aggregates produced
Kuroda, Y., Hashida, H., Nachi, Y., Yamazaki, N., & Miyachi, Y. by mechanical grinding, Proc. of the Japan Concrete
2004. A closed-loop concrete system on a construction Institute, Vol.26 No.1: 1627–1532 (in Japanese).

10
Sustainable Construction Materials and Technologies – Chun, Claisse, Naik & Ganjian (eds)
© 2007 Taylor & Francis Group, London, ISBN 978-0-415-44689-1

Site trials of concrete with a very low carbon footprint

P.A. Claisse, E. Ganjian & H. Sadeghi-Pouya


Faculty of Engineering and Computing, Coventry University, Priory Street, Coventry, UK

ABSTRACT: This paper reports on six site trials of sustainable concrete mixtures. The first three were con-
crete barriers for landfill, the fourth was a trench fill and the fifth and six were roads and car parks. The methods
and mixtures evolved from moderately conventional designs containing ashes and slags and some cement which
were blended at the plant to a super-sulphated pre-blended powder containing waste plasterboard and no cement.
The strengths were not as high as a typical structural concrete but were fully adequate for each application. The
paper concludes that while the technical viability of each mix was demonstrated, problems with insurance,
capital funding, and environmental regulators have prevented their wider application.

1 INTRODUCTION Extensive monitoring of the first three trials was


carried out until 2006 when they were demolished.
1.1 The six trials Monitoring of the fourth is planned and is in progress
on the fifth and sixth.
This paper reports on six site trials of sustainable
concrete mixtures carried out by the Construction
Materials Applied Research Group at Coventry 1.2 The “novel blended cement”
University. The objectives of the paper are:
For the first four trials the cementitious components
• To illustrate how a wide and evolving range of sus- were delivered to the batching plant and mixed on site
tainable concrete mixtures have performed well (in the plant for mixes trials 1 to 3 and in the truck-
under site conditions. mixer for trial 4). This was found to be inaccurate and
• To investigate the design and exploitation of the difficult and also unlikely to lead to commercial
site trials. exploitation. Therefore for trials 5 and 6 a pre-blended
• To discuss how trials of this type may be optimised powder was made which could be treated exactly like
for their primary purpose which is to persuade cement at a batching plant.
industrial enterprises to exploit the results of the The components of the “novel blend” are:
underlying research.
• To demonstrate a wide range of applications for • Basic oxygen slag from steel manufacture (80%)
concrete with relatively low strength. • Waste plasterboard (15%)
• Kiln by-pass dust from cement manufacture.(5%)
The first three trials were intended to demonstrate the
These components were chosen partially because the
viability of concrete barriers as part of a composite
client was interested in finding uses for waste gypsum.
waste containment system for landfills. They were
Once the gypsum had been included to make a “super-
constructed in 1999–2000 with a total of 70 m3 of
sulphated” mix any cement could have caused problems
concrete. Each cell contained two different concrete
with expansion. The components were inter-ground to
mixtures.
form a grey powder which looks exactly like cement.
The fourth trial was a trench trial of a single mix
intended for use as mine or trench backfill. It was
constructed in 2004 with 7 m3 of concrete.
2 TRIALS 1–3
The fifth trial was a slab in a car park built in 2006
with 16 m3 of semi-dry concrete.
2.1 Introduction
The sixth trial was an access road which was con-
structed in 2006 by stabilising 72 m3 of soil with a Three cells were constructed on a licensed landfill
sustainable “cement” and then placing 6 m3 of a semi- operation site at Risley, Cheshire UK with different
dry paste (grout) as a road base. cementitious composite mineral waste materials

11
[Claisse, 2000, 2003a, 2003b, 2006, Ganjian 2004a, 2.4 Observations from the construction
2004b, 2006a, 2006b]. This landfill site receives both
During the construction of cell numbers 2 and 3 the
domestic and industrial waste.
mix proportions actually used were different to what
was designed in laboratory due to some practical prob-
2.2 Layout and construction methods of the cells lems encountered in the batching plant and placement
of some of materials (inaccurate weightings of differ-
A typical test cell is shown schematically in Figure 1. ent materials and partial hydration of CKD while stored
The barrier is made up of two layers of concrete with at the plant). The mixes actually made were tested and
a layer of clay between them. These inverted pyramid showed higher permeabilities than the mixes designed
shape cells measured 8 metres wide and contained initially in the laboratory.
waste to a maximum depth of 1.1 metres. The slopes
of the cell sides were 30° and the cells contained
5.4 m3 of waste. The excavation was carried out with 2.5 Emplacement of waste and leachate
a hydraulic excavator which was also used to place Due to size and shape constraints of the cells shredded
the concrete and paste mixes designed for the differ- waste was used. It was placed and compacted up to the
ent cells. The compaction of concrete layers was car- top level of the test cells. A leachate which provided the
ried out by two poker vibrators and the compaction of most aggressive solution representing the leachates
clay layer was carried out using the outside surface of found in the landfill was obtained from the leachate
the excavator’s bucket treatment plant for the site and the cells were filled
100 mm below the top giving a 1 m head at the deepest
point. The cells were covered with a tarpaulin rain
2.3 Mixture designs cover to prevent rainwater ingress and contain odour.
The primary containment method for the barriers is
“chemical” containment. In this system any leachate 2.6 Instrumentation and sampling
entering the barrier is buffered to high pH which
causes harmful species to precipitate and become Two types of sampling lines were used between the
bound in the barrier. The mix designs were therefore layers of the cell liners using 3 mm plastic tubes in both.
developed to give a good buffering capacity. This was In one type the end of the 3 mm plastic tubes were
measured by monitoring the “through pH” of the elu- glued inside porous stone discs of 60 mm diameter. In
ent from the permeability test cells. The mix designs the other type the layer was drilled and the 3 mm plastic
and their properties are shown in tables 1 and 2. Waste tubes ends were sealed in place in the set concrete with
sodium sulphate solution from lead-acid battery recyc- sponge around the end of the line. The sampling lines
ling was used as mix water in two mixtures. were placed as an array in the various liner materials

Barrier (lower concrete) width


7.87m

Tarpaulin supported on
timbers (buried in trench
at edges)
Waste depth
1.1m
30 degrees

Figure1. Typical trail test cell layout.

12
Table 1. Composition of mixes used in the three trial cells at Risley.

Proportions used

kg/m3 % By mass

Composition of top layer concrete for cell No.1:


Spent Borax from silver refining 450 18.5
Ferrosilicate sand 895 36.8
20 mm Limestone 1085 44.7
Water 210
Composition of top layer mortar for cell No.2:
Ferrosilicate slag sand (5 mm) 1575 65.9
Cement Kiln Dust (CKD) – 60% 490 20.5
Lagoon Ash from coal burning – 40% 325 13.6
Water 200
Composition of top layer concrete for cell No.3:
Ferrosilicate slag (150 mm to dust) 0
Limestone (20 mm) 715 29.8
Ferrosilicate slag sand (5 mm) 1105 46
Cement Kiln Dust – 60% 340 14.2
Lagoon Ash from coal burning – 40% 240 10
Water 220
Composition of lower layer concrete for cell No.1:
Ground Granulated Blastfurnace Slag (GGBS) 180 7.6
Ordinary Portland Cement (OPC) 20 0.9
Chrome Alumina Slag (40 mm) 1515 64.2
Green Sand (ex-casting) 645 27.3
Na2SO4 solution from battery recycling 295
Composition of lower layer concrete for cell No.2:
Chrome Alumina Slag (40 mm) 1175 49.6
Chrome Alumina Slag (5 mm) 720 30.4
Green sand from casting moulds 100 4.2
Cement Kiln Dust – 60% 165 7
Pulverised Fuel Ash – 40% 210 8.8
T1Sodium sulphate Solution (lt) 165
Composition of lower layer concrete for cell No.3:
Chrome Alumina Slag (40 mm) 1175 50.3
Chrome Alumina Slag (5 mm) 720 30.8
Green sand 110 4.7
Ordinary Portland Cement – 5.2% 25 1.1
Cement Kiln Dust – 69.8% 185 7.9
Lagoon Ash from coal burning – 25% 120 5.2
Water 240

Table 2. Properties of concrete used in cells 1,2 and 3.

7 days 28 days Intrinsic permeability Intrinsic permeability


strength strength to water @ to leachate @ Thro’ pH Through pH
(MPa) (MPa) 28 days (m/s) 28 days (m/s) water# leachate#

Cell 1 top 5 4.5 1.5  108 4.0  108 10 –


Cell 1 base 11 13 No flow 2  1012 – 8.5
Cell 2 top 1.1 1.7 4.5  109 5  109 11.8 12.3
Cell 2 base 4.4 6.9 2.3  109 4.5  109 10.1 9.9
Cell 3 top 0.9 1.3 1.2  108 7.5  109 12.2 12.1
Cell 3 base 2.8 6 1.2  108 6.2  109 8.5 7.6

* Initial pH of leachate: 5.1–5.4.


# The “through pH” is the pH of the outflow from the permeability test.

13
and levels. Liquid samples were obtained by applying Ca cell 2
Model top of clay
a vacuum to the lines. Model bottom of clay
1300
Experimental top of clay
1100
2.7 Initial observations Experimental bottom of clay
900

Cl ppm
Cell 3 needed to be refilled after 12 months. The rea- 700
500
son for this was inadequate compaction of the clay
300
layer leading to an increased permeability. The effect- 100
ive indicated permeability was calculated and found -100
0 1 2 3 4 5
to correspond to nearly the same permeability as a Time years
Bentonite Enhanced Sand liner and indicates satisfac-
tory performance even when very poor construction Figure 2. Concentrations of calcium in site trial cell 2.
practice was evident but it did affect the modelling
considerably. The permeability calculated from these Na cell 2 Model top of clay
site observations was therefore used for the clay layer.
Model bottom of clay

Experimental top of clay


2.8 Comparison between model and observations
Experimental bottom of clay
The capacity factor, and diffusion coefficient values 2500
obtained from laboratory diffusion tests on the top and 2000
bottom mixes used in the site trial cells together with Cl ppm
1500
the initial concentrations of different elements in site 1000
leachate and the mixes used in the cell (from pore 500
pressed solutions) were used to model the transport in 0
the barriers. The model simulates pressure driven flow 0 1 2 3 4 5

and diffusion using a finite step code written to run as Time years

a macro in Microsoft Excel. The modelled concentra-


tion is plotted against measured collected sample con- Figure 3. Concentrations of sodium in site trial cell 2.
centration values in figures 2 to 4 for Ca, Na and K for
cell 2. On these graphs error bars are shown between K cell 2 Model top of clay
the 10th and 90th percentiles from the probability cal-
culations at ages of two and four years. The observed Model bottom of clay

concentrations which are shown on the graph are Experimental top of clay
based on the average from up to four different samples Experimental bottom of clay
18000
taken in different parts of the cells. For some of these 16000
a considerable spread of results was recorded. 14000
12000
Cl ppm

10000
8000
3 TRIAL 4 6000
4000
2000
3.1 Introduction 0
0 1 2 3 4 5
This trial was a trench fill. The total quantities of Time years
materials used were:
Red Gypsum: 5.3 Tonne Figure 4. Concentrations of potassium in site trial cell 2.
BOS weathered slag: 8 Tonne
Water: 2400 litres
Calculated yield: 7.4 m3
This mix was selected to give a strength which was
3.2 Observations
adequate for trench filling but not too high for subse-
quent excavation if this became necessary. 3.2.1 From loading mixer
Mix procedure. • Some difficulties were experienced with the con-
Both the slag and the gypsum were supplied in sling veyor and the entire loading process took approxi-
bags containing approximately one tonne each. These mately two hours.
were discharged onto a conveyor and loaded directly • The anticipated problems with handling the red
into a truck-mixer. The trench was approximately gypsum did not occur.
5 meters long by 1 meter wide by 2 meters deep. The • The gypsum had not consolidated in the sling bags
mix filled the trench to within 0.5 meters from the top. and flowed freely out of them.

14
Table 3. Mix proportions of concrete mix used in Lowdham Grange site trial.

Mix proportions (kg/m3)

Mix Code Blended novel binder Water Recycled Agg. W/B Slump

PG15/BPD5/BOS80 (RA-RCC) 400 100 1900 0.25 0

3.2.2 From samples taken was adopted to be similar to the existing layers of
• The flow of the first sample was measured to be constructed car park area to provide comparable data
545 mm (very close to 560 mm target). between conventional sub-bases and the RCC layer.
• Some unmixed lumps of red gypsum were observed. The mixture design used the “novel blend” and is
These were extracted using a 5 mm sieve. The shown in table 3.
quantity was observed to decrease from the first to
the second sample but increased again for the third
sample. 4.2 Placing concrete and compaction
• Initial set was 1.5 hours from discharge and final To give a thickness of 100 mm after compaction a
set approximately 7 hours. layer of 160 mm of concrete was placed and levelled
manually. As the concrete was delivered in three truck
3.2.3 From discharge loads; placing and compaction of RCC layer was car-
• The material was observed to flow freely in the ried out in three segments of the allocated area. As a
trench. result, a slightly different moisture content and com-
• A small number of agglomerated lumps up to paction level was expected for sections. The work-
150 mm in size were observed. ability of the mixes on site was, however, observed to
• The material was self-compacting and air could be be very consistent. The hot weather on the day was
seen escaping (venting to surface) indicating that compensated for with accurate batching of water con-
vibration was not necessary. tent. The placed concrete layer was then compacted
• The trench into which the mix was poured had partly using a 3-Tonne vibrating roller.
filled up with rain water since it was pumped out
earlier in the morning. The first 0.5 m3 discharge into
the trench initially appeared to mix with the water 4.3 Testing
in the trench, but very rapidly “clear” water separated The test results are shown in table 4.
out on top of the mix. The mix did not appear to be
adversely affected by being poured into standing
water. It is suggested that this degree of cohesion is 5 TRIAL 6
superior to the performance of foamed concrete
where some grout loss might be observed in these 5.1 Introduction
circumstances.
A 22 m length of the site access road (4 m wide) was
• The surface of the pour remained reasonably flat constructed using stabilised soil and a paste (grout)
along the trench even though it was only poured
from one end. It was difficult to see the exact slope sub-base both of which used the “novel blend” in
due to the free water on the surface but the final place of cement.
slope was minimal. Table 5 shows the proportions of materials used for
soil stabilisation and semi-dry paste. The volume of
stabilised soil needed for the site trial was estimated
3.3 Testing
at about 72 m3 in a loose condition including wastage.
The 28 days result of the average of 3 cubes (50 mm) For the semi-dry paste, the volume of material needed
which were taken from top, middle and bottom of the was estimated to be about 6 m3. Half of the area was
truck mixer load was 1.8 MP constructed using a conventional base course with
same thickness as the semi-dry compacted paste.
Finally, the surface of the whole road was paved using
4 TRIAL 5 50 mm bituminous of wearing surface.
4.1 Introduction
5.2 Construction method – stabilised soil
A 6 m by 17 m area of car park was used for a sub-base
trial. The area was stripped of the existing hardcore to The blended powder was spread over the area using a
expose the sub grade, which was hard clay. This design volumetric method. In order to achieve the required

15
Table 4. Compressive strength of laboratory and site RCC layer.

Laboratory tests Insitue tests

Strength at days (MPa) Strength at days (MPa)


Density Density
Mix Code 3 7 28 kg/m3 14 28 90 kg/m3

RCC (Lab.) 0.96 2.02 10.80 2390 – – – –


RCC (Site-Truck 1) 0.70 1.20 5.47 2350 – – – –
RCC (Site-Truck 2) 0.68 1.29 4.70 2232 – – – –
RCC (Site-Truck 3) 0.99 1.42 7.10 2293 – – – –
Core (Location 1) – – – – Soft 8.7 13.41 2257
Core (Location 2) – – – – Soft 10.11 15.43 2226

Table 5. Mix proportions of stabilised soil and semi-dry the required amount water was adjusted based on visual
compacted paste (grout) mixes used. inspection and past experience.
Moisture
Mix Code Soil % Binder % content % 5.4 Test results

Stabilised soil (soil50/ The test results are shown in tables 6 and 7.
Binder50) 50 50 14
Semi-dry paste (PG15/
BPD5/BOS80-.13) – 100 13 6 DISCUSSION

6.1 Strengths
The strengths of the mixtures from all of the trials
amount of binder per cubic metre of the compacted soil, (except the soil stabilisation) are summarised in table 8.
150 mm of the blended powder was spread over the It may be seen that the material for trials 5 and 6 are the
trail area. The mixture of soil and powder was blended highest despite having no ordinary cement in it. This
using a rotavating blending machine. The powerful and was helped by the very low water contents in the mix-
heavy blade of the machine provided a homogeneous tures but it still demonstrates that viable mixtures can
blend of soil and binder along the road. be made without cement. The “novel blend” was not
As the natural moisture of the soil used was not designed for use as a partial replacement of cement and
enough to provide the optimum compaction of sta- is not recommended for use with any cement.
bilised soil, extra water was added to the mixture using
a mobile sprinkler. Then the mixture was blended again
6.2 Interpreting the trials
using rotavating blender and levelled using the JCB.
The control of the water content visually was quite chal- Transport processes in landfills are associated with a
lenging at that stage because of the hot weather and high degree of uncertainty. The processes which were
quick evaporation. However, despite of this, the mois- modelled in trials 1–3 used real landfill leachate which
ture content and compaction of the stabilised soil was was undergoing biological reactions throughout the
satisfactory. experiment and took place in a site environment with
all of the associated uncertainty. The combination of
these factors with the uncertainty associated with the
5.3 Construction method – base course
stated assumptions in the model has given rise to
A layer of 100 mm semi-dry compacted paste was some unexpected events. Nevertheless this is a useful
designed to be laid on top of the stabilised soil. As the exercise to indicate likely trends in a real environment.
water content of the paste was limited to 13%, a volu- Long term results which will involve transport
metric mixer was used to mix the blended binder with processes far closer to the steady state are actually
water. The mixer contained a vessel to accommodate likely to be more accurate.
the binder and a 1600 litre tank of water. The binder In all of the trials the batching was less accurate
passed to a screw by means of a belt conveyer where than it was in the laboratory work but in every case
the water was added and mixed in the extending arm. the mix proved tolerant enough to perform adequately.
The only challenge was measuring the amount of water The conditions of a site trial are likely to be worse than
because the mixer was not equipped by any means to full-scale production because of problems with plant.
measure the water added to the mixture. Therefore, For example in trial 4 the mixing in the truckmixer

16
Table 6. Compressive strength of stabilised sub-grade together with in-situ density and moisture.

Laboratory tests Insitue tests

Strength at days (MPa)


Dry Density Dry Density
Mix Code 3 7 28 Moisture % kg/m3 Moisture % kg/m3

Unstabilised Soil-B (Lab.) 0.08 0.21 0.13 13.40 1835.1 – –


Soil-B 50/Binder 50 (Lab.) 0.94 1.43 5.98 13.90 2030.15 – –
Soil 50/Binder 50 (Site-Mid) 0.78 1.11 5.80 8.02 2033.06 8.90 1755
Soil 50/Binder 50 (Site-End) 0.96 1.15 5.10 7.90 2027.55 8.90 1793

Table 7. Compressive strength of laboratory and site semi-dry paste layer.

Laboratory tests Insitue tests

Strength at days (MPa) Strength at days (MPa)


Density Density
Mix Code 3 7 28 Moisture % kg/m3 14 28 90 kg/m3

Semi dry paste (Lab.) 5.10 12.80 30.55 13 2540 – – – –


Semi dry paste (Site-Begin) 3.20 6.64 19.90 8.55 2487 – – – –
Semi dry paste (Site-End) 2.95 6.20 22.40 7.76 2492 – – – –
Core (Mid) – – – – – 10.75 30.1 46.41 2381
Core (End) – – – – – 8.64 26.1 38.98 2011

Table 8. Summary of strengths.

Trial Pour Cementitious component Strength

1 Cell 1 top Spent borax 100% 4.5


2 Cell 2 top CKD 60%, Lagoon ash 40% 1.7
3 Cell 3 top CKD 60%, Lagoon ash 40% 1.3
1 Cell 1 base GGBS 90%,OPC 10%, Sodium sulphate 13
2 Cell 2 base CKD 60%, PFA 40%, Sodium sulphate 6.9
3 Cell 3 base OPC 5%, CKD, 70%, Lagoon ash 25% 6
4 Trench fill BOS 60%, Red Gypsum 40% 1.8
5 Sub-base BOS 80%, PB 15%, BPD 5% 10.8
6 Base course BOS 80%, PB 15%, BPD 5% 30.55

was visibly incomplete but the mix still performed A major mine backfill project has been planned
well. In each case it was concluded that the mix would with the mix from trial 4. This would involve placing
perform adequately in full scale use. The road in trial 100,000 m3 per year for the foreseeable future (the void
6 has been used by heavy vehicles and plant for a con- to be filled is 10 million m3). The material would be
siderable time and is performing very well with no poured down bore-holes into a partially flooded mine.
signs of distress. This project has received full regulatory approval but
awaits funding. This project would require a significant
capital investment and the company has recently been
6.3 Future use of the research
taken over so there may be a long delay.
The experimental programme for trials 1–3 cost over A further site trial was planned with the “novel
0.5 million pounds and the barriers were scheduled to blend” used in trials 5 and 6. This would have involved
be tested in a full-scale waste containment cell filling a dis-used pedestrian subway in Coventry city
(approximately one hectare) but the site operator’s centre. Despite being fully contained by the existing
insurers would not carry the risk, despite further structure this pour did not receive approval from
containment being designed to go below the experi- the Environment Agency and will not now go ahead.
mental liner. The environmental concerns were all addressed but

17
the relevant committee twice delayed the decision to REFERENCES
subsequent monthly meetings and did not give approval
in time. The matter was complicated because the Claisse P A, Ganjian E, Tyrer M and Atkinson A, 2000.
committee mistakenly associated the trial with com- Concrete without calcium or silica. Proc. British Cement
plications at the local cement works including tyre Association Concrete Communication Conference at
University of Birmingham June. pp.117–122, ISBN
burning trials and a release of kiln dust which spread 0 7210 1570 0
across a large part of the town. Claisse, P A Atkinson A, Ganjian E and Tyrer M, 2003a.
Nevertheless the pressure is growing to reduce the Recycled Materials in Concrete Barriers. ACI publication
environmental impact from cement production and SP212-59. Proc. 6th Canmet/ACI conference on the
site trials represent the only route to take solutions Durability of Concrete, Thessaloniki, Greece, June
from the laboratory into practice. pp. 951–971.
Claisse, P A Atkinson A, Ganjian E and Tyrer M, 2003b.
Performance criteria for concrete as a barrier for leachate
7 CONCLUSIONS in waste containment. Proc. International conference on
the performance of construction materials, Cairo, Feb.
18–20. ISBN 977-237-192 pp. 1135–1144
Viable mixtures which contain little or no Portland Claisse P, Ganjian E, Atkinson A and Tyrer M, 2006.
cement can be made for a wide variety of applications. Measuring And Predicting Transport in Composite
Site trials represent the best route to develop these Cementitious Barriers. ACI Materials Journal, Vol 103;
mixtures for commercial use. Number 2 pp. 113–120
Pre-blended mixtures are the best way to use pow- Ganjian E, Claisse P, Tyrer M and Atkinson A, 2004a.
der which contains several mineral wastes. Preliminary investigations into the use of secondary
While it is relatively easy to demonstrate the via- waste minerals as a novel cementitious landfill liner,
bility of cementitious mixtures which are sustainable Construction & Building Materials Journal, Vol 18;
Number 9; pp. 689–699 ISSN 0950-0618
there are many difficulties which may prevent their Ganjian E, Claisse P, Tyrer M and Atkinson A, 2004b.
industrial use. These include: Selection of cementitious mixes as a barrier for landfill
leachate containment. ASCE Journal of Materials in
• Insurance problems
Civil Engineering, Vol 16; Number 5 October.
• Lack of capital investment
pp. 477–486 ISSN 0899-1561
• Environmental concerns which may or may not Ganjian E, Claisse P, Tyrer M and Atkinson A, 2006a.
have any scientific basis. Factors affecting measurement of hydraulic conductivity
in low strength cementitious materials. Cement And
Concrete Research, Vol 36; Number 12 pp. 2109–2114
ACKNOWLEDGEMENTS Ganjian E, Claisse P and Tyrer M, 2006b. Use of
Unclassified Ashes as Controlled Low Strength
The authors acknowledge the considerable support pro- Materials for a Novel Cementitious Landfill Liner. Ash
vided to enable us to carry out the work reported in this Tech 2006. 15–17 May UK Quality Ash Association.
paper. Supporting organisations have included
ENTRUST, MIRO, Lafarge PLC, Huntsman Tioxide,
WRAP, EPSRC and NERC and our major partners have
been Imperial College and Birmingham University.

18
Sustainable Construction Materials and Technologies – Chun, Claisse, Naik & Ganjian (eds)
© 2007 Taylor & Francis Group, London, ISBN 978-0-415-44689-1

Sustainability of the cement and concrete industries

T.R. Naik
UWM Center for By-Products Utilization, University of Wisconsin-Milwaukee, Milwaukee, WI, USA

ABSTRACT: Sustainability is important to the well-being of our planet, continued growth of a society, and
human development. Concrete is one of the most widely used construction materials in the world. However, the
production of portland cement, an essential constituent of concrete, leads to the release of significant amount
of CO2, a greenhouse gas (GHG); production of one ton of portland cement produces about one ton of CO2 and
other GHGs. The environmental issues associated with GHGs, in addition to natural resources issues, will play
a leading role in the sustainable development of the cement and concrete industry during this century. For exam-
ple, as the supply of good-quality limestone to produce cement decreases it will become more difficult to pro-
duce adequate amounts of portland cement for construction. There is a possibility that once there is no more
limestone, say in a geographical region, and thus no portland cement, all of the employment associated with the
concrete industry as well as new construction projects will be terminated. Due to limited natural resources, con-
cern over GHGs, or, both, there are regions in the world where cement production is being curtailed, or, at least,
cannot be increased to keep up with the population increase. Therefore, it is necessary to look for sustainable
solutions for future concrete construction. A sustainable concrete structure is constructed in order to ensure that
the total environmental impact during its life cycle, including its use, will be minimal. Sustainable concrete should
have a very low inherent energy requirement, be produced with little waste, be made from some of the most plen-
tiful resources on earth, produce durable structures, have a very high thermal mass, and be made with recycled
materials. Sustainable constructions have a small impact on the environment. They use “green” materials, which
have low energy costs, high durability, low maintenance requirements, and contain a large proportion of
recycled or recyclable materials. Green materials also use less energy and resources, and can lead to high-
performance cements and concrete. Concrete must keep evolving to satisfy the increasing demands of all of
its users. Designing for sustainability means accounting for the short-term and long-term environmental
consequences in the design.

1 INTRODUCTION to the production of portland cement. As limestone


becomes a limited resource, employment and con-
According to the World Commission on Environment struction associated with the concrete industry will
and Development of the UN, sustainability means decline. Therefore, those involved with these indus-
“meeting the needs of the present without compro- tries must develop new techniques for creating
mising the ability of the future generations to meet concrete with a minimal use of limestone. Concrete
their own needs” [UNFCCC COP9 Report 2004]. The production is not only a valuable source of societal
sustainability of the cement and concrete industries is development, but also a significant source of employ-
imperative to the well-being of our planet and to ment. Concrete is the world’s most consumed man-
human development. However, the production of made material. It is no wonder that in the U.S.A.
portland cement, an essential constituent of concrete, alone, concrete construction accounted for two mil-
leads to the release of a significant amount of CO2 lion jobs in 2002 [United States House Resolution
and other greenhouse gases (GHGs) [Malhotra 2004]. 394 2004]. About 2.7 billion m3 of concrete was pro-
The environmental issues associated with CO2 will duced in 2002 worldwide. This equals to more than
play a leading role in the sustainable development of 0.4 m3 of concrete produced per person annually
the cement and concrete industry during this century. worldwide. Therefore, to create not only sustainable
One of the biggest threats to the sustainability of the societal development, but also to sustain employ-
cement industry is the dwindling amount of limestone ment, such as batch plant operators, truck drivers,
in some geographical regions. Limestone is essential ironworkers, laborers, carpenters, finishers, equipment

19
Table 1. CO2 Emissions in 2002.
Limestone
Country Percent CO2

Crusher U.S.A. 25
E.U. 20
Russia 17
Grinder Aggregates Japan 8
China 15
India 10
Raw meal
Total CO2 emissions worldwide: 21 billion tons
[Malhotra 2004].
Kiln
energy conservation, and physical, environmental, and
technological resources for new and existing build-
Clinker Additives ings. It is also important to take into account the impact
of construction technologies and methods when cre-
ating sustainable structures [McDonough et al. 1992].
Grinder An integrated sustainable design process can reduce
project costs and operating costs of the building or the
infrastructure construction.
Cement Concrete There are many challenges associated with port-
land cement production. Of these, energy and resource
Figure 1. Limestone for cement and concrete [modified
conservation, the cost of producing portland cement,
from Worrell and Galtisky 2004]. and GHG emissions are the most significant. Therefore,
supplementary cementing materials such as fly ash
and slag should replace larger amounts of portland
operators, and testing technicians, as well as profes- cement in concrete. However, before any construction
sional engineers, architects, surveyors, and inspectors, occurs, all aspects of the building materials to be used
the concrete industry must continue to evolve with should be evaluated. In order to build structures and
the changing needs and expectations of the world. infrastructures that are cost efficient, environmentally
friendly, and durable, the impact of the building mate-
2 WHAT IS SUSTAINABILITY? rials on local and worldwide air conditions must be
examined [McDonough et al. 1992]. CO2 emissions
Limestone is used to manufacture portland cement are expected to rise by about 50% by 2020 from the
(Fig. 1). Currently, portland cement is the most com- current levels (Table 1) due to portland cement
monly used material in producing concrete. production [Malhotra 2004].
Entire geographical regions are running out of lime- For each ton of portland cement clinker, 1.5 to
stone resources to produce cement. And major metro- 10 kg of NOx is released into the atmosphere. In 2000,
politan areas are running out of materials to use as worldwide cement clinker production was approxi-
aggregates for making concrete. Sustainability requires mately 1.5 billion tons. It means that in 2000 between
those in the construction industry to take the entire 23 and 136 billion kg of NOx was produced to make
life-cycle, including construction, maintenance, dem- portland cement clinker [Malhotra 2004].
olition, and recycling of buildings into consideration If the challenges associated with reducing CO2,
[McDonough et al. 1992, Worrell & Galtisky 2004]. NOx, and other GHGs are to be met, then the concrete
A sustainable concrete structure is one that is con- industry must develop other materials to replace port-
structed such that the total societal impact during its land cement. Use of blended cements and organic chem-
entire life cycle is minimal. Designing with sustain- ical admixtures must be significantly increased for
ability in mind includes accounting for the short-term sustainability of the cement and concrete industries.
and long-term consequences of the structure. In order
to decrease the long-term impact of structures, the 3 CONCRETE
creation of durable structures is paramount.
Building in a sustainable manner and scheduling For over 200 years, concrete has been accepted for
appropriate building maintenance are significant in its long-lasting and dependable nature. In addition to
the “new construction ideology” of this new century. durability and dependability, concrete also has superior
In particular, to build in a sustainable manner means energy performance, is flexible in design, affordable,
to focus attention on the effects on human health, and is relatively environmentally friendly [Cement

20
Association of Canada 2004]. It can be expected that minimize the maintenance needs of the concrete con-
concrete will be needed to both increase industrializa- struction, and limit the amount of non-renewable spe-
tion and urbanization while protecting the environment. cial repair materials that need to be used in the
To do this, the concrete industry should consider recy- maintenance of the concrete [Coppola et al. 2004].
cling industrial by-products such as fly ash safely and Concrete producers are creating sustainable solu-
economically. When industrial by-products replace tions for many market sectors including agriculture and
cement, even up to 70%, in concrete, the environmental construction. In agriculture, integrated waste manage-
impact improves along with the energy efficiency, and ment solutions have been developed that convert
durability of concrete [Naik et al. 2003]. manure into biogas, nutrient rich fertilizer, and reusable
Concrete is a building material that is not only water. In construction, industrial, commercial, and
strong and durable, but can also be produced in ways institutional buildings are being constructed so that they
that are environmentally friendly and architecturally are more energy efficient, have better air quality, and
moldable in esthetically pleasing forms [National necessitate less maintenance [McDonough et al. 1992].
Building Museum 2004]. With sustainable concrete U.S. foundries generate over 7 million tons (8 mil-
structures and infrastructure, the concrete industry lion tons) of by-products. Wisconsin alone produces
can develop a sustainable future for generations to nearly 1.1 million tons (1.25 million tons) of foundry
come. Furthermore, buildings that are constructed to by-products, including foundry sand and slag. Most
be both durable and environmentally friendly often of these by-products are landfilled. Landfilling is not
lead to higher productivity because the buildings gen- a desirable option because it not only causes a huge
erally lead to better air quality and therefore, higher financial burden to foundries, but also liability for
productivity [Coppola et al. 2004]. One example of future environmental costs, and restrictions associ-
the advantage of sustainable concrete is buildings ated with landfilling. One of the innovative solutions
constructed with concrete that have reduced mainte- appears to be high-volume uses of foundry by-products
nance and energy costs. Another is concrete high- in concrete and other construction materials [Naik &
ways, which reduce the fuel needed for heavily loaded Kraus 1999].
trucks. A third example of the benefits of sustainable In addition, in 1996 the USA produced 136 million
concrete construction is illustrated in insulating con- tons of construction and demolition (C & D) debris,
crete homes that have energy reductions of up to 40% about 1.5 kg per person per day. About 25 to 40% of
[Cement Association of Canada 2004]. landfill space is C & D debris [McKay 2004]. If this
The cement and concrete industries can make sub- trend continues, the cost of landfilling will continu-
stantial contributions to sustainable developments by ously increase, as will the potential health and envi-
creating and adopting technologies that can reduce the ronmental risks of landfill materials. Furthermore,
emissions of greenhouse gases. The cement and con- the cost of landfilling is escalating due to shrinking
crete industries could contribute to meeting the goals landfill space and stricter environmental regulations.
and objectives of the 1997 Kyoto Protocol [UNFCCC Such C & D debris (e. g., concrete as well as gypsum
COP9 Report 2004]. Among other things, Kyoto wallboards from C & D debris) can be recycles to
Protocol requires to meet a target of reduction in GHGs make new concrete [UWM-CBU 2007].
to 1990 level. Those involved with the manufacture of A study was reported in 1999 whose aim was to eval-
portland cement would have a huge impact on the sus- uate the environmental impact of controlled low-strength
tainable development of the concrete industry as a materials (CLSM) incorporating cement and indus-
whole because currently cement production contributes trial by-products such as coal fly ash and used foundry
slightly over 7% of worldwide GHGs (primarily CO2); sand [Naik and Kraus 1999]. The results demonstrated
or, about 1.6 billion tons of GHGs. Any future taxes on that excavatable flowable slurry incorporating fly ash
GHG emission would have noticeable and noteworthy and foundry sand as a replacement for up to 85% of
economic impact on the price of cement. fly ash could be produced. In general, inclusion of
There are a number of characteristics that apply to both clean and used foundry sand caused a reduction
innovative concrete products. First, they are produced in the concentration of certain contaminants. The use
with precast or cast-in-place reinforced concrete ele- of foundry sand in flowable CLSM slurry, therefore,
ments that are made with portland cement and poz- provided a favorable environmental performance.
zolanic materials that include renewable and/or
recycled components. Second, innovative concrete
products are constructed to enhance the performance 4 PORTLAND CEMENT
of concrete elements, which may also contain recy-
cled concrete as aggregates. High-performance mate- Portland cement is not an environmentally friendly
rials are intended to reduce cross-sections and the material because its manufacture creates greenhouse
volume of concrete produced. They are also intended gas emissions; and, it also reduces the supply of good-
to increase the durability of concrete structures to quality limestone and clay. As good engineers, we

21
must reduce the use of portland cement in concrete. Although cement production is energy inefficient,
We must use more blended cements in order to reduce there have been major initiatives that have reduced
the need of portland cement clinker per ton of blended energy consumption [Worrell 2004]. Of these, the
cement produced by blending with the clinker other most significant has been the replacement of wet pro-
pozzolanic materials, such as coal or wood fly ash, duction facilities with dry processing plants. In addi-
slag, silica fume, and/or other pozzolanic materials. tion, the cement industry has also moved away from
As a cement production feed material, instead of clay, petroleum-based fuel use.
industrial by-products such as used foundry sand Despite these advances, there are still some short-
and/or coal combustion products (CCPs) such as fly comings when energy use is evaluated for the concrete
ash should be used in optimum possible quantity. industry. Dry process cement plants use pre-heaters,
The most energy intensive stage of the portland which increase the alkali content of cement [Worrell
cement production is during clinker production. It 2004]. Thus, cement producers need to continue to
accounts for all but about 10% of the energy use and develop ways to control the alkali content without
nearly all of the GHGs produced by cement produc- increasing the energy consumption levels of the cement
tion. Kiln systems evaporate inherent water from the [Coppola et al. 2004]. Furthermore, current innova-
raw meal and calcine the carbonate constituents dur- tions and energy savings are linked to the amount of
ing clinker preprocessing [Worrell & Galtisky 2004]. energy consumption by converting wet-process to
Sources of CO2 and GHG emissions in the manu- dry-process cement production and the number of
facturing of portland cement [Malhotra 2004] are: pre-heaters needed to complete the process [Worrell
2004].
– from calcinations of limestone  5055%;
For each million tons of capacity, a new portland
– from fuel combustion  4050%; and,
cement plant costs over 200 million dollars. The cost
– from use of electric power  010%.
associated with the production of portland cement,
along with the CO2 emissions and energy issues,
makes it unlikely that developing countries will be
5 INNOVATIVE CEMENT PRODUCTS able to employ modern technology to reduce GHGs.
Also, government regulations of GHGs will likely
While the embodied energy linked to concrete pro- force the cement industry to create blended cements
duction is low, pozzolanic materials (PM), especially and use supplementary materials for blended cements
coal fly ash, have been used by the concrete industry in order to meet the societal development needs
for over 70 years. Their use can contribute to a further [Malhotra 2004, Worrell 2004].
reduction of concrete’s embodied energy. When used To produce one ton of portland cement, 1.6 tons of
wisely and judiciously, PM can improve the long- raw materials are needed. These materials include
term properties of concrete. Fly ash can, and does, good quality limestone and clay. Therefore, to manu-
regularly replace portland cement in concrete [Malhotra facture the current production of 1.6 billion tons of
2004, Naik et al. 2003, Mehta 2002]. cement annually, at least 2.5 billion tons of raw mate-
One process that is even more environmentally rials are needed [Wu 2000].
friendly and productive is the use of blended cements. As good engineers, we must employ environmen-
Blended cements have been used for many decades. tally friendly materials to reduce the use of portland
Blended cements and are made when various amounts cement by replacing a major part of portland cement by
of clinker are blended and/or interground with one or PMs for use in concrete. In the USA, such materials –
more additives including fly ash, natural pozzolans, primarily fly ash, slag, silica fume, natural pozzolans,
slag, silica fume, and other PM. Blended cements rice-husk ash, wood ash, and agricultural- products
allow for a reduction in the energy used and also ash – are available, for up to 70% replacement [Naik
reduce GHG emissions [Malhotra 2004, Mehta 2002]. et. al 2003]. All these materials can be used to sup-
Most innovative concrete mixtures make use of plement the use of cement in concrete mixtures while
PMs to partially replace cement. The advantages of improving product durability.
blended cements include increased production capac- One of the important benefits of the increased use
ity, reduced GHG emissions, reduced fuel consump- of other types of cementitious materials (such as
tion in the final cement production, and recycling of PMs) is the reduction of GHG emissions. With a
PMs [Worrell 2004, Cement Association of Canada replacement of cement with other recyclable resources,
2004]. worldwide CO2 emissions would be reduced. A
The manufacture of portland cement is the third replacement of 50% of cement worldwide by other
most energy intensive process, after aluminum and cementitious materials would reduce CO2 emissions
steel. In fact, for each ton of portland cement, about by 800 million tons. This is equivalent to removing
six million BTU of energy is needed [Naik & Kraus approximately 1/4 of all automobiles in the world
1999]. [Malhotra 2004].

22
Fly ash availability in the USA in 2005 was esti- rainwater and gray-water (shower, sink, bath and
mated at 120 million tons by the American Coal Ash laundry excess); wastes–recycle, air–create clean air;
Association [ACAA 2006]; by 2010 it is estimated to energy–use solar and wind energy, recycle waste
be 160 million tons. Portland cement availability in energy; responsibility to nature–create silence; and,
2002 was estimated at 80 million tons; by 2010 it is maintenance–minimize or eliminate for future
estimated to be 100 million tons. The fly ash disposal generations.
challenge and the limited availability of portland Materials are critical to creating sustainable and
cement have the same solution: replace large amounts responsible concrete designs. In order to ensure that
of portland cement with fly ash to create durable and the most effective and environmentally friendly mate-
sustainable concrete. rials are being used, the entire life-cycle of the struc-
ture should be taken into consideration. Material
choice should include anticipation of the extraction,
6 THE HANNOVER PRINCIPLES – DESIGN processing, transport, construction, operation, dis-
FOR SUSTAINABILITY posal, re-use, recycling, off-gassing and volatile
organic compounds (VOC) associated with the mate-
In 1991, as the planning of the World’s Fair was rial [McDonough 1992]. According to McDonough,
underway, the City of Hannover, Germany asked constructions should be flexible to serve a variety of
William McDonough and Michael Braungart to cre- different needs (e.g., today’s storage building can be
ate sustainability principles to guide the large-scale tomorrow’s school). Adapt materials that are sustain-
development of EXPO 2000 in Hannover. “The able in their process of extraction, manufacture, trans-
Hannover Principles – Design for Sustainability” also formation, and degradation, as well as recyclability.
include directives concerning the use of water. Consider toxicity, off-gassing, finish, and mainte-
Although these guidelines were created for the World nance. Recycling is essential. Make allowance for
Fair, they are still a good tool to guide current and disassembly and reuse. Plan for reuse of the entire
future development around the world [McDonough structure in the future. Minimize use of hazardous
1992]. chemicals. Eliminate waste that cannot be part of a
Designers, planners, government officials, and all naturally sustainable cycle. Any solid wastes remain-
those who participate in the construction of new build- ing must be dealt with in a non-toxic manner. Life-
ings and infrastructures should use the Hannover cycle costs must be studied, analyzed, and incorporated
Principles. A new design philosophy has developed in planning and construction of a building or infra-
from these principles and should be included in sus- structure. Life-cycle cost analysis process must eval-
tainable systems and construction in the future. There uate energy use and environmental impact during the
are a number of examples of societies that have cre- life of the product, process, and/or activity. This
ated sustainable and environmentally friendly com- process must include extraction and processing of
munities. There is hope that the Hannover Principles raw materials, manufacturing, transportation, mainte-
will inspire development and improvements that are nance, recycling, and returning to the environment.
committed to sustainable growth with practical limits Costs and benefits must be evaluated and understood
to create a sustainable and supportive future for com- in both the short-term and long-term. Demolished
munities and the world. concrete must be recycled. It can be readily used in
The Hannover Principles by William McDonough new concrete for aggregates.
[McDonough 1992]: Insist on rights of humanity and For the sustainability of the cement and concrete
nature to co-exist; recognize interdependence; respect industries, use less water and portland cement in con-
relationships between spirit and matter; accept crete production; and use more blended cements and
responsibility for consequences of design; create safe tailor-made organic chemical admixtures. The devas-
objects of long-term value; eliminate the concept of tation of air is a global problem, regardless of the
waste; rely on natural energy flows; understand the locality in which the pollution is created [McDonough
limitations of design; and, seek constant improvement 1992]. The overall design of concrete structures must
by the sharing of knowledge. not contribute to atmospheric degradation. Those
The Hannover Principles are not “cast-in-concrete”. involved in the cement and concrete industries must
They were devised to provide a tangible document evaluate ozone depletion and global warming through-
that could evolve and be adapted as our understanding out the construction and planning process. A major
of our interdependence with nature becomes more contribution to this effort is the use of more blended
important over time. portland cement to minimize global climate change.
For sustainability, consider your actions on the Water resources are being depleted by various uses
following [McDonough 1992]: materials–use indige- [Bourg 2004]. Therefore, potable water should be
nous materials; land use–protect and create rich soil; conserved to serve life-sustaining needs rather than
urban context–preserve open spaces; water–use infrastructural needs. Rainwater and surface run-off

23
water can be used as a water conservation method by mortar and primitive concrete for several millenni-
recycling these water resources in construction instead ums in Egypt, Italy, Mexico, and India. The use of by-
of using potable water. Gray water should be recycled products such as rice-husk ash, wood ash, silica fume
and used for grass, shrubs, plants, trees, and gardens; and other pozzolanic materials, in addition to coal fly
as well as for concrete production [McDonough ash, can help to reduce the need for portland cement
1992]. Furthermore, mixtures with less water should in addition to creating more durable concrete and
be developed with new technologies to create mortar reducing greenhouse gas emissions [Malhotra 2004,
and concrete containing a minimal amount of water. Mehta 2002, ACI 2004]. This will also contribute to
Benjamin Franklin said over 200 years ago in Poor the improvement of air quality, reduction of solid
Richard’s Almanac, “When the well’s dry, we know wastes, and sustainability of the cement and concrete
the worth of water.” Many facilities may have require- industry [Mehta 2002].
ments that can be completed with non-potable water. In summary, for sustainability of the cement and
By using non-potable water, a significant amount of concrete industries: use less portland cement; use less
money can be saved by avoiding or reducing potable water; use application-specific high-quality, durable
water purchases and sewerage costs. To be as effective aggregates; and, use organic chemical admixtures.
as possible, non-potable water for construction and Fundamental laws of nature state that we cannot
building uses should be identified early in the planning create or destroy matter; we can only affect how it is
and designing process to be most cost-effective. Four organized, transformed, and used. To manage natural
ways to utilize and recycle water are to reuse water on resources, humanity must obey the rules of nature:
site for repeated cycles of the same task, treat and use only what you need and never use a resource
reuse water on site for multiple purposes, use gray faster than nature can replenish it.
water after solids have been eliminated, and collect Resources are extracted from the earth by 20%
non-potable water from sources such as rainwater, more than the earth produces. Therefore, what is con-
lakes, rivers and ponds for use in construction [Bourg sumed in 12 months will take 14.4 months to be
2004]. replenished. The use of sustainable development pro-
Energy efficiency, providing the same (or more) cedures will reduce that rate [Time Magazine 2002].
services for less energy, helps to protect the environ- “The issue is not environment vs. development or
ment. When less energy is used, less energy is generated ecology vs. economy; the two can be (and must be)
by power plants, thus reducing energy consumption integrated” [Ricoh Company 2004].
and production. This in turn reduces GHGs and
improves the quality of the air. Energy efficiency also
helps the economy by saving costs for consumers and 8 CONCLUSIONS
businesses. According to McDonough [1992]: (a) use
buildings’ thermal inertia (e.g., concrete building’s As Kofi Annan, U.N. Secretary General, said in 2002,
mass allows it to retain heat); (b) use day lighting and “We have the human and material resources needed to
natural ventilation; (c) use wind power and solar achieve sustainable developments, not as an abstract
power; (d) recycle waste energy; (e) judiciously use concept but as concrete reality” [Time Magazine
color materials on surfaces; (f) reduce heat-islands in 2002]. Professionals involved in the cement and con-
buildings; and, (g) manage and moderate micro- crete industries have the responsibility to generate
climates of buildings. lasting innovations to protect both the industries’
future viability and the health of our environment.
Large volumes of by-product materials are generally
7 WASTE MATERIALS disposed in landfills. Due to stricter environmental
regulations, the disposal costs for by-products are
Engineers, architects, planners, and builders should rapidly escalating. Recycling and creating sustainable
reuse industrial by-products and post-consumer construction designs not only contributes to reduced
wastes in concrete and other cement-based construc- disposal costs, but also aids in the conservation of
tion materials. Post-consumer wastes that should be natural resources. This conservation provides techni-
considered for use in concrete include glass, plastics, cal and economical benefits. It is necessary for those
tires, and demolished concrete, and clay bricks. To do involved in the cement and concrete industries to
this successfully, designers must watch for harmful eliminate waste and take responsibility for the life
hydration reactions of portland cement and changes cycle of their creations. In order to be responsible
in volume of concrete. The recycling of industrial engineers, it is necessary to think about the ecology,
by-products has been well established in the cement equity, and economy of our design [McDonough 1992].
and concrete industries over the past couple of decades Engineers must apply forethought into direct and
[UWM-CBU 2007]. The use of coal fly ash in concrete meaningful action throughout our development prac-
began in the 1930s, but volcanic ash has been used in tices. Sustainable designs must be used as an alternative

24
and better approach to traditional designs. The impacts Sponsored by the ACI Board Advisory Committee on
of every design choice on the natural and cultural Sustainable Developments, Washington, D. C.
resources of the local, regional, and global envi- Mehta, P.K. 2002. “Greening of the Concrete Industry for
ronments must be recognized in the new design Sustainable Development.” ACI Concrete International
24(7): 23–28.
approaches developed and utilized by the cement and Naik, T.R., & Kraus, R.N. 1999. “The Role of Flowable
concrete industries. Slurry in Sustainable Developments in Civil Engineering.”
Proc. of the ASCE Conference on Materials and
Construction – Exploring the Connection, Cincinnati,
REFERENCES Ohio, 9 pages.
Naik, T.R., Kraus, R.N., Ramme, B.W., Siddique, R. 2003.
ACAA 2006. American Coal Ash Association CCPs Survey. “Long-Term Performance of High-Volume Fly Ash
http://www.acaa-usa.org/PDF/2005_CCP_Production_ Concrete Pavements.” ACI Materials Journal 100(2):
and_Use_Figures_Released_by_ACAA.pdf (2006). 150–155.
ACI Board Advisory Committee on Sustainable Development National Building Museum 2004. “Liquid Stone: New
2004. “White Paper.” Architecture in Concrete.” Washington, D.C.
Bourg, J. 2004. “Water Conservation.” http://www. Ricoh Company, Ltd. 2004. “Sustainable Developments:
wbdg.org/design/resource.php?cn0&cx0&rp50 Planning for our Future.” Time Magazine.
(2004). Swedish National Testing and Research Institute 2003.
Cement Association of Canada 2004. “Concrete Thinking for a “Concrete for the Environment.” Published on Behalf of
Sustainable Future.” http://www.cement.ca/cement. the Nordic Network Concrete for Environment, Boras,
nsf/e/6ABDCDE126A87A6C85256D2E005CC53B? Sweden, 8 pages.
OpenDocument (November 15, 2005). Time Magazine 2002. p. A8.
Coppola, L., Cerulli, T., & Salvioni, D. 2004. “Sustainable UNFCCC COP9 Report 2004. “Delivering the Kyoto Baby.”
Development and Durability of Self-Compacting Refocus, International Renewable Energy Magazine,
Concretes.” Eighth CANMET/ACI International Kidlington, Oxford, UK: 52–53.
Conference on Fly Ash, Silica Fume, Slag and Natural United States House Resolution 394 2004.
Pozzolans in Concrete, Las Vegas, NV: 29–50. UWM-CBU (University of Wisconsin-Milwaukee-Center
http://www.cbu.uwm.edu (June 30, 2004). By-Product Utilization) 2007. http://www.cbu.uwm.
Malhotra, V.M. 2004. “Role of Supplementary Cementing edu/ (2007).
Materials and Superplasticizers in Reducing Greenhouse Worrell, E., & Galtisky, C. 2004. “Energy Efficiency
Gas Emissions.” Proc., ICFRC International Conference Improvement and Cost Saving Opportunities for Cement
on Fiber Composites, High-Performance Concrete, and Making.” Lawrence Berkeley National Laboratory,
Smart Materials, Chennai, India: 489–499. Publication No. LBNL-54036, 62 pages.
McDonough, W.P. 1992. “The Hannover Principles: Design Wu, Z. 2000. “Development of High-Performance Blended
for Sustainability.” EXPO 2000, The World’s Fair, Cement.” Ph. D. thesis, T. R. Naik advisor, Department
Hannover, Germany. of Civil Engineering and Mechanics, College of
McKay, D.T. 2004. “Sustainability in the Corps of Engineering and Applied Science, 177 pages.
Engineers.” a paper presented at the Technical Session

25
Sustainable Construction Materials and Technologies – Chun, Claisse, Naik & Ganjian (eds)
© 2007 Taylor & Francis Group, London, ISBN 978-0-415-44689-1

Closed Cycle Construction – A process for the separation and


reuse of the total C&D waste stream

E. Mulder & L. Feenstra


TNO Science and Industry, Department of Separation Technology, Apeldoorn, The Netherlands

T.P.R. de Jong
Delft University of Technology, Faculty of Civil Engineering and Geosciences, Delft, The Netherlands

ABSTRACT: In The Netherlands, construction and demolition (C&D) waste is already to a large extent being
reused. Especially the stony fraction is crushed and reused as a road base material. In order to increase the per-
centage of reuse of the total C&D waste flow to even higher levels, a new concept has been developed. In this
concept, called ‘Closed Cycle Construction’, the processed materials are being reused on a higher quality level
and the quantity of waste that has to be disposed of is minimised. For concrete and masonry, the new concept
implies that the material cycle will be completely closed, and the original constituents (clay bricks, gravel, sand,
cement stone) are recovered in thermal processes. The mixed C&D waste streams are separated and decontam-
inated. For this purpose several dry separation techniques are being developed. The quality of the stony fraction
is improved so much, that this fraction can be reused as an aggregate in concrete. The new concept has several
benefits from a sustainability point of view, namely less energy consumption, less carbon dioxide emission, less
waste production and less land use (for excavation and disposal sites). One of the most remarkable benefits of
the new concept is that the thermal process steps are fuelled with the combustible fraction of the C&D waste
itself. Economically the new process is more or less comparable with the current way of processing C&D waste.
On the basis of the positive results of a feasibility study, currently a pilot and demonstration project is being car-
ried out. The aim is to optimise the different process steps of the Closed Cycle Construction process on a labo-
ratory scale, and then to verify them on a large scale. The results of the project are promising, so far.

1 THE ‘CLOSED CYCLE CONSTRUCTION’ and four institutes (including TNO and the Delft
CONCEPT University of Technology), and supported by the Dutch
Government.
In The Netherlands, construction and demolition The new concept, called ‘Closed Cycle Construc-
(C&D) waste is already to a large extent being reused. tion’ is principally based on closing the material cycles
The stony fraction is crushed and for more than 95% for especially masonry and concrete in the construction
reused as a road base material. In order to increase the sector. Besides, also the remaining mineral fractions of
percentage of reuse of the total C&D waste flow to C&D waste are being re-utilised. In short this means
even higher levels, a new concept has been developed that, after deconstruction/demolition of a building,
by TNO. In this concept, called ‘Closed Cycle Con- concrete rubble, masonry debris and mixed stony rub-
struction’, the processed materials are being reused ble are separated and treated individually, gaining min-
on a higher quality level and the quantity of waste that erals that can be re-used as raw materials for the
has to be disposed of is minimized. manufacture of new construction products (clay bricks
On the basis of the positive results of a feasibility and concrete). One of the most remarkable benefits of
study, currently a pilot and demonstration project is the new concept is that the thermal process steps are
being carried out. The aim of this project is to optimise fuelled with the combustible fraction of the C&D
the different process steps of the Closed Cycle waste itself.
Construction process on a lab scale, and to verify them In fact, in the Closed Cycle Construction concept
on a large scale. The project is managed by TNO, and four different C&D waste streams are distinctly
carried out by a consortium of ten Dutch companies processed, namely clean concrete rubble, clean

27
Figure 1. Distinct treatment of four different C&D waste streams.

masonry debris, mixed rubble and mixed C&D waste separation techniques are being developed. The quality
(also including wood, plastic, plasterboard, glass, of the stony fraction is improved to a level that it can be
etc.). This is shown in figure 1. For concrete, this new re-used as an aggregate in concrete.
technology involves a rotary kiln in which the uncon- For demolition waste that has not been separated at
taminated concrete rubble is thermally treated at a the source, advanced detection and separation tech-
temperature of about 700°C to dehydrate the cement niques are being developed, to sort out contaminants
stone. The concrete rubble pieces disintegrate and the like gypsum and hazardous materials. The remaining
original components are set free. After treatment, only material is divided into a heavy (stony) fraction and a
2% of hardened cement paste remains attached to the light (combustible) fraction. The combustible fraction
sand and gravel grains. (wood, plastic, paper, bituminous roofing material) is
For masonry debris, the new technology consists of a cleaned up and prepared as a fuel for the thermal
three-step process. In the first step, the large pieces of process steps.
debris are thermally treated at a temperature of about
550°C, to set free the majority of the original ceramic
bricks. These whole bricks can be used for restoration 2 THERMAL TREATMENT OF
purposes or for the construction of buildings in an old CONCRETE RUBBLE
fashioned appearance. Subsequently, the remaining
pieces of brick and mortar are physically separated. In To be able to close the material cycle for concrete
the third step, the remaining ceramic fraction is crushed completely, high quality raw materials must be pro-
and reused as raw material for the production of new duced from concrete rubble (Dijk 2002). These raw
ceramic bricks. materials need to fulfil the criteria that are set for pri-
To be able to process the entire supply of C&D mary raw materials. For this reason, a thermal process
waste, the above mentioned processes have to be imple- has been developed for the treatment of concrete
mented in an overall process. This overall process also rubble.
includes process steps for the treatment of mixed C&D The process step suitable for setting free the differ-
waste. The mixed C&D waste streams are separated and ent components of concrete is based on the input of a
decontaminated. For this purpose several dry density combination of thermal and mechanical energy. As is

28
Coarse
Concrete rubble aggregates

Vibrating
screen

Rotary kiln

Air

Jaw crusher separator


Fine
Heater aggregates

Magnet

Cement stone
Reinforcement
steel

Figure 2. Flow scheme of thermal treatment of concrete rubble.

schematically shown in figure 2, the installation exists same quality as primary gravel and sand. The per-
of the following unit operations: formance of the recovered aggregate however has to
be verified experimentally (Mulder et al. 2002).
– a jaw crusher to reduce the size of the coarse con-
The dehydrated cement stone fraction can be used
crete rubble to below 10 cm;
as a substitute for part of the Portland cement clinker in
– a magnet, to remove any reinforcement steel pres-
the cement production process. The cement stone can
ent in the concrete rubble;
be directly fed to the Portland cement mill, or even
– a rotary kiln for the combined input of thermal
added after the mill. This saves a lot of energy and raw
energy (to disintegrate the matrix) and mechanical
materials.
energy (to further release the different concrete
components);
– a vibrating screen and air separator to separate the
3 THERMAL TREATMENT OF
following three fractions: coarse aggregate (prima-
MASONRY DEBRIS
rily gravel), fine aggregate (sand) and cement stone.
The proposed process is based on the experiences of In co-operation with the Delft University of
Mitsubishi, TNO and KEMA (Larbi et al. 2000, Technology, at TNO a PhD study was carried out into
Shima et al. 1999). The heating step must be per- recycling options for masonry debris (Dijk 2002).
formed on a temperature of as least 700°C to obtain The aim of the process development was closing the
clean aggregate fractions, sand and gravel (Larbi et al. material cycle for ceramic clay bricks within the pro-
2000). Preliminary investigations on a laboratory scale duction chain. This resulted in a three-step process
in which the concrete rubble was treated at 700°C, that is described in more detail in the next paragraphs.
showed that from 1 ton of concrete 450 kg gravel The first step in the recycling of masonry debris is a
(4 mm), 350 kg sand (4 mm), 130 kg cement stone thermal process, to recover whole bricks. The process
(150 µm) and 10 kg reinforcement steel can be is based on the difference in linear expansion coeffi-
recovered (Larbi et al. 2000). The remaining 60 kg cient between mortar and brick. This means that with
was originally present as hydration water, and was increasing temperature, strains are built up in brick
emitted as vapour. and mortar, causing shear stresses on the interface.
If the concrete is treated at a relatively high tem- Because of the fact that this interface, in general, is the
perature (750°C) there is hardly any residual weakest part of the masonry, this phenomenon leads to
cement paste left attached to the aggregate grains. In crack formation on the interface, setting free the whole
that case, the gravel and sand are supposedly of the bricks.

29
Figure 5. Recovered whole clay bricks.

Figure 3. Demolition of masonry.


In the experiment with the cement-based mortar,
2.5 tonnes of masonry debris pieces were piled on
kiln cars and fed into a stationary chamber kiln. The
masonry debris was treated at 540°C for twenty four
hours. After the thermal treatment the bricks were
hand sorted. The result was: 900 kg whole bricks,
1120 kg broken bricks and brick parts, 500 kg mortar
and some steel anchors. So, the recovery rate was
36% of the total mass of masonry input.
In the experiment with the lime-containing mortar
2200 kg of bricks were mechanically set free. The
individual bricks were piled in large wire baskets, put
on the kiln car, and in the same way fed into the sta-
tionary chamber kiln. This is shown in figure 4. These
bricks were treated at 650°C for 12 hours. These
bricks were mechanically treated in a shaking trough,
placed up front a shovel, to loosen and separate the
Figure 4. Masonry debris in baskets, on a kiln car.
mortar parts. The result was: 900 kg whole bricks,
850 kg broken bricks and 450 kg of bricks that were
not clean. So, the recovery rate was 41% in this spe-
In the laboratory, optimum process conditions were cific case. This is higher than in the former case, but
determined. Especially the temperature required to sep- at the cost of more thermal energy and an extra
arate all the mortar from the brick’s surface was investi- labour-intensive pre treatment.
gated for different brick types and different mortar In both cases the bricks had a grey appearance at
systems. It appeared that for cement dominated mor- the bottom and top side. The facing sides however,
tars, the best temperature was around 540°C. However, were clean. The bricks were of good technical and
mortar types also containing lime, require even higher environmental quality, in accordance with the Dutch
temperatures. In the case of feeding big lumps of standard NEN 2489 (dimensions and strength), and
masonry debris, this leads in that case to a relatively with the Dutch Building Materials Decree (leaching
high percentage of cracked bricks. This is caused by the of heavy metals and salts).
fact that the critical quartz solid phase transition tem-
perature of 573°C must be passed twice, leading to
internal stress. This high cracking percentage can be 4 SEPARATION OF MIXED C&D WASTE
substantially decreased by a pre treatment, in which the STREAMS
individual bricks are mechanically separated. This is
quite easy, because these mortar types are rather weak. Mixed C&D waste streams will have to be separated
To verify the laboratory experiments, two experi- and extensively cleaned up, in order to gain enough
ments were carried out on semi-practical scale (one quality to reuse the different fractions. In the Closed
with a cement dominated mortar and one with a mor- Cycle Construction project the aim is to end up with
tar also containing lime). a decontaminated mineral aggregate fraction that can

30
Figure 6. Principle of pre-concentration and decontamination with X-ray sorting.

be reused in concrete and a decontaminated com-


bustible fraction that can be used as a fuel in the ther-
mal processes, described before. The challenge in this
respect is to find the right combination of a cheap bulk
separation technique (as a rough pre-concentration)
and one or more automated sorting techniques for the
further clean-up of the pre-concentrated fractions. This
approach already proved successful in the processing
of recycle glass and metallic scrap. An example is
worked out in figure 6. In this example the dry density
separator produces as heavies an aggregate of 98%
purity and combustible lights of 80% purity. Assuming
a typical concentration factor of 10 for a single stage
industrial automatic sorting step, the final aggregate
quality will be of 99.8% purity and the lights will have
98% purity. Light materials that are unsuitable for
combustion in conventional processes, such as PVC,
can be concentrated in a separate waste stream. Figure 7. Principle of colour sorting (Scan & Sort) 1  con-
veyor, 2  metal sensor, 3  colour camera, 4  lighting,
5  blow bar, 6  main stream, 7  reject.
4.1 Dry separation techniques
With regard to the pre-contamination of the mixed ability to separate coarse material (larger than 50 mm)
C&D waste stream, several dry density separation is unique for this dry technology and is of high rele-
techniques were investigated experimentally, on a pilot vance for C&D waste sorting. Unfortunately separa-
scale (Jong & Fabrizi 2004). All investigated separators tion of larger sizes then 40 mm could not be
showed variable but satisfactory efficiency. The best investigated in the present project due to practical lim-
choice depends on a trade off between economy and itations of the applied equipment. Disadvantage is sand
required product quality, and on factors such as space loss in the product and the lower efficiency for finer
requirements, capacity requirements, whether or not material (5 to 20 mm). However, in aggregates a certain
classification in narrow size fractions is possible, etc. sand level is tolerated and in combustible fractions it
The tests resulted in sufficient quantitative data to sup- causes only a minor increase in ash content.
port a tailor made decision for a given operation. Although of lower separation efficiency, the air jig
The dry sand fluidised bed shows the highest prod- provides a favourable solution when prior classifica-
uct purities for 20 mm oversize and obtains product tion into several size fractions is impractical and a
qualities that are similar to wet jigging. The principle significant fines percentage (2 to 20 mm) is present,

31
Kringbouw X-ray test

0.70
0.65
0.60 Bitumen
0.55
Metal Glass
0.50
0.45 Gypsum

0.40 Metal
Hue

0.35 Organics
Stone/tile
0.30 Plastic
0.25
Stone
0.20
Tile
0.15
Organics Wood
0.10
0.05
0.00
6.0 8.0 10.0 12.0 14.0 16.0 18.0 20.0 22.0

Zeff

Figure 8. Concentration of components in CDW using X-ray transmission imaging.

for which the fluidised bed is unsuitable. Both separa- materials (see figure 7). It can handle mass streams of
tors would also work well together, the jig treating the up to 40 tonnes per hour. Computer controlled noz-
material up to 30 mm, the fluidised bed the 30 mm zles blow out the detected materials. The camera is
oversize. Prior removal of lights and fines with air analyzing size, shape, colour and position of particles
sifting is recommended. on the belt. The information is then used to generate
Ballistic separators and air tables require prior impulses instructing the nozzles to blow out single
classification into rather narrow particle size fractions. particles or allow them to pass.
A high screening efficiency is of paramount impor- The results gained with the CombiSense exceeded
tance. For damp feed appropriate screening technology expectations. It could well be used to increase product
must be applied. Air tables show additional displace- quality and avoid the presence of unwanted materials
ment of tile and glass fragments in the lights. Ballistic in the stream to be recycled.
separation is very suitable as high volume pre- Total wood recovery and grade from the light frac-
concentration wherever narrow classification can be tion are high, reaching values of 83% and 92%
done and there is sufficient head-room available. respectively. 3% of stones and tiles are separated with
wood; by more effective density separation a large
proportion of this heavy material could be removed
4.2 Automatic sorting techniques
and grade would be about 95%. It can be concluded
With regard to the automatic sorting techniques, that colour sorting can be effectively used for wood
required for the further clean-up of the pre- removal from mixed CDW.
concentrated fractions, two techniques have been Colour sorting also allows a good removal of gyp-
extensively investigated (de Jong et al. 2005). Both sum form the heavy fraction showing a recovery of
techniques have their own advantages. 94%. This is a good result because in recycle aggre-
Automatic colour sorting of the light and heavy gate the presence of that mineral should be avoided
fractions was investigated with the Scan & Sort due to its sulphate content. The grade is only 5.6%
CombiSense 1200 at the Department of Mineral because of the presence of stones and tiles of similar
Processing at RWTH Aachen, Germany. Its optical colour in the concentrate. These could be easily
system incorporates a high-speed camera with 1 bil- removed by density separation in a second stage.
lion colours recognition and a special conductivity Glass recovery and grade are 96% and 56%. Thus
sensor permitting the identification of a variety of the CombiSense separator would be also useful for

32
Table 1. Feed characterization of fraction 20–40 mm.
40  80 mm fraction. The smaller and larger material
Amount in input material was not sorted. The 20 mm material was only a
small fraction; the fractions 80 mm cannot be
Fraction Weight [g] Wt% [g/g] sorted on the available DE-XRT sorter due to limita-
tions in geometry and air jets. This is not a principle
Wood 9837 47.2 limitation, but a limitation of the experimental device.
Stone 8109 38.9 The fractions of C&D waste were analysed on
Glass 590 2.8 composition in the categories wood, stone, glass, gyp-
Gypsum 264 1.3 sum, metal, plastic, textile, paper & cardboard and
Metal 569 2.7 others (‘rest’). The DE-XRT sorting machine that was
Plastic 929 4.5
Textile 230 1.1
available at CommoDas GmbH in Wedel, Germany, was
Paper/cardboard 66 0.3 adjusted and trained to concentrate wood in the usual
Rest 20 mm 271 1.3 way.
Total 20863 100.0
The composition of the 20  40 mm input material
and the component split after sorting are given in tables
1 and 2 respectively. The component split indicates the
recovery; e.g. 43% of the input feed is recovered as
Table 2. Component split after sorting. wood in the wood concentrate, that is 47% of the feed
Component split
input. The remaining 4% of wood is lost in the reject.
The results of the 40  80 mm fraction are more or less
Fraction Product [%] Reject [%] comparable.
The test results indicate that from mixed C&D waste
Wood 42.7 4.4 in the 20 to 80 mm size range a wood fraction can be
Stone 0.4 38.4 sorted out with an excellent quality for re-use as a
Glass 0.1 2.8 secondary fuel, and without any pre-treatment other
Gypsum 0.0 1.3 than screening and sifting.
Metal 0.1 2.6
Plastic 1.6 2.8
Textile 0.7 0.4
Paper/cardboard 0.3 0.1 5 BENEFITS OF ‘CLOSED CYCLE
Rest 20 mm 0.9 0.4 CONSTRUCTION’
Total 46.8 53.2
The new concept as a whole has several advantages.
The most illustrative advantages are:
glass removal from mixed building waste, where – Closing the material cycles for concrete and
glass comprises the disturbing component. masonry within their own chain. With regard to
A second automatic sorting technique that was the framework of sustainable development, this
investigated in the project, is a sorting based on Dual- fulfils one of the objectives of the Dutch govern-
energy X-ray transmission. On a lab-scale prelimi- ment. It also fits into the industries policy of pro-
nary experiments were carried out, to ‘image’ the ducer’s responsibility and long-term raw materials
different components in mixed C&D waste. In figure 8 availability.
is shown that an effective split can be made between – Recovery of high-grade raw materials for the pro-
organic and inorganic materials, as well as an effective duction of new concrete and ceramic bricks means
metal recognition in the same pass. Utilising dedicated higher profits for the C&D waste treatment indus-
imaging software specific components such as gypsum try, because of higher prices for their products.
or asbestos can be removed as well. The production of high-grade raw materials also
In addition to the lab-scale experiments mentioned reduces the excavation of primary materials, such
above, experiments were carried out with DE-X-ray as sand, gravel, clay and marl.
sorting, on a larger scale (1 to 2 m3). Also here the – Utilising the combustible fraction of demolition
main conclusion is that this type of automatic sorting waste as a fuel doubles the environmental profit.
is especially useful for the separation of organic and First, in reducing the amount of waste to be dis-
inorganic materials. Especially the sorting of wood at posed of, and second in reducing the amount of
high purity and recovery is possible. Metal separation, fuel that is required for the thermal treatment of
also of parts that contain only smaller metal inserts, is concrete and masonry rubble.
well possible in addition. – Re-use of the recovered cement stone fraction
As preparation for the tests the material (mixed in the production of new cement (as replacement
C&D waste) was screened in a 20  40 mm and of part of the Portland cement clinker) leads to

33
less excavation of marl, and less carbon dioxide treated recycled concrete for general use in concrete. In
emissions. Woolley, G.R., Goumans, J.J.J.M. & Wainwright, J.P.
– The integrated character of the process finally (eds.), Waste Materials in Construction; Proc. Wascon
implies a reduction in transport costs. This means 2000 intern. Conf., Harrogate, UK: 129–139, Pergamon.
Mulder, E., Blaakmeer, J., Tamboer, L. & Nijland, T.G. 2002.
less fuel consumption and less exhaust gases. A closed material cycle for concrete, as part of an inte-
grated process for the reuse of the total flow of C&D
waste. In Dhir, R.K., Dyer, T.D. & Halliday, J.E. (eds),
REFERENCES Sustainable Concrete Construction; Proc.International
Conference ‘Challenges of Concrete Construstion’,
Dijk, K. van 2002. Closing the clay brick cycle (thesis), Dundee, September 2002: 555–562. London, England:
ISBN 90-90 17911-9, AVDS b.v., Noordwijk, the Thomas Telford Publishing.
Netherlands. Shima, H., Tateyashiki, H., Nakato, T., Okamoto, M. &
Jong, T.P.R. de & Fabrizi, L. 2004. Dry separation of mixed Asano, T. 1999. New technology for recovering high
construction and demolition waste, Recycling quality aggregate from demolished concrete, Paper pre-
International, December 2004: 24–27. sented on the Fifth International Symposium on East
Jong, T.P.R. de, Fabrizi, L. &. Kuilman, W. 2005. Dry density Asian Recycling Technology, June 15–17, Tukuba, Japan,
separation of mixed construction and demolition waste, Proceedings pp. 106–109.
presentation for the 2005 Sortierkolloquium, TU Berlin.
Larbi, J.A., Heijnen, W.M.M., Brouwer, J.P. & Mulder, E.
2000. Preliminary laboratory investigation of thermally

34
Sustainable Construction Materials and Technologies – Chun, Claisse, Naik & Ganjian (eds)
© 2007 Taylor & Francis Group, London, ISBN 978-0-415-44689-1

Effect of GRP industrial waste on durability of cement mortars

F. Tittarelli & G. Moriconi


Department of Materials and Environment Engineering and Physics, Università Politecnica delle Marche,
Via Brecce Bianche, Ancona, Italy

ABSTRACT: Certain durability aspects of sustainable mortars manufactured by the addition of Glass
Reinforced Plastic (GRP) industrial waste have been investigated. Mechanical and porosimetric characteriza-
tion, water absorption and shrinkage measurements were carried out on cement mortars manufactured by
replacing 0%–10%–15%–20% of the aggregate volume with GRP waste. An increase in porosity (25%) and,
consequently, a decrease in mechanical strength (up to 40% depending on the addition rate), as well as higher
deformability, were detected on the mortars manufactured by GRP waste addition. Moreover, unexpectedly,
capillary water absorption and drying shrinkage of GRP mortars resulted in significantly lower values (70% and
50%, respectively) than those of the reference mortar manufactured without GRP addition. This decrease could
involve enhanced durability, even if only in a supporting role.

1 INTRODUCTION re-using GRP industrial waste in manufactured con-


crete elements could be considered.
A judicious use of resources, achieved by the use of With this aim, the feasibility of re-using GRP indus-
by-products and waste materials, and a lower environ- trial waste coming from a shipyard to manufacture con-
mental impact, achieved through reduced carbon diox- crete was evaluated. In particular, three types of GRP
ide emission and reduced natural aggregate extraction wastes are produced in general: GRP bars, 1 meter long
from quarries, represent two main actions that meet and 1–2 cm thick, coming from faulty products; small
sustainable building development [Malhotra 2003]. pieces, 1–2 cm in size, and a fine powder, about 0.1 mm
Concrete can be a viable solution to environmental in size.
problems making the re-use of solid waste products In previous works [Tittarelli et al. 2004, Tittarelli &
from other industries possible in concrete production. Moriconi 2005] the finest GRP waste was physically
This will reduce the need to landfill these materials and chemically characterized in order to outline com-
while still maintaining an acceptable, and sometimes patibility issues with cement, if any.
even better, concrete quality [Damtoft et al. 2003, In this work cement mortars manufactured by par-
Hendriks & Janssen 2003]. tially replacing the aggregate volume with GRP waste
Glass Reinforced Plastic (GRP) is a composite mate- powder were investigated in terms of mechanical and
rial made of glass fibres dispersed in a resin, usually porosimetric properties, water absorption and shrink-
polyester, widely used in several fields from building to age measurements.
furniture to boats. Every year, in Western Europe, GRP Future research should deal with possible leaching
processing produces 40000 tons of industrial waste of toxic substances in deionized water.
[Kelderman 2000]. In Italy this waste is landfilled, due
to the difficulty of separating the glassy part from the
polymeric matrix. Concrete made with recycled glass
2 EXPERIMENTAL
[Dyer & Dhir 2001, Shao et al. 2000, Corinaldesi et al.
2003, Ambrosie & Pera 2003, Quian et al. 2003] or
2.1 Materials
polymeric addition [Zhao 1995] has already been pro-
posed in the literature. In particular, the polyester con- A commercial portland-limestone blended cement
crete is particularly resistant to chemical agents as well type CEM II/A-L 42.5 R according to the European
as to thermal cycles and can be useful for light weight Standards EN-197/1 was used. The Blaine fineness of
constructions [Zhao 1995]. Therefore, the feasibility of cement was 0.415 m2/g and its density was 3.05 kg/m3.

35
Table 1. Chemical analysis of cement. For each mixture, carried out according to UNI EN
1015-2, prismatic specimens (40  40  160 mm)
Oxide (%) were manufactured, wet cured for two days and air
dried for 1 month at room temperature.
SiO2 29.67
Al2O3 3.74
Fe2O3 1.80 2.3 Tests
TiO2 0.09
CaO 59.25 2.3.1 Mechanical characterization
MgO 1.15 Compressive and flexural strengths were determined
SO3 3.25 on mortar specimens in conformance with UNI EN
K2O 0.79 1015-11 by observing strength loss for an increasing
Na2O 0.26 dosage of the GRP powder at different curing times.
L.O.I. 11.62
2.3.2 Pore structure characterization
Three specimens for each mortar type were tested
after 28 days of wet curing by means of the mercury
intrusion technique, by avoiding the inclusion of
coarser aggregate in the analyzed sample.

2.3.3 Capillary water absorption


Capillary water absorption tests were carried out on
mortar specimens according to Italian Standard UNI
10859.

2.3.4 Water absorption at atmospheric pressure


Water absorption tests at atmospheric pressure were
carried out on mortar specimens according to the pro-
Figure 1. GRP industrial waste powder. cedure reported in UNI 7699.

2.3.5 Drying shrinkage test


The chemical composition of cement is reported in
Prismatic specimens (100  100  500 mm) were
Table 1.
prepared according to Italian Standard UNI 6555-73
Natural sand with 5 mm maximum size was used
“Hydraulic Shrinkage Determination”. After one day of
as aggregate, with volume mass of 2620 kg/m3 and
wet curing, the specimens were stored at constant temp-
water absorption of 3.0%.
erature (20  2°C) and constant relative humidity
A GRP powder coming directly from a shipyard as
(70  2%).
an industrial waste was used (Fig. 1). Its chemical and
physical characterization has already been reported in
a previous work [Tittarelli et al. 2004, Tittarelli &
Moriconi 2005]. 3 RESULTS
A 30% aqueous solution of an acrylic-based super-
plasticizer was added, when required, in order to 3.1 Mechanical characterization
maintain the same workability level.
The development with time of flexural strength of
mortars manufactured with increasing GRP waste
2.2 Specimens
addition as a partial aggregate volume replacement is
Mortar mixtures with cement to sand ratio 1:3 (by given in Figure 2. The results show that GRP addition
weight) and W/C of 0.50 were manufactured by replac- produces a limited decrease in the flexural strengths
ing the 0–10–15–20% of aggregate volume with the of mortars, especially at longer ages, probably due to
GRP industrial waste powder. the presence of glass fibres.
The use of GRP waste powder as partial aggregate On the other hand, aggregate replacement with GRP
replacement did not show any segregation problem and waste caused a strong reduction in compressive strength
the resultant mixtures show similar characteristics to (up to 40% depending on the addition rate), due to the
traditional ones. At 15% and 20% replacement rate, lower stiffness of the GRP powder with respect to natu-
GRP appreciably decreases mortar workability and, at ral sand and the low glass content, which was therefore
these rates, a superplasticizer was added at a dosage of unable to develop any pozzolanic behaviour (Fig. 3).
0.25% and 1% by weight of cement, respectively, in The stress/strain curves carried out on the speci-
order to achieve comparable workability. mens after one month of air curing (Fig. 4) showed

36
10 Table 2. Porosimetric values of mortars manufactured with
sand partially replaced by GRP at dosages of 0, 10, 20, 40%
(by volume), respectively.
Flexural Strength (MPa)

6 Specific
GRP Porosity Mean radius surface
4
0% GRP (%) (%) ( Ǻ) (m2/g)
10% GRP
2
15%GRP
20%GRP
0 16 629 3.8
0 10 21 250 7.9
0 5 10 15 20 25 30 15 19 314 9.9
Time (days) 20 20 250 9.5

Figure 2. Development with time of flexural strength of


mortars manufactured with sand partially replaced by GRP
at dosages of 0–10–15–20% (by volume), respectively. 120
0%

Cumulative Volume (mm /gr)


100 10%GRP

3
45 15%GRP
40 20%GRP
Compressive Strength (MPa)

80
35
60
30
25 40
20
20
15 0% GRP
10 10% GRP 0
15% GRP
5 10 100 1000 10000 100000
20% GRP
Pore radius (Å)
0
0 5 10 15 20 25 30
Time (days) Figure 5. Porosimetric tests carried out on mortars manu-
factured with sand partially replaced by GRP at dosages of
Figure 3. Development with time of compressive strength 0, 10, 20, 40% (by volume), respectively.
of mortars manufactured with sand partially replaced by
GRP at dosages of 0–10–15–20% (by volume), respectively.
It is evident that the mortar total open porosity increases
45 with the GRP addition even if the mean radius signifi-
40
0% GRP cantly decreases. Both micropores (50 nm), related
35 to drying shrinkage, and macropores (50 nm), detri-
30
15% GRP 10% GRP mental to strength and impermeability, are negatively
influenced by the GRP addition.
(MPa)

25
20% GRP
20
15 3.3 Water absorption at atmospheric pressure
10
Figure 6 shows the results of water absorption tests at
5
atmospheric pressure obtained on mortars with
0
0 0.5 1 1.5 2 2.5 3
increasing aggregate volume replacement by GRP
Strain (%) addition. It is evident that, at the end of the test, as
expected, the total amount of water absorbed increased
Figure 4. Stress-strain curves of mortars manufactured with with the GRP addition due to the higher open porosity
sand partially replaced by GRP at dosages of 0–10–15–20% of the cement mortar previously detected. However,
(by volume), respectively.
unexpectedly, the curves showed no significant separa-
tion in the first hours of full immersion in water.
that the partial aggregate replacement with GRP
waste powder increased deformability of the mortars.
3.4 Capillary water absorption
The results of water absorption test were again con-
3.2 Pore structure characterization
firmed and better highlighted during the capillary
The porosimetric results obtained by the mercury water absorption test. The relative capillary absorp-
intrusion technique are reported in Table 2 and Figure 5. tion coefficient (CArel), defined as the ratio between

37
5 1000

Capillary absorbed water (mg/cm )


2
900
4 800
Absorbed water (%)

700
600
3
500
400
2 0%GRP
300
10% GRP
0% GRP 200
15%GRP
1 10% GRP 100 20% GRP
15% GRP
0
20% GRP 0 200 400 600 800 1000
0 1/2
0.01 0.1 1 10 100 1000 Time (s )

Time (hours)
Figure 7. Capillary water amount absorbed as a function
Figure 6. Water amount absorbed as a function of time by of time per square unit by mortars manufactured with sand
mortars manufactured with sand partially replaced by GRP partially replaced by GRP at dosages of 0–10–15–20% by
at dosages of 0–10–15–20% by volume respectively, fully volume, respectively.
immersed in water.
0.6

Table 3. Capillary absorption coefficients (CA), relative


0.5

Drying Shrinkage (mm/m)


capillary absorption coefficients (CArel) and relative absorp-
tion capillary index (ICrel) for mortars manufactured with 0.4
sand partially replaced by GRP at dosages of 0–10–15–20%
by volume, respectively. 0.3

0.2
GRP CA 0% GRP
(%) (mg/cm2 s1/2) CArel ICrel 0.1
10% GRP
15% GRP
20% GRP
0 3.87 0
10 1.20 0.31 0.43 0 5 10 15 20 25 30
Time (days)
15 1.41 0.36 0.50
20 1.20 0.31 0.42
Figure 8. Drying shrinkage measurements up to 1 month
carried out on mortars manufactured with sand partially
replaced by GRP at dosages of 0–10–15–20% by volume,
respectively.
the capillary absorption coefficient (CA) of the GRP
mortar to that of the mortar without GRP addition
(Table 2), showed that GRP was able to decrease the These unexpected results could be explained by a
capillary water absorption even in a more porous certain “hydrophobic effect” produced by the GRP
cement matrix, of about 70%. The capillary absorption addition on the cement mortar. This could be due to
coefficient (CA) represents the slope of the initial the polymeric part of the GRP, which may be able to
(up to t  30 minutes) linear part of the water absorp- compensate for the higher porosity of the GRP mortar
tion curve reported in Figure 7. Therefore, water with respect to the reference mortar with the same
absorption is initially more effectively counteracted by water-cement ratio. This is especially valid for short
the presence of GRP. This would indicate that, when a water contact periods.
mortar made with GRP is exposed to short periods of
contact with water, as in the case of rain, it will not
3.5 Drying shrinkage test
absorb as much water as expected for a common mor-
tar manufactured with the same water-cement ratio. Figure 8 shows the results obtained up to 1 month of
The relative capillary absorption index (ICrel) is storage at room temperature and constant relative
defined as the ratio of the area subtended by the water humidity (70  2%). It is evident how, unexpectedly,
absorption curve of the GRP mortar to the area of the the drying shrinkage of the mortar with GRP waste
absorption curve of the reference mortar (Figure 7) and addition at the dosage rate of 10% by aggregate vol-
it is related to the corresponding amount of water ume came out to be almost 50% of the drying shrink-
absorbed during the full contact time. As shown in age of reference mortar without GRP, in spite of higher
Table 3, when more prolonged contact between water porosity and lower mechanical performance of the
and the cement matrix occurs, the value of ICrel is lower GRP mortars.
than 0.5. This implies that aggregate partial replace- Perhaps, the polymeric part of the GRP addition
ment by GRP addition is able to reduce the water could play an important role, but further investigation
absorption by at least 50%. has to be carried on in order to verify this hypothesis.

38
Moreover, if shrinkage is restrained and no creep Corinaldesi, V., Gnappi, G., Montenero, A. & Moriconi, G.
effects are considered, the lower the modulus of elas- 2003. Re-use of recycled glass as aggregate for mortar
ticity such as that of GRP mortar, the lower will be the and concrete (in Italian), Proceedings of the 4th
induced elastic tensile stress for a given shrinkage International Congress Added Value and Recycling of
Industrial Waste, L’Aquila, Italy, June 24–27, 2003.
strain. So, instead of comparing concretes on the basis Damtoft, J.S., Glavind, M., & Munch-Petersen C. 2003.
of shrinkage strain, it may be better to compare them Proceedings of the two-Day International Seminar on
on the basis of the induced tensile stress. Multiplying Sustainable development in Cement and Concrete
the shrinkage strain after 28 days of drying by the elas- Industries, Milano, Italy, 17–18 October 2003.
tic modulus at the same age, the results obtained for the Dyer, T.D. & Dhir, K.R. 2001. Chemical reactions of glass
four mortars are: 15.3 MPa for the reference mortar cullet used as cement component, Journal of Materials in
and 6.0 MPa, 11.8 MPa and 15.7 MPa for GRP mortars Civil Engineering 13(6): 412–417.
manufactured with sand partially replaced by GRP Hendriks, C.F., Janssen, G.M.T. 2003. Use of recycled mate-
waste at dosages of 10–15–20% by volume, respec- rials in constructions, Materials and Structures 36(11):
604–608.
tively. It is evident that the drying shrinkage behaviour Kelderman, H. 2000. Recycling Manager Europe
may not be a problem, especially for the GRP mortar Thermosets, After almost 10 years. Proceedings of the
with 10% of volume aggregate replacement. Ercom Conference of the European Alliance for SMC,
Brussels 14 November 2000.
Malhotra, V.M. 2003. Concrete Technology for sustainable
4 CONCLUSIONS development, Proceedings of the two-Day International
Seminar on Sustainable development in Cement and
An increase in porosity (25%) and consequently, a Concrete Industries, Milan, Italy, 17–18 October 2003.
decrease in mechanical strength (up to 40% depending Quian, X., Shen, B., Mu, B. & Li, Z. 2003. Enhancement of
aging resistance of glass fibre reinforced cement,
on the addition rate), as well as higher deformabil- Materials and Structures 36(6): 323–329.
ity, was detected on the mortars manufactured by GRP Shao, Y., Lefort, T., Moras, S. & Rodriguez, D. 2000. Studies
waste addition. Nevertheless, unexpectedly, capillary on concrete containing ground waste glass, Cement and
water absorption and drying shrinkage of GRP mortars Concrete Research 30: 91–100.
resulted significantly lower (70% and 50%, respec- Tittarelli F. & Moriconi G. 2005. Re-Use of GRP Industrial
tively) than those of the reference mortar made without Waste in Cementitious Products, In R.K. Dhir et al. (ed.),
any GRP addition, which may involve enhanced dura- Proceedings of the International Conference on Global
bility, such that this is not only related to mechanical construction: ultimate concrete opportunities, Young
strength. researcher’s forum, Dundee, Scotland, 7 June 2005.
ISBN: 0 7277 3407 5: 153–164. London, Thomas Telford
These results demonstrated the potential of re-using Publishing, United Kingdom.
an abundant industrial by-product, at present land- Tittarelli F., Moriconi G., Pauri M.G. & Favoni O. 2004.
filled, to manufacture durable precast elements without Re-use of GRP industrial waste in new blended cements,
any structural target, contemporarily matching an envi- Proceedings of the VII Congresso AIMAT, Ancona, Italy,
ronmental issue. 29 June – 2 July 2004. Published on CD-ROM.
Zhao, S. 1995. Microstructure and properties of styrene acry-
late polymer cement concrete, Heron 40(4): 263–284.
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Ambrosie, J. & Pera, J. 2003. Durability of glass-fibre


cement composites – comparison between normal
Portland and Calcium Sulfoaluminate cements, Oral pres-
entation at Sixth CANMET/ACI International Conference,
Thessaloniki, Greece, 1–7 June 2003.

39
Sustainable Construction Materials and Technologies – Chun, Claisse, Naik & Ganjian (eds)
© 2007 Taylor & Francis Group, London, ISBN 978-0-415-44689-1

Engineering properties of oil palm shell (ops) hybrid concrete for


lightweight precast floor slab

C.H. Ng, Z. Ideris, S.P. Narayanan, M.A. Mannan & V.J. Kurian
School of Engineering and Information Technology, Universiti Malaysia Sabah, Sabah, Malaysia

ABSTRACT: An experimental study on the engineering properties of OPS hybrid concrete for precast floor
slab was conducted. Conventional crushed stone as partial replacement of OPS was employed. Three conditions
of curing to simulate the laboratory curing condition, practical curing condition, and without curing are applied.
The slump, demoulded density, compressive strength, flexural strength, splitting tensile strength and modulus
of elasticity were determined. OPS concrete with 30% crushed stone as coarse aggregate fulfilled the minimum
strength requirement for lifting/transportation and at service. Since the air dry density of this concrete is
2000 kg/m3, it can be accepted as lightweight concrete. Hence, OPS hybrid concrete with crushed stones can be
used to manufacture lightweight precast floor slab. The results of this ongoing research on the potential use of
OPS concrete for lightweight precast floor slabs are reported.

1 INTRODUCTION transportation and service condition. The minimum


strength requirement of precast slabs at the time of lift-
Precast systems using structural lightweight concrete ing/transporting is 10–15 N/mm2 (The Government of
have several potential advantages over normal weight the Hong Kong Special Administrative Region &
concrete (NWC), including reduced dead load of the Halften Limited 2003, BS EN 13747 2005) and at serv-
structure offers a reduction in foundation size, smaller ice is 35 N/mm2 (if reinforced) to 40 N/mm2 (Smorgon
lifting equipments for placing precast panels, floor slabs Steel Group 2004, Elliott 2006a, b).
requiring smaller supporting systems, lower density,
making it particularly suitable with large pour area,
high thermal insulation for buildings, inherent fire
2 MATERIALS AND METHODS
resistance, as well as reduced construction cost due to
time saving and flexibility of design (Pang & Lo
2.1 Materials
2005). Oil palm shell (OPS) concrete has been inves-
tigated for a number of years (Mannan & Ganapathy Malaysian ordinary Portland cement (ASTM Type I)
2001, 2002; Mannan et al 2002, 2006, Teo et al 2005, is used as binder, sand as fine aggregate and, OPS and
2006a) and also its potential in structural concrete crushed granite as coarse aggregate. The properties of
production (Teo et al 2006b). Its application in pre- OPS, granite and sand are shown in Table 1. Testing
cast floor slab is yet to be studied. of aggregates is done as per relevant BS or ASTM.
With OPS as the only coarse aggregate, the modulus
of elasticity of such concrete is approximately one third
2.2 Mix proportion
of the NWC (Mannan & Ganapathy 2002). Therefore,
in this study, for the application of precast floor slab For 1.0 m3 of concrete, 450 kg of cement, 629 kg sand,
conventional crushed stone as partial replacement of 341 kg OPS, 313 kg crushed granite and 7.5 litres
OPS was employed to produce OPS hybrid concrete. super plasticizer is employed. Free water/cement
Three conditions of curing simulated the laboratory (W/C) ratio is 0.38. OPS aggregate used in this inves-
curing condition, practical curing condition, and with- tigation is in saturated surface condition.
out curing. The slump, demoulded density, compressive
strength, flexural strength, splitting tensile strength and
2.3 Test methods
modulus of elasticity were determined. OPS concrete
with 30% crushed stone as coarse aggregate ful- The compressive strength of standard cubes (100 mm)
filled the minimum strength requirement for lifting/ and cylinder (100 mmø  200 mm) is determined as

41
Table 1. Properties of OPS, crushed granite and river sand.

Coarse aggregate Fine aggregate

No Property of aggregates Unit OPS Granite River sand

1 Maximum size mm 12.50 19.00 1.18


2 Specific gravity (SSD)  1.34 2.63 2.43
3 Water absorption capacity (24 hrs) % 21.30 2.04 3.89
4 Moisture content as received % 11.68 0.78 0.69
5 Los Angeles abrasion value % 2.90 11.85 
6 Bulk density, compacted kg/m3 646 1481 
7 Fineness modulus  6.30 6.94 1.33
8 Aggregate impact value, AIV % 6.60 12.60 
9 Aggregate crushing value, ACV % 7.12 15.95 

Table 2. Curing conditions for OPS hybrid concretes. Table 3. Cube strength for OPS hybrid concrete at differ-
ent ages and curing conditions.
Duration of curing (days)
Compressive strength (N/mm2)
No Curing symbol Mould Water Room
No Curing symbol 1 day 3 days 7 days 28 days
1 C-1 1 27 
2 C-2 1 6 21 1 C-1 17.30 29.50 35.97 38.53
3 C-3 1  27 2 C-2 17.30 29.50 35.97 37.45
3 C-3 17.30 28.05 32.20 34.76

per BS 1881: Part 116 and Part 110 respectively.


Table 4. Cylinder Compressive strength for OPS hybrid
Beams of 100  100  500 mm size for flexural test concrete at different ages and curing conditions.
(ASTM C 78-02), and 150ø  300 mm size cylinders
for splitting tensile (ASTM C 496) and modulus of Compressive strength (N/mm2)
elasticity tests (ASTM C 469-02) are employed. The
performance of OPS hybrid concrete under three cur- No Curing symbol 3 days 7 days 28 days
ing conditions are studied (Table 2). For C-1 curing,
the samples are demoulded after one day, kept in water 1 C-1 15.70 20.60 21.57
for 27 days and then tested whereas for C-2 the sam- 2 C-2 15.70 20.60 21.17
ples are demoulded after a day, kept in water for 6 days 3 C-3 14.45 18.25 19.35
and left without curing for 21 days and then tested.
The C-1 simulates the usual laboratory curing which
is an ideal condition of curing while C-2 curing con- respect to either normal weight or structural light-
forms to that recommended for ASTM Type-1 cement. weight concrete lab.
C-3 indicates no curing. The demoulded density is between 1,985 to
Tests for compressive strength are carried out at 2,130 kg/m3. The air-dry density can be calculated by
1, 3, 7, 28 days whereas for flexural strength and subtracting the mass of water lost to the air, typically
splitting tensile strength at 3, 7 and 28 days. Modulus between 50 to 150 kg/m3 for lightweight concrete
of elasticity is taken at 28 days only. For all tests, each with normal weight fine aggregate (Neville, 2005).
result is the average of three samples.
3.2 Compressive strength
Table 3 and Table 4 shows the compressive strength of
3 RESULTS AND DISCUSSION
OPS hybrid concrete (cured under 3 curing conditions)
at different ages. All specimens achieved 1-day and
3.1 Slump and demoulded density
28-day compressive strength of more than 15.00 N/mm2
The slumps obtained (BS 1881, Part 102) is in the and 35.00 N/mm2 respectively. They therefore fulfil the
range of 90–100 mm. Maximum slump, as per ASTM minimum strength requirement of precast slabs at the
C143 with tolerances as established by ASTM C94, time of lifting/transporting of 10–15 N/mm2 and at
for concrete to be vibrated shall be 100 mm with service of 35 N/mm2 (if reinforced).

42
Table 5. Flexural strength for OPS hybrid concrete at dif- Table 6. Splitting tensile strength for OPS hybrid concrete
ferent ages and curing conditions. at different ages and curing conditions.

Flexural strength (N/mm2) Splitting strength (N/mm2)

No Curing symbol 3 days 7 days 28 days No Curing symbol 3 days 7 days 28 days

1 C-1 3.17 4.28 5.79 1 C-1 2.84 3.11 3.50


2 C-2 3.17 4.28 5.08 2 C-2 2.84 3.11 3.34
3 C-3 3.08 4.17 4.52 3 C-3 2.75 3.08 3.19

3.5 Modulus of elasticity


The 28-day compressive strength of cubes and Under C-1, the modulus of elasticity (28 days) of OPS
cylinders were higher under C-1 curing condition com- hybrid concrete is in the range of 2.03–2.19  104
pared to C-2 and C-3. These results are similar to that N/mm2. Only C-1 curing condition is employed, as it
reported by Mannan & Ganapathy (2002). is not believed to affect the modulus of elasticity
The 28-day cube compressive strength is approxi- (Neville 2005). This modulus of elasticity is higher
mately 62–69% higher that of the OPS concrete pro- than that of the OPS concrete reported by Mannan &
duced (Mannan & Ganapathy 2001) due to the addition Ganapathy (2002). Kett (2000) pointed that the Ec of
of 30% crushed granite as partial replacement. NWC ranges from 1.4 to 4.1  104 N/mm2.
It is also observed that the 28-day cylinder com- Modulus of elasticity can also be calculated from
pressive strength of OPS hybrid concrete is approxi- the ACI 318 (2005) using Equation 1 in SI units:
mately 56% of its cube compressive strength.
(1)
3.3 Flexural strength
where Ec  Modulus of elasticity; w  unit weight of
The flexural strength of OPS hybrid concrete at dif- concrete (between 1400 to 2500 kg/m3); and
ferent ages and curing regimes is shown (Table 5). fíc  ultimate strength of a standard cylinder.
The 28-day flexural strength of OPS hybrid concrete From Equation 1, modulus of elasticity of OPS
is approximately 13% to 15% of its compressive hybrid concrete is 1.91  104 N/mm2.
strength. This is higher compared to flexural strength
of OPS concrete reported by Mannan & Ganapathy
(2002) because 30% of OPS have been replaced by 4 CONCLUSIONS
crushed granite. The relation between the flexural and
compressive strength for NWC depends on the type The conclusions drawn from this investigation are
and properties of coarse aggregate used (Neville 2005). summarised below:
The flexural strength of NWC ranges between
11% and 23% of the compressive strength. 1. The 28-day compressive strength of OPS hybrid
concrete ranges between 34.76 and 38.53 N/mm2.
The cylinder compressive strength is about 56% of
the cube compressive strength.
3.4 Splitting tensile strength
2. The 28-day flexural strength of OPS hybrid con-
The splitting tensile strength at different ages and cur- crete is between 4.52 and 5.79 N/mm2 averaging
ing conditions is shown (Table 6). The strength of 14% of its compressive strength.
OPS hybrid concrete under C-1 curing condition is 3. The 28-day splitting tensile strength for OPS
higher than that under C-2 and C-3 curing condition. hybrid concrete is between 3.19 and 3.50 N/mm2.
Similar to flexural strength, the splitting tensile strength It is approximately 9% of its 28-day compressive
is dependant on the curing condition. Also, OPS hybrid strength.
concrete exhibits higher splitting tensile strength than 4. The 28-day modulus of elasticity of OPS hybrid
that of OPS concrete. concrete is in the range of 2.03–2.19  104 N/mm2.
The 28-day splitting tensile strength of OPS hybrid 5. Generally, the OPS hybrid concrete obtains better
concrete under C-1 and C-2 curing is approximately engineering properties than that of OPS concrete
9% of its compressive strength. In general, the tensile under the C-1 curing, which is an ideal curing
strength of NWC ranges from 7% to 11% of its com- condition.
pressive strength, with an average of 10% (Hassoun & 6. OPS hybrid concrete fulfils the minimum
Al-Manaseer 2005). strength requirement of precast slabs at the time of

43
lifting/transporting and at the time of service. BS EN13747. Precast concrete products – Floor plates for
Hence, the use of OPS hybrid concrete for light- floor systems. London: British Standard Institution.
weight precast concrete floor slab is recommended. Elliott, K.S. 2006a. Precast concrete structures. Elsevier
Butterworth-Heinemann.
Elliott, K.S. 2006b. Design and construction of precast con-
crete structures, 27–28 July 2006, Kota Kinabalu, Sabah.
ACKNOWLEDGEMENTS Halften Limited. 2003. Precast lifting and fixing system.
Hassoun, M.N. & Al-Manaseer, A. 2005. Structural con-
This work is supported through research grant LPIPM: crete: Theory and design, 3rd ed.:51. Hoboken, New
CREAM/UPP04-02-10-04-11 from the Construction Jersey, USA: John Wiley & Sons, Inc.
Industry Development Board of Malaysia. Kett, I. 2000. Enginerring concrete: Mix design and test
methods. Boca Raton, Florida, USA: CRC Press LLC.
Mannan, M.A., Basri, H.B., Zain, M.F.M., & Islam, M.N.
2002. Effect of curing conditions on the properties of
REFERENCES OPS-concrete, Building and Environment, 37(11):
1197–1171.
ACI Committee 318, 2005. Building Code Requirements for Mannan, M.A., & Ganapathy, C. 2001. Long-term strengths
Structural Concrete, ACI 318-05, Farmington Hills, M.I., of concrete with oil palm shell as coarse aggregate,
p. 443. Cement and Concrete Research 31(9): 1319–1321.
ASTM, C 29M-97, Standard test method for bulk density, Mannan, M.A., & Ganapathy, C. 2002. Engineering proper-
(“unit weight”), and voids in aggregate, Annual Book of ties of concrete with oil palm shell as coarse aggregate,
ASTM Standards. Construction and Building Materials, 16 (1): 29–34.
ASTM, C 94, Standard specification for ready-mixed con- Mannan, M.A., & Ganapathy, C. 2004. Concrete from an
crete, Annual Book of ASTM Standards. agricultural waste-oil palm shell (OPS), Building and
ASTM, C 78-02, Standard test method for flexural strength Environment, 39(4): 411–418.
of concrete (Using simple beam with third-point load- Mannan, M.A., Alexander, J., Ganapathy, C., & Teo, D.C.L.
ing), Annual book of ASTM Standards. 2006. Quality improvement of oil palm shell (OPS) as
ASTM, C127-04, Standard test method for density, relative coarse aggregate in lightweight concrete, Building and
density (specific gravity), and absorption of coarse Environment, 41(9): 1239–1242.
aggregate, Annual book of ASTM Standards. Neville, A.M. 2005. Properties of concrete. 4th ed. Harlow,
ASTM, C131-03, Standard test method for resistance to UK: Pearson Education Limited.
degradation of small-size coarse aggregate by abrasion Pang, H.W., & Lo, T.L. 2005. Lightweight Precast Systems
and impact in the Los Angeles machine, Annual book of in Buildings – The Way Ahead. Materials Science and
ASTM Standards. Technology in Engineering Conference, Hong Kong. 1–20.
ASTM, C 143, Standard test method for slump of hydraulic- Smorgon Steel Group, 2004, Humeslab Technical Manual,
cement, Annual Book of ASTM Standards. Australia.
ASTM, C469-02, Standard test method for static modulus of Teo, D.C.L., Mannan, M.A., & Kurian, V.J. 2005. Utilisation
elasticity and Poissonís ratio of concrete in compression, of solid waste Oil Palm Shell (OPS) in concrete produc-
Annual book of ASTM Standards. tion. Proceedings of the International Conference on
ASTM, C 496, Standard test method for splitting tensile Natural Resources and Environmental Management,
strength of cylindrical concrete specimens, Annual book Kuching, Sarawak, Malaysia.
of ASTM Standards. Teo, D.C.L., Mannan, M.A., & Kurian, V.J. 2006a. Flexural
Basri, H.B., Mannan, M.A., & Zain, M.F.M. 1999. Concrete behaviour of reinforced lightweight conrete beams made
using waste oil palm shells as aggregate, Cement and with Oil Palm Sheel (OPS). Journal of Advanced
Concrete Research 29 (4): 619–622 Concrete Technology (4): 1–10
BS 812. Part 110. Method for determination of aggregate Teo, D.C.L., Mannan, M.A., & Kurian, V.J. 2006b. Structural
crushing value (ACV). London: British Standards concrete using Oil Palm Shell (OPS) as lightweight
Institution. aggregate. Turkish Journal of Engineering and
BS 812. Part 112. Method for determination of aggregate Environmental Sciences (30): 251–257
impact value (AIV). London: British Standards Institution. The Government of the Hong Kong Special Administrative
BS 1881. Part 102. Method for determination of slump. Region. 2003. Code of Practice for Precast Concrete
London: British Standard Institution. Construction 2003. Hong Kong.
BS 1881. Part 110. Method for making test cylinders from
fresh concrete. London: British Standard Institution.
BS 1881. Part 116. Method for determination of compres-
sive strength of concrete cubes. London: British Standard
Institution.

44
Sustainable Construction Materials and Technologies – Chun, Claisse, Naik & Ganjian (eds)
© 2007 Taylor & Francis Group, London, ISBN 978-0-415-44689-1

Durability of concrete mixed with fine recycled aggregates

Salomon Levy
PhD, Professor University UNINOVE. Chairman of TC MAB Technical Committee for Safety Environment of the
Brazilian Concrete Institute IBRACON

Paulo Helene
Full Professor. Universidade de São Paulo. Escola Politécnica. Av. Prof. Almeida Prado, Brazil. President of the
Brazilian Concrete Institute IBRACON

ABSTRACT: In this paper an analysis was conducted on the influence of use of 20%, 50% and 100% con-
tents of two types of fine recycled aggregates (from demolish concrete and from old masonry) on the following
properties of concrete: water absorption by immersion, pore volume, carbonation and resistivity. This analysis
was not restricted to compare mixtures from a table of results. All the analysis was based on concrete family
behavior. The Mix Design Nomograms (MDN) was made for concrete families: one as reference and six others
with different recycled contents to replace the natural fine aggregate. The MDN obtained for the properties
studied permitted compare class 20 MPa, 30 MPa and 40 MPa concretes. The results obtained indicate that the
carbonation depth reached a minimum and the resistivity reached a maximum when 50% contents of fine recy-
cled masonry aggregates were used. However, this tendency was not repeated for pore volume and water
absorption. Thus, it should conclude that the durability like a carbonation and resistivity are physical-chemical
phenomena that, in this case, were inversely related to water absorption and volume of pores.

1 INTRODUCTION Wirquin et al (2000) reported that the processes of


water absorption in recycled aggregate and in natural
At the present time, several research investigations aggregate concretes are similar and obey the same
can be found conducted in worldwide (SANTOS, laws. Also Mehta & Monteiro (1994) reported that
2007), (ETXEBERRIA, 2006), (COLLINS, 2000) the water, as a primary agent, is able to deteriorate
supporting the production and the use of concrete natural and artificial materials, such as concrete.
with recycled aggregate from the technical and eco- Water, ions and gas penetrating the concrete poros-
nomic point of view. ity can also accelerated the concrete degradation kinet-
This work was conducted with the aim of under- ics during the service life of the structure.
standing the essential properties for predicting the
behavior of concretes produced with recycled aggre-
2 PURPOSE
gates during your service life. The target was under-
standing more about the durability of concretes
This work aims to analyze the influence of two types
prepared with recycled aggregates.
of fine aggregates, one from recycled concrete, and
The use of fine recycled aggregates for producing
the other from recycled masonry on four (4) proper-
concretes with structural purposes has been discussed
ties of concrete: water absorption, pore volume, car-
worldwide, but many authors (VINCKE, J 1994) and
bonation and resistivity. These properties has directly
(RILEM, 1994) recommend that such aggregates
influence in the durability of a concrete.
should not be utilized in structural concretes, due to
their high water absorption.
This paper shows one analysis of the influence of 3 MATERIALS AND METHODS
recycled aggregates on the durability of concretes. To
reach that answer 4 (four) properties were selected, such To conduct this work, seven concrete families were pre-
as water absorption, pore volume, carbonation and the pared, three with fine recycled masonry aggregates,
resistivity properties intimately relates to the durability three with fine recycled concrete aggregates and a ref-
of a concrete and, consequently of a structure. erence concrete with natural quartz river sand.

45
Table 1. Composition of the aggregates used in the prepa- In order to obtain the recycled aggregates, the
ration of the concretes. demolished old concrete and masonry were passed
through a jaw crusher and the resulting product was
Concrete family Fine aggregates content later subjected to a sieving operation.
The fractions corresponding to fine and coarse
Reference 100% natural quartz river sand
aggregates were used to produce the six (6) recycled
FRCA* 20–80 20% FRCA – 80% natural quartz river concrete families (see Table 1), always with the
sand aggregates at SDS condition. The results were com-
FRCA 50–50 50% FRCA – 50% natural quartz river
pared to those measured for a reference concrete fam-
sand
FRCA 100–0 100% FRCA – 0% natural quartz river ily, produced exclusively with natural aggregates.
sand
FRMA** 20–80 20% FRMA – 80% natural quartz river 3.2 Concrete mix proportion
sand
FRMA 50–50 50% FRMA – 50% natural quartz river Three dry aggregate/cement ratios by mass were used
sand to compose each concrete family: 3/1; 4.5/1 and 6/1.
FRMA 100–0 100% FRMA – 0% natural quartz river All mixtures had the same fresh workability mea-
sand sured by slump test (70  10) mm, what means, these
concretes has the workability enough for many appli-
FRCA* fine recycled concrete aggregate. cations like, for instance, columns in buildings. For
FRMA** fine recycled masonry aggregate. each mixture the recycled aggregate replace 0%,
20%, 50% and 100% of natural fine aggregates by
The proportions of the aggregates used in the prepa- mass. In this way, the total of seven concrete families
ration of the seven families are indicated in Table 1. and 21 different mix proportions were produced.
The main tests were performed beginning at 28 days.
All specimens were cured in a standard humid chamber
3.1 Materials
during their first 14 days; after that, they were kept
Blended Portland Cement, comprised of 35% blast exposed to laboratory ambient conditions (55% to
furnace slag, with a Blaine fineness of 385 m2/kg, 65% RH and 20° to 26°C).
density of 2990 kg/m3 and compressive strength at
28 days of 49 MPa (7105 psi) was used in all concrete
3.3 Properties measured
mixtures.
The fine natural aggregate used was natural washed The following properties were measured: compres-
quartz river sand, with a density of 2650 kg/m3, fine- sive strength by ASTM C39; water absorption and
ness modulus of 2.6, and water absorption of 1.8% at total pore volume by ASTM C642; accelerated car-
a saturated dry surface condition (SDS), according bonation by RILEM CPC-18 method, and resistivity
with ASTM C270. by ASTM G57. In addition, the cement content, water
The coarse natural aggregate used was crushed content, W/C ratio by mass, entrapped air, slump test
granite gravel, with a density of 2700 kg/m4, maxi- and fresh concrete density were measured.
mum size of 25 mm, fineness modulus of 7.0, and
0.8% water absorption at a SDS. Both are usual and
sound aggregates in the Sao Paulo city region. 4 DATA RESULTS
The fine recycled concrete aggregate (FRCA) that
were used had been obtained from crushing old con- Table 2 presents the data results for each mixture.
crete structures, six months old. These old concrete
presented compressive strength of 25 MPa, (3626 psi)
and water cement ratio W/C of 0.66. The FRCA had 5 CONSTRUCTING THE MDN
a density of 2320 kg/m3, maximum particle size of
2.4 mm; fineness modulo of 2.5, and 10.3% water A Mix Design Nomogram (MDN) was constructed
absorption at SDS. for each of the seven (7) concrete families, one for the
The fine recycled masonry aggregate (FRMA) had reference concrete family, three for concrete made
been obtained from crushing one-year-old clay brick with FRCA and three for concrete made with FRMA,
walls covered with bastard mortar (cement, calcium as presented in Fig. 1, as an example.
hydroxide and natural sand). The FRMA were com- Then, the corresponding MDN was used to obtain
posed of 76% clay brick, and 24% bastard mortar, by the W/C for the desired compressive concrete
weight. The density was 1890 kg/m3, maximum parti- strength of 20 MPa, 30 MPa and 40 MPa, (2900 psi;
cle size of 2.4 mm, fineness modulus of 2.5, and 4350 psi and 5800 psi) at 28 days, for each family. The
13.0% water absorption at SDS. results are presented in Table 3.

46
Table 2. Result for each mixture.

Mix proportion (cement: sand river: fine recycled aggregate:


coarse aggregate: W/C) fc at 28d MPa
Concrete Aggregate
families replacement 1.3 1.4,5 1.6 1.3 1.4,5 1.6

Natural 1: 1.24: 0.0: 1.76: 0.40 1: 2.08: 0.0: 2.42: 0.51 1: 2.92: 0.0: 3.08: 0.75 48.5 41.9 26.5
FRCA 20 1: 0.99: 0.25: 1.76: 0.46 1: 1.64: 0.416: 2.42: 0.58 1: 2.34: 0.58: 3.08: 0.69 56.1 36.7 27.5
50 1: 0.62: 0.62: 1.76: 0,44 1: 1.04: 1.04: 2.42: 0.61 1: 1.46: 1.46: 3.08: 0.75 46.3 33.8 26.96
100 1: 0.0: 1.24: 1.76: 0,47 1: 0.0: 2.08: 2.42: 0.61 1: 0.0: 2.92: 3.08: 0.80 46.6 30.2 23.3
FRMA 20 1: 0.99: 0.25: 1.76: 0,39 1: 1.64: 0.416: 2.42: 0.55 1: 2.34: 0.58: 3.08: 0.70 49.0 38.2 26.6
50 1: 0.62: 0.62: 1.76: 0,45 1: 1.04: 1.04: 2.42: 0.56 1: 1.46: 1.46: 3.08: 0.74 49.5 40.0 29.4
100 1: 0.0: 1.24: 1.76: 0.50 1: 0.0: 2.08: 2.42: 0.66 1: 0.0: 2.92: 3.08: 0.81 42.8 36.6 27.0

fc (MPa)
(%)
60.0 25.0

Total volume pores


Compressive Strength

Water absorption
50.0 20.0

40.0 15.0

30.0 10.0

Cement Content Cement Content


3
C (kg/m )
20.0 3
C (kg/m ) 5.0
(w/c) (w/c)

600 500 400 300 200 0.40 0.60 0.80 600 500 400 300 200 0.40 0.60 0.80
3 3
dry aggregate/cement ratio

4 4 dry aggregate/ciment ratio

5 5

6 6

7 7
m (kg/kg) m (kg/kg)

Water absorption = 3.866 * (w/c) + 8.047


Compressive strengh fc28 = exp (-2.098*w/c) * 125.089 Total Volume Pores = 5.978 * (w/c) + 17.667
Compressive strengh fc91 = exp (-1.896 * w/c) * 119.463
Figure 2. Water absorption and total volume pore for con-
Figure 1. Strength MDN for concrete family100%–0% crete family FRCA 100%–0%.
FRCA.
Table 3. Water cement ratio from MDN for desired com-
pressive strength. Figure 2 shows the correspondence between pore
volumes and water absorption with W/C. Figure 3
Concrete shows the carbonation behavior and Fig. 4 presents
families: W/C ratio the resistivity property as a function of W/C ratio.
compressive Aggregate Knowing each W/C ratio for each compressive
strength at 28d: replacement 20 MPa 30 MPa 40 MPa
strength, were possible to construct the correspon-
Natural 0% 0.91 0.68 0.52 dence between the durability properties (water
20% 0.80 0.66 0.57 absorption; pore volume; carbonation and resistivity)
FRCA 50% 0.92 0.69 0.52
with the amount of fine recycled aggregate replacing
100% 0.87 0.68 0.54 natural aggregates, as showed in Fig. 5, Fig. 6, Fig. 7,
20% 0.86 0.65 0.50 and Fig. 8. Also was possible to find the cement con-
FRMA 50% 0.95 0.73 0.57
tent, resistivity, carbonation, pore volume and water
100% 1.03 0.76 0.56 absorption for each W/C to reach the specified com-
pressive strength as showed in Tables 4 and 5.

47
6 DISCUSSION natural aggregate was replaced by FRMA. When the
natural aggregate was replaced by FRCA, no signifi-
The water absorption, as well as the total pore vol- cant alterations were recorded in the carbonation
ume, increases with the amount of natural aggregates depth, independently of the replacement content.
replaced by recycled aggregates. This behavior was When using FRCA or FRMA, also with 100% of
expected, since the absorption of the fine recycled replacement, the carbonation depth is still lower when
aggregates, FRCA and FRMA, was 6 to 10 times compared to reference concrete families made by nat-
higher than the natural aggregates. ural aggregates (see Fig. 3). The explanation of this
The carbonation depth, for the same compressive behavior is supported by the highest cement content
strength, reached an optimal value when 50% of the of recycled concretes to achieve the same compres-
sive concrete strength of natural aggregates concrete.
Fine recycled aggregate concretes need a higher
Carbonation Depth

8.0 cement content to achieve the same compressive


strength as compared to reference concrete, as shown
6.0

Resistivity
10
4.0
9

2.0 (kg/kg) 8
Cement Content
3 (w/c)
C (kg/m ) 7

600 500 400 300 200 0.40 0.60 0.80 6


3 Cement Content
dry aggregate/cement ratio

3 5
C (kg/m )
(w/c)
4

dry aggregate/ciment ratio


600 500 400 300 200 0.40 0.60 0.80
5 3

6 4

7 5

(kg/kg) 6

Reference Family eCO2 = 15.490 * W/C 7


- 4.604 (28 days) m (kg/kg)
Resistivity = -0.527 * log(w/c) + 7.164
Family FRCA 100%-0% e CO2 = 9.516 *W/C
- 1.619 (28 days)
Figure 4. Resisitivity for concrete family 100%–0% FRCA.
Figure 3. Carbonation MDN for concrete reference family
and 100% FRCA.
Water Absorption (%)
Water Absorption (%)

11 11

9 9

7 7

5 5
0 20 50 100 0 20 50 100
Fine Recycled Concrete Aggregate (%) Fine Recycled Masonry Aggregate (%)
Legend 20 MPa 30 MPa 40 MPa

Figure 5. Evolution of water absorption with the amount of natural aggregate being replaced by FRCA and FRMA to
achieve 20 MPa, 30 MPa and 40 MPa at 28 days.

48
30,0 30,0

Total Volume Pores (%)


Total Volume Pores (%)

24,0 24,0

18,0 18,0

12,0 12,0
0 20 50 100 0 20 50 100
Fine Recycled Concrete Aggregate (%) Fine Recycled Masonry Aggregate (%)

Figure 6. Evolution of total pore volume and carbonation depth as a function of replacement of natural aggregate by FRCA
and FRMA to achieve 20 MPa, 30 MPa and 40 MPa at 28 days.

12 Carbonation Depth (mm)


12
Carbonation Depth (mm)

8 8

4 4

0 0
0 20 50 100 0 20 50 100
Fine Recycled Concrete Aggregate (%) Fine Recycled Masonry Aggregate (%)

Legend 20 MPa 30 MPa 40 MPa

Figure 7. Evolution of carbonation depth as a function of replacement of natural aggregate by FRCA and FRMA to achieve
20 MPa, 30 MPa and 40 MPa at 28 days.

30 30
Resistivity (KΩ .cm)

Resistivity (KΩ .cm)

24 24

18 18

12 12

6 6
0 20 50 100 0 20 50 100
Fine Recycled Concrete Aggregate (%) Fine Recycled Masonry Aggregate (%)

Legend 20 MPa 30 MPa 40 MPa

Figure 8. Evolution of resistivity with the amount of natural aggregate was being replaced by FRCA and FRMA to achieve
20 MPa, 30 MPa and 40 MPa at 28 days.

49
Table 4. Cement content and carbonation depth for all concrete families.

Concrete
families:
Compressive Cement content (kg/m3) Carbonation depth (mm) Resistivity (kΩ.cm)
strength Aggregate
at 28d: replacement 20 MPa 30 MPa 40 MPa 20 MPa 30 MPa 40 MPa 20 MPa 30 MPa 40 MPa

Natural 0% 179 291 397 9.6 6.0 3.5 13.3 17.0 20.4
FRCA 20% 239 325 404 6.0 4.6 3.6 14.2 15.0 15.8
50% 216 330 445 6.5 4.6 3.3 11.7 10.7 9.8
100% 266 366 461 6.7 4.9 3.6 7.2 7.4 7.5
FRMA 20% 220 329 434 6.4 4.3 2.8 19.3 18.3 17.3
50% 191 300 407 5.8 4.0 2.7 30.6 26.8 23.3
100% 217 332 455 9.0 5.8 3.5 26.6 23.9 21.3

Table 5. Water absorption and pore volume for all concrete families.

Concrete
families: Water absorption (%) Pore volume (%)
Compressive Aggregate
strength at 28d: replacement 20 MPa 30 MPa 40 MPa 20 MPa 30 MPa 40 MPa

Natural 0% 7.3 6.6 6.1 16.0 14.6 13.6


FRCA 20% 7.3 7.2 7.1 15.8 15.7 15.6
50% 9.7 9.0 8.5 20.2 19.0 18.1
100% 11.4 10.7 10.1 22.9 21.7 20.9
FRMA 20% 7.5 6.9 6.5 15.9 15.1 14.4
50% 8.0 7.6 7.3 16.7 16.2 15.8
100% 8.2 8.9 9.4 19.0 18.6 18.3

in Table 4 and Table 5. This higher alkaline reserve concrete family produced with the replacement of
acts to protect the concrete surface against carbona- 50% of natural aggregate by FRMA, minimum values
tion mechanism. were obtained for carbonation and maximum values
Clifton (1993) reported that the positive effect of were obtained for resistivity. The reason for this obser-
the alkaline reserve in relation to carbonation can vation can be justified why the replacement of natural
increase the service life of concrete structures, aggregate reach better compaction, the high density.
because they last longer without depassivation of
reinforcement, which means an increase in the corro-
sion initiation period (Tuutti 1982). 7 CONCLUSIONS
Concerning resistivity, the Comité Euro-
International du Béton (bulletin CEB 192) presents By applying the very clear concepts proposed for exper-
criteria for assessing the reinforcement corrosion imental concrete mix design by Helene & Monteiro
probability as a function of concrete resistivity, classi- (1993) to the properties studied in this work, it was pos-
fying concretes from 5 kΩ.cm to 10 kΩ.cm, as high cor- sible to observe and compare the behavior of concrete
rosion probability and concretes with more than families and not only between isolated mixtures.
10 kΩ.cm as low and negligible risks of steel reinforce- Under the conditions of this research it is possible
ment corrosion. All the resistivity measurements were to conclude that:
conducted under the same conditions. Comparing data Concrete made with recycled aggregates (20%;
results with CEB criteria, only when the FRCA replace 50% and 100% replacement) from old masonry or
100% of natural aggregates the corrosion probability from old concrete can have the same fresh workabil-
can be considered high. In all the others mixtures the ity and can achieve the same 28-day compressive
corrosion probability is low or negligible. strength as concrete made with natural aggregates in
All the properties investigated – absorption, total the range from 20 MPa to 40 MPa.
pore volume, carbonation and resistivity – could The carbonation depth always decreased when the
be expected to present consistent behavior. For the replacement was 20% or 50%. For FRMA concrete

50
family this improvement in behavior also occurred ASTM G 57. “Method for Field Measurement of Soil
when the replacement was 100%. This behavior shows Resistivity Using the Wenner Four-Electrode Method –
that carbonation depth strongly depends on the chemi- G 57”. In:. Annual Book of ASTM Standards. 2003
cal composition of the concrete and not only on its Clifton, J. 1993. Service life prediction. ACI Materials
Journal 90 (6) (Nov. Dec. 1993) 611–17.
physical aspects. Collins, R. BRE 1995–1996. “Use of recycled materials as
When 50% of the natural fine aggregate was sub- aggregates in the construction industry”– v2 issue 3 & 4.
stituted by FRMA, the resistivity reached maximum Brussels ETN Recycling in construction, March–
values. September 2000.
The replacement of natural aggregates by recycled Etxeberria, M; Barra, M. & Vazquez, E. (1ed.) 2006
ones has been shown to be technically viable; how- “Utilización de árido reciclado para la fabricación de
ever, it will be necessary to take into account that hormigón estructural.” Madrid España: Asociación
the recycled aggregates had water absorption about Científico-Técnica del Hormigón Estructural ACHE.
10 times higher than that of natural aggregates, and 189p. ISBN – 84-89670-55-2.
Helene, Paulo & Monteiro, P. J. 1993. Designing concrete
this fact increased both total pore volume and water mixtures for strength, elastic modulus and fracture energy.
absorption of the concrete. Materials and Structures 26 (162) (Oct. 1993) 443–52.
When the natural aggregate is replaced by the 20% Levy, S. M. 2001 Contribution for durability of concretes
or 50% of recycled aggregates from old concrete or manufactured with recycled aggregates from demolished
old masonry the resulting recycled concrete may have masonry and concrete structures (in Portuguese).
the same, and sometimes better, behavior than the ref- Universidade de São Paulo USP. São Paulo. 2001 (Ph.D.
erence concrete made with natural aggregates. This Thesis).
fact justifies the efforts to use these concretes, which Mehta, P. K. & Monteiro, P. J. 1994. Concrete Structure,
can contribute to the preservation of the environment Properties and Materials. PINI. São Paulo.
RILEM (International Union of Testing and research
and can achieve the same final performance at proba- Laboratories for materials and Structures): “Specifications
bly lower costs than those of ordinary concretes. for Concrete with Recycled Aggregates”. Materials and
This investigation shows that it is possible to eval- structures, No 27, pp.557–559.
uate the influence of recycled aggregates in the depth RILEM CPC 18. “Measurement of Hardened Concrete
of carbonation concrete. Also shows that the tradi- Carbonation Depth”. Materials and Structures 21 (126)
tional approach by pore volume is not enough for (Nov. 1988) 435-5.
understand the phenomena. The CO2 gas penetration Santos, D. R. & Pazini, F. E. Propriedades do concreto pro-
depends not only from porosity but also from con- duzido com agregado graúdo reciclado de resíduo da etapa
crete materials, which means chemicals aspects. de produção das alvenarias. A Construção em Goiás (ISSN
1677-0579). Ano XXXIX, no 476, Jan., 2007, p. 4–11.
The use of Mix Design Nomogram (MDN) intro- Teranishi, K.; Narikawa, Y. D. M. & Kikuchi, M . Application
duced by Helene & Monteiro (1993), allows the of Recycled Aggregate Concrete for Structural Concrete.
researchers to make a correct and relevant compari- Part 3 – Production of Recycled Aggregate by Real-Scale
son between the different concrete families, adopting Plant and Quality of Recycled Aggregate Concrete. In
the same reference compressive concrete strength, Dhir R. K.; Henderson N.A. & Limbachiya M. C. (eds.)
instead of the usual poor comparison between indi- Sustainable Construction: Use of Recycled Aggregate. pp.
vidual mixture results. 143–156. Thomas Telford Publishing. Thomas Telford
The results obtained in this work point towards the Limited, 1 Heron Quay, London.
effective possibility of using fine recycled aggregates Tuutti, K. 1982. Corrosion of steel in concrete. Cement and
Concrete Research Institute. Stockholm. 1982 (Ph.D.
in the production of new concretes, since the maxi- Thesis)
mum substitution limits of 50% are complied with. Vincke, J. & Rousseau, E. “Recycling of construction and
Demolition Waste in Belgium: Actual situation and Future
Evolution”. Demolition and reuse of Concrete and Masonry,
REFERENCES Proceedings of the Third International RILEM Symposium,
Edited By Lauritzen, E.K. Published by E&FN Spon, 2–6
ASTM C 270. “Standard Specification for Mortar for Unit Bondary Row, London SE 1 8HN, First Edition, 1994.
Masonry” In:. Annual Book of ASTM Standards. 2003 pp. 57–69.
ASTM C 39. “Standard Test Method for Compressive Wirquin, E. & R. Zahaarieva. Hahdjeva & F. Buyle-Bodin
Strength of Cylindrical Concrete Specimens” In:. Annual 2000. Utilisation de l’absortion d’eau des bétons comme
Book of ASTM Standards. 2003. critères de leur durabilité-Aplication aux bétons de granu-
ASTM C 642. “Standard Test Method for Density. lats recycles (in French). Materials and Structures 33 (July
Absorption. and Voids in Hardened Concrete” In:. 2000) 403–408.
Annual Book of ASTM Standards. 2003.

51
Sustainable Construction Materials and Technologies – Chun, Claisse, Naik & Ganjian (eds)
© 2007 Taylor & Francis Group, London, ISBN 978-0-415-44689-1

An experimental investigation on the viability of using fine concrete


recycled aggregate in concrete production

S.R. Sarhat
The High Institute for Comprehensive Professions, Ghadames-Libya

ABSTRACT: This paper presents an experimental investigation on the feasibility of full or partial replace-
ment of fine natural aggregate (FNA) with fine recycled concrete aggregate (FRA) in concrete production. The
studied variables were the FRA substitution ratio, the water-cement ratio, and the effect of presence of materi-
als finer than 0.075 mm in FRA. Workability, compressive and splitting tensile strength were measured. The
experimental results indicate that the replacement of FNA with FRA is feasible. Only marginal effects were
noticed on workability and splitting tensile strengths with substitution of up to 45%, which even led to an
increase in the compressive strength. It can be concluded from the results that the water–cement ratio is a key
factor that affects the workability and the strength of concrete made with FRA. Also, the results show that the
presence of up to 10% of materials finer than 0.075 mm in FRA does not affect workability or strength charac-
teristics in the case of partial replacement of fine aggregate.

1 INTRODUCTION 2 EXPERIMENTAL PROGRAM

Using recycled aggregates larger than 4.75 mm in The studied parameters in this investigation were:
production of new concrete is a well-studied topic all
– The substitution ratio of natural sand with fine
over the world, while the fine portion from demolition
recycled aggregates.
of concrete, which represents about 30% to 60% of
– The water-cement ratio.
the crushed demolition materials [Solayman 2005], is
– The effect of the presence materials finer than
disposed of. The main reason for this situation is that
0.075 mm in FRA.
the fines exhibit high water absorption ratios, which
lead to a weak performance of the concrete matrix
[Wainwright et al. 1994]. 2.1 Characterization of fine recycled concrete
Some countries are suffering from a lack of appro- aggregates
priate natural fine aggregate for construction proj- FRA were obtained by crushing concrete parts result-
ects. In Libya, for example, the natural sands are too ing from demolition of an old concrete building built
fine and usually do not achieve the grading require- in 1970. The concrete was crushed in a large crushing
ments according to the BS: 882–1992 standards; how- plant used to obtain coarse and fine aggregates from
ever, people use it because they simply have no other crushing natural stones. Considerable efforts were
alternatives. Also, sand extraction both in riverbeds made to keep the obtained fine recycled aggregates
and on the seacoast has had, sometimes, serious without dirty. The grading curve of the FRA lay in
impacts [Evangelista & de Brito 2004]. To find solu- grading zone 2 according to BS: 882–1992.
tions for the fine waste resulting from concrete crush- The fine natural aggregates used in this investigation
ing and to minimize natural sand extraction, which were a common type of natural sand in Libya, which
subsequently would minimize the environmental always has a grading curve in zone 3. The main charac-
impact of this extraction, more research efforts are teristics of the FNA and FRA are presented in Table 1.
required.
In the present investigation, a research program 2.2 Mixture proportions
was achieved to study the feasibility of full or partial
replacement of fine natural aggregates with fine recy- The mixture proportions, expressed by mass as
cled concrete aggregates (FRA). cement, coarse aggregate, and fine aggregate were

53
1:1.75:3.3 for all mixes. These proportions are recom- 0.6, .65, 0.7). An FRA replacement ratio of 45% was
mended by the municipal regulations in Libya to fixed for all mixtures in this group. Finally, another
obtain a structural concrete for normal residential and four mixtures were used to study the effect of the
public buildings. The methodology of absolute vol- presence of materials finer than 0.075 mm in FRA.
ume was used to find the concrete composition for Fine materials contents of 0.0%, 10%, 20% and 30%
each batch. Ordinary Portland cement was used for all were investigated. A W/C of 0.65 and an FRA
the mixtures; and crushed coarse limestone aggre- replacement ratio of 45% were used in all the four
gates, having a surface specific gravity of 2600 kg/m3, mixtures of this group. Tables 1 to 3 show the mix-
water absorption of 2.5%, and maximum size of tures compositions used in 1 m3for all groups.
15 mm, were used. Although the obtained FRA has only 5% fine
Mixtures used in this investigation can be divided materials content, this factor was studied in this
into three groups. The fist group was prepared to investigation for two reasons. First, it was found
investigate the feasibility of replacing FNA with recently in Libya that sand portion resulting from
FRA. Six concrete mixtures with various substitution crushing natural stones in the crushing plants con-
ratios (0.0%, 15%, 30%, 45%, 60%, 100%) were cast tains 8 % to 30% materials finer than 0.075 mm
and tested. The water-cement ratio (W/C) was fixed [Mansur et al. 2004]. Secondly, these crushing plants,
at 0.6. In the second group, four mixtures were used without any doubts, will be used to get coarse and
to study the effect of the water-cement ratio (0.55, fine recycled aggregates from crushing old concrete
if a considerable efforts are made by the municipal
authorities and people to adopt recycling. In this case,
Table 1. Properties of FNA and FRA. the FRA may contain high percents of fine materials.
The workability of each mixture was evaluated
Properties FNA FRA through the standard slump test. Also, for each mix-
ture, six 150  150  150 mm cubes were produced
Surface dry specific density (kg/m3) 2640 2330 for measurement of compressive strength, and six
Compacted bulk density (kg/m3) 1640 1520
cylinders with 150 mm diameter and 300 mm height
Water absorption (%) 4.1 12.5
% Materials finer than 0.075 mm % 1.5 5 were produced for measurement of splitting tensile
strength.

Table 2. Mixtures compositions (for 1 m3) and test results of specimens cast for studying FRA substitution.

Specimens F0R F15R F30R F45R F60R F100R

% FRA Replacement 0 15 30 45 60 100


Cement (Kg) 351.53 349.9 348.3 346.7 345.51 340.96
FNA (Kg) 615.18 520.48 426.67 333.7 241.86 0.0
FRA (Kg) 0.0 91.85 182.86 273.03 362.79 596.68
Coarse aggregate (Kg) 1160.1 1154.7 1149.4 1144.1 1140.8 1125.1
Water (Kg) 210.92 209.94 209.28 208.2 207.36 204.58
Slump (mm) 85 70 65 50 35 25
Compressive strength MPa 40 40.6 42 41.7 41 40.1
Indirect tensile strength MPa 3.4 3.3 3.2 3.2 3.1 3

Table 3. Mixtures compositions (for 1 m3) and test results of the specimens cast for studying water-cement ratio.

Specimens FW1 FW2 FW3 FW4

Water-cement ratio 0.55 0.6 0.65 0.7


Cement (Kg) 353.06 346.7 340.78 335.4
FNA (Kg) 340 333.7 328 322.82
FRA (Kg) 278.1 273.03 268.37 264.13
Coarse aggregate (Kg) 1165.43 1144.11 1124.6 1106.8
Water (Kg) 194.24 208.2 221.5 234.8
Slump (mm) 20 50 70 95
Compressive strength MPa 43 41 36 28
Splitting tensile strength MPa 3.5 3.2 3.0 2.75

54
Table 4. Mixtures compositions (for 1 m3) and test results of specimens cast for studying the effect of materials finer than
0.075 mm.

Specimens F0F F10F F20F F30F

% Fine materials 0.0 10 20 30


Cement (Kg) 340.78 340.78 340.78 340.78
FNA (Kg) 328 328 328 328
FRA (Kg) 268.37 241.5 214.7 187.86
Materials finer than 0.075 mm 0.0 26.8 53.67 80.52
Coarse aggregate (Kg) 1124.6 1124.6 1124.6 1124.6
Water (Kg) 221.5 221.5 221.5 221.5
Slump (mm) 55 50 35 15
Compressive strength MPa 41 42.5 39 37
Splitting tensile strength MPa 3.2 3.35 3 2.85

After demolding at an age of one day, the speci- 90 85


mens were cured at 20oC and 100% relative humidity.
All tests were carried out based on BS:1881–1993. 80
70
70 65
2.3 Concrete mixing 60
Slump mm

The production process, based on the procedures 50 45


explained by [Roose & Massivbau 1999] was fixed
40 35
for all mixtures. First, the aggregates were mixed with
20% of the water for exactly two minutes. After that 30 25
they were covered with a PE-foil for ten minutes. The
cement and the rest of the water were added and 20
mixed for another two minutes before casting into 10
moulds. Due to the high water-cement ratio used in
all mixtures, no superplasticizers were used. 0
0% 15% 30% 45% 60% 100%
Substitution
3 TEST RESULTS
Figure 1. Effect of FRA substitution ratio on workability.
3.1 Substitution of FNA with FRA
50
The workability index used in this investigation,
The compressive strength

slump, was greatly affected by increasing the substi- 45


tution ratio. The results obtained are presented in
40
Figure 1. There was a gradual decrease in slump as
the substitution ratio increased. Also, it is clear from 35
Figure 1 that, up to 45% substitution ratio, values of
the slump were acceptable and it was possible to get a 30
workable mixture.
25
Table 1 and Figure 2 show obviously that the vari-
ous substation ratios of FRA led to small increases in 20
the compressive strength of all mixtures. These 0% 15% 30% 45% 60% 100%
results can be explained by two probable reasons. Substitution
Firstly, the FRA used in this investigation was well
graded in comparison with the FNA. Secondly, the Figure 2. Effect of FRA substitution ratio on the compres-
FRA may possess a significant quantity of cement sive strength.
(both hydrated and non-hydrated), thus it is possible
that part of this cement adds up to the cement from with 30% FRA, which led to a 5% increase. The split-
the mixture, increasing the global cement ratio of the ting tensile strength decreased slightly as the substitu-
mixture [katz 2003]. The best improvement in com- tion ratio of FNA with FRA was increased. However,
pressive strength was achieved by replacing FNA no distinct trend is visible.

55
3.2 Water-cement ratio It can be concluded from Figures 6 to 8 that up to
10% content of materials finer than 0.075 mm had a
The results show that the W/C is still a prime factor
marginal effect on workability and even led to an
which affects the workability and other mechanical
increase in the compressive and splitting tensile
properties of concrete containing FRA. It is clear from
Figures 3 to 5 that increasing the W/C resulted in a
considerable increasing in workability while this was 4
also accompanied by a significant decreasing in com- 3.5
3.5 3.2
pressive and splitting tensile strengths. A W/C of 0.6 3

splitting tensile strength


was enough to get a workable mixture with a reason- 3 2.75
able strength without using super-plasticizers or other 2.5
additives. For W/C less than 0.6 it was difficult to get 2
an acceptable workability without using additives.
1.5
1
3.3 Materials finer than 0.075 mm
0.5
It is known that a high content of materials finer than
0.075 mm may jeopardize the quality of the concrete, 0
0.55 0.6 0.65 0.7
so this content is limited by standards. For example,
water-cement ratio
according to BS: 882–1999, The maximum acceptable
limit for materials finer than 0.075 is 16%. Figure 5. Effect of water-cement ratio on the splitting ten-
sile strength.

100 95 43 42.5
90 42
75 41
compressive strength

80 41
70
40
Slump mm

60 39
50 39
50
38 37
40
37
30 20 36
20
35
10
0 34
0% 10% 20% 30%
0.7 0.65 0.6 0.55
Water-cement ratio microfines content

Figure 3. Effect of water-cement ratio on workability of Figure 6. Effect of microfines content on the compressive
concrete containing FRA. strength.

3.4
50 3.3
splitting tensile strength

45
3.2
Compressive strength

40
35 3.1
30 3
25
20 2.9
15 2.8
10
2.7
5
0 2.6
0.55 0.6 0.65 0.7 0% 10% 20% 30%
Water-cement ratio Microfines content

Figure 4. Effect of water-cement ratio on the compressive Figure 7. Effect of microfines content on the splitting ten-
strength. sile strength.

56
60 55 – Water-cement ratio is a prime factor and it affects
the properties of concrete made with FRA. For a
50
50 substitution ratio of 45%, increasing the water-
cement ratio led to a significant decrease in work-
40
ability, compressive strength, and splitting tensile
35 strength.
slump mm

– When FRA was partially used, up to 10% content


30 of materials finer than 0.075 mm had only a mar-
ginal effect on workability and led to increase the
20 15 compressive and splitting tensile strength. In con-
trast, higher contents of these microfines (20%
10 and 30%), noticeably decreased workability and
strength characteristics.
0
0.00% 10% 20% 30%
Microfines content ACKNOWLEDGEMENT

Figure 8. Effect of microfines content on the workability. This experimental work was supported by the
University of Al-Jabel Al-Gharby in Libya. Thanks to
Mohammed Mosa, Hatem Jalal and Mohammad
Balgho, who carried out a part of this work in their
strength of concrete made with 45% FRA substitution graduation project under the supervision of the author.
ratio, while increasing the fine materials content to
20% and 30% led to considerable decreases in these
properties. The compressive strength decreased by REFERENCES
4.8% and 9.8%, respectively. Also, 4.7% and 11%
decreases in splitting tensile strength were recorded. British standards, BS: 882–1999. Specification for aggre-
Workability was the property most affected by gates from natural sources for concrete.
increasing the content of fine materials in the FRA. British standards, BS:1881–1993. Testing concrete.
The slump decreased by 75% when the content of Evangelista, L. & de Brito, J. 2004. Criteria for the use of
fine materials increased to 30%. fine recycled concrete aggregates in concrete production.
Inter. Conf., The use of recycled materials in building and
structures, Barcelona, SPAIN., Nov. 2004.
Katz, A., 2003. Properties of concrete made with recycled
4 CONCLUSIONS aggregate from partially hydrated old concrete., Cement
and Concrete Research 33: 703–711.
The following conclusions can be reached from the Mansur, A., Masaud, A., Adulsalam, A., & Almssai, N.,
present investigation concerning the feasibility of 2004. Using crushing plants` by-products in concrete
using fine recycled concrete aggregates: production. Building materials and structural engineer-
ing; Proc. 2nd Natio. Conf., Alkhoms, Libya. Nov., 2004.
– The replacement of natural fine aggregate with Roose, F., & Massivbau, L., 1999. Verification of the dimen-
fine recycled concrete aggregate is feasible espe- sioning values for concrete with recycled aggregates .
cially when the natural aggregates do not achieve Technische universital munchen. 1999.
the grading requirements. Solayman, M., 2005. Classification of recycled sands and
– The substitution ratio of FRA, the water-cement their applications as fine aggregates for concrete and
ratio and the content of fine materials are key bituminous mixtures . Phd. Thesis,University of Kassel,
Germany, 2005.
parameters for concrete made with FRA. Wainwright, P., Tevorrow, A., Yu, Y., & Wang, Y., 1993.
– With a substitution ratio of up to 45%, FRA has no Modifying the performance of concrete made with
major impact on workability and splitting tensile coarse and fine recycled aggregates . Demolition and
strength; and may even lead to an increase in the reuse of concrete and masonry., 3rd Inter. RILEM Symp.,
compressive strength. Odense, Oct. 1993.

57
Sustainable Construction Materials and Technologies – Chun, Claisse, Naik & Ganjian (eds)
© 2007 Taylor & Francis Group, London, ISBN 978-0-415-44689-1

Effect of different recycled aggregates on mortar performance

V. Corinaldesi, S. Monosi & G. Moriconi


Università Politecnica delle Marche, Ancona, Italy

ABSTRACT: This work was aimed at evaluating both mechanical and rheological behaviour of cementitious joint
mortars prepared with three different kinds of recycled aggregate: one is made of concrete scraps obtained as
rejected material from precast concrete production, one is based on recycled bricks and the last one is a miscellany
of rubble from a demolition waste recycling plant. The experimental results showed that mechanical strength of the
mortars prepared by substituting the natural sand with each one of these recycled aggregates is significantly lower
than the reference. Nevertheless, the bond strength at the interface between mortar and brick was higher for mortars
prepared with recycled aggregates and, in particular, when the fine aggregate demolition waste recycling was used.

1 INTRODUCTION 100
REF
In Italy, every year more than 20 million tonnes of con- 80 REC
% Passing the sieve

CON
struction and demolition waste are produced. They are
60 BRI
mainly constituted of debris coming from demolished
structures made of masonry or reinforced concrete. At 40
present, only 10% of this material is recycled and the
remainder is disposed of in landfills for inert materials 20
if it is not unlawfully disposed of by other means.
This work is aimed at evaluating the possibility of 0
reusing waste from building demolition as aggregate 0.01 0.1 1 10
for joint mortars. The annual production of joint mor- Sieve opening (mm)
tar can be estimated as approximately 1 million cubic
meters; therefore the total amount of material poten- Figure 1. Grain size distribution of the aggregates fractions.
tially recyclable could be significant.
A previous study [Sani et al. 2005] carried out on As aggregate, three different kinds of recycled aggre-
leaching behaviour of cementitious mixtures pre- gate were alternatively used: the first, indicated below as
pared with recycled aggregates coming from the ‘CON’, is made of concrete scraps obtained as rejected
same source showed that the environmental impact of material from precast concrete production (50–55 MPa
these mortars can be sustainable. strength class); the second, ‘BRI’, is obtained by crush-
In order to evaluate the quality of joint mortars ing red bricks (with a compressive strength of 11 MPa)
made of recycled aggregate, both mechanical behav- and the last, ‘REC’, is miscellaneous rubble from a
iour of cementitious mortars and rheological behav- demolition waste recycling plant. Its mean composition
iour of cementitious pastes were evaluated. The mortars is 70% concrete, 27% masonry and 3% bitumen. As a
were prepared with three different kinds of recycled reference material, a natural sand, ‘REF’, was used. The
aggregate. particle size and physical properties of these aggregate
Finally, the interaction between the mortar and fractions are reported in Fig. 1 and Table 1 respectively.
brick, in terms of bond strength developed at the
interface mortar-brick, was studied.
3 MIXTURE PROPORTIONS
2 MATERIALS
3.1 Mortars
A commercial portland-limestone blended cement type The proportions of the mortar mixtures are given in
CEM II/B-L 32.5 R according to EN-197/1 was used. Table 2. The cement to sand ratio was 1:3 (by mass);

59
Table 1. Characterization of the recycled aggregate Table 3. Dosages of cement paste ingredients (g).
fractions.
CEM CEM CEM CEM
Aggregate type REF REC BRI CON REF REC BRI CON
Mixture
Volumic mass 2.59 2.42 2.18 2.38 Water/Cement 0.62 0.82 1.22 0.78
in s.s.d.*
conditions (kg/m3) Water 280 370 550 350
Water absorption (%) 3.1 7.8 17.3 10.4 Cement 450 450 450 450
Fraction passing 10 8 20 10 Natural sand 135 – – –
150 µm sieve (%) (150 µm)
Blaine fineness of 0.145 0.793 0.474 0.483 Recycled rubble – 108 – –
the fraction under (150 µm)
150 µm (m2/g) Recycled brick – – 270 –
(150 µm)
* s.s.d.  saturated surface-dried. Recycled concrete – – – 135
(150 m)

Table 2. Mortar mixture proportions (kg/m3). Table 4. Results of the mechanical tests on mortars at dif-
ferent curing times.
M- M- M- M-
REF REC BRI CON M- M- M- M-
Mixture Mixture REF REC BRI CON
Water/Cement 0.62 0.82 1.22 0.78
Flexural 1 day 2.8 1.6 1.6 1.9
Water 280 370 550 350 Strength 7 days 5.7 4.4 3.8 5.4
Cement 450 450 450 450 (MPa) after: 28 days 6.6 5.0 4.7 6.9
Natural sand 1350 – – –
Compressive 1 day 5.0 4.0 3.0 2.2
Recycled rubble – 1350 – –
Strength 7 days 21.5 13.4 12.3 15.0
Recycled brick – – 1350 –
(MPa) after: 28 days 27.8 17.2 16.4 21.1
Recycled concrete – – – 1350

4 MECHANICAL CHARACTERIZATION
OF MORTARS
the water content of each mortar was set to achieve
the same consistency of 110  5 mm, evaluated For each mortar mixture nine prismatic specimens
according to EN 1015-3. Obviously, the higher the (40  40  160 mm) were manufactured and wet
water absorption of the aggregate fractions (see Table cured at 20°C. The compressive and flexural strengths
1), the higher the water amount necessary to reach the were evaluated after 1, 7 and 28 days of curing accord-
target consistency (see Table 2). ing to EN 196-1.
The results are reported in Table 4. Mortars contain-
ing recycled aggregates developed lower compressive
3.2 Pastes and flexural strengths with respect to the reference
In order to evaluate the rheological behaviour of the cementitious mortar, particularly when the type ‘BRI’
‘carrier’ phase of the mortars, made of water with aggregate was used. A 28-day compressive strength
very fine materials (excluding aggregate particles value higher than 20 MPa could be reached only for
with diameter higher than 150 µm), four cementitious the mortar made with type ‘CON’ recycled aggregate.
pastes were prepared. In this case, the shape of the concrete particles, sharp-
Their composition, reported in Table 3, was deter- cornered, plays a positive role in improving bond
mined on the basis of the mortar mixture composition, strength at the interface between the aggregate and sur-
by using the same water to cement ratio and by adding rounding cement paste.
to the pastes an amount of powder (obtained by sieving
at 150 µm the aggregate fractions) proportional to the 5 RHEOLOGICAL CHARACTERIZATION
percentages of material passing the sieve of 150 µm for OF PASTES
each kind of aggregate.
These percentages were 10%, 8%, 20% and 10% The rheological behaviour of the cement pastes was
for ‘REF’, ‘RIC’, ‘BRI’ and ‘CON’ type, respectively tested every 15 minutes up to one hour after the ingre-
(see Figure 1). dients were mixed.

60
Table 5. Results of the rheological tests on cement pastes.

CEM CEM CEM CEM


Mixture REF REC BRI CON

Yield stress (Pa) 49.4 6.3 3.9 7.6


Plastic viscosity 0.67 0.07 0.04 0.08
.
(Pa s)
Thixotropy 182 855 955 522
(Pa/s)

The experimental apparatus was a rotating rheometer


based on coaxial rotary cylinders with a slowly increas-
ing shear rate (D) ranging from 0 to 100 s1. The walls
of the concentric cylinders were not smooth but rough-
ened in order to reduce (if not totally eliminate) the ‘slip’
phenomenon, i.e., the development of a water-rich layer
close to the rotating cylinder which produces a lubricat-
ing effect, making flow easier and not representative of Figure 2. Masonry model for bond strength evaluation.
the bulk material [Saak et al. 2002].
The rheological behaviour was described by means the bond strength developed during the shearing of a
of the Bingham flow model: masonry unit with respect to the other along a mortar
layer 10 mm thick. In this way the masonry behaviour
  y  η D (1) in the absence of normal stress was investigated, cor-
responding to the constant term in the Mohr-Coulomb
where τ is the shear stress (Pa), τy is the yield stress friction law.
(Pa), η is the plastic viscosity (Pa s) and D is the
# The tested model, shown in Figure 2, is composed
shear rate (s1). of three bricks; it has a symmetric structure, thus
The Bingham curves for each cement paste were avoiding eccentric loads. For this purpose the geome-
extrapolated from experimental tests. The slope of the try of the model was always kept under careful con-
down-curve (decreasing shear rate) was used to cal- trol. The configuration of the model was chosen to
culate the plastic viscosity, while the intercept at zero avoid the influence of lateral deformations of the
shear rate was used to calculate the yield stress. brick portions emerging from the joined portion. The
Thixotropy (which is the property of certain gels, applied load (L) was measured and at the same time
such as cement paste, to be rigid when left standing the vertical displacement of the central brick (δ) was
but to become fluid when put into movement) was also monitored.
calculated as the area included between the up-curve The 250  120  55 mm bricks used for the
and the down-curve. triplet test were characterized by a total open porosity
The results obtained after 30 minutes from mixing of 43%, by a water absorption value after 24 hours of
of the ingredients are reported in Table 5. 19% and by an Initial Rate of Absorption value very
It is quite evident that the presence of very fine par- close to 2 kg/m2/min, which is the recommended
ticles coming from the recycled aggregate fractions value [Groot & Larbi 1999] for obtaining the maxi-
causes a lowering of both yield stress and plastic vis- mum bond strength value.
cosity with respect to the reference paste and, at the Generally, only one joint was found cracked at the
same time, they produce an anti-thixotropic effect. end of the test, so that the bond strength was calcu-
These results seem to indicate a higher ability of lated by dividing the maximum load by twice the
recycled aggregate mortars to permeate the open fracture area where brick and mortar were in contact
porosity of the brick surface and consequently, to (approximately 120  200 mm); the test results are
improve adhesion to it, as already demonstrated in reported in Table 6.
previous work [Moriconi et al. 2003]. A good mortar-brick adhesion depends mainly on
the quality of the interfacial zone, which is indicated
by higher bond strength values. In this regard, the
6 MORTAR-BRICK BOND STRENGTH recycled-aggregate mortars, in spite of poor mechan-
EVALUATION ical behaviour (see Table 4), showed higher mortar-
brick bond strength than the reference mortar (see
In this work a test method, derived from the draft EN Table 6), confirming previous results [Moriconi et al.
1052-3 [CEN 1996], was followed in order to evaluate 2003].

61
Table 6. Results of the triplet tests. prepared with recycled aggregates and, in particular,
when the aggregate fraction coming from recycling of
M- M- M- M- demolition waste is used.
Mortar type REF REC BRI CON For joint mortars, the mechanical performance of
the overall mortar-brick system, strictly related to the
Bond strength 0.39 1.14 0.52 0.98
(MPa) mortar-brick adhesion, makes the mortar bond strength
certainly more important than its mechanical strength.
In conclusion, the use of materials coming form
C&D waste recycling instead of sand for the produc-
The presence of recycled material lowers the yield tion of jointing mortars proved to be profitable not only
stress value as previously pointed out by means of for the obvious environmental advantages, but also in
rheological tests (cf. Table 5 and [Moriconi et al. terms of improvement of the mortar-brick interface,
2003]); in this way the mortar could better permeate which is generally recognized as the weak chain link of
the brick surface assuring a physical interlock and, as the masonry assemblage.
a consequence, an improved bond.
In particular, the mortar prepared with type ‘REC’
aggregate shows a very high mortar-brick bond
strength value (about three times that of reference REFERENCES
mortar). On the basis of these results, the simultane-
CEN 1996. prEN 1052-3. Methods of test for masonry; Part 3:
ous presence of recycled concrete and brick seems to Determination of initial shear strength, Draft for public
cause a synergistic effect. comment.
Moreover, some tests carried out on masonry Corinaldesi, V. & Moriconi, G. 2006. Mechanical behaviour
assemblies [Corinaldesi & Moriconi 2006] showed of a masonry assemblage manufactured with recycled-
that their mechanical performance is mainly depend- aggregate mortars, submitted to be published in Cement
ent on the bond strength between the mortar and brick and Concrete Research.
and is generally improved when masonry is manufac- Groot, C. & Larbi, J. 1999. The influence of water flow (rever-
tured with recycled-aggregate mortars. sal) on bond strength development in young masonry,
Heron 44(2): 63–77.
Moriconi, G., Corinaldesi, V. & Antonucci, R. 2003.
Environmentally-friendly mortars: a way to improve
7 CONCLUSIONS bond between mortar and brick, Materials & Structures,
36(264): 702–708.
The experimental results show that mortars contain- Saak, A.W., Jennings, H.M. & Shah, S.P. 2001. The influ-
ing recycled aggregates developed a lower mechani- ence of Wall Slip on Yield Stress and Viscoelastic
Measurements of Cement Paste, Cement and Concrete
cal strength with respect to the reference cementitious Research 31: 205–212.
mortar, particularly when the fraction based on recy- Sani, D., Moriconi, G., Fava, G. & Corinaldesi, V. 2005.
cled bricks was used. Leaching and mechanical behaviour of concrete manu-
Nevertheless, the bond strength at the interface factured with recycled aggregates, Waste Management
between the mortar and the brick is higher for mortars 25(2): 177–182.

62
Sustainable Construction Materials and Technologies – Chun, Claisse, Naik & Ganjian (eds)
© 2007 Taylor & Francis Group, London, ISBN 978-0-415-44689-1

Researching recycled aggregate structural concrete for buildings

N. Morohashi & T. Sakurada


Department of Architecture and Architectural Engineering, College of Industrial Technology, Nihon University,
Narashino, Chiba, Japan

ABSTRACT: This study used recycled aggregate concrete for floor slabs, which are plane members with a
large surface area subject to drying, and added a drying shrinkage reducing agent to mitigate drying shrinkage.
The relationship between use of this agent and the influence of drying shrinkage on cracking was investigated.
The result found that, when a drying shrinkage reducing agent was added to recycled aggregate concrete-based
floor slabs, not only were drying shrinkage cracks lessened but also post-yield strength against bending
increased to give satisfactory bending properties. This suggests that recycled aggregate concrete could be used
for members of reinforced concrete structures.

1 INTRODUCTION Table 1. Mixing of concrete.

In recent years in Japan, there has been a growing need Weight(kg/m3)


for recycling materials in the building sector, particu-
W/C Fine Coarse
larly the chunks of concrete produced when reinforced
Series (%) Water Cement aggregate aggregate
concrete structures are demolished. This study reviews
the possibility of using recycled aggregate concrete for R 58.0 183 316 814 867
members of reinforced concrete structures. R A-R (normal) (recycled)
Previous studies reported that drying shrinkage
cracks developing in reinforced concrete were caused FR 54.0 191 354 713 808
FR A-FR (recycled) (recycled)
by drying shrinkage due to fugitive emission of mois-
ture from within the concrete [Architectural Institute of *A-: drying shrinkage reducing agent.
Japan 2003; Shrinkage Cracking in Reinforced Con-
crete Structures]. Tanano et al. [2006] reported in their
research for wall members that more drying shrink- concrete are shown in Table 2. Recycled aggregate
age cracks develop when recycled aggregate concrete concrete used in this research was grouped into two
is used in reinforced concrete than when normal con- series: R series of 100% recycled coarse aggregate
crete is used. This suggests that drying shrinkage cracks with 100% natural sand, and FR series of 100% recy-
developing in recycled aggregate concrete may affect cled coarse aggregate with 100% recycled sand. The
durability. Hence, this study reviews the effect of dry- recycled aggregate use in this study was manufactured
ing shrinkage on cracking, using recycled aggregate by crushing dismantled concrete with a jaw crusher at
concrete for floor slabs, which are plane members a recycled aggregate concrete plant. Each series was
whose large surface area is subject to airing, and then further reviewed for the dependence of the effect on
adding a drying shrinkage reducing agent to mitigate whether or not a drying shrinkage reducing agent had
drying shrinkage. The effect of this agent on strength been added. Floor slabs were tested for bending at the
against bending of floor slabs as structural members material age of 5 weeks, when no drying shrinkage
is also examined. cracks had yet developed, and also after one year had
elapsed, during which drying shrinkage cracks devel-
oped. Floor slabs tested for bending at the material age
2 SUMMARY OF EXPERIMENTS
of one year were observed in terms of the rate of dry-
ing shrinkage as well as for any drying shrinkage
2.1 Specimen
cracks. Figure 1 illustrates the shape of a specimen.
The mixing ratios of the concrete prepared in this Floor slab reinforcements were double reinforcement
study are shown in Table 1 and the series of floor slab (double layred), with D10 (SD295A) used for the

63
main ones. To review the bonding force between recy- on site. After addition, the mixture was stirred at high
cled aggregate concrete and reinforcements, a lap speed for about 2 minutes. Regarding the properties
splice of 20 db (200 mm) in lapped length was used for of fresh concrete with drying shrinkage reducing
three bottom reinforcements and the remaining two agent added, it was found that both the air content and
were made through bar arrangement. With the cover- slump tended to be lower than those of concrete to
age thickness of 30 mm both for top and bottom sur- which no such agent had been added.
faces, concrete was flat-cast from the top. To identify
the drying shrinkage of recycled aggregate concrete,
100  100  400 mm specimens for length changes 3 TRANSITION OF CONCRETE STRENGTH
used in the JIS-A-1129 method of testing for changes AND YOUNG’S MODULUS
in concrete length were prepared together with the
floor slabs for measuring the rate of drying shrinkage. The transition of compressive strength is shown in
Figure 2 and that of Young’s modulus is shown in
Figure 3. Actual measurements of compressive
2.2 Drying shrinkage reducing agent
strength and Young’s modulus for recycled aggregate
For this research, a glycol ether-based drying shrink- concrete tended to increase with increasing material
age reducing agent was added at the rate of 10 kg/m3 age. Recycled aggregate concrete with drying shrink-
age reducing agent added showed both higher com-
Table 2. Series of concrete of floor slab. pressive strength and Young’s modulus than in the
case without this agent. This is probably because air
Series/ Drying
the rate of Age of shrinkage
content decreased and made the concrete more dense.
substitution flexural reducing On the other hand, actual measurements of Young’s
Specimens (%) Type experiment agent modulus tended to become lower than the values
determined using a standard formula for the calcula-
1) SR R series/ SR 5 weeks non addition tion of reinforced concrete structures [Architectural
2) A-SR recycled coarse addition
3) SRK aggregate 100 SRK 1 year non addition Institute of Japan 1999; AIJ Standard for Structural
4) A-SRK recycled sand 0 addition Calculation of Reinforced Concrete Structures].

5) SFR FR series/ SFR 5 weeks non addition


6) A-SFR recycled coarse addition 4 RATE OF DRYING SHRINKAGE
7) SFRK aggregate 100 SFRK 1 year non addition
8) A-SFRK recycled sand 100 addition
Figure 4 shows the transition of the rate of drying
A-: Drying shrinkage reducing agent, 10 kg/m3. shrinkage. The length-change specimens’ rates of

2100
50 2000 50 180
60

5-D10@120
600
480

600
60

dimensions in mm
110 35

Thickness of cover concrete:30 mm


180
35

300 500 500 500 300

Figure 1. Shape of floor slab.

64
drying shrinkage sharply increased until a material age started from the periphery of the floor slabs with their
of 27 weeks to above the target limits [Architectural large surface area subject to airing and, as the material
Institute of Japan 2003. JASS 5] of 800  106 and age advanced, extended inward. At one year, floor
stabilized thereafter. Recycled aggregate concrete slabs to which no drying shrinkage reducing agent
with drying shrinkage reducing agent added tended to had been added showed many fine drying shrinkage
have lower rates of drying shrinkage than in the case cracks, whereas floor slabs with agent showed fewer
without this agent. On the other hand, the rates of dry- drying shrinkage cracks. Thus, the smaller rate of
ing shrinkage of the floor slabs showed no increase drying shrinkage tended to cause fewer drying shrink-
until a material age of 3 weeks. This is probably age cracks.
because there was no fugitive emission of moisture
from within the concrete, since they underwent wet-
5.2 Width and depth of drying shrinkage cracks
compress curing. The rates of drying shrinkage of
the floor slabs tended to become lower than those of Figure 6 shows the width and depth of the drying
the specimens for length change. This is probably shrinkage cracks, which were measured after visually
because the shrinkage of floor slabs was restricted by selecting representative cracks. Figure 6 a) shows that
the arrangement of the reinforcement. the width of drying shrinkage cracks in recycled
aggregate concrete changed little up to one year. The
depth of drying shrinkage cracks at one year was
5 DRYING SHRINKAGE CRACKS ON FLOOR about 0.02 mm to 0.04 mm. Figure 6 b) shows that the
SLABS depth of drying shrinkage cracks was 9.5 mm to
17.0 mm, so it can be assumed that none of the cracks
5.1 Drying shrinkage cracks had reached the reinforcements in the floor slabs.
Figure 5 shows the drying shrinkage cracks that had
developed at one year. Drying shrinkage cracks were
-500
periodically observed by visually checking the top
surface of the floor slabs. Drying shrinkage cracks
Rate of drying shrinkage ε × 10-6

500

60 800
1000

1500
40
σB (N/mm2)

Floor slab Specimens for length change


2000 : SRK : LR
: A-SRK : A-LR
1 year : SFRK : LFR
20 : A-SFRK : A-LFR
5 weeks
:R 0 4 8 12 16 20 24 28 32 36 40 44 48 52 54
: A-R age (week)
0
0 4 8 12 16 20 24 28 32 36 40 44 48 52 56
Figure 4. Transition of rate of drying shrinkage.
age (week)

Figure 2. Transition of compressive strength (R series).


A D G

3 E

C F
E(×104 N/mm2)

2 a) SFRK (Non addition)


1 year
5 weeks

A D G
1
: R Measured value
: R FC Standard formula E
: A-R Measured value
: A-R FC Standard formula
0 C F
0 4 8 12 16 20 24 28 32 36 40 44 48 52 56
age (week) b) A-SFRK (Addition)

Figure 3. Transition of modulus of elasticity (R series). Figure 5. Drying shrinkage cracks (1 year).

65
0.30 Table 3. Test results.
Width of cracks W(mm)

A D G
0.25 B H
E Member Maximum
0.20 C F I
Top of floor slab
yield load
0.15
σB Py δy Pmax δmax failure
0.10
Specimens (N/mm2) (kN) (mm) (kN) (mm) mode
0.05
0 1) SR 27.5 57.0 3.89 78.8 40.02 F
0 4 8 12 16 20 24 28 32 36 40 44 48 52 2) A-SR 35.2 66.9 3.61 97.4 40.00 F
age (week) 3) SRK 32.8 59.7 4.25 89.6 38.67 F
(a) Width of drying shrinkage cracks (SFRK) 4) A-SRK 40.3 64.9 4.02 95.4 40.11 F
5) SFR 30.3 52.5 4.03 79.6 40.00 F
6) A-SFR 33.6 59.8 2.88 74.0* 38.04 FS
35
7) SFRK 34.8 59.2 5.28 89.4 40.11 F
Depth of cracks D(mm)

30 A D G
B E H
8) A-SFRK 38.3 59.4 3.85 90.1 24.08 FS
25 C F I
20 Top of floor slab σB: compressive strength.
15 F: flexural failure FS: bond splitting failure after yield.
10 * A-SFR: load of sprit failure 69.9(kN), δ  20.00(mm).
5
SFR type SFRK type
0
0 4 8 12 16 20 24 28 32 36 40 44 48 52
0.40
(5 weeks) (1 year)
age (week)
σt = 200 N/mm2
0.30
Wmax (mm)

(b) Depth of drying shrinkage cracks (SFRK) Restriction Value


0.25 mm
0.20
Figure 6. Transition of width and depth of drying shrink-
age cracks.
0.10

6 BENDING PROPERTIES
0
SFR

A-SFR

SFRK

A-SFRK
6.1 Maximum flexural cracks at allowable unit
stress for long-sustained loading
Table 3 lists the results of the flexural experiments.
Figure 7 shows the maximum flexural crack width at Figure 7. Maximum flexural crack widths under service
loading (FR series).
allowable unit stress for long-sustained loading on the
FR series which gave large rates of drying
Flexural crack widths were determined by measur- 126 :SRK
ing flexural cracks which developed in the net-flexural 108 :SR
floor slab section along bottom reinforcement lines δ

under a microscope (graduated at 0.02 mm minimum). 90


At one year, the maximum flexural crack width was 72
P (kN)

within the target RC standard limit of 0.25 mm. Since


crack widths on the bottom surface (tensile edge) of a 54
plane member are subjected when considering its
36
durability, the maximum flexural crack width on the
distorted bottom surface is assumed to be larger. Floor 18
slabs to which a drying shrinkage reducing agent had
0
been added tended to suffer smaller maximum flex- 10 20 30 40 50
ural crack widths than in the case without such agent. δ (mm)
Maximum flexural crack widths at one year tended to
be larger than those at 5 weeks. Figure 8. Load-deflection curves (R series).

6.2 Load-deflection curve


intensity by σt  100 N/mm2 each time. Post-member
Figure 8 shows the load-deflection curve. The load yield control of deflection was based on a yield
was repeatedly applied in the positive direction only deflection of δy. Strength against bending tended to
while gradually raising the main reinforcement stress be larger than that at 5 weeks. This is probably

66
126 the drying shrinkage reducing agent was effective
SRK type SFRK type
: SRK : SFRK
in minimizing cracks.
108 4) Experiments for floor slab bending found that the
:A-SRK : A-SFRK δ
90 maximum flexural crack width at allowable unit
stress for long-sustained loading tended to be
P (kN)

72 smaller when a drying shrinkage reducing agent had


54 been added than in the case without such agent.
5) Post-member yield strength against bending of
36 floor slabs with drying shrinkage reducing agent
added increased faster with increasing concrete
18
strength than in the case without such agent.
0
10 20 30 40 50 As mentioned above, when a drying shrinkage reduc-
δ (nm) ing agent was added to recycled aggregate concrete-
based floor slabs, not only were drying shrinkage
Figure 9. Load-deflection curves (Envelope curve). cracks lessened but also satisfactory strength against
bending was obtained. This suggests that the availabil-
ity of a drying shrinkage reducing agent and recycled
because the compressive strength of concrete was aggregate concrete could be used for members of rein-
larger at one year than at 5 weeks. Figure 9 shows forced concrete structures. Future studies are needed
load-deflection envelope curves. The rigidity of dry- to review how bar arrangement-dependent restrictions
ing shrinkage reducing agent-added floor slabs before by reinforcements affect the floor slabs’ rate of drying
the material yielded was larger than in the case with- shrinkage as well as drying shrinkage cracks.
out such agent.
After the member yielded, the load increased with
increasing deflection in all floor slabs, demonstrating ACKNOWLEDGEMENTS
satisfactory strength against bending, while in the case
with a drying shrinkage reducing agent added to the The authors would like to acknowledge the support of
FR series, A-SFRK suffered bond splitting failure. the Tokyo Disposal Association for Construction
Waste and F Company of admixture manufacturer.

7 CONCLUSION
REFERENCES
Regarding drying shrinkage cracks of floor slabs for
which recycled aggregate concrete was used, the fol- Architectural Institute of Japan 2003. Shrinkage Cracking in
lowing findings were obtained in this study: Reinforced Concrete Structures – Mechanisms and
Practice of Crack Control
1) Actual measurements of compressive strength and Hiroyuki Tanano, Tadatsugu Kage, Hitoshi Hamasaki and
Young’s modulus tended to be larger when a dry- Noriaki Nishiura 2006. Research on Practical use and
ing shrinkage reducing agent had been added than Performance Evaluation of Recycled Aggregate
in the case without this agent. Concrete, Proceedings of the Japan Concrete Institute,
2) The drying shrinkage rate of drying shrinkage Vol.28: pp. 131–136
Architectural Institute of Japan revised 1999. AIJ Standard
reducing agent-added specimens for length
for Structural Calculation of Reinforced Concrete
change tended to be lower than in the case without Structures – Based on Allowable Stress Concept
such agent. Architectural Institute of Japan 2003. Japanese Architectural
3) Since drying shrinkage cracks of floor slabs Standard Specification for Reinforced Concrete Work
decrease with decreasing rate of drying shrinkage, JASS 5

67
Sustainable Construction Materials and Technologies – Chun, Claisse, Naik & Ganjian (eds)
© 2007 Taylor & Francis Group, London, ISBN 978-0-415-44689-1

Recycling of concrete in precast concrete production

V. Corinaldesi & G. Moriconi


Università Politecnica delle Marche, Ancona, Italy

ABSTRACT: This work aimed at evaluating the influence of the use of recycled concrete aggregates on the
mechanical performance of precast concrete. Recycled concrete was obtained as scraps of the precasting
process itself and characterized by physical properties quite close to those of ordinary aggregates, due to the
high strength class of the original concrete, which was in the range 50–55 MPa. Several substitution percentages
were tried, between 5% and 30% by weight of the total amount of aggregate used for preparing concrete, in
order to establish the maximum replacement percentage that could allow the same concrete strength class to be
maintained. For this purpose, several concrete mixtures were prepared using rejected concretes coming from
different precasting plants. Concrete performance was evaluated after 1, 7 and 28 days of wet curing, in terms
of compressive strength. The results obtained showed that the quality of the old concrete influences the maxi-
mum substitution percentage that can be tolerated. When the original strength class is 55 MPa, the substitution
can be carried out at a percentage of up to 30%. In addition, the drying shrinkage of two concrete mixtures
prepared with 70% of one of these recycled concrete fractions was monitored for 100 days of curing at a rela-
tive humidity of 65% and a temperature of 15°C. The results obtained were encouraging, particularly when a
shrinkage-reducing admixture was added to the concrete mixture in addition to a water-reducing admixture.

1 INTRODUCTION completion, as well as an economic achievement


[Corinaldesi & Moriconi 2001].
At present, it is widely accepted that economic devel- In fact, the disposal of cementitious waste pro-
opment must be sustainable, as far as minimisation of duced during manufacturing of precast concrete ele-
environmental impacts and safe-guarding of non- ments implies growing problems related to increasing
renewable resources is concerned. In particular, the transportation costs and increasing charges for their
opportunity of re-using solid waste materials as a delivery to the landfill. On the other hand, their down-
replacement for those extracted from quarries in build- cycling as backfill in road or pavement sub-bases, for
ing construction is becoming more and more wide- example, even if excellent from a technical and eco-
spread [Bassan & Galimberti 1995, Bassan 1996, nomical point of view, can be a concern due to the
Corinaldesi & Moriconi 2002a, Corinaldesi et al. 2001, potential leaching of hazardous substances derived
Moriconi et al. 2003]. This approach is consistent with from the cement, at least as far as Italian Standards
the concept of solid waste, accepted in the European are concerned [Carrescia et al. 2004].
Community as well as in the individual member Coun- On the other hand, the recycling of waste materials
tries, as a new resource that can be recycled in the pro- as aggregates for new concrete in the prefabrication
duction process and not simply disposed of in landfills. process could be considered ideal. Moreover, since the
The main objective of the research program is to waste material volume in prefabrication plants is rela-
demonstrate that scraps coming from the manufacture tively low, limited replacement of natural with recy-
of precast, reinforced concrete (R/C) or prestressed cled aggregate (RA) could be sufficient to manage all
concrete (P/C) elements, can be re-used as RAs to of the production scraps, at the same time gaining fur-
partially replace natural aggregates from quarries in ther environmental advantage, in terms of reduced
the production of concrete for manufacturing new extraction from quarries.
reinforced concrete elements with unchanged mechan- The use of nontraditional materials to manufacture
ical performance. concrete can affect the mechanical behavior as well as
The goal would be remarkable from an environ- the durability of the final products, as suggested by the
mental point of view, implying concrete life-cycle results of the research so far carried out [Corinaldesi

69
et al. 2001, Corinaldesi & Moriconi 2002b, Corinaldesi is sufficient to achieve a standard grain size distribu-
et al. 2002a, Corinaldesi et al. 2002b, Corinaldesi & tion, regardless of the original grain size distribution,
Moriconi 2006]. even when this is almost monomodal with a relatively
Recent research developments have highlighted two high maximum grain size, as shown in Figure 2.
very important aspects that justify this work. The first Moreover, the crushing step appears necessary to
one is related to the durability of RA concrete, which achieve a grain size distribution consistent with optimal
was shown to be higher than that of an ordinary con- aggregate grading when crushed recycled-concrete frac-
crete [Corinaldesi & Moriconi 2002b, Corinaldesi tions are combined with ordinary aggregate fractions.
et al. 2002b]. This result can be ascribed to two factors: Finally, the RA shape obtained after crushing was
(i) the filling effect, and sometimes pozzolanic reac- optimal for use in concrete manufacturing, according
tion, of the fine RA fractions and (ii) the improvement to Italian European Standards UNI EN 933-3 and
of the interface between RA and the surrounding UNI EN 933-4.
cement paste, which is better the higher the concrete
content of the RA. The second aspect is related to the
2.2 Chemical and physical characterization of the
mechanical strength loss of RA concrete, which is
recycled-concrete aggregate
strongly dependent on the RA quality; in fact, it is
completely cancelled out when RA consists of con- The physical properties of the recycled-concrete
crete belonging to a strength class equal to or higher aggregate fractions were determined after laboratory
than that of the new concrete in which they will be grinding.
introduced [Coppola et al. 1995]. The water content of each fraction was determined
by drying according to UNI EN 1097-5. The aggre-
gates’ apparent densities and their water absorptions
2 MATERIALS AND METHODS were then determined by following the methods in UNI
EN 1097-6. The results obtained are reported in Table 2.
2.1 Preparation and set up of the recycled-concrete Alkali-silica reactivity tests were also carried out
aggregate fractions according to ASTM C289. No reactivity of the exam-
ined fractions, all characterized by a very low value of
The first step was cataloguing, based on the concrete
dissolved silica, could be observed.
original strength class and structural use reported
in Table 1, the various grain size fractions of production
scraps received from different prefabrication plants. 2.3 Recycled-aggregate concrete mixtures
Each recycled-concrete fraction grading has been
The influence of recycled-concrete aggregate on
characterized as received, before laboratory crushing
workability of fresh concrete and compressive strength
to a maximum grain size of 10 mm. The grain size
of hardened concrete, was evaluated on twelve mix-
distribution of each crushed fraction was then deter-
tures laboratory prepared by varying the RA origin
mined without any preliminary sieving. The results
and the natural aggregate replacement percentage
reported in Figure 1 show that a single crushing step
(see Table 3).
The reference mixture (Ref, 0% replacement) was
Table 1. Cataloguing of the recycled-concrete fractions. prepared by combining a natural sand (0–5 mm) and
two crushed natural stone fractions (2–10 mm and
Structural Strength class 5–25 mm, respectively).
Fraction Plant element (MPa) Test mixtures were prepared by using B, D, E, F and
H recycled-concrete crushed fractions (characterized
A 1 P/C Beam 55
B 1 R/C Column 50 by grain size distributions within 0–12 mm, as shown in
C 1 Extruded P/C 55 Figs. 1–2) by replacing the finer of the two natural
Hollow-core Slab crushed fractions (2–10 mm) at percentages varying
D 2 – (1) n.a. (3) from 5 to 30% by mass of the total aggregate amount.
E 3 – (2) n.a. (3) Water to cement ratio (0.5) and fresh workability
F 4 P/C Hollow-core n.a. (3) (fluid consistency) were kept constant for all the mix-
Slab tures as well as the dosage of an acrylic-based super-
G 5 R/C Column 50 plasticizer equal to 1% by mass of cement.
H 5 P/C Hollow-core 55
Slab
I 5 P/C Beam 55 2.4 Compression tests on recycled-aggregate
(1)
concretes
Concrete crushed by mechanical pliers and crusher.
(2)
Concrete crushed by mechanical pliers. Compressive strength tests were carried out on 100 mm
(3)
Data not available. cubic specimens after 1, 7 and 28 days room curing.

70
100
A

Cumulative (%) passing the sieve


A CRUSHED
80 B
B CRUSHED
C
60 C CRUSHED
D
D CRUSHED
40 F
F CRUSHED

20

0
0.01 0.1 1 10 100 1000
Sieve opening (mm)

Figure 1. Grain size distribution of recycled-concrete fractions A, B, C, D and F before (filled symbols) and after (empty
symbols) crushing.

100
E
Cumulative (%) passing the sieve

80 E CRUSHED
G
G CRUSHED
60 H
H CRUSHED
I
40
I CRUSHED

20

0
0.01 0.1 1 10 100 1000
Sieve opening (mm)

Figure 2. Grain size distribution of recycled-concrete fractions E, G, H and I before (filled symbols) and after (empty
symbols) crushing.

Table 2. Main physical properties of the recycled-concrete The results are reported in Figures 3, 4 and 5 respec-
aggregate. tively. Except the B fraction, with lower strength class
and higher water absorption, the replacement of natu-
Water Specific gravity in s.s.d.(*) ral crushed aggregate with recycled concrete did not
Fraction absorption (%) conditions (g/cm3)
cause significant changes in the 1-day, 7-day and
A 8.34 2.31 28-day compressive strengths, independently of the
B 9.21 2.16 RA origin and replacement percentage.
C 7.70 2.25
D 5.56 2.34 2.5 Drying shrinkage tests
E 7.26 2.24
F 7.63 2.22 In order to evaluate the behavior of concretes containing
G 7.86 2.18 recycled concrete as aggregate in terms of drying
H 8.34 2.21 shrinkage, two concrete mixtures were prepared with the
I 9.97 2.07 same water to cement ratio of 0.45 and the same work-
ability (170 mm slump, corresponding to fluid consis-
(*)
s.s.d.  saturated surface-dried. tency), by varying the kind of chemical admixture.

71
Table 3. Concrete mixture proportions (dosages expressed as kg/m3 of concrete).

Natural fine Natural coarse Recycled-concrete


Natural crushed crushed crushed
Superpl. sand fraction fraction fraction
Mixture W/C Water Cement Admix. (0–5 mm) (2–10 mm) (5–25 mm) (0–12 mm)

Ref 0.50 175 350 3.5 535 535 715 –


B-5% 0.50 175 350 3.5 535 89 715 82 (type B)
B-10% 0.50 175 350 3.5 535 178 715 165 (type B)
B-30% 0.50 175 350 3.5 535 – 715 490 (type B)
D-5% 0.50 175 350 3.5 535 89 715 88 (type D)
D-10% 0.50 175 350 3.5 535 178 715 177 (type D)
E-5% 0.50 175 350 3.5 535 89 715 85 (type E)
E-10% 0.50 175 350 3.5 535 178 715 170 (type E)
F-5% 0.50 175 350 3.5 535 89 715 85 (type F)
F-10% 0.50 175 350 3.5 535 178 715 170 (type F)
H-5% 0.50 175 350 3.5 535 89 715 83 (type H)
H-10% 0.50 175 350 3.5 535 178 715 165 (type H)

70
Compressive strength after 1 day of curing (MPa)

60

50

40

30

20

10

0
Ref B-5% B-10% B-30% D-5% D-10% E-5% E-10% F-5% F-10% H-5% H-10%

Figure 3. Compressive strength after 1 day of curing of recycled-aggregate concretes.

In Table 4 the mixtures proportions of these con- this aggregate fraction was combined with 30%
cretes are reported. of natural sand in order to guarantee optimal
The mixture indicated as ‘H-70%’ was prepared grain size distribution of the whole inert fraction
with the same acrylic-based superplasticizer previ- according to the Bolomey particle size distribution
ously employed, at the dosage of 0.8% by mass of curve.
cement in order to achieve a 25% water reduction. The ‘H-70%  SRA’ mixture was prepared by
This concrete was prepared by using the recycled- using a multifunction superplasticizer obtained by
concrete aggregate type ‘H’ as coarse aggregate attaching a shrinkage reducing group (SRA) to the
(see Table 1, Table 2 and Fig. 2). 70% by volume of polycarboxylate polymer. In this way both water

72
70
Compressive strength after 7 days of curing (MPa)

60

50

40

30

20

10

0
Ref B-5% B-10% B-30% D-5% D-10% E-5% E-10% F-5% F-10% H-5% H-10%

Figure 4. Compressive strength after 7 days of curing of recycled-aggregate concretes.

70
Compressive strength after 28 days of curing (MPa)

60

50

40

30

20

10

0
Ref B-5% B-10% B-30% D-5% D-10% E-5% E-10% F-5% F-10% H-5% H-10%

Figure 5. Compressive strength after 28 days of curing of recycled-aggregate concretes.

dosage and concrete shrinkage can be reduced. It was In both concretes, the aggregate fractions were pre-
added at a dosage of 1.6% by mass of cement, in viously water soaked. This operation is particularly
order to achieve the same water reduction (25%) important for the recycled concrete aggregate, which
obtained in the previous concrete mixture. had a water absorption of 8.34%, as shown in Table 2.

73
Table 4. Mixture proportions of recycled-aggregate concrete, kg/m3 of concrete.

Mixtures H-70% H-70%  SRA

Water/Cement 0.45 0.45

Water 165 165


Cement 365 365
Natural sand (0–5 mm) 550 545
Recycled concrete (0–12 mm) 1195 1190
Superplasticizing admixture 3 –
Superplasticizer with SRA – 6

100

50 H-70%
Drying shrinkage (microstrain)

H-70%+SRA
0

-50

-100

-150

-200

-250
0 20 40 60 80 100
Curing time at 15˚C and 65% R.H. (days)

Figure 6. Free drying-shrinkage measurements vs. curing time.

Absorbed water can provide an internal water supply, value of drying shrinkage was less than 250 µm/m
thus reducing drying shrinkage of concrete. after 100 days of testing. Therefore, if previously water
After 28 days of curing, the compressive strength soaked, the recycled-concrete aggregate seems to per-
values, measured on 100 mm concrete cubes were form satisfactorily in terms of drying shrinkage.
45 MPa and 49 MPa for the ‘H-70%’ and the
‘H-70%  SRA’ concrete respectively.
For the evaluation of concrete drying shrinkage, 3 CONCLUSIONS
three prismatic specimens (100 by 100 by 500 mm)
were cast for each concrete mixture, wet cured for 2 Preliminary results obtained on mechanical perform-
days at a temperature of 15°C, then cured at the same ance of concrete made by replacing crushed natu-
temperature and a relative humidity of 65% up to 100 ral aggregate with recycled concrete, discarded by
days. The results obtained are reported in Fig. 6. prefabrication plants and re-used on the spot, confirm
By comparing drying-shrinkage strains, the effec- that making RA concrete for structural use is feasible
tiveness of the superplasticizer incorporating a shrink- and cheap. This practice could provide an adequate
age reducing group is evident after 100 days: concrete solution to environmental issues, such as increasingly
shrinkage was decreased by 75%. The measured value limited availability of material from quarries and
of drying shrinkage was very low in this case, less than landfill space. Furthermore, this approach would
60 µm/m after 100 days of testing. Also, in the make concrete a more sustainable material by lower-
absence of a special superplasticizer, the measured ing its environmental impact.

74
The results obtained showed that the quality of the CANMET/ACI International Symposium, San Francisco,
old concrete influences the maximum substitution U.S.A., September 16–19, 2001. Publication SP-202:
percentage which can be tolerated. When the original 161–180. Farmington Hills, MI, USA: American Concrete
strength class is 55 MPa, the substitution can be car- Institute.
Moriconi, G., Corinaldesi, V. & Antonucci, R., 2003.
ried out at a percentage of up to 30%. Environmentally-friendly mortars: a way to improve
In addition, the drying shrinkage behavior of concre- bond between mortar and brick, Materials & Structures
tes prepared with 70% of one of these recycled concrete 36(264): 702–708.
fractions was good, particularly when a shrinkage- Corinaldesi, V. & Moriconi, G., 2001. Role of Chemical and
reducing admixture was added to the concrete mixture Mineral Admixtures on Performance and Economics of
beyond that of simply a water-reducing type. Recycled-Aggregate Concrete, In V.M. Malhotra (ed.), Fly
Ash, Silica Fume, Slag and Natural Pozzolans in Concrete;
Proc. Seventh CANMET/ACI International Conference,
ACKNOWLEDGEMENTS Madras, India, July 22–27, 2001. Publication SP-199:
Volume 2, 869–884. Farmington Hills, MI, USA:
American Concrete Institute.
The writers acknowledge the grant of the ministry of Corinaldesi, V. & Moriconi, G. 2002b, Durability of
University and Research of Italy (MIUR), as well as Recycled-Aggregate Concrete Incorporating High Volume
the contribution of the Association of Cement of Fly Ash, In S. Burn (ed.), Durability of Building
Producers (AITEC) and of the Precasting Companies Materials and Components; Proc. 9th International
Precompressi Centro-Nord, Generale Prefabbricati Conference, Queensland, Brisbane, Australia, March
and RDB. 17–20, 2002. Paper 71.
Corinaldesi, V., Orlandi, G. & Moriconi, G. 2002a, Self-
Compacting Concrete Incorporating Recycled Aggregate,
In R.K. Dhir, P.C. Hewlett and L.J. Csetenyi (eds.),
REFERENCES Innovations and Developments in Concrete Materials and
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Bassan, M. & Galimberti, V., 1995. Recycling of concrete: of Concrete Construction’, Dundee, Scotland, U.K., 9–11
foreseeable development possibilities in Italy, Proc. R’95, September 2002. Thomas Telford, London, U.K., 2002:
World Congress on Integrated Resources Management, 455–464.
Geneva, February 1–3. Corinaldesi, V., Moriconi, G. & Tittarelli, F. 2002b, Durability
Bassan, M., 1996. Recycling of concrete: reality, goal, of Reinforced Concrete for Sustainable Construction, In
prospective (in italian), Proc. 15° ATE Congress on V.M. Malhotra (ed.), Innovation in Design with Emphasis
“Demolition techniques and reuse of building waste”, on Seismic, Wind and Environmental Loading, Quality
Milano, May 28. Control and Innovation in Materials/Hot Weather
Carrescia, P.G., Fava, G. & Sani, D., 2004. Regulation aspects Concreting; Proc. Fifth ACI International Conference,
and a dynamic leaching test for non-ferrous slag recycling Cancun, Mexico, December 10–13, 2002, Publication SP-
in concrete manufacturing, Proc. VII AIMAT Congress, 209: 169–186. Farmington Hills, MI, USA: American
Ancona, Italy, Paper 46. Concrete Institute.
Corinaldesi, V. & Moriconi, G. 2002a. Rubble Processing to Corinaldesi, V., & Moriconi, G. 2006, Behavior of Beam-
Manufacture Structural Recycled-Aggregate Concrete, In Column Joints Made of Sustainable Concrete under
Wang Pei-ming (ed.), Proc. 5th International Symposium Cyclic Loading, Journal of Materials in Civil
on Cement and Concrete, Shanghai, China, 2002. Tongji Engineering 18(5): 650–658.
University Press, Shanghai, China, Volume 2: 796–802. Coppola, L., Monosi, S., Sandri, S. & Borsoi, A. 1995,
Corinaldesi, V., Tittarelli, F., Coppola, L. & Moriconi, G. Recycling of demolished r.c. and p.r.c. structures to man-
2001. Feasibility and Performance of Recycled-Aggregate ufacture new concrete (in Italian), L’Industria Italiana
Concrete Containing Fly Ash for Sustainable Building del Cemento, 705: 715–728.
Development, In V.M. Malhotra (ed.), Sustainable
Development of Cement and Concrete; Proc. Three-Day

75
Sustainable Construction Materials and Technologies – Chun, Claisse, Naik & Ganjian (eds)
© 2007 Taylor & Francis Group, London, ISBN 978-0-415-44689-1

Concrete paving products made with recycled demolition aggregates

K. Tang, M.N. Soutsos & S.G. Millard


Department of Engineering, University of Liverpool, Liverpool, UK

ABSTRACT: The potential for using construction and demolition waste (C&DW) derived aggregate in the
manufacture of concrete paving blocks is being investigated at the University of Liverpool. Market research
indicated that economic benefits might be achieved by using recycled demolition aggregates in precast concrete
paving products. The mechanical properties, i.e., compressive and tensile splitting strength, of paving blocks
made with recycled demolition aggregates were also investigated. Levels of aggregate replacement were deter-
mined that produced blocks with similar mechanical properties to those of blocks made using only natural
aggregates, without requiring an increase in the cement content.

1 INTRODUCTION Table 1. Supplier gate price for quarried aggregates used


in concrete paving blocks.
In 1999, C&DW in the EU amounted to 450 million
tonnes [Symonds, 1999], approximately 25% of all £/tonne
waste generated that year. Only 25% of this C&DW
6 mm limestone (20% of total aggregate) 8.00 to 10.00
was recycled or re-used. In 2005, the UK produced Medium grading sand (80% of total 6.00
72.5 million tonnes of C&DW [EIONET, 2005] aggregate)
(including excavated soils) of which only 35% was Total cost of importing quarried aggregates 6.40 to 6.80
recycled [Communities and local government, 2005].
During this time, 270 million tonnes of quarried
aggregates were extracted [ODPM, 2006]. As a waste
reduction measure, the UK Government aims to Concrete paving blocks were selected for investiga-
increase the use of recycled and secondary aggregates tion for the following reasons:
from 40 million tonnes up to 55 million tonnes by
2006 and up to 60 million tonnes by 2011 [Collins • High usage. It is estimated that 100 square feet
et al. 2005]. Recycled aggregates are currently used ( 9 m2) per person of paving blocks are installed
primarily for low-grade applications such as granular annually in Europe [Concrete network, 2006].
sub-base of road pavements. There is therefore a need • The risk of steel corrosion damage resulting from
to investigate a high value market for C&DW derived chloride contaminated C&DW will not be an issue
aggregates. because conventional paving blocks are not rein-
As precast concrete paving blocks are low-profit- forced with steel.
margin products, block-making factories will be • The production of concrete paving products is a
interested in C&DW derived aggregates if the price is manufacturing process where the supply and stor-
lower than that of quarried aggregate. The price of age of materials is more easily managed than with
natural aggregates (see Table 1) is likely to increase, concrete used for in-situ construction.
especially after the introduction of the Aggregate The use of crushed concrete- and masonry-derived
Levy Tax. This will encourage companies to consider aggregates to replace both coarse and fine natural
using recycled demolition aggregate which will almost aggregates in concrete building blocks has already
certainly be cheaper. In areas such as North West been investigated at the University of Liverpool
England, where precast factories are situated close to [Soutsos et al. 2004]. Building blocks using up to
urban areas and local natural aggregate resources are 60% replacement of quarried coarse aggregate with
limited [Soutsos et al. 2004], use of recycled demoli- concrete-derived C&DW aggregate achieved a simi-
tion aggregates may also reduce transportation costs. lar compressive strength to those made using 100%

77
quarried limestone aggregate, without requiring an demolition material supplied was crushed to the
increase in the cement content. Poon and Chan stud- required coarse (6 mm) and fine (4 mm to dust)
ied the use of recycled crushed clay brick and recycled aggregate size.
concrete aggregate in the manufacture of concrete
paving blocks [Poon et al,. 2006]. The paving blocks
had a compressive strength between 25 and 63 MPa at 3 MATERIALS & EXPERIMENTAL
28 days, depending on the percentage of recycled METHODS
material used. Both studies also showed a different
detrimental influence on the mechanical properties 3.1 Recycled aggregates used in this project
depending on whether recycled concrete- or recycled
The use of recycled aggregate in designated concrete
masonry-derived aggregates were used. For this rea-
mixes is now permitted by BS 8500-2:2002 [BSI,
son, recycled concrete and recycled masonry were
2002]. This is the first UK specification for the use of
investigated separately in this project.
C&DW derived aggregates in concrete. The grading
of 6 mm recycled aggregate from both concrete and
masonry demolition waste was found to be similar
2 AVAILABLE OF C&DW-DERIVED to that of quarried limestone (see Fig. 3). However,
AGGREGATE recycled 4 mm-to-dust aggregate derived from masonry
demolition waste was found to be significantly finer
The market demand for C&DW-derived aggregates than natural medium graded sand. The converse was
can be assured in an urban area such as Liverpool,
where on-going replacement of infrastructure is asso-
ciated with high costs of C&DW disposal. Currently,
demolition of around 20,000 houses is planned in
Merseyside as part of a ‘housing market renewal’
[Clover, 2005] scheme. As part of a regeneration plan
to build a dual carriageway road into Liverpool city
centre, hundreds of houses will be demolished by
2008 [BBC, 2006].
The concrete C&DW that was crushed to produce
aggregate for this study came from a reinforced con-
crete tower block (see Fig. 1). The masonry C&DW
came from the demolition of a row of council houses
(see Fig. 2). Demolition waste material was transported
and crushed at a local crushing plant. The crusher was
unable to crush all of this material into the required size
despite utilizing a ‘choke feed’ technique [Soutsos et al.
2004]. Even with this technique only 30% of the total Figure 2. Demolition of a masonry council house.

Figure 3. Sieve grading of natural aggregate and C&DW


Figure 1. Demolition of a reinforced concrete tower block. derived aggregate.

78
found to be true for fine recycled aggregate derived 50
from concrete demolition waste (see Fig. 3).
Recycled aggregate from both concrete and masonry
demolition wastes had a much higher water absorp-
tion and a lower density (see Table 2). The lower den- 45
sity and higher water absorption of C&DW-derived

Compressive strength (MPa)


aggregates were expected to be problematic [Soutsos
et al. 2004].
40

3.2 Preliminary trials – development of


‘vibro-compaction’ technique 35
The block-making industry uses a heavy vibrating
compactor to compress the concrete into a block
mould. In the first phase of the project, the factory 30
procedure was replicated in the laboratory by using a
vibration hammer to compact the concrete from
above. However, preliminary trials using a range of
water-cement ratios indicated that, despite using sim- 25
ilar mix proportions to the factory, the target com- 0.25 0.30 0.35 0.40
pressive and tensile splitting strengths of 49 MPa and
3.6 MPa, respectively, were not achieved. A study of Free W/C
the compressive strength results also indicated that
Figure 4. Compressive strength (7-day) vs water-cement
for a water-cement ratio below 0.30, full compaction ratio, using vibration compaction from above.
was not achieved (see Fig. 4). Another approach was
investigated to improve the compaction, which involved
increasing the compressive force and dispensing with
vibration. A pressure of up to 15 N/mm2 was applied
to the fresh concrete to compact the specimens. The
resulting low compressive strength indicated that
compression alone was insufficient and that simulta-
neous compression and vibration was necessary to
achieve the required compaction.
Efforts were then focused on modifying the exist-
ing frame used with the vibration hammer to enable
compression and vibration from both above and
below. A small metal table was converted to a vibrat-
ing table by attaching a clamp-on-vibrator.
This table was used in conjunction with the vibration
hammer so that specimens could be vibrated above and
below, while they were being compacted (see Fig. 5).
The use of this combined vibro-compaction technique,
together with the use of a superplasticiser, enabled the Figure 5. Combination of vibrating table and vibration
wet density of paving blocks to be increased from hammer to cast concrete paving blocks.

Table 2. Relative density and water absorption (% of dry mass).

Fine aggregate Coarse aggregate

Sand Concrete Masonry Limestone Concrete Masonry

Relative density (Saturated 2.44 2.25 2.42 2.69 2.38 2.26


and Surface Dry)
Relative density (oven dry) 2.41 1.82 2.01 2.67 2.27 2.11
Moisture Absorption 1.5 13.56 13.42 0.65 7.24 8.83

79
2230 kg/m3 (achieved by vibro-compaction only) 4 THE EFFECT OF RECYCLED
to 2390 kg/m3. Compressive strengths greater than DEMOLITION AGGREGATE ON THE
49 MPa and tensile splitting strengths greater than MECHANICAL PROPERTIES OF
3.6 MPa were achieved at 28 days. The original texture CONCRETE PAVING BLOCKS
of concrete paving blocks cast in the laboratory using
the improved vibro-compaction technique compared 4.1 Series I: Concrete-derived C&DW aggregate
well with that of paving blocks obtained from the After successfully replicating the industrial block-
factory (see Fig. 6). making procedure in the laboratory, the replacement
of quarried limestone with concrete-derived C&DW
aggregates was studied. The mix proportions of the
control mix using only natural aggregates was con-
verted to a volumetric ratio and natural aggregate was
replaced by an equal volume of C&DW-derived aggre-
gate. This volumetric replacement approach allows for
the different density of recycled aggregates and
enables production of blocks of the same physical size
from different mixes (see Table 3 & 4). Each series of
mixes commenced with an initial cement content of
230 kg/m3. This was incrementally raised to 380 kg/m3
to yield specimens with a range of cement contents but
the same replacement aggregate ratio.
It was thought that the fine aggregate, i.e., 4 mm-to-
dust, would have the most detrimental effect on com-
pressive strength [Soutsos et al. 2004]. Studies were
planned using a replacement of either coarse or fine
aggregate alone, to quantify the relative effects of each.
Concrete paving blocks use a high ratio of 4:1
fine/coarse aggregate in order to achieve a high-qual-
ity surface finish. It was found that a reduction in the
water-cement (W/C) ratio was required to obtain a
Figure 6. Cross-section texture: industry and laboratory comparable compressive strength for a block using
cast specimens. concrete-derived aggregate (see Fig. 7). A reduction

Table 3. Mix proportions (kg/m3) for concrete paving blocks – Replacement of coarse natural aggregate with masonry-
derived coarse aggregate.

Fine aggregate
Coarse aggregate (6 mm) (4 mm-to-dust)

Mix Type Cement Limestone Masonry Sand Masonry Free W/C

Control (100% quarried aggregate) 230 380 1521 0.39


305 380 1521 0.36
380 380 1521 0.33
25% Coarse replaced 230 285 80 1520 0.48
305 285 80 1520 0.40
380 285 80 1520 0.39
50% Coarse replaced 230 190 160 1520 0.47
305 190 160 1520 0.39
380 190 160 1520 0.36
75% Coarse replaced 230 95 240 1520 0.42
305 95 240 1520 0.35
380 95 240 1520 0.33
100% Coarse replaced 230 319 1520 0.39
305 319 1520 0.33
380 319 1520 0.32

80
Table 4. Mix proportions used for concrete paving blocks – Replacement of fine fraction of aggregates with concrete-
derived aggregates.

Fine aggregate
Coarse aggregate (6 mm) (4 mm-to-dust)

Mix Type Cement Limestone Concrete Sand Concrete Free W/C

Control (100% quarried aggregate) 230 380 1521 0.39


305 380 1521 0.36
380 380 1521 0.33
25% Fine replaced 230 380 1140 351 0.38
280 380 1140 351 0.35
330 380 1140 351 0.33
380 380 1140 351 0.31
50% Fine replaced 230 380 760 701 0.41
280 380 760 701 0.37
330 380 760 701 0.35
380 380 760 701 0.33
75% Fine replaced 230 380 380 1052 0.39
280 380 380 1052 0.36
330 380 380 1052 0.34
380 380 380 1052 0.33
100% Fine replaced 230 380 1402 0.42
280 380 1402 0.38
330 380 1402 0.36
380 380 1402 0.34

80 5.0

75
Control 4.5
70
Tensile splitting strength (MPa)

25%-C
Compressive strength (MPa)

65 Control
4.0
60 50%-C 25%-C

3.5 50%-C
55
75%-C
50
3.0
45 100%-C

40 2.5
75%-C
35
100%-C 2.0
30

25 1.5
0.30 0.35 0.40 0.45 0.30 0.35 0.40 0.45
Free W/C Free W/C
(a) Compressive strength (b) Tensile splitting strength

Figure 7. Effect of W/C on 7-day strength of blocks using different replacement levels (%) of concrete-derived fine
aggregate.

81
80 5.0
28 days
75
28 days 4.5
70

Tensile splitting strength (MPa)


65
Compressive strength (MPa)

4.0
60
3.5
55

50 7 days
3.0
45 7 days

40 2.5

35
2.0
30

25 1.5
0 20 40 60 80 100 0 20 40 60 80 100
Replacement ratio (%) Replacement ratio (%)
(a) Compressive strength (b) Tensile splitting strength

Figure 8. Effect of replacement level (%) on strength of blocks using concrete-derived fine aggregate.
(All mixes contained 380 kg/m3 of cement. The free water had to be increased with increasing replacement levels to maintain
the same workability).

80 5.0

75
4.5
70 Control
Control
Tensile splitting strength (MPa)

65 4.0
Compressive strength (MPa)

25%-M 25%-M
60
50%-M
3.5
55
50%-M
50
3.0
75%-M
45

40 2.5

35 75%-M
100%-M 2.0
30
100%-M
25 1.5
0.20 0.30 0.40 0.50 0.20 0.30 0.40 0.50
Free W/C Free W/C
(a) Compressive strength (b) Tensile splitting strength

Figure 9. Effect of water cement ratio on 7-day strength of blocks using different replacement levels (%) of masonry-
derived coarse aggregate.

82
80 5.0

75 28 days
4.5
70 28 days

65

Tensile splitting strength (MPa)


4.0
Compressive strength (MPa)

60

55 3.5

50 49MPa
3.0
45
7 days
40 2.5

35 7 days
2.0
30

25 1.5
0 20 40 60 80 100 0 20 40 60 80 100
Replacement ratio (%) Replacement ratio (%)
(a) Compressive strength (b) Tensile splitting strength

Figure 10. Effect of replacement level (%) on strength of blocks using masonry-derived coarse aggregate.
(All mixes contained 380 kg/m3 of cement. The free water had to be increased with increasing replacement levels to maintain
the same workability).

in the water-cement ratio also necessitated an increase 4.2 Series II: Masonry-derived C&DW aggregate
in the cement content to obtain a high-quality surface
The replacement of newly quarried limestone aggregate
finish. It appears that the consistency of the mix is
with masonry-derived C&DW aggregate was investi-
dependent on the FREE water content, i.e., the FREE
gated separately from concrete-derived aggregate.
water content needs to be constant for all water-
It was again found that a lower W/C is needed if
cement ratios. This observation is consistent with the
blocks made using masonry-derived C&DW aggre-
design of normal concrete mixes. The total water con-
gate are to have the same strength as blocks using
tent will of course increase to account for the higher
quarried limestone. A lower W/C also necessitated an
percentages of water absorption of the recycled dem-
increase in cement content. The dependence of the
olition aggregate.
mix consistency on the free W/C using masonry-
Fig. 8 shows that the detrimental effect on the
derived C&DW aggregate was similar to that observed
compressive strength from replacing natural fine
using concrete-derived aggregate (see Fig. 9). It was
aggregates with concrete-derived C&DW aggregates
concluded that a replacement level of up to 60% for
is relatively small, with a reduction 10% in the 28-
the coarse masonry derived aggregate could be
day strength at a replacement level of 75%. However,
recommended (see Fig. 10).
the resulting tensile strength showed considerable
variability and hence a conservative recommendation
of a maximum replacement level of 60% for fine
concrete-derived C&DW aggregates is made. Further 5 CONCLUSIONS
experimental work is being conducted to investigate
the combined use of both coarse and fine concrete With the introduction of the Aggregate Levy Tax, eco-
derived C&DW aggregates. It is to be hoped that nomic benefits might be achieved from using recycled
these studies will confirm and further increase demolition aggregates in the manufacture of precast
confidence in the above replacement level recom- concrete paving blocks. Concrete paving blocks, with a
mendations. replacement of up to 60% of coarse natural aggregates

83
with recycled masonry-derived aggregates, can still British Geological Survey. Construction aggregates.
achieve equivalent strength without the need for http://www.mineralsuk.com/britmin/mpfaggregates.
increased cement content. It was also concluded that a pdf British Geological Survey (15/7/2006)
replacement of 60% of the fine natural aggregate with Collins, R. J., Dunster, R. J. & Kennedy, J. 2004. Improving
Specifications for use of Secondary and Recycled Aggre-
concrete-derived aggregates could be recommended. gates in Construction: Research Report. http://www.
aggregain.org.uk/templates/temp_agg_publication_details.
rm?id2298&publication1869 The Waste &
ACKNOWLEDGEMENTS Resources Action Programme (WRAP) (28/08/05).
Soutsos, M. N., Millard, S. G., Bungey, J. H., Jones, N.,
The authors wish to thank the Veolia Environmental Tickell, R. G., and Gradwell, J. 2004. Using recycled
Trust and the Flintshire Community Trust Ltd. (AD demolition waste in concrete building blocks. Proceedings
Waste Ltd.) for funding this project. The authors are of the Institute of Civil Engineers: Engineering
also grateful to the following industrial collaborators Sustainability 157(3):139–148.
for their assistance: Clean Merseyside Centre, Concrete Network. Concrete pavers. http://www.concrete
Mashalls Ltd., Forticrete Ltd., Liverpool City Council, network.com/concrete/pavers/index.html (1/9/2006).
Poon, C.S. & Chan, Dixon. 2006. Paving blocks made with
Liverpool Housing Action Trust, RMC Readymix recycled concrete aggregate and crushed clay brick,
Ltd., W.F. Doyle & Co. Ltd. and DSM Demolition Ltd. Construction and building materials, 20 (2006): 569–57.
Clover, Charles. 2005. Prescott’s bulldozers ready to demol-
ish Victorian terraces. http://www.telegraph.co.uk/
REFERENCES news/main.jhtml?xml/news/2005/01/29/npres29.xml
Telegraph (1/5/2006)
Symonds. 1999. Construction and Demolition Waste BBC. Homes demolition plan challenged. http://news.
Management practices and their economic impacts. bbc.co.uk/2/hi/uk_news/england/merseyside/4842686.
Report to DG XI. European Commission. stm British Broadcasting Corp. (1/5/2006)
EIONET. Construction and demolition waste. http://waste. British Standards Institution. 2002. Concrete – Complemen-
eionet.eu.int/waste/4 European Environment Agency tary British Standard to BS EN 206-1, Part 2: Specification
(28/08/05). for constituent materials and concrete. BSI, London, BS
Communities and local government. Construction and 8500-2:2002.
demolition waste survey: England and Wales 1999/2000 British Standards Institution. 2003. Concrete paving blocks –
Summary. http://www.communities.gov.uk/index.asp? Requirements and test methods. BSI, London, BS EN
id1143366 (15/07/05). 1338: 2003.

84
Sustainable Construction Materials and Technologies – Chun, Claisse, Naik & Ganjian (eds)
© 2007 Taylor & Francis Group, London, ISBN 978-0-415-44689-1

Using tires rubber waste for modification of concrete properties

G. Skripkiu– nas, A. Grinys & M. Daukšys


Kaunas University of Technology, Building Materials and Structures Research Center, Department of Building
Materials. Kaunas, Lithuania

ABSTRACT: Utilization of used tires or other vulcanized rubber waste is an important ecological problem for
all countries. Rubber waste has long-term decay in natural conditions due to high durability for lot of climate or
soil exposure and biological attacks. Used tires or other vulcanized rubber waste in most countries are burned
up, but this has negative effect on environment. The aim of investigation was to study the possibilities to use
granulated rubber waste as elastic additive for Portland-cement concrete.
Used tires or other vulcanized rubber waste were crumbed into different sizes fractions 0/0.5 mm, 0/1 mm
and 0/3 mm. The rubber additive was used as fine aggregate replacement in concrete mixtures by 3.2 per cent
of aggregates mass. Previous results indicate that using elastic additives from rubber waste increase freezing
and thawing resistance of concrete. This additive works as damping agent reducing the stresses inside the con-
crete. The influence of different fractions granulated tires rubber waste on the properties of fresh and hardened
concrete was tested in this investigation. The effect of this additive on technological properties, air content in
fresh concrete, density, compressive strength, porosity, abrasive resistance and deformation properties of con-
crete was investigated.
The experimental results indicate the reduction of compressive strength and modulus of elasticity of concrete
for all fractions of rubber waste. Rubber waste has no influence on capillary porosity of hardened concrete but
increases air content and closed porosity of concrete and has positive effect on freezing and thawing resistance
of concrete.
The results of investigation showed that crumbed rubber waste additive could be used for modification of
Portland-cement concrete properties and utilization of used tires or other vulcanised rubber waste.

1 INTRODUCTION to increase their resistance to the freezing and thaw-


ing and deicing salts [Skripkiu– nas et al. 1997b, Žiogas
Abundant numbers of used tyres, which do not et al 1996]. The most effective way of the increase of
decompose in natural environment, are disposed in resistance of concrete to freezing and thawing and deic-
the world each year. There are approximately 275 mil- ing salts is the air entraining [Powers 1945, Sheikin
lion waste tyres generated annually in the United et al. 1979, Sheikin & Dobshic 1989b].
States [Papakonstantinou & Tobolski 2006] and about Concrete resistance of freezing and thawing may
180 million in European Union [Silvestravičiu– te. & be increased using light porous aggregates. Such
Budriene. 2002]. aggregates increase the amount of air entraining; cre-
The world faces a problem of further utilization of ate the so-called “reserve” pores, and damper the
tyre waste. One of the most popular methods is to pile stresses that occur in concrete. Easily deformed
used tyres in landfills as due to low density and poor aggregates in concrete increase the relaxation of ten-
degradation they cannot be buried in landfills sions stresses occurring in concrete during the freez-
[Kerševičius 2002]. In industry higher amounts of rub- ing and thawing processes. Those inner stresses along
ber tyre waste can be utilized as fuel (production of with outer loads enhance the formation of micro-
steam or electricity, in cement and lime industry, kilns cracks in concrete. Therefore concrete containing
for firing pottery or earthenware) as well as production with elastic additives in aggregates is highly resistant
of various pigment soot, bitumen pastes, roof and floor to freezing and thawing [Skripkiu– nas et al 2001c,
covers; this waste is also used in paving industry. Savas et al. 1996].
Using concrete and reinforced concrete elements In this investigation the influence of fineness of
in countries of cold climatic zones there is a necessity rubber waste particles on mechanical properties,

85
porosity parameters and freezing and thawing resist- EN 12390-3 [Standard 2001e], abrasive resistance – by
ance of concrete were tested. LST L 1428.15 [Standard 2006f], porosity of concrete –
by water absorption kinetics [Standard 1978g] and
freezing – thawing resistance of concrete – by volumet-
2 MATERIALS ric freezing after immersing in 5 per cent NaCl solution
[Standard 2005h].
Portland cement CEM I 42.5R was used for investiga- In order to examine the effect of crumbed rubber
tion. Water content for normal consistency cement waste on the characteristics of concrete mixture and
slurry 24.5 per cent, specific area of cement particles hardened concrete four concrete mixtures were pro-
371 m2/kg. For fine aggregate was used sand fraction portioned and mixed under laboratory conditions.
(fr.) 0/4 mm with bulk density 1560 kg/m3. In the inves- Concrete mixtures with crumbed rubber particles of
tigation, part of sand was replaced by the rubber waste fraction 0/0.5, 0/1, 0/3 (3.2 per cent from aggregate
from used tires (3.2 per cent from aggregate by mass). by mass) and control mixture without rubber addi-
For coarse aggregate was used crushed granite fr. tives where tested. Proportions of concrete mixtures
2/8 mm and 11/16 mm with bulk density 1480 kg/m3 are presented in table 1.
and 1510 kg/m3 respectively. Coarse aggregate content
in all concrete mixtures was the same. Plasticizing
admixture based on policarboxile polymers was used 4 RESULTS
with density of solution 1040 kg/m3. In all mixtures
content of plasticizing admixture was the same –0.6 4.1 Characteristics of mixtures
per cent from cement content.
It was determined that rubber waste affects the prop-
Mechanically crushed rubber waste from used tires
erties of concrete mixture. In concrete mixtures con-
was used. Rubber waste was classificated to fractions
taining rubber waste less value of density is obtained,
0/0.5; 0/1 and 0/3. The technological equipment for
however air content is higher in this concrete. The
used tires rubber waste processing is installed in JSC
decrease of density of concrete mixture due to rubber
“Metaloidas” Siauliai, Lithuania. The density of
waste applied may be explained by higher total air
crushed rubber waste particles is 1020 kg/m3.
content in concrete mixtures. Lower density of con-
crete mixture is obtained due to less density of rubber
3 TEST METHODS waste particles compared with sand particles density.
It was determined that the slump of mixtures with
Cement and aggregates were dosed by weight while fine rubber waste particles (fr. 0/0.5 and fr. 0/1) was
water and chemical additives were dosed by volume. decreased by 2–2.5 cm from the point of view of mix-
Chemical additives in the form of solutions were tures without rubber waste; while the slump of the
mixed with water used in preparation of concrete mixture with coarse rubber waste (fr. 0/3) was 1 cm
mixtures. Concrete mixtures were mixed for 3 min. in higher compared to the mixture without rubber addi-
the laboratory in forced type concrete mixer. tives (Fig. 2). Using fine rubber waste particles (fr.
The consistency and density of concrete mixture 0/0.5 and fr. 0/1), the decrease of the slump in con-
were determined by EN 12350-2 [Standard 1999] and crete mixtures may be explained by more compli-
12350-6 [Standard 1999b]. Concrete specimens – cubes cated surface texture and large specific surface of
100  100  100 mm were cured in conditions accord- rubber waste particles than that of the control mixture
ing EN 12390-2 [Standard 2000c] and tested after 28 with fine sand aggregates (0/4 fr.). Rubber particles of
days. Density of concrete was determined by EN more complicated texture and large specific surface
12390-7 [Standard 2000d], compressive strength – by adsorb larger amount of water than round particles of

Table 1. Proportions of concrete mixtures.

Materials content for 1m3 of concrete mixture

Rubber Crushed Crushed Sand


waste Rubber Cement, granite 2/8 granite 11/16 0/4 fraction, Superplas-
fraction waste, kg kg fraction, kg faction, kg kg tycizer, % Water, l

0/0.5 22.8 451 380 569 821 0,6 158


0/1 22.8 451 380 569 821 0,6 158
0/3 22.8 451 380 569 821 0,6 158
– – 451 380 569 881 0,6 158

86
fine aggregate sand (0/4 fr.). This results in the Using fine fraction rubber additives (fr. 0/0.5 and
decrease in the slump characteristics of concrete mix- fr. 0/1) air content in concrete mixture increases up to
tures. Using coarse fraction rubber waste (fr. 0/3) in 2.6–2.8%, while using coarse fraction rubber additive
mixtures, the increase in the slump from the point of (fr. 0/3) air content remains the same as that con-
view of control mixture was obtained due to the tained in concrete mixture without rubber additives
increased coarseness of fine aggregates. (Fig. 3). As rubber waste is light and porous aggre-
gates, their application results in increased air content
2495
in concrete mixtures.
2500
2490
2480 2476
2470
4.2 Properties of hardened concrete
2470
Density, kg/m3

Dependence of concrete compressive strength on the


2460
coarseness of rubber additive is presented in Fig. 4.
2450
2440
2436 From this figure can see that concrete compressive
2430
strength decreases when rubber waste is added.
2420
Mostly (about 20 per cent) concrete compressive
2410
strength decreases when fr. 0/1 rubber additive is
2400
used; when fr. 0/0.5 and fr. 0/3 rubber additives are
- 0/0.5 0/1 0/3 used concrete compressive strength decreases less
Fraction of rubber waste (10–13 per cent). Accepted that air content of con-
crete with fr. 0/3 rubber additives is less than in other
Figure 1. Effect of the fineness of rubber additive on mixtures with rubber additives, it can be stated that
density of concrete mixture.
increasing coarseness of rubber additives results in
decreased compressive strength of concrete.
The abrasion resistance of concrete with different
26
25.5 rubber waste particles fraction are presented in Fig. 5.
25
As can be see, the coarseness of rubber waste additive
24.5
has no effect on abrasion resistance of concrete.
24
Slump, cm

90
80.0
23 22.5 80
Compressive strength, MPa

72.6 70.0
22 70
22 64.0
60
21 50
40
20 30
- 0/0.5 0/1 0/3
20
Fraction of rubber waste
10
0
Figure 2. Effect of the fineness of rubber additive on the - 0/0.5 0/1 0/3
Fraction of rubber waste
slump of concrete mixture.
Figure 4. Effect of the fineness of rubber additives on con-
crete compressive strength.
3 2.8
2.6
2.5 0.25
0.22
0.21 0.21
Air entrainment, %

0.20
2
Abrasive resistance, g/cm

2 0.20
1,5 1.5
1.5 0.15

1 0.10

0.5
0.05

0
- 0/0.5 0/1 0/3 0.00
- 0/0.5 0/1 0/3
Fraction of rubber waste Fraction of rubber waste

Figure 3. Effect of the fineness of rubber additive on air Figure 5. Effect of the fineness of rubber additives on con-
content in concrete mixture. crete abrasive resistance.

87
0.70 2.50 2.26
0.59 0.59 2.12
0.60 0.56 0.56
Pores distribution parameter

2.00
1.75
0.50

Closed porosity, %
0.40 1.50

0.30 1.00 0.85


0.20
0.50
0.10

0.00 0.00
- 0/0.5 0/1 0/3 - 0/0.5 0/1 0/3
Fraction of rubber waste Fraction of rubber waste

Figure 6. Effect of the fineness of rubber additives on the Figure 9. Effect of the fineness of rubber additives on the
pores distribution parameter. closed porosity of concrete.

2.50
2.24 2.24
pores remain of the same size as those in concrete
2.00 without rubber additives.
Average pores diameter

1.46 1.46
Rubber waste additive does not increase the open
(capillary) porosity of concrete, and using fine rubber
parameter

1.50

additive (fr. 0/0.5) it even reduces (Fig. 8). However,


1.00
using rubber additives the close porosity is much
0.50
higher than that of concrete without any rubber addi-
tives due to larger amount of air contained in such
0.00 kind of concrete mixtures and close pores contained
- 0/0.5 0/1 0/3
in rubber particles themselves (Fig. 9).
Fraction of rubber waste
Concrete freezing and thawing resistance can be
predicted using the criterion KF. According to this cri-
Figure 7. Effect of the fineness of rubber additives on the
average pores diameter parameter. terion a concrete is considered to be frost resistant
when the volume of closed pores exceeds the increase
volume of water in concrete capillary pores during
12.00 the water freezing [Sheikin et al. 1979]:
9.38 9.67
10.00 9.13
8.15
(1)
Open porosity, %

8.00

6.00

4.00 where Pu – closed porosity of concrete (air pores);


Pa – open porosity of concrete (capillary pores).
2.00
After calculation criterion KF according to closed
0.00 and open porosity of concrete it was obtained that
- 0/0.5 0/1 0/3
Fraction of rubber waste
concrete with fine rubber waste additives (fr. 0/0.5
and 0/1 mm) has the highest value of this criterion.
Figure 8. Effect of the fineness of rubber additives on the The value of this criterion is about 2.6–2.9 times
open porosity of concrete. higher than that of concrete without rubber additives.
When concrete has coarse rubber waste additives (fr.
0/3), the frost resistant criterion is equal to 2.1 and is
4.3 Porosity and durability of concrete also higher than that of concrete without rubber addi-
tives, that have frost resistance criterion equal to 1.0.
Parameters of concrete with different rubber waste The freezing and thawing resistance of concrete
particles fraction porosity are presented in Fig. 6, Fig. 7, with fr. 0/0.5, fr. 0/1, 0/3 rubber waste additives and
Fig. 8, Fig. 9. without any rubber waste additives was determined
Having added rubber waste into concrete no changes by volumetric freezing in the air and thawing in 5 per
in the distribution of pores according to their size is cent NaCl solution. After 610 freezing and thawing
observed (Fig. 6), while the average size of pores cycles, samples were checked visually (Fig. 10). No
changes a little more (Fig. 7). Having added fr. 0/0.5 cracks and fragmentation was observed in samples
and fr. 0/3 of rubber additive the pores become slightly with rubber additives, but in samples without rubber
larger, while having added fr. 0/1 rubber additive the additives a network of cracks was observed in the

88
2. Fine rubber additives (fr. 0/0.5 and 0/1) increase
air content in the concrete mixture; while coarse
rubber additives (fr. 0/3) do not change the amount
of air contained in concrete mixture.
3. The concrete strength is decreasing while the
coarseness of rubber waste additives is increasing.
4. Rubber waste additives and their coarseness have
no effect on concrete abrasion resistance charac-
teristics.
5. According to porosity parameters the most signif-
icant resistance to freezing and thawing resistance
predicted for concrete with fine rubber waste
additives (fr. 0/0.5). Increasing coarseness of rub-
ber additives cause the decrease in the resistance
of concrete to freezing and thawing.

REFERENCES

C. G. Papakonstantinou, M. J. Tobolski. 2006. Use of waste


tire steel beads in Portland cement concrete. Cement and
Concrete Research, N. 9, V. 36, pp. 1686–1691.
. . .
I. Silvestravičiu–te, L. Šleinotaite-Budriene. 2002. Possibility
to use scrap tires as an alternative fuel in cement industry.
Environmental research, engineering and management.,
No. 3(21), pp. 38–48. (in Lithuanian)
V. Kerševičius. 2002. Rubber waste – raw materials for
building: technical and economical aspects of utilization.
Environmental research, engineering and management,
N. 3(21), pp. 72–77. (in Lithuanian)
Kerševičius V., Skripkiu– nas G. 1997b. Durability problems
of concrete pavements. Building and architecture.
Materials of conference. Kaunas, “Technologija”,
pp. 217–222. (in Lithuanian)
Žiogas V., Štuopys A., Navickas A. 1996. Research on freez-
ing – thawing durability of the vibration pressed fine con-
crete. Building and architecture. Materials of conference.
Kaunas, “Technologija”, pp. 238–242. (in Lithuanian)
T.C. Powers. 1945. A working hypothesis for the further stud-
ies of frost resistance of concrete. ACI Materials Journal.
V. 16, N.4, pp. 245–272.
Sheikin A. E., Schekovskyj J. V., Bruser M. I. 1979.
Properties and composition cement based concrete.
Moscow: Stroiizdat, 344 c. (in Russian)
Sheikin A. E., Dobshic L. M. 1989b. Resistance to frost of
cement based concrete.- Leningrad: Stroiizdat, 128c. (in
Russian)
Kerševičius V., Skripkiu– nas G. 2001c. Utilization of rubber
Figure 10. Concrete samples with different fractions of waste in Portland cement concrete. Environmental
rubber waste additives and control sample after 610 cycles research, engineering and management. Nr. 4(18),
of freezing and thawing. pp. 40–45. (in Lithuanian)
Savas, B. Z., Ahmad, S., and Ferdoff, D. 1996. Freeze-thaw
angles of concrete cubes which indicate the beginning durability of concrete with ground waste tire rubber.
of concrete fragmentation. Transportation Research Record. N. 1547, pp. 80–88
EN 12350-2:1999 standard. 1999. Testing fresh concrete.
Part 2: Slump test.
5 CONCLUSIONS EN 12350-6:1999 standard. 1999b. Testing fresh concrete.
Part 6: Density.
1. Fine rubber waste additives (fr. 0/0.5 and 0/1) EN 12390-2:2000 standard. 2000c. Testing hardened con-
reduce the slump of concrete mixture, while crete. Part:2: Making and curing specimens for strength
coarse rubber waste additives (fr. 0/3) increase it. tests.

89
EN 12390-7:2000 standard. 2000d. Testing hardened con- GOST 12730.4-78 standard. 1978g. Concretes. Methods of
crete. Part 7: Density of hardened concrete. determination of porosity parameters.
EN 12390-3:2001 standard. 2001e. Testing hardened con- LST L 1428.17:2005 standard. 2005h. Concrete. Test meth-
crete. Part 3: Compressive strength of test specimens. ods. Determination of frost resistance.
LST L 1428.15:2006 standard. 2006f. Concrete. Test meth-
ods. Determinations of wear resistance.

90
Sustainable Construction Materials and Technologies – Chun, Claisse, Naik & Ganjian (eds)
© 2007 Taylor & Francis Group, London, ISBN 978-0-415-44689-1

Employment of waste sand to compose fibre reinforced


cement composites

J. Katzer
Technical University of Koszalin, Poland

ABSTRACT: This lecture describes the research on concrete based on waste sand obtained from hydrograd-
ing of all-in-aggregate in the Central Pomerania in Poland. Concrete was modified by replacing from 0 to 25%
of cement for the silica fume and adding from 0 to 2% of steel fibres. The received results of the research on the
fresh concrete mixtures and properties of hardened composite are presented on charts. The author noted a con-
siderable improvement in compression strength and watertightness of the examined concrete mixes.

1 INTRODUCTION all-in-aggregate of Central Pomerania described by


Katzer (2003) is summarized in Table 1.
Natural aggregates in Central Pomerania in Poland In the mentioned pit deposits, fractions from 0 to
are of glacial origin and they occur in a form of sands 4.0 mm constitute 97% by weight of all aggregate.
and all-in-aggregates. In the region there are 38 docu- Documented deposits of aggregate in this region reach
mented and described pit deposits (Katzer 2003, over 100 billion of kilograms. Approximately half of it
Katzer & Kobaka 2005a). The main mineral compo- is constituted by deposits hydrograded during the
nent of Central Pomerania aggregate is quartz and exploitation. Waste sand is a by-product of hydrograd-
crystalline rock, dominated by granite. In the Figure 1 ing natural all-in-aggregate. During the process of
you can see a photograph of magnified Pomeranian hydrograding, all-in-aggregate is divided into gravel
sand. White grains are quartz, black grains are gran- and sand. There is a deficit of gravel in the region,
ite. The majority of grains have an ellipsoidal shape. therefore gravel received during hydrograding of
The rest of grains have a spherical or flaky shape. all-in-aggregate is constantly being sold. Sand received
As far as smoothness of the grain surface is con- during the process of hydrograding, due to its excessive
cerned fine aggregate is composed of angular and amount, is called waste sand. This sand, because of the
partially subrounded grains. Grading of sands and excess of fine aggregate in the Central Pomerania
region, is stored on continuously growing wasteheaps
close to the aggregate pits. Figures 2 and 3 show the
constantly growing wasteheaps of waste sand near the
aggregate pit in Sepolno Wielkie located near the city
of Bialy Bor in the Central Pomerania region.
A bar chart of grading of aggregate in Central
Pomerania is presented in Figure 4. There are three
kinds of aggregate available in the region: natural
sand, waste sand and all-in-aggregate. As it is shown
in Figure 4, in comparison to natural sand, waste sand
is characterized by considerably higher grain-size dis-
tribution, a smaller amount of stone dust and a higher
content of minerals and crystal rocks than the natural
sand obtained from the same aggregate pit, which is a
significant advantage from the point of view of design-
ing and future cement composites production. Apart
from that, this sand has lower factors of graining
changeability and a higher content of crystal rocks
Figure 1. Waste sand. than all-in-aggregate out of which it was sifted. Waste

91
Table 1. Sands and all-in aggregates with their known graining parameters.

Fraction groups [%]

Ordinal 0.0 mm– 0.5 mm– 2.0 mm– Hummel fineness Specific surface
number Name of deposit 0.5 mm 2.0 mm 32.0 mm modulus [m2/kg]

1 Brzezno 84.6 14.1 1.3 54.4 10.295


2 Jawory 25.9 46.9 6.6 79.1 6.423
3 Kalisz Pom. 59.1 39.8 10.0 74.8 8.022
4 Klepino 55.1 31.6 13.3 81.3 32.094
5 Piekary 58.5 37.5 4.0 69.1 8.096
6 Pniewo 89.5 10.1 0.4 49.2 11.652
7 Sianow 39.8 54.2 6.0 79.8 6.437
8 Siemianowice 67.7 29.5 2.8 64.4 8.600
9 Swiecianowo 22.8 38.5 2.3 70.6 7.044
10 Swidwinek 95.5 4.5 0.0 28.5 20.551
11 Welnianka 85.6 12.7 1.8 49.0 12.412
12 Wegorzewo 49.5 46.2 4.3 74.9 7.221
13 JastrowieI 49.8 49.0 1.2 71.7 6.975
14 Mielenko 58.3 40.9 0.8 67.9 7.684
15 Parsecko 52.4 46.6 1.0 69.6 7.561
16 Sepolno 24.3 65.9 8.9 92.4 4.656
17 Boboliczki 33.2 55.6 11.2 88.1 5.565
18 Chlebowo 46.2 39.6 14.2 80.2 7.755
19 Cieszeniewo 34.1 54.8 11.1 86.0 5.860
20 Golce 43.1 53.7 3.3 76.0 6.718
21 JastrowieII 24.1 56.2 19.6 98.6 4.653
22 Karsno 17.0 76.5 6.5 84.5 4.376
23 Kuznica Czarn. 47.9 40.8 11.3 82.5 6.658
24 Ledyczek 34.8 53.5 11.7 85.8 6.290
25 Mielecin 41.4 45.8 12.8 83.7 6.650
26 Nowogardek 39.8 50.6 9.6 81.8 6.187
27 Oskowo 27.1 58.6 14.3 – –
28 Polanow 23.8 57.9 18.4 98.1 4.826
29 Babino 47.5 46.6 5.9 77.5 6.170
30 Ratajki 12.6 71.8 15.5 104.4 3.752
31 Rzesznikowo 26.0 63.7 10.2 91.6 5.109
32 Siecino 45.3 39.0 15.7 82.1 7.492
33 Spore 55.5 38.8 5.3 72.6 7.410
34 Siemirowice 23.5 64.8 11.7 93.7 4.578
35 Stary Chwalim 29.2 55.1 15.7 92.1 5.123
36 Walkowice 16.1 70.4 13.5 99.0 4.533
37 Warblewo 19.6 54.0 26.4 104.2 4.308
38 Zelkowo 20.0 70.5 9.6 94.9 4.621

sand sifted during the process of hydrograding is Dondelewski 1980, Marcinkowski & Dondelewski
washed and as a result deprived of clay and other fine 1984). These research programmes concerned con-
material. It has a great significance because specific cretes produced in the same way as ordinary concrete
surface of aggregate is strongly related to the amount without any admixtures or additives. It has been
of fine particles present in it. Waste sand is also free established that concrete based on waste sand is char-
from other deleterious substances such as salt con- acterized (in comparison to ordinary concrete) by rel-
tamination, organic impurities and unsound particles, atively high cavity, porosity and absorption, law
usually present in natural aggregate. For the last resistance to local mechanical damage, abrasion and
25 years in Central Pomerania there have been several acid attack. It is also less frost and water resistant.
research programmes concerning designing, produc- The grading characteristics of aggregate directly
tion technology and technical parameters of concrete influences parameters of the concrete based on it.
based on the waste sand (Dondelewski & Maciek Using fine aggregate as a main component of concrete
1995, Maciek et al. 1978, Maciek & Dondelewski affects its behaviour. The big surface area of the fine
1980, Maciek & Dondelewski 1981, Marcinkowski & aggregate determines the amount of water necessary

92
Table 2. Physical features of waste sand.

Feature Symbol Size

Loose bulk density ρnl 1631 kg/m3


Compacted bulk density ρnz 1805 kg/m3
Fineness modulus: 3.279
– by Kuczynski UK
– by Hummel UH 66.4
– by Abrams UA 2.206
Cavity of:
– loose aggregate jl 38%
– compacted aggregate jz 32%
Porosity P 3.39%

Figure 2. A wasteheap of hydrograined sand in aggregate (1998). Despite the limitations mentioned above, for
pit in Sepolno Wielkie. the last 25 years there have been numerous attempts
to produce different precast elements from concrete
based on waste sand. The main reason for these
attempts is the general availability of waste sand in
Central Pomerania, its very low price and short
distances for the transportation of the aggregate.
Numerous civil engineering applications of fine aggre-
gate concretes presented for example by Katzer &
Kobaka (2005a) have proved that meticulously made
fine aggregate concrete is characterized by satisfac-
tory strength and durability in order to be applied in
civil engineering as a standard construction material.
Today fine aggregates find more and more applic-
ations in the production of different kinds of cement
composites such as steel fibre reinforced concretes
(SFRC), ferrocement and precast elements with dense
Figure 3. A wasteheap of hydrograined sand in aggregate reinforcement. This issue was widely described and
pit in Sepolno Wielkie. discussed by many researchers e.g. Johnston (2001),
Maidl (1995), Nawy (1996) and Neville (1995).
The facts mentioned above forced the author to
prepare a research programme of concretes based on
the waste sand and modified by silica fume (SF) and
steel fibre (Vf) to increase their durability and strength
characteristics.

2 RESEARCH PROGRAMME

Fine aggregate concrete was composed of Portland


Cement 32.5 (CEM I, 400 kg/m3) and waste sand.
Properties of the used waste sand are summarized in
Table 2. The water to cement ratio (w/c) was equal to
0.50. The examinations were carried out with the help
of an experimental design. The author used the central
composite experimental design based on Plackett-
Figure 4. Grading of aggregates of Central Pomerania. Burman design thoroughly described by Hicks (1982),
Mann (1950) and Schenck (1979). The subject of the
to wet all the solids. More water is needed (comparing research was defined as complex material whose inte-
to ordinary concrete) to maintain the same workabil- rior structure was unknown and unavailable for an
ity of the fresh concrete mix what was stated in previ- observer. The observer knew the input parameters
ous publications by Brzezicki (1997) and Hudson which were the addition of steel fiber (Vf), and silica

93
Figure 6. Raw silica fume used to the tests.
Figure 5. The scheme of the arrangement of measuring
points.

Table 3. Experimental design values of input factor.

Input factor

in natural
values
in code values
Number of Number of SF Vf
experiment realization x1 x2 [%] [%] Figure 7. The geometry of the employed steel fibre in mm
(a  5 mm, b  3 mm).
1 2 1.000 1.000 5.0 0.4
2 5 1.000 1.000 5.0 1.6
3 10 1.000 1.000 20.0 0.4
4 9 1.000 1.000 20.0 1.6 Figure 6. The geometry of hooked steel fibres of a
5 1 1.682 0.000 0.0 1.0 length equal to 50 mm and circular cross-section, with
6 8 1.682 0.000 25.0 1.0 an aspect ratio l/d  50 and breaking strength of
7 3 0.000 1.682 12.5 0.0 1100 MPa is presented in Figure 7. All mixes were
8 4 0.000 1.682 12.5 2.0 modified by a constant amount of plasticizer equal to
9,10,11 7,6,11 0.000 0.000 12.5 1.0 1.8% (by mass of cement). The superplasticizer (SNF)
was based on sulphonated naphthalene formaldehyde
condensates. Rotary drum mixer was utilized to make
fume (SF). The output parameters were strength and the mixtures.
other properties of concrete. The applied experimen- Vebe test procedure was used to determine consis-
tal design is presented in Figure 5 and in Table 3. The tency. Each specimen was vibrated in two layers, with
objectivity of the experiments was assured by the each layer composing half of the thickness. Each layer
choice of the sequence of the realization of specific was vibrated for 20 s. The first step of curing was to
experiments from a table of random numbers. All cal- keep the specimens in their molds covered with poly-
culations connected with specifying a correlation ethylene sheets for 24 h. The specimens were then
coefficient and graphic interpretation of the model removed from their molds. The second step of curing
were carried using a statistical computer programme was to keep the specimens at 22°C and approximately
widely described by Bayramov (2004), Borovikov & 100% relative humidity until the age of 28 days.
Borovikov (1998) and Lee-Ing & Chung-Ho (2002). Thereafter, the specimens were kept at a constant room
Polynomial fit was used to achieve contour plots. temperature. There were applied moisture curing and
Fitted functions were characterized by a correlation manufacturing techniques of specimens, to the proce-
coefficient equal to at least 0.9. dures described by Toutanji & Bayasi (1998). Applied
Eleven concrete mixes were modified by the addi- manufacturing and curing procedures were prepared
tion of silica fume (from 0% to 25%), and reinforced with regard to the results of the earlier research pro-
by steel fibre (from 0% to 2%). A photograph of mag- gramme on fine aggregate concretes (Katzer & Kobaka
nified raw silica fume used to the tests is presented in 2005b) and steel fibre reinforced concretes based on

94
fine aggregate and modified by silica fume (Katzer &
Piatek 1999).
The specimens were in a form of cubes and
beams. From each concrete mix 30 cube specimens
150 150 150 mm, 6 cylinder specimens φ150 500 mm
and 6 beam specimens 100 100 500 mm were made.
The research programme covered the examinations of
features of the concrete samples after 120 days of cur-
ing because of high silica fume reactivity in time.
This reactivity has a significant influence on concrete
parameters examined after 28 days of curing.
The research programme was divided into three
main stages. The first stage covered the testing of prop-
erties of fresh concrete mix. The second stage covered Figure 8. The cycle no.1 – eightfold load.
the testing of compressive strength, flexural strength,
deflection of the beams and establishing stress-strain
curves. The third stage covered testing of watertight-
ness after different cycles of compressive load.
The examination of watertightness of concrete
samples does not reflect watertightness of concrete
composite in an actual construction. Each, even the
simplest construction works within constantly chang-
ing conditions, where loads appear and disappear in
time. The influence of the changeability of static loads
in time on concrete parameters has already been well
known, especially as far as ultimate compressive
strength is concerned (Lenkiewicz & Pidek 1970).
Keeping the above facts in mind, the author has
worked out a watertightness test procedure after a
cycle of loads. Specimens from each concrete mix
were divided into three independent groups, which
were subjected to different cycles of compressive load.
The cycle no. 1 was an eightfold load until the
moment of causing stress of 45% of breaking stress
and unload of samples. The samples were loaded with
Figure 9. An apparatus for evaluating concrete water-
an increasing force at a uniform rate (the speed of
tightness.
growing of stress 0.5  0.1 MPa/s). In these condi-
tions the achieved pulse frequency was 1/35 Hz. The
course of the first cycle of load was presented in
Figure 8. The test was carried out under constant pressure of
The cycle no. 2 was a single load of the samples 1.2 MPa within 72 hours. After this period of time
until the moment of causing stress of 90% of breaking samples were split and the depth of water penetration
stress and unload of the samples. was measured. The results were presented with the
The cycle no. 3 was a comparative cycle therefore use of a leaking speed parameter kv which was
there was no pre-load of the samples. These samples described by Katzer (2004) and counted according to
were treated as control samples. After the cycle of the Equation (1):
load, samples were dried in temperature 60°C.
Drying the samples was to eliminate the influence (1)
of absorption of vapour from air by samples during
their curing on watertightness examination. Then sam- where xmax  maximum depth of water penetration in
ples were subjected to the watertightness evaluating. meters, hi  pressure of water in meters H2O, ti  time
Watertightness of fine aggregate concrete was tested of lasting of the pressure in seconds.
using an apparatus which supplies water from below The expression of watertightness with the use of
and can test six samples under a constant pressure of parameter kv allows to compare watertightness of both
0.2 MPa to 1.2 MPa simultaneously. The used appara- samples which were thoroughly penetrated by water
tus is shown in Figure 9 and widely described by during the experiment and the ones which remained
Katzer (2006). tight until the completion of it. One may also compare

95
Figure 10. Scheme of four point loading of a concrete
beam. All dimensions in mm.

the watertightness of samples examined with varied Figure 11. Ultimate compressive strength.
methods.
To realize the flexural strength examination under
four point loading, two concentrated loads were applied
on the samples in spacing 1/3 of the span. The scheme
of four point loading of the concrete beam is presented
in Figure 10. The flexural strength examinations were
carried out on specimens 100 100 500 mm. The estab-
lishing stress-strain curves was carried out on speci-
mens φ150 500 mm with axial compression. The
examination was finished after having achieved about
0.9 failure load.

3 RESULTS OF THE RESEARCH

Consistency of fresh concrete mixture determined Figure 12. Flexural strength ff.
with the help of Vebe procedure varied from 7 to 11
seconds. The maximum amount of air in analyzed
fresh concrete mixtures was equal to 4%. Most of the
analyzed mixtures was characterized by amount of air
from 2.5% to 3%. Density of fresh concrete mixture
modified by silica fume and steel fibre is described
by the Equation 2.

(2)

where x  SF [%], y  Vf [%].


Density of fresh concrete mixture increase together
with the increase of steel fibre addition. Plain concrete
is characterized by density equal to 2064 kg/m3, and
concrete modified by 2% of steel fibre is characterized
by density equal to 2200 kg/m3. Addition of silica fume Figure 13. Deflection db of a beam 100*100*500 mm.
does not seem to influence this property of fresh
concrete mixture.
The results of the ultimate compressive strength The results of flexural strength examinations are
examination are shown in Figure 11. Both silica fume presented in Figure 12. The shape of the presented sur-
and steel fibre cause the growth in ultimate compres- face shows a big influence of the steel fibre addition
sive strength, and both of their influences accumulate. on acquiring quasi-plastic features by the composite.
The growth of ultimate compressive strength appears Concrete mix without any silica fume admixture has
mainly because of the addition of steel fibre. Above a the biggest flexural strength. During the flexural
certain optimum amount of the steel fibre addition strength examination deflection was measured at the
(about 1.5%) ultimate compressive strength of the imposed force F  2 2.5 kN. The results of the
examined composites slightly decreases. deflection examination are shown in Figure 13.

96
Figure 14. Stress-strain σ-ε axial compression curves. Figure 16. Watertightness kV [1012 m/s] of fine aggregate
concrete composite after preload no. 2.

Figure 15. Watertightness kV [1012 m/s] of fine aggregate


concrete composite after preload no. 1. Figure 17. Watertightness kV [1012 m/s] of fine aggregate
concrete composites not subjected to preload.

Figure 14 shows the interdependence σ-ε for chosen


composites. kv  680·1012 m/s. The equation (4) describes the
Watertightness of fine aggregate concrete compos- surface pictured in Figure 16.
ites subjected to cycles of preload no. 1 is shown in
Figure 15. Watertightness of the described composites
increases both in relation to the addition of SF as well (4)
as of Vf. The increases of watertightness are at a uni-
form rate in both directions and they are close to a lin- Watertightness of fine aggregate concrete composites
ear relation. A comparative concrete mix has kV  which were not subjected to any preload is shown in
340 1012 m/s and the most tight of the maximum Figure 17. Watertightness of concrete without any
additions SF and Vf kV  120 1012 m/s. The equa- additions expressed with the use of parameter equals
tion (3) describes the surface pictured in Figure 15. 230 1012 m/s. Modifying the concrete mix solely
with steel fibre reinforcement allowed to achieve
watertightness of 103 1012 m/s. Modifying the con-
(3) crete mix solely with silica fume allowed to achieve
39 1012 m/s. It is visible in Figure 17 that the addi-
Watertightness of fine aggregate concrete composites tion of reinforcement worsens the tightness attained
subjected to the cycles of pre-load no. 2 is shown in with silica fume when its quantity exceeds 10%. With
Figure 16. Watertightness increases mainly with regard the increase of the amount of silica fume the tightness
to the increasing addition of Vf. The addition of SF of the fine aggregate concrete composite grows, espe-
influences the improvement of watertightness of the cially in concrete mixes of a high content of rein-
described composites but its significance is very lim- forcement. With the addition of more than 15% of
ited in this case. The non-modified concrete mix has silica fume all concrete mixtures are characterized by
kv  3985 1012 m/s, and the concrete mix with max- considerable tightness, which stabilizes at a level of
imum addition of SF and Vf was characterized by 2523 1012 m/s.

97
4 DISCUSSION composites already significantly depends on the
amount of the addition of Vf.
Ultimate compressive strength (which was 24 MPa Concrete, “working” in a construction carries most
for plain concrete) grew by over 100% (to 50 MPa) frequently loads causing about half of the breaking
for the optimal concrete mixture. All concretes were stress and to a certain extent changing in time.
made of Portland Cement 32.5 (400 kg/m3) without Bearing this in mind the most important for the appli-
admixtures. It proves that there are yet other possibil- cation in engineering is watertightness of fine aggre-
ities of achieving significantly bigger strengths. For gate concrete composites under cycles of preloads
this feature the combination of the two additives in no. 1. In such a case watertightness of fine aggregate
the cured composite is very effective. concrete composite modified only by silica fume
The results of flexural strength examinations dis- examined in a traditional way is very high. The same
close the effectiveness of steel fibre addition behav- concrete subjected to the cycle of loads no. 1 loses
iour with this kind of loading. Plain concrete mix about 80% of its primary watertightness and in result
obtains the strength 2.75 MPa, and concrete reinforced it fails to meet the primarily requirements as far as
by 2% of steel fibre equals 6 MPa. Despite of the pass- watertightness is concerned.
ing 120 days of curing, silica fume additive worsens
significantly flexural strength obtained thanks to the
steel fibre itself. Despite this negative tendency con- 5 CONCLUSIONS
crete mixes of maximum 15% of silica fume and from
1.5% to 2% of steel fibre additive are characterised by The presented research on discussed types of con-
much higher strength than plain mixture. cretes let the author state that:
The deflection measurement, similar to the flexural
strength described above, shows the acquirement of 1. The addition of both silica fume and steel fibre
quasi-plastic features by SFRC composite. The deflec- improves ultimate compressive strength.
tion of composite modified by 25% of silica fume and 2. Steel fibre improves flexural strength of the
2% of steel fibre is five times smaller than the deflec- examined concretes and it decreases deflection
tion of composites modified by silica fume alone. and linear strain.
Watertightness of fine aggregate fibre reinforced 3. Despite 120 days of curing silica fume does not
composites without any preload reaches the level improve flexural strength and it does not decrease
from kV  23 to 230 1012 m/s. Composites which strain under axial load.
were subjected to the pre-load cycle of load no. 1 are 4. The relatively high watertightness of the described
characterised by watertightness from kV  120 to composites after the cycle of loads is achieved due
340 1012 m/s, and composites subjected to the to the addition of steel fibres.
preload cycle of load no. 2 from kV  680 to 5. Subjecting samples to the cycles of preload has an
3985 1012 m/s. If one assumes the watertightness of extended influence on their later watertightness.
composites without load as a point of reference then 6. Watertightness of not loaded fine aggregate con-
the relation of watertightness of not modified fine crete composites depends greatly on the addition
aggregate concrete, loaded with the cycle of load no. of SF.
1 and no. 2 is 1:5:29. A similar relation for a compos- 7. Watertightness examined on samples not pre-
ite modified with a maximum addition of SF and Vf is loaded does not allow for any assessing of water-
1:1.5:1.7. It is observable in the above proportions tightness of preloaded ones.
how significant is the influence of the addition of 8. The addition of steel fibres allows to sustain a rel-
steel fibre and the kind of preload onto watertightness atively high watertightness in fine aggregate con-
of fine aggregate concrete composites. crete composites subjected to preload.
There is an increasing influence of the amount of 9. It is possible to obtain composites, on the basis of
additions of steel fibres on sustaining tightness of waste sand, which are characterized by very high
fine aggregate concrete composites with the increase chosen features.
in preload. The addition of silica fume so much tight-
ening the structure of concretes subjected to no pre-
load loses its primary meaning with the increasing
load. In Figure 17 one may see that watertightness of REFERENCES
fine aggregate concretes depends mainly on the
Bayramov, F. et al. 2004. Optimalisation of steel fibre rein-
amount of addition of SF. In Figure 15, after the pre- forced concretes by means of statistical response surface
load causing 45% of breaking stress watertightness in method, Cement & Concrete Composites, 26/2004:
a relative extent depends on the amount of the addi- 665–675.
tion of SF and Vf. With load causing 90% of breaking Borovikov, I.P. & Borovikov, V.P. 1998. STATISTICA: Data
stress watertightness of fine aggregate concrete Preparation and Analysis. Filini, Moscow.

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Brzezicki, J.M. 1997. Influence of aggregate grain shape on Lee-Ing, T. & Chung-Ho, W. 2002. STATISTICA V5.5 and
mechanical properties of concrete. PhD thesis. Institute Basic Statistic Analysis, TasngHai Publisher, Taiwan.
of Fundamental Technological Research, Polish Lenkiewicz, W. & Pidek, W. 1970. Wytrzymalosc betonu na
Academy of Sciences, Warsaw, Poland. sciskanie w elementach debiutujacych,. XVI Konferencja
Dondelewski, H. & Maciek, L. 1995. Mikrokrzemionka jako Naukowo-Techniczna Komitetu Inz ynierii PAN i
aktywny skladnik betonu mikrokruszywowego, Cement Komitetu Nauki PZITB, Krynica: 97–101.
Wapno Gips 6/95. Maciek, L. et al. 1978. Badania betonów wykonanych z
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Hudson, B. 1998. Impact of manufactured sand in concrete. Środkowego, Materialy Budowlane 9/80.
Quarry 98/6(12): 31–34. Maciek, L. & Dondelewski, H. 1981. Konsekwencje zas-
Johnston, C.D. 2001. Fiber reinforced cements and con- tosowania betonu drobnokruszywowego w niektorych
cretes, Gordon and Breach Science Publishers. konstrukcjach prefabrykowanych, Prace Instytutu
Katzer, J. 2003. Beschreibung der granulometrischen Budownictwa Ladowego, WSInz w Koszalinie 1981.
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64–69. wowych, Archiwum Inz ynierii Ladowej – Tom XXVI Z.
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99
Sustainable Construction Materials and Technologies – Chun, Claisse, Naik & Ganjian (eds)
© 2007 Taylor & Francis Group, London, ISBN 978-0-415-44689-1

Portland cement concrete using high levels of microfines

P.N. Quiroga
Escuela Colombiana de Ingeniería, Bogotá, Colombia

D.W. Fowler
International Center for Aggregates Research, The University of Texas at Austin, TX, USA

ABSTRACT: Aggregates are the most widely used building material. Nearly all roadways and a large percent-
age of other buildings and infrastructure utilize aggregates, the primary component in bases, Portland cement
concrete, and asphalt concrete. In the U.S., nearly 3 billion tons of aggregates are produced each year. An increas-
ingly larger percentage of aggregates are obtained by crushing; supplies of natural sands and gravels are becom-
ing increasingly difficult to obtain due to environmental limitations and depletion of resources. Manufactured
aggregates include relatively high percentages of microfines, i.e., aggregates smaller than 75-µm that tradition-
ally have been viewed as a waste material. Specifications generally limit the amount of microfines in most aggre-
gate applications. Considerable research has been conducted with the objective of demonstrating that higher
amounts of microfines can be used to produce quality building materials. This presentation will focus on appli-
cations to Portland cement concrete. Results of research will be presented showing how aggregates with high
microfine contents can be optimized for use in concrete; the results of strength and durability properties of high
fines concrete will be compared to traditional concretes made with natural sands.

1 INTRODUCTION devices like vibrating tables or rheometers were used


to assess workability. In general, it was observed
Since 1996 the International Center for Aggregate that slump and flow decrease with the amount of
Research (ICAR) has conducted industry-sponsored microfines.
research projects related to concrete made with man- Figure 1 shows the flow for mortar mixtures with a
ufactured aggregates with high microfines at the fixed water-cement ratio (W/C). Manufactured fine
University of Texas at Austin [Ahn & Fowler 2001, aggregates (MFA) resulted in lower flows but some of
Quiroga & Fowler 2004]. Many types of aggregates these values are just slightly lower than for the natural
have been used to make mortar and concrete mixtures sand control mixture, even for microfine contents as
with different amounts and types of microfines. The high as 15 percent. For microfine contents higher than
effect of different variables such as shape and texture 7 percent some mixtures had flow values lower than
of aggregate, amount of microfines, and type and 70 percent of the control mixture. Flow tends to decrease
amounts of admixtures and cementitious materials on with increasing amounts of microfines, although for
the performance of fresh and hardened mortar and less than about 10 percent the rate of decrease is low.
concrete has been observed. The results of some For microfines contents higher than 15 percent, the
of the studies performed in this research will be flow was very low for the materials used.
presented as follows. For some mixtures a high range water reducer
admixture (superplasticizer) based on carboxylic acrylic
ester co-polymers was used. Figure 2 shows the
dosage of the superplasticizer required to achieve a
2 FRESH MORTAR AND CONCRETE given slump for a set of concrete mixtures with
different amounts of microfines from trap rock (TR).
The workability of mortar and concrete mixtures was All these mixtures had the same W/C of 0.41, the
evaluated in a quantitative way by means of traditional same amount of paste and the same type of aggregate.
tests such as flow and slump as well as in a qualitative The dosage of superplasticizer increased with the
way by evaluating properties such as cohesion, amount of microfines but the increase was low for
compactability and finishability. In a few cases different microfines content of 10% or lower.

101
160 600

Super dosage (ml/100 kg)


140 500
120 400
MFA
100
Flow (%)

Natural 300
80
200
60
40 100

20 0
0% TR-15% GR-15% LS-15%
0
Microfines
0 10 20 30
Microfines Content (%)
Figure 3. Superplasticizer dosage (ml/100 kg of cement)
Figure 1. Flow vs. microfines content for fixed W/C required to reach 120 mm-slump for different types of
mortar mixtures. microfines.

600 45
Dosage (ml/100 kg)

500 40

Compressive Strength (MPa)


35
400
30
300
25
200 20

100 15

10
0
TR-0% TR-5% TR-10% TR-15% TR-20% 5

Microfines 0
Natural LS-1 LS-2a LS-2b LS-2c GT QZ DI DO BA SS
Sand
Fine Aggregate
Figure 2. Superplasticizer dosage (ml/100 kg of cement)
to reach the target slump of 120 mm, for different amounts
of microfines from trap rock. Figure 4. 28-Day compressive strength of concrete
mixtures with W/C  0.53.

The type of microfines affects the performance of


concrete. To evaluate that effect, some mixtures were and drying shrinkage of concrete mixtures with and
made with the same W/C (0.41), the same paste con- without microfines were evaluated. In general, the
tent, the same type of aggregate (plus 75 µm sieve performance in terms of strength and durability of
size) but with different type of microfines. Microfines concrete mixtures with manufactured aggregate with
obtained by sieving fine aggregate from three differ- high microfines was equal or better than mixtures with
ent sources were used. Figure 3 shows the dosage of natural sand with no microfines.
superplasticizer required to reach 120-mm slump for Figures 4 and 5 show the 28-day compressive and
mixtures without microfines, mixtures with 15% trap the 28-day flexural strengths of a set of eleven con-
rock microfines (TR), mixtures with 15% granite crete mixtures with the same W/C (0.53) and the same
microfines (GR) and 15% limestone microfines (LS). paste content. These mixtures had the same coarse
The superplasticizer demand increases for mixtures aggregate but different fine aggregates: one natural
with 15% microfines, but it also varies with the type sand without microfines and ten crushed sands with
of microfines. microfines content as indicated in Table 1.
In this case, the superplasticizer demand for lime- In general, mixtures with manufactured aggregate
stone microfines was significantly lower than for gran- with high microfines had compressive strengths slightly
ite and trap rock microfines. Besides the effect on higher and flexural strengths significantly higher than
superplasticizer demand, it was observed that the effect the control mixture with natural sand.
of these three types of microfines on other aspects of Figure 6 shows for a different set of concrete mix-
workability such as cohesion, finishability and com- tures the flexural strength for different types of aggre-
pact ability, evaluated qualitatively, was different. gates (plus 75 µm sieve size) and different types and
amounts of microfines. As expected, strength depended
significantly on the type of aggregate but it was not
3 HARDENED CONCRETE affected significantly by the amount and type of
microfines.
As for hardened concrete, compressive strength, flexural Drying shrinkage did not increase significantly in
strength, abrasion resistance, chloride ion permeability, mixtures with high microfines as compared with

102
6 0,030

5 0,025
Flexural Strength (MPa)

Shirnkage (%)
4 0,020

3
0,015

0,010
2
0,005
1
0,000
0 0% 5% 10% 15% 20%
Natural LS-1 LS-2a LS-2b LS-2c GT QZ DI DO BA SS
Sand Microfines amount (%)
Fine Aggregate

Figure 7. 28-day drying shrinkage of concrete with differ-


Figure 5. 28-Day flexural strength of concrete mixtures
ent amounts of microfines – W/C  0.41.
with W/C  0.53.

Table 1. Fine aggregate details. 3000

2500

Charge Passed (C)


Fine aggregate Microfines content (%)
2000
Limestone 1 LS-1 14.3 1500
Limestone 2 LS-2a* 4.5
1000
Limestone 2 LS-2b* 13.3
Limestone 2 LS-2c* 7.4 500
Granite GT 13.3 0
Quartzite QZ 13.5 0,0 7,5 15,0 20,0
Diabase DI 15.8 Microfines amount (%)
Dolomite DO 16.7
Basalt BA 14.3 Figure 8. Resistance to chloride ion penetration of concrete
Sandstone SS 10.3 with different amounts of microfines with W/C  0.41.
* Limestones 2a, 2b and 2c differ in the crushing speed
used to obtain them.
4 MICROFINES CHARACTERIZATION

10 From some of the results previously presented it can be


Flexural Strength (MPa)

8
concluded that the type of microfines has a significant
Microfines
effect on the performance of concrete. Furthermore, in
6 0% the screening process made at the beginning of the
4
TR-15% research, it was found that some types of microfines
GR-15%
2
may result in very high water demand and their use in
LS-15%
concrete might be questioned. Consequently, microfines
0
TR GR LS IN AZ
should be characterized to evaluate if they can be used
Coarse and fine aggregate (plus No. 200) for concrete or to determine the maximum amounts in
which they can be used.
Figure 6. 28-day flexural strength of concrete with differ- The methylene blue value (MBV) test [Yool 1998,
ent types of microfines – W/C  0.41. Dumitru 1999] and the water demand test using the
Vicat apparatus [Dewar 1999] were used in the
attempt to find a proper test for microfines. The MBV
mixtures without microfines. For a set of concrete measures the amount of methylene blue dye that can
mixtures with water cement ratio of 0.41, the 28-day be absorbed by a powder material such as microfines
drying shrinkage of mixtures containing fine aggre- or clay particles. Some clay such as smectites is able
gate with 20% microfines, was 0.029%, just 11% to absorb great amounts of methylene blue giving
higher than mixtures with no microfines (0.026 %) as high MBV. It is believed that microfines contami-
can be seen in Figure 7. nated with clays or with very small particles that
As for resistance to chloride ion penetration, in could increase water demand will result in high MBV.
general, concrete with manufactured aggregate with The flow of a set of mortar mixtures was compared
high microfines had less chloride ion permeability with the MBV of the microfines of the different aggre-
than concrete without microfines, as can be seen in gates used. It was observed that flow tends to decrease
Figure 8. with increasing MBV, although the correlation is not

103
160 700

Dosage (ml/100 kg)


140
GR
120 600
TR
Flow (%)

100
500
80 LS
60 400
40
20 300
0 0,54 0,56 0,58 0,6 0,62 0,64
0 2 4 6 8 10 Wet packing (Vicat test)
Methylene Blue Value
Figure 10. Dosage of superplasticizer to reach 120-mm
Figure 9. Flow vs. methylene blue value of fixed W/C slump vs. packing degree of microfines.
mortar mixtures.

particularly in the fresh state (i.e. workability). There is


very strong (R2  0.40) as can be seen in Figure 9. general agreement that proper grading with the right
However, four data points in the left bottom part of the amount of each fraction size will result in concrete with
figure indicate that low MBVs do not ensure good good workability, low water demand, and low paste con-
workability. The mixture with very low flow and very tent. In other words, a good aggregate grading will
high MBV that is shown in the right bottom of the result in economical and durable concrete since cement
figure suggests that MFA with very high MBVs might is one of the most expensive components of concrete,
not be suitable for concrete. and cement paste is the concrete component that shrinks
The Vicat water demand test run for microfines is and that is more easily attacked by acids, sulfates, and
similar to the Vicat test used for consistency of cement the environment in general.
pastes. The purpose is to measure the amount of water Aggregate with a high packing degree (volume of
required to reach the target consistency. It is expected solids to total volume) has low voids, so a smaller
that the higher the water demand in the test, the higher amount of paste is needed for filling these voids. It
the water demand in concrete. The packing degree, φ, has been found that aggregate packing degree is
defined as the volume of solids divided by the total related to aggregate grading. Good gradings have
volume, is related to the water demand by the follow- high packing degree and conversely poor grading
ing equation: tend to have low packing degrees. In fact some meth-
ods to optimize aggregate grading are based on pack-
ing concepts.
(1) Some methods have been devised to optimize
aggregate grading. Many ideal size distributions such
as the “0.45 power chart” have been proposed since
the beginning of concrete technology, and a number of
Where: procedures have been developed in order to optimize
Ww  weight of water aggregate grading in practical ways. For example, the
Wmf  weight of microfines or powder “18–8” specification has been used in the United
SGmf  specific gravity of microfines or powder States for some years. The aim is to limit the maxi-
Three types of microfines: traprock (TR), granite mum and minimum amounts of aggregate fractions as
(GR) and limestone (LS) were characterized with this shown in Figure 11. However, this method alone does
test. Figure 10 shows the relation between the amounts not ensure good grading since aggregate blends that
of superplasticizer required to reach a 120-mm slump fit the limits still can have an excess or deficit of
in a set of concrete mixtures made with these three coarse or fine particles.
microfines and the packing degree of microfines. Shilstone [2002] has proposed the use of the
from these results it was concluded that this test “0.45 power chart” along with the “coarseness chart”.
might be a good indicator of the microfines suitabil- A good grading will usually be near to the ideal straight
ity for concrete. line of the 0.45 power chart (Figure 12). For the coarse-
ness chart, aggregate is divided in three fractions: large,
Q, intermediate, I, and fine, W. Large aggregate is
5 GRADING OPTIMIZATION composed by the plus 3/8-in (9.5 mm) sieve particles,
intermediate is composed by the minus 3/8-in and plus
Research has shown that aggregate grading plays a key N4, and fine is composed by the minus N4 and plus
role on the performance of Portland cement concrete, N200 sieve particles. The coarseness chart gives the

104
30 50
percentage retained

25 45

Workability factor
IV III
20 40
II
15 35
I
10 30
V
5 25

0 20
1 1/2

3/4

1/2

3/8

N4

N8

N16

N30

N50

N100

N200

MF
100 90 80 70 60 50 40 30 20 10 0
Coarseness factor
Sieve Size (a) The coarseness chart

Figure 11. Iowa DOT version of the “18–8” specification. 120

100
relationship between the modified workability factor

Cumulative Passing (%)


(WF), and the coarseness factor (CF), that can be com- 80
puted from equations (2) and (3)
60

(2)
40

Where:
W  minus N8 sieve particles 20

C  amount of cement in sacks per cubic yard of


0
concrete 0 0,2 0,4 0,6 0,8 1 1,2
[d/D]^0.45
(b) The 0.45 power chart
(3)
Figure 12. (a) The “coarseness chart” [Shilstone 2002] and
(b) the “0.45 power chart”.
Where:
Q  Plus 3/8-in. sieve particles
I  Minus 3/8 in. and plus N8 sieve particles
Figure 12 presents the coarseness chart which is (minus No 8) is considered as mortar. According to
divided into five zones. The diagonal bar, which sep- Shilstone, mortar is the most important part of the mix-
arates zone V from the others, also separates rocky ture because it is the key to strength, durability, work-
mixtures from sandy mixes. Mixtures in zone I are ability, finishability, pumpability, wearability and cost.
prone to segregation. Mixtures in zone IV have too Shilstone states that “most problems are caused by sand
much fine aggregate and are likely to crack, yield low grading that increase or decrease the amount of minus
strength, and segregate during vibration. Zone II is No 8 sieve particles”. The “mortar factor,” defined as
the desirable zone. Zone III is an extension of zone II the volume of the minus N8 sieve material (including
for maximum size of aggregate of 0.5 in. or less. aggregate, cement, water and air), allows the engineer
Although a uniform blend should have material to have a better idea of the mixture behavior.
retained in every sieve, Shilstone [2002] points out
that the amount retained in a single sieve is not as
important as the amounts retained in two adjacent 6 HIGH MICROFINES AGGREGATE
sieves. Accordingly, sieves are grouped in clusters of GRADING OPTIMIZATION
two: 2 in. and 1-1/2 in., 1 in. and 3⁄4 in., N4 and N8,
N16 and N30, and N50 and N100. The workability of more than 100 concrete mixtures
Excess material in one sieve in a cluster can com- with high microfines was evaluated both quantita-
pensate for a deficiency on the other sieve of the cluster. tively (by means of the slump test and a flow test on a
Deficiencies in two adjacent sieves in different clusters vibrating table) and qualitatively. The aggregate grad-
can be acceptable, as long as there is a peak at the other ing was analyzed using the “18–8” specification, the
sieve of the cluster. It is in the N4-N8 cluster where the “0.45 power chart”, and the “coarseness chart”.
effect of shape and texture is more significant. Based on these results and on the performance in
All minus N200 sieve materials are classified as the field of some concrete mixtures with high
paste. The combination of paste and fine aggregate microfines the following guidelines were developed:

105
30 used the recommended sub zones are II-a and II-b.
When superplasticizer is used, the recommended sub
percentage retained

25
zones are II-b and II-c. Finally, it is recommended
20 that aggregate grading follow the 0.45 power chart.
15

10
7 CONCLUSIONS
5

0 From the results of these projects the following con-


3/4

1/2

3/8
1 1/2

MF
N4

N8

N16

N30

N50

N100

N200
1

clusions can be made.


Good quality concrete in terms of strength and
Sieve Size durability can be made from manufactured fine
aggregate with high microfines content.
Figure 13. Modified version of the “18–8” specification
Characterization tests to assess microfines suit-
for high microfines aggregate.
ability for concrete are required since some microfines
might be harmful for concrete.
50
More research is required to establish the suitabil-
ity of the methylene blue and the water demand tests
45 to characterize microfines for use in concrete.
Workability factor

IV
40 Proper grading and water reducing admixtures can
II-c III be used to control the tendency of sand with high
35 II-b microfines to increase the water demand.
I II-a
30
V
25

20 REFERENCES
100 90 80 70 60 50 40 30 20 10 0
Coarseness factor Ahn, N. and Fowler, D. An Experimental Study on the
Guidelines for Using Higher Contents of Aggregate
Figure 14. Coarseness chart for high microfines aggregates. Microfines in Portland Cement Concrete. Research
Report ICAR 102-1F, International Center for Aggregates
Research, 2001.
De Larrard, F. Concrete Mixture Proportioning: a Scientific
It is recommended to perform the methylene Approach. London, 1999.
blue test using the Ohio DOT standard (Appendix Dewar, J. D. Computer Modelling of Concrete Mixtures.
A.1) on microfines. An high MBV usually indicates a E & FN Spon, London, 1999.
high probability of claylike and harmful particles. Dumitru, I., Zdrilic, T. and Crabb, R. Methylene Blue
Microfines with MBV higher than 6 should be further Adsorption Value (MBV). Is It a Rapid and Test Method
evaluated using petrographic examination or chemi- for the Assessment of Rock Quality? Conference
cal analysis. Proceedings 43rd Annual Conference of the Institute of
For microfines and cementing materials the pack- Quarrying Australia. October 1999.
Hudson, B.P. Manufactured Sand for Concrete. Proceedings
ing density should be obtained in saturated condi- of the Fifth Annual Symposium International Center for
tions. The Vicat test (ASTM C 187) is recommended Aggregates Research, Austin, Texas, 1997.
for that purpose. The wet packing density values pro- Quiroga, P. and Fowler, D. The Effect of Aggregate
vide a comparison of different types of microfines Characteristics on the Performance of Portland Cement
and gives an indication of the effect of microfines on Concrete. ICAR Report 104, Austin, TX, 2004.
concrete water demand. The wet packing density can Quiroga, P. and Fowler, D. Guidelines for Proportioning
be determined by means of equation 1. Optimized Mixtures with High Microfines. ICAR,
A modified version of the “18–8” specification Austin, TX, 2004.
(Figure 13) is recommended for high microfines con- Shilstone, J.M, Sr. and Shilstone, J.M., Jr. Performance-
Based Concrete Mixtures and Specifications for Today.
crete since the original specification is intended for Concrete International, February 2002.
concrete with no microfines. Yool, A.I.G, Lees, T.P. and Fried, A. Improvements to the
As for the coarseness chart, the recommendation is Methylene Blue Dye Test for Harmful Clay in Aggregates
to divide the desired zone II in three sub zones: II-a, for Concrete and Mortar Cement and Concrete Research
II-b, and II-c (Figure 14). When no superplasticizer is Vol 28, No 10, 1998, pp 1417–1428.

106
Sustainable Construction Materials and Technologies – Chun, Claisse, Naik & Ganjian (eds)
© 2007 Taylor & Francis Group, London, ISBN 978-0-415-44689-1

Utilization of organo-modified reservoir sludge as fine aggregates in


cement mortars

W.Y. Kuo, J.S. Huang, T.E. Tan & C.Y. Chou


Department of Civil Engineering, National Cheng Kung University, Tainan, Taiwan

ABSTRACT: Disposal of reservoir sludge has become a major problem in most of principal reservoirs in
Taiwan. For the purposes of economy and ecology, we attempt to study the feasibility of using reservoir sludge as
a substitute for a portion of fine aggregates in cement mortars. Through a cationic-exchange reaction with cationic
surfactants, reservoir sludge in Taiwan mainly composed of smectite clay is first organo-modified. As a partial
replacement of fine aggregates, the percentage of organo-modified reservoir sludge (OMRS) added in cement
mortars ranges from 1% to 100%. The compressive strengths and permeability ratios of cement mortars with
various percentages of OMRS particles were measured and then compared to those of plain cement mortars.
Experimental results indicate that it is possible to replace up to 30% by weight of fine aggregates by OMRS par-
ticles in cement mortars for normal practice. Furthermore, excellent waterproof of cement mortars is achieved
when the percentage of OMRS particles is within the range of 5–50%. Meanwhile, the microstructure of cement
mortars is characterized by using SEM, EDS and MIP to evaluate the effects of OMRS particles on the improve-
ments of mechanical properties of cement mortars.

1 INSTRUCTIONS paid less attention as compared to sewage sludge


which has been reused as artificial lightweight aggre-
In Taiwan, more than 40 principal reservoirs with a total gates [Bhatty & Reid 1989; Tay & Yip 1989; Yip &
effective storage volume of approximately 1.6  109 m3 Tay 1990], foamed materials [Wang et al. 2005], man-
have been consecutively constructed for the purposes ufacture bricks [Tay 1987a] and a partial replacement
of flood control, irrigation and water supply. Over the for cement in concretes [Monzo et al. 1996,1999;
past decades, most of the principal reservoirs have been Pandey & Sharma 2000; Tay 1987b,c; Tay & Show
experiencing an annual 0.5% reduction of total effec- 1991]. Nevertheless, reservoir sludge is expected to
tive storage volume due to the poor geological nature be much less hazardous as compared to municipal
in their drainage basins. To increase the capacity of sewage sludge with some heavy metals or toxic sub-
public water supply and ensure the safety of reservoirs, stances and could be extensively used as construction
some renovation and improvement programs have and building materials.
been approved and are currently being undertaken by Smectite clays such as montmorillonite, saponite
the government authorities in Taiwan. Therefore, the and hectorite are the primary compounds of reservoir
disposal and utilization of huge amount of evacuated sludge in Taiwan. The typical chemical structure
reservoir sludge are of importance and become urgent of smectite clays consists of an edge-shared octahe-
when both economy and ecology are concerned. dral sheet with aluminum or magnesium hydroxide
Most of the reservoir sludge in Taiwan is mainly and two silicate tetrahedral sheets with sodium or cal-
composed of gravel, sand and more than 60% smectite cium cations; the sodium and calcium cations could
clays containing SiO2, Al2O3 and CaO. Among them, be chemically replaced by a cationic-exchange reaction.
gravel and sand can be separately used as coarse and Through the cationic-exchange reaction with organic
fine aggregates in concretes. But, the water absorption surfactants, reservoir sludge in Taiwan can be organo-
of smectite clays causes detrimental expansion to a modified [Kuo et al. 2007]. The organo-modified reser-
certain extent when they are mixed with water and voir sludge (OMRS) particles are hydrophobic and then
thus can not be directly used in concretes. The dis- can be utilized as a substitute for a portion of fine
posal and utilization of reservoir sludge have been aggregates in cement mortars. The hydrophobic OMRS

107
particles, which can prevent water from penetrating was washed and filtered repeatedly at least three
the interlayer regions between silicate sheets in smectite times to get rid of the excess of organic ions. Finally,
clays, can be characterized by using thermo-gravimetric the OMRS slurry was dehydrated at 110°C for 24
analysis (TGA). By conducting a series of compres- hours and then ground into OMRS particles. The size
sion and permeability tests on cement mortars with distribution of OMRS particles was determined from
different percentages of organo-modified reservoir a sieve analysis; more than 80% of the OMRS parti-
sludge, the feasibility of using reservoir sludge as fine cles are between 75 µm and 600 µm. Before the
aggregates in cement mortars is evaluated. Also, the OMRS particles are used as fine aggregates in cement
microstructures of cement mortars containing differ- mortars, it is necessary to check if the hydrophilic
ent percentages of OMRS particles are characterized reservoir sludge becomes hydrophobic after being
by using mercury intrusion porosimetry (MIP) and organo-modified by the cationic surfactant dodecy-
EDS to provide more physical insights. lamine. Hence, thermo-gravimetric analyses (TGA)
on the RS and OMRS particles were separately con-
ducted and then compared to each other.
2 MATERIALS AND METHODS
2.2 Preparation of OMRS cement mortars
2.1 Preparation of OMRS particles
To evaluate the validity of OMRS particles used as a
The reservoir sludge (RS) used here was evacuated replacement for fine aggregates in cement mortars,
from the A-Kung-Tien reservoir in Kaohsiung County various mix proportions of cement mortars with
of southwestern Taiwan. It is found that more than OMRS particles are proposed and listed in Table 1.
60% of the reservoir sludge is smectite clays and its The constituents of the cement mortars we studied
specific gravity is 2.72. The cation exchange capacity here are normal portland cement, quartz sands, OMRS
(CEC) of the reservoir sludge determined from atomic particles and water. For the cement mortars we pro-
absorption spectrometer analyzer is 25 meq/100 g. The duced, the ratio of quartz sands and cement was fixed
dosage of cationic surfactant used for the cation- and equal to 2.75. The percentage of OMRS particles,
exchange reaction of a reservoir sludge sample can be expressed as a replacement fraction of the total weight
calculated from the following equation: of quartz sands in a mixture proportion of cement
mortar, ranges from 1% to 100%; the percentages of
(1) OMRS particles considered here are 0, 1, 5, 10, 20, 30,
40, 50, 80 and 100%. From Table 1, it is noted that the
required mixing water for the cement mortars with the
Wherein, X is the dosage of cationic surfactant, Ce same consistency increases with increasing percent-
is the CEC value of the reservoir sludge sample age of OMRS particles.
expressed in a unit of meq/100 g, W is the total weight
of the reservoir sludge sample, Mw  185.35 g/mol is 2.3 Test methods of cement mortars
the molecular weight of cationic surfactant, dodecy- The effects of OMRS particles on the compres-
lamine C12H27N, and Q  1 is the number of valence sive strengths of cement mortars are evaluated by
electron. Besides, extra 10% of required amount of
cationic surfactant is added to ensure that any reservoir
sludge sample can be thoroughly organo-modified Table 1. Mix proportions of cement mortars with OMRS
particles.
through the cation-exchange reaction, leading to a
coefficient of 1.1 given in Equation (1). Dosage of OMRS Sand Cement Water
At fist, 500 g reservoir sludge was stirred in a beaker OMRS(%) W/C (kg/m3) (kg/m3) (kg/m3) (kg/m3)
with 4000 ml distilled water at room temperature.
Twelve hours later, 25 g dodecylamine C12H27N, cal- 0 0.485 0 1375 500 240
culated from Equation (1), was stirred in another beaker 1 0.49 14 1361 500 245
with 1000 ml distilled water at higher temperature. 5 0.50 69 1306 500 250
After the cationic surfactant was completely dissolved 10 0.53 138 1237 500 265
in water, the pH value of mixing water was adjusted to 20 0.57 275 1100 500 285
about 3–4 by the addition of 1 M hydrochloride acid 30 0.62 413 962 500 310
40 0.70 550 825 500 350
solution. Then, the resulting solution was slowly poured 50 0.80 688 687 500 400
into the beaker with reservoir sludge suspension solu- 80 1.25 1100 275 500 625
tion. In order to complete the cation-exchange reaction, 100 1.64 1375 0 500 820
the compound solution was vigorously stirred at room
temperature for additional 12 hours. Next, the organo- * Flow table spread value of cement mortar was 100%.
modified reservoir sludge in the compound solution

108
conducting a series of compression tests. The wet 3 RESULTS AND DISCUSSIONS
cement mortars containing OMRS particles were cast
into 50 mm  50 mm  50 mm cubic steel molds. 3.1 Characterization of OMRS particles
One day later, the cubic cement mortar specimens
Experimental results of thermogravimetric analyses
were removed from steel molds and cured in water at
(TGA) on the RS and OMRS particles are shown in
room temperature for additional 2, 6 or 27 days.
Figure 1. The total weight of each sample for TGA
Cubic cement mortar specimens cured in water were
tests is initially about 50 mg at the starting tempera-
dried and then trimmed before compression testing.
ture of 50°C and then decreases con-secutively when
The 3-day, 7-day and 28-day cement mortar specimens
the test temperature is heated up from 50°C to
were loaded under a constant rate of 300 KPa/sec in
1000°C at a constant rate of 30°C/min under nitrogen
compression tests. On the other hand, the effects of
atmosphere. Based on the derivative weight curves of
OMRS particles on the permeability of cement mor-
RS and OMRS particles, it is found that the weight
tars are evaluated by employing JIS A1404 test
percentage of absorbed water in the interlayer regions
method for waterproof agent of cement for concrete
between silicate sheets of smectite clays in RS parti-
construction. The disk steel molds for permeability
cles, evaporated at around 150°C, is roughly 2% and
tests have an inner diameter of 150 mm and a height
much larger than that in OMRS particles. From
of 40 mm. The disk cement mortar specimens were
Figures 1, it is also seen that the cationic surfactant
removed from steel molds after 48 hours curing.
dodecylamine in the interlayer regions between sili-
The disk cement mortar specimens were cured at a
cate sheets of smectite clays for OMRS particles is
temperature of 20  3°C and a humidity of more than
decomposed at the temperatures from 300°C to 500°C
80% for additional 19 days and then oven-dried to
with a loss of around 5% total weight. Moreover, the
a constant weight at 80°C before permeability testing.
weight loss curves for both RS and OMRS particles at
During permeability testing, a constant hydraulic
the temperatures from 500°C to 1000°C are similar.
pressure of 200 KPa was imposed on the bottom
Therefore, it can be concluded that the OMRS particles
surface of each disk cement mortar specimen. After
we used here have been organo-modified and become
permeability testing, both the top and bottom surfaces
hydrophobic before they are mixed with water, quartz
of each disk cement mortar specimen were wiped and
sands and cement.
then its resulting weight was recorded and used to
calculate the increase of total weight. The permeabil-
ity ratio (PR) is defined as the ratio of the increase 3.2 Compressive strength
of total weight of any cement mortar specimen con-
The measured 3-day, 7-day and 28-day compressive
taining OMRS particles to that of plain cement mor-
strengths of cement mortar specimens containing var-
tar specimen with a water-cement ratio of 0.485.
ious percentages of OMRS particles are listed in
When the PR value of a cement mortar specimen con-
Table 2 and shown in Figure 2; in each case, three
taining OMRS particles is less than 1.0, its water-
proofing performance is better than plain cement
mortar. On the contrary, the waterproofing perform- 100 0
ance of a cement mortar specimen is worse than
plain cement mortar when its PR value is larger
than 1.0.
The pore size distributions of 28-day cement mor- 95 -0.3
Derivative weight (%/min)

tar specimens containing various percentages of


OMRS particles were measured by using mercury
Weight (%)

intrusion porosimetry. The cement mortar specimens


with a dimension of 10 mm  10 mm  15 mm were 90 -0.6

first dried in an oven heated up to 110°C and then


placed in a chamber of MIP. The percentages of
OMRS particles we studied here were 0%, 10%, 50%
85 -0.9
and 100%. The variation of total weight for each
cement mortar specimen was recorded as the pressure Weight of RS
Weight of OMRS
in the chamber was increased from zero up to roughly Derivative weight of RS
Derivative weight of OMRS
400 MPa. Consequently, the pore size distribution of 80 -1.2
each cement mortar specimen was obtained from MIP 0 100 200 300 400 500 600 700 800 900 1000
measurement. In addition, the locations of OMRS par- Temperature (°C)
ticles distributed in 28-day cement mortar specimens
were identified by using EDS with point-mapping Figure 1. Experimental results of thermogravimetric analysis
images. on RS and OMRS particles.

109
Table 2. Compressive strengths and permeability ratios of particles could be up to 95% of their 28-day compres-
cement mortars with OMRS particles. sive strengths. Meanwhile, the 28-day compressive
strengths of cement mortars with 1% and 5% OMRS
Compressive strength (MPa) particles are close to those of plain cement mortars. In
Dosage of Permeability
addition, the 7-day compressive strengths of cement
OMRS(%) ratio 3-day 7-day 28-day
mortars with 10%, 20% and 30% OMRS particles are
0 1 31.7 42.4 44.7 around 72% of their 28-day compressive strengths.
1 0.72 33.4 42.1 43.8 As compared to plain cement mortars, the 28-day
5 0.17 30.2 39.6 42.3 compressive strengths of cement mortars with 10%,
10 0.09 21.4 29.1 37.6 20% and 30% OMRS particles drop within the range
20 0.06 18.2 26.9 35.4 of 16%–32%. The decreasing 28-day strengths of
30 0.04 14.1 19.7 30.2 cement mortars with OMRS particles result from the
40 0.03 9.2 13.0 22.5 increasing water-cement ratios to attain a constant
50 0.05 6.5 11.5 15.0
flow table spread value of 100% when the percentage
80 0.64 2.3 3.6 4.7
100 1.27 1.1 1.5 2.2 of OMRS particles is increased. Besides, the hydration
of cement mortars is apparently retarded due to the hin-
drance of hydrophobic OMRS particles to water diffu-
sion when the percentage of OMRS particles is more
50 than 10%.
Similar results can be found in group II including
(0%,W/C=0.485)
(1%,W/C=0.49)
(5%,W/C=0.50)
the cement mortars with 40% or 50% OMRS parti-
40 cles. In group II, the 28-day compressive strengths of
(10%,W/C=0.53) cement mortars are more than 15 MPa but less than
Compressive Strength (MPa)

(20%,W/C=0.57)
25 MPa, and the 7-day compressive strengths of cement
(30%,W/C=0.62)
mortars only reach 66% of their 28-day compres-
30
sive strengths. Again, the higher water-cement ratios
required for the cement mortars with 40% and 50%
(40%,W/C=0.70) OMRS particles to have a flow table spread value of
20 100% result in a significant decrease of 28-day com-
(50%,W/C=0.80)
pressive strengths.
A dramatic reduction of compressive strengths
10 occurs for the cement mortars with a percentage of
80% or 100% OMRS particles, denoted as group III.
(80%,W/C=1.25)
Because of the excessively high water-cement ratios
(100%,W/C=1.64)
0
required to keep the consistency of cement mortar
0 5 10 15 20 25 30 35 slurry with an extra amount of hydrophobic OMRS
Age (days) particles, the development of compressive strengths
for the cement mortars becomes much slower even
Figure 2. Compressive strengths of cement mortars contain- after 7 days curing. As expected, the 28-day compres-
ing various dosages of OMRS particles at different curing sive strengths of cement mortars with 80% and 100%
ages of 3, 7 and 28 days. OMRS particles are tremendously reduced and could
be less than 10 MPa.
Experimental results of groups I suggest that OMRS
cement mortar specimens were measured and then particles can be used in normal-strength cement mor-
averaged. From Figure 2, it is quite consistent that tars. If the percentage of replacement for fine aggre-
either the 3-day, 7-day or 28-day compressive strengths gates is less than 30%, the 28-day compressive
of cement mortar specimens decrease with increasing strengths of cement mortars drop at a maximum of
percentage of OMRS particles. According to the mag- 30% but are still higher than 25 MPa which satisfies
nitude of 28-day compressive strengths, the cement the design requirement of normal-strength cement
mortar specimens with different percentages of OMRS mortars. Meanwhile, experimental results of group II
particles can be divided into three groups. indicate that the 28-day compressive strengths of
28-day compressive strengths of cement mortar cement mortars are within a range of 15–25 MPa
specimens with 1%–30% OMRS particles are more when the percentage of replacement for fine aggre-
than 25 MPa. Thus, cement mortar specimens with gates varies from 30% to 50%. Thus, the cement mor-
1%–30% OMRS particles are classified as group I. tars in group II can be used as intermediate-strength
It is noted that the 7-day compressive strengths of cement mortars in minor structural facilities and
cement mortar specimens with 1% and 5% OMRS components. In group III, the 28-day compressive

110
0.4 influenced by the percentage of OMRS particles we
0%,W/C=0.485 introduced and the water-cement ratio we used.
10%,W/C=0.53
50%,W/C=0.80
As compared to plain cement mortars, the accessi-
100%,W/C=1.64 ble pore volume of intermediate pores ranging from
Accessible pore volume, (10-2 cm3/g)

0.3 0.2 µm to 2 µm is significantly reduced for cement


mortars with OMRS particles. It can be attributed to
the obstruction of OMRS particles around capillary
pores when mercury is forced to flow into cement
0.2 mortar specimens in MIP tests, resulting in the reduc-
tion of accessible pore volume of intermediate pores.
Therefore, it is verified that the space of capillary
pores can be partially filled if an adequate amount of
0.1 OMRS particles is introduced in cement mortars. On
the other hand, the total volume of accessed pores is
reduced and the pore size distribution of cement mor-
tars becomes more continuous as the percentage of
0 OMRS particles is 10%. Meanwhile, the pore sizes of
0.001 0.01 0.1 1 10 cement mortars containing 50% OMRS particles are
Effective size of access, equivalent diameter, (10-6 m) mainly within a range from 0.01 µm to 0.05 µm and
the total volume of accessed pores is much lower than
Figure 3. Mercury intrusion porosimetry curves of cement that of plain cement mortars. However, the total vol-
mortars containing 0%, 10%, 50% and 100% OMRS particles. ume of accessed pores become higher and the pore
sizes are mostly between 0.1 µm and 0.2 µm when
100% OMRS particles are introduced in cement mor-
strengths of cement mortars are lower than 10 MPa. tars. The reason for higher porosity and larger pore size
Hence, cement mortars in group III can be used as could be due to the difficulty in mixing for cement
controlled low-strength materials (CLSM) in con- mortars with 100% OMRS particle even their water-
struction if the percentage of replacement for fine cement ratio is increased to 1.64.
aggregates is higher than 80%. Although the total volume of accessed pores is
reduced for cement mortars containing 10% OMRS
particles, their compressive strengths are lower than
3.3 Permeability ratio
those of plain cement mortars. The reason for those is
Experiment results of permeability tests on cement primarily due to the retardation of cement hydration
mortars with various percentages of OMRS particles and lower strength of OMRS particles as compared to
are listed in Table 2. The PR value is dramatically quartz sands. When the percentage of OMRS particles
reduced when the percentage of OMRS particles in is higher than 10%, the 3-day, 7-day and 28-day com-
cement mortars is increased up to only 5%. Hence, it pressive strength of cement mortars are much lower
is obvious that OMRS particles used in cement mor- than those of plain cement mortars. Nevertheless, lower
tars not only act as fine aggregates but also act as dif- PR values of cement mortars containing more than
fusion barriers to provide excellent waterproof 10% OMRS particles can be achieved.
performance. As the percentage of OMRS particles is The EDS raw data of plain cement mortars and
increased from 10% up to 50%, the PR values of cement mortars containing 10%, 50% and 100%
cement mortars become much lower and are less than OMRS particles as listed in Tables 3–6, respectively.
0.1. However, the PR values increase significantly From Tables 3–6, it is found that the Si/Ca ratio
when the percentage of OMRS particles in cement increases with increasing percentage of OMRS parti-
mortars is larger than 50%. If 80% sands are replaced cles; the Si/Ca ratios of cement mortars containing
by OMRS particles, the PR value of cement mortars 0%, 10%, 50% and 100% OMRS particles are 0.17,
is increased to 0.64 but still less than 1. Up to 100% 0.36, 0.54 and 0.79, respectively. Meanwhile, the con-
replacement of sands by OMRS particles, the PR tent of element Al increases with increasing percentage
value of cement mortars becomes 1.27. of OMRS particles. For instance, the EDS scattered
molecules of Si and Ca point-mapping images for
cement mortars containing 0% and 50% OMRS par-
3.4 Microstructural characterization
ticles are shown in Figures 4 and 5, respectively. It is
The MIP curves of 28-day cement mortars with 0%, also found that some white points in the Si charts are
10%, 50% and 100% OMRS particles are shown absent in the Ca charts of Figures 5; these white points
in Figure 3. From Figure 3, it is found that the pore in the Si charts are identified as OMRS particles. The
size distribution of cement mortars is significantly above finding verifies that OMRS particles mainly

111
Table 3. EDS raw data for the cross-section of a plain Table 6. EDS raw data for the cross-section of a cement
cement mortar. mortar containing 100% OMRS particles.

Element Weight (%) Atomic(%) Element Weight (%) Atomic(%)

Mg 0 0 Mg 1.67 2.35
Al 2.72 3.81 Al 11.83 15.05
Si 13.40 18.00 Si 30.58 37.39
K 2.78 2.68 K 5.69 5.00
Ca 77.80 73.23 Ca 38.68 33.15
Ti 0.47 0.37 Ti 1.09 0.78
Mn 0 0 Mn 0 0
Fe 2.84 1.92 Fe 9.77 6.01
Ni 0 0 Ni 0 0
Cu 0 0 Cu 0 0
Total 100 100 Total 100 100

Table 4. EDS raw data for the cross-section of a cement


mortar containing 10% OMRS particles.

Element Weight (%) Atomic(%)

Mg 0 0
Al 5.37 7.23
Si 22.09 28.55
K 5.16 4.79
Ca 60.81 55.08
Ti 0.66 0.50
Mn 0 0
Fe 5.91 3.84
Ni 0 0
Cu 0 0
Total 100 100

Table 5. EDS raw data for the cross-section of a cement


mortar containing 50% OMRS particles.

Element Weight (%) Atomic(%)

Mg 0 0
Al 9.27 12.16
Si 26.75 33.69
K 4.65 4.21
Ca 49.52 43.70
Ti 0.98 0.73
Mn 0 0
Fe 8.57 5.43
Ni 0 0
Cu 0 0
Total 100 100

composed of SiO2 and Al2O3 can disperse well in the


cross-sections of cement mortars even though the
dosage of OMRS particles is up to 50%. As a result,
the OMRS particles organo-modified by dodecylamine
molecules with single hydrophobic carbon chain are
easier to disperse in cement mortars than those by Figure 4. EDS scattered molecules of Si and Ca point-
quaternary ammonium chloride molecules with two mapping images of a plain cement mortar.

112
cationic-exchange reaction. The experimental results
show that the compressive strengths of cement mor-
tars decrease as the percentage of OMRS particles is
increased. If the percentage of OMRS particles is less
than 30%, the 28-day compressive strengths of cement
mortar are higher than 25 MPa which satisfies the
design requirement of normal-strength cement mor-
tars. Meanwhile, the compressive strengths of cement
mortars are within a range of 15–25 MPa when the
percentage of OMRS particles varies from 30% to
50%. Thus, the cement mortars containing 30%–50%
OMRS particles can be used as intermediate-strength
cement mortars in minor structural facilities and
components. However, the compressive strengths of
cement mortars with more than 80% OMRS particles
are lower than 10 MPa.
Furthermore, the permeability ratios of cement
mortars are dramatically reduced when the percentage
of OMRS particles is increased up to only 5%. Hence,
OMRS particles used in cement mortars not only act
as fine aggregates but also act as diffusion barriers to
provide excellent waterproof performance. As the per-
centage of OMRS particles is increased from 10% to
50%, the PR values of cement mortars become much
lower. But, the PR values increase significantly when
the percentage of OMRS particles is larger than 80%.
From MIP measurements, it is found that the pore
size distribution and the total volume of capillary pores
in cement mortars are dramatically influenced by the
percentage of OMRS particles we introduced. As com-
pared to plain cement mortars, the volume of intermedi-
ate pores ranging from 0.2 µm to 2 µm is significantly
reduced for cement mortars containing OMRS particles.
However, the total volume of capillary pores in cement
mortars containing 100% OMRS particles become
higher due to the difficulty in mixing. Therefore, it is
verified that the capillary pores in cement mortars can
be partially filled if adequate amount of OMRS particles
is used. The EDS raw data and scattered molecules point-
Figure 5. EDS scattered molecules of Si and Ca point- mapping images for cement mortars containing OMRS
mapping images of cement mortar containing 50% OMRS particles also show that the OMRS particles organo-
particles. modified by dodecylamine molecules with single hydro-
phobic carbon chain are easier to disperse in cement
carbon chains [Kuo et al. 2006]. Hence, a considerable mortars.
amount of OMRS particles without forming clusters However, the strength of single OMRS particle is
can be used as fine aggregates in cement mortars. lower than quartz sand. When the percentage of
OMRS particles is higher than 10%, the compressive
strengths of cement mortars become weaker even
4 CONCLUSIONS though their total volume of accessed pores is lower
as compared to plain cement mortars. Therefore, 5%
The feasibility of using reservoir sludge for replace- OMRS particles used as a substitute for fine aggre-
ment of fine aggregates in cement mortars is studied gates in cement mortar is preferred when workability,
here. Since smectite clays are the primary compounds strength and permeability are sought. Cement mortars
of reservoir sludge in Taiwan, reservoir sludge are first containing 10% to 30% OMRS particles can provide
organo-modified before they are mixed with water. sufficient compressive strengths and excellent water-
Thermogravimetric analyses indicate that hydrophilic proofing performance if appropriate water-cement ratio
reservoir sludge become hydrophobic through a is used.

113
REFERENCES Tay, J.H. 1987a. Bricks manufactured from sludge. Journal
of Environmental Engineering 113 (2): 278–284.
Bhatty, J.I. & Reid, K.J. 1989. Moderate strength concrete from Tay, J.H. 1987b. Properties of pulverized sludge ash blended
lightweight sludge ash aggregates. Cement and Concrete cement. ACI Material Journal September-October:
Composites 11(3): 179–187. 358–364.
Kuo, W.Y., Huang, J.S. & Lin, G.H. 2006. Effects of organo- Tay, J.H. 1987c. Sludge ash as filler for portland cement
modified montmorillonite on strength and permeability concrete. Journal of Environmental Engineering 113 (2):
of cement mortars. Cement and Concrete Research 36: 354–351.
886–895. Tay, J.H. & Show, K.Y. 1991. Properties of cement made
Kuo, W.Y., Huang, J.S. & Tan, T.E. 2007. Organo modified from sludge. Journal of Environmental Engineering 117
reservoir sludge as fine aggregate in cement mortars. (2): 236–246.
Construction and building materials 21: 609–615. Tay, J.H. & Yip, W.K. 1989. Sludge ash as lightweight con-
Monzo, J., Paya, J., Borrachero, M.V. & Corcoles, A. 1996. crete material. Journal of Environmental Engineering
Use of sewage sludge ash (SSA) – cement admixtures in 115 (1): 56–64.
mortars. Cement and Concrete Research 26: 1389–1398. Wang, K.S., Chiou, I.J., Chen, C.H. & Wang, D. 2005.
Monzo, J., Paya, J., Borrachero, M.V. & Mora, E.P. 1999. Lightweight properties and pore structure of foamed
Mechanical behavior of mortars containing sewage sludge material made from sewage sludge ash. Construction and
ash (SSA) and portland cement with different tricalcium Building Materials 19: 627–633.
aluminate content. Cement and Concrete Research 29: Yip, W.K. & Tay, J.H. 1990. Aggregate made from inciner-
87–94. ated sludge residue. J. Materials in Civil Engineering 2
Pandey, S.P. & Sharma, R.L. 2000. The influence of mineral (2): 84–93.
additives on the strength and porosity of OPC mortar.
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114
Sustainable Construction Materials and Technologies – Chun, Claisse, Naik & Ganjian (eds)
© 2007 Taylor & Francis Group, London, ISBN 978-0-415-44689-1

Study on fly ash-saturation in cementitious materials

Long Guangcheng, Liu Yunhua & Xie Youjun


School of Civil Engineering and Architecture, Central South University, Changsha, China

ABSTRACT: The concept of fly ash-saturation is put forward based on the index of maximum compressive
strength and optimum strength factor of unit fly ash in mortar and concrete system, respectively. Experiments
are also carried out to investigate the effect of water to binder ratio (w/b) and type of fly ash on fly ash-saturation
under full hydration condition in mortar system. The results indicate that the value of fly ash-saturation in mortar
is influenced by w/b and type of fly ash. In investigated area, fly ash-saturation in mortar and concrete ranges from
20% to 30% of total binder by weight. The fly ash-saturation for optimum compressive strength of mortar/concrete
differs from one based on optimum unit strength factor of fly ash.

1 INTRODUCTION such as best strength or lowest permeability etc. and to


let fly ash exerts best contribution to cement-based
It is well known that the utilization of fly ash in materials. In this paper, this threshold is named as fly
cement-based materials is of great importance not ash-saturation. Obviously, the fly ash-saturation is
only for improving application technology of industrial affected by many factors such as properties of cemen-
by-products but also for upgrading properties of titious materials system, type of fly ash, water to binder
cement-based materials [Mehta 1999] For several (cement and mineral admixture) ratio (w/b) etc. In
decades, much efforts has been focused on develop- addition, it is noted that the concept of ‘full hydration’
ing some new technologies of high value-added uti- for fly ash-saturation in this paper is the adequately
lization of natural or industrial waste such as fly ash. hydration under corresponding to w/b condition and is
Many achievements related to effects of fly ash on not necessary to complete hydration of each cement or
properties of cement-based materials have been docu- fly ash particle, which is evaluated by index of the
mented [Mehta 1999, SHI Huisheng et al 2004, Long highest value of compressive strength of sample.
et al 2005, Babu K G et al 1996, Baoju et al 2003]. In order to assess the strength contribution of unit
However, most of results are obtained from experi- fly ash and efficiency of fly ash in cement-based mate-
ments under a limited age condition. In terms of hydra- rials, the index of unit strength-factor, λ, is put for-
tion theory of cement and the physical and chemical ward. λ is defined as strength contribution of unit fly
action of minerals admixtures including fly ash in con- ash in sample with fly ash to one of unit cement in
crete, effect of fly ash on properties of concrete/mortar control sample ratio. In this study, it is assumed that
is time-dependent. And therefore the results gained the strength of sample with fly ash is composed of two
within limited age might not reflect the whole or long- parts of strength contributions of fly ash and cement.
term effects of fly ash on properties of cement-based And strength contribution of cement in sample with
materials. Furthermore, the information related to fly ash can be calculated by one of unit cement in con-
strength contribution of unit fly ash on concrete/mortar trol sample multiplying mass percent of cement in
is limited. In order to know systematically the effi- sample. It is expected that the result is not be affected
ciency of fly ash and to develop some new methods for by such assumption. So, one can obtain the equation
high value-added utilization of fly ash in concrete, it is (1) as followings.
necessary to study the reasonable amount range of fly
ash in concrete and the relationship between content of
fly ash and properties of concrete with fly ash. (1)
On basis of above analysis and plenty of practices,
it follows that under ‘full hydration’ condition, there where: γc is named as strength contribution of unit
exists a certain threshold of fly ash to make cement- cement, obtaining from compressive strength of con-
based materials system obtain optimum properties trol sample dividing by 100; α is the replacement of

115
cement by fly ash, expressed by weight percent. R is sand to binder (cement and fly ash) is 2.5 for all mor-
the compressive strength of sample with fly ash. It is tar samples. The flowability for all mortar samples
obvious that the limit of λ is equal to 1 when α is zero. ranges from 135 mm to 150 mm measured by flow
In following section, the fly ash-saturation under table test according to ASTM C230-90.
full hydration condition is investigated by experiment Concrete sample is made by stainless steel mold
on basis of the consideration of optimum strength of with 100 mm  100 mm  100 mm. Mix proportion
mortar and concrete and the best unit strength-factor of raw materials in concrete mixture is: 500 kg/m3
of fly ash in cement-based materials. binder; 610 kg/m3 sand; 1230 kg/m3 coarse aggregate;
140 kg/m3 water; The slump for all concrete samples
ranges from 10 mm to 30 mm. Water-reducer is added
2 EXPERIMENTAL DETAILS to improve workability of mortar and concrete sample.
In order to let cement and fly ash ‘fully hydrate’
2.1 Raw materials within a limited age, the following procedure of cur-
ing treatment for mortar sample was chosen: sample
Cement used is Grade 32.5 Ordinary Portland cement
was demolded at 1 day after casting and cured in
according to Chinese Standard GB 175-1999. Its
water with a temperature of 22°C for four days and
chemical compositions are listed in Table 1. Three
then cured in water with a temperature of 60°C for
types of fly ash such as grade I ( FAI), grade II(FAII)
two days. For Concrete sample, two curing conditions
and one denoted as UFA was used . UFA is derived
are used. One is standard curing condition (20  2°C,
from grade II fly ash by grinding. Their chemical
RH
95%) for 90d. The other is heat water with a
compositions and physical properties are given in
temperature of 60°C curing condition for 12 h after
Table 1 and Table 2. The tree types of fly ash in this
demolded at 1d and then standard curing until 90d
paper are similar to class F according to ASTM
age. Due to the consideration of side effects of excess
standard. A naphthalene sulphonic acid was used to
high temperature on microstructure and properties of
improve workability of sample.
sample, heat water with a temperature of only 60°C is
River sand with fineness modulus of 2.2 was used
chosen as a rapid curing condition. The details for
for the mortar specimen. Its size distribution is
curing treatment can be referred documents [LONG
0.162.3 mm. For the concrete samples, gravel with a
Guangcheng et al 2005].
maximum diameter of 25 mm was employed as coarse
aggregate. Its apparent density was 2700 kg/m3. River
sand with a fineness modulus of 2.8 and an apparent 3 RESUTLS AND DISCUSSION
density of 2650 kg/m3 was used as fine aggregate.
3.1 Effects of amount of fly ash on strength of
mortar and unit strength factor under fully
2.2 Sample preparation and test
hydration condition
Mortar sample is prepared by stainless steel mold
Figure 1 shows the result of effect of amount of fly
with 40 mm  40 mm  160 mm. The weight ratio of
ash FAI on compressive strength of mortar with a
w/b of 0.30 and its unit strength factor under specific
Table 1. Chemical composition of cement and fly ash x% condition.
by weight.
From result shown in Figure.1, one can see that
Raw materials SiO2 Al2O3 Fe2O3 CaO MgO SO3
under investigated condition, the compressive strength
of mortar firstly increases with increasing amount of
Cement 24.3 4.8 3.8 55.3 4.2 2.2 fly ash and then gradually reduces after more than
FAI 52.7 31.8 5.7 3.7 1.2 0.2 30% replacement of cement by fly ash. The variation
FAII & UFA 51.2 29.5 6.1 3.1 3.0 0.7 of flexural strength of mortar is similar to that of com-
pressive strength of mortar. This shows that there is an
optimum amount of fly ash to make compressive or
Table 2. Physical properties of fly ash. flexural strength of mortar come up to maximum under
specific condition. This optimum amount of fly ash is
Residue Blaine about 30% in this experiment. That is to say, fly ash-
passing Water- Ignition Specific saturation is 30% replacement of cement by fly ash
45 µm content/ loss/ Density/ area/ with respect to maximum strength index of mortar. In
sieve/% % % g.cm3 m2.kg1 addition, it can be found that the relationship between
variation of strength of mortar and amount of fly ash
UFA 2.6 0.47 5.0 2.53 700
FAI 4.0 0.20 3.5 2.30 500
under investigated experimental condition differs
FAII 8.0 0.17 6.0 2.16 310 from that of under standard curing condition (20  2°C
and RH
95%)within 28 days age. The reason is that

116
under standard curing condition the efficiency of fly of fly ash can improve adaptability of mortar/concrete
ash cannot be brought into play completely with a lim- to high temperature curing [LIU Baoju et al 2005].
ited age such as 28 days age. On the other hand, fly ash particles can play a physi-
Further, from the results given in Figure1b, unit cal filling role and a chemical reaction effect on
strength factor of fly ash varies with various content of cementitious materials system. A lack of fly ash par-
fly ash in mortar. There exists an optimum content ticles will lead to an insufficient area available for the
of fly ash, i.e 20%, to make its unit strength factor precipitation of hydrates and an excess of fly ash par-
maximum. The unit strength factor of fly ash reduces ticles will contribute to the dispersion of the cement
greatly with increasing amount of fly ash when the grains, which both result in a reduction of compres-
replacement of cement by fly ash is more than 30%. sive strength of sample [Martin Cyr et al 2006].
However, even if the replacement of cement by fly ash Obviously, the effect of fly ash on sample varies with
is up to 60% the unit strength factor of fly ash is still amount of fly ash. When the total physicochemical
equal to about 1, which shows a considerable contri- effects of fly ash comes up to the best the compressive
bution of fly ash to compressive strength of mortar. strength of sample is the highest. And it is the corre-
This also indicates that, under full hydration condi- sponding optimum amount of fly ash.
tion, unit fly ash has a high strength contribution to
cement-based materials. At the same time, one can
3.2 Effect of w/b on fly ash-saturation in mortar
also see that the optimum content of fly ash for max-
imum compressive strength of mortar differs from Figure 2 shows the effects of w/b on fly ash-saturation
that for maximum unit strength factor of fly ash. This (FAI) of mortar system. From the result given in fig-
may be the reason that, on the one hand, the addition ure.2a, it can be seen that the compressive strength of

70
12 30% amount of FAI
70
40%
compressive strength/MPa

60 20%
Compressive strength /MPa

Flexural strength /MPa

50%
60
50 10%
10

50 40 0%
Control sample

30

40 8
0 10 20 30 40 50 60 0.28 0.32 0.36 0.40 0.44
replacement of cement by FAI / % by mass water to binder ratio
(a) Compressive strength (a) Compressive strength

4 4.2

3.6
20%
Unit strength factor λ

Unit strength factor λ

10%
3
3.0
30%

2.4
2 40%

1.8 50%

1 1.2
0 10 20 30 40 50 60
0.27 0.30 0.33 0.36 0.39 0.42 0.45
replacement of cement by FAI / α% Water to binder ratio / by mass
(b) Unit strength factor
(b) Unit strength factor
Figure 1. Effect of content of fly ash FAI on strength and
unit strength factor of mortar with a w/b of 0.30. Figure 2. Effect of w/b on fly ash-saturation in mortar.

117
mortar reduces with increase of w/b. Moreover, the 65
amount of fly ash for maximum compressive strength 60
FAI
of mortar varies with w/b. when w/b is equal to 0.3, the

Compressive strength /MPa


compressive strength of mortar comes up to maximum 55 UFA
when the replacement of cement by fly ash FAI is 30%. 50
However, after w/b is more than 0.34 the compressive
strength of mortar with 20% fly ash is up to maximum, 45

i.e. fly ash-saturation varies with w/b of mortar with 40


respect to compressive strength of mortar. This may be
35
the reason that under a low w/b condition, mortar with FAII
a higher content of fly ash will have a higher water to 30
cement ratio. Therefore, more cement particles can be
25
hydrated and fly ash particles play fully physical and 10 20 30 40 50
chemical role in mortar system, which results in a max-
Content of fly ash /by mass %
imum compressive strength of mortar.
Fig.2b shows that there is a reducing tendency of (a) Compressive strength
unit strength-factor with increasing w/b. Moreover,
5
for all investigated w/b, the unit strength factor of fly
ash reached maximum when replacement of cement
by fly ash is 20%. This indicates within investigated 4
area, fly ash-saturation in mortar is different for various UFA
Unit strength factor λ
assessing indices.
3
FAI

3.3 Effects of type of fly ash on fly ash-saturation 2


The physical and chemical effect of fly ash on prop-
FAII
erties of cement-based materials depends on charac- 1
teristics of hydration environment and properties of
fly ash. As to a defined hydration environment, the
physical and chemical effect of fly ash is determined 0
0 10 20 30 40 50
by type of fly ash. Figure 3 gives the experimental
Content of fly ash / by mass%
result of effect of fly ash type on fly ash-saturation in
mortar with a w/b of 0.3. (b) unit strength factor
Figure 3 shows that type of fly ash greatly influenced
compressive strength of mortar. And the optimum con- Figure 3. Effect of fly ash type on fly ash-saturation in
tent of fly ash for maximum compressive strength of mortar with w/b of 0.3.
mortar differs from each other with respect to type of
fly ash. Moreover, the most noteworthy is that the
strength of mortar with UFA is considerable large and
3.4 Fly ash-saturation in concrete with respect to
the one of mortar with FAII is much less compared with
maximum compressive strength
mortar with FAI. UFA is derived from FAII by grinding
treatment. This indicates that mechanical grinding treat- Compared with mortar, concrete system includes coarse
ment to fly ash can remarkably improve strength contri- aggregate and its microstructure differs from that of
bution of fly ash on cement-based materials system. mortar. Therefore, the physical and chemical effects of
This may result from the improvement of size distribu- fly ash on concrete may be different from that of mortar
tion and chemical reaction of UFA particles by mechan- and so does the fly ash-saturation. With respect to con-
ical treatment. Therefore UFA show good physical crete system, the influences of replacement of cement
filling effect and chemical reaction role in sample com- by fly ash on compressive strength of concrete and its
pared with FAII. unit strength factor are given in Figure 4.
The result shown in Figure 3b indicates that the vari- From the result shown in figure 4a, one can see that
ation of unit strength factor of fly ash with replacement there exists an optimum amount of fly ash to make
of cement by fly ash is similar to each other for three compressive strength of concrete reach maximum
types of fly ash. Furthermore, the fly ash-saturation is whether under standard curing of 90 days age condi-
the same for three types of fly ash and it is about 20%. tion or under heat water curing for 12 h and standard
Compared with FAI or UFA, the unit strength-factor of curing until 90 days age condition. In this experiment,
FAII is much less. The less chemical activity and larger the optimum content of fly ash is the same, i.e. 20%
particles diameter of FAII is responsible for this result. both for two kinds of curing condition. In addition, it

118
95
12h heat water curing,90 days
which depends on w/b of concrete or mortar, charac-
standard curing, 90 days teristics of hydration system, fly ash type and aggre-
w/b=0.28, UFA gates type etc. Moreover, there are many kinds of fly
compressive strength /MPa

90 ash including various physical properties such as


fineness and chemical properties. Therefore, this
issue can not be solved clearly by a simple paper with
85 limited space. From present study, following conclu-
sions can be obtained.

1) There exists a fly ash-saturation range for maxi-


80
mum strength of mortar and concrete or maximum
strength-factor of unit fly ash in cement-based
materials under fully hydration condition. The
75
proposition of fly ash-saturation is reasonable and
0 10 20 30 40 50
replacement of cement by fly ash /%
valid.
2) Parameter of water to binder ratio and type of fly
(a) Compressive strength
ash can greatly influence fly ash-saturation in
2.5 cementitious materials. In this investigated area, fly
concrete, w/b=0.28, UFA ash-saturation ranges from 20% to 30% replace-
unit strength fator of fly ash

12h heat water curing,90 days


ment of cement by fly ash for mortar or concrete
system.
2.0 3) Fly ash-saturation for maximum compressive
strength of cementitious materials differs from
that for maximum strength-factor of unit fly ash.
4) Mechanical grinding treatment to fly ash can
1.5 remarkably improve its strength contribution on
cement-based materials.

1.0
0 10 20 30 40 50
REFERENCES
replacement of cement by fly ash /% Mehta P. K 1999. Advancements in concrete technology,
(b) unit strength factor Concrete International, 21 (6): 69–76
SHI Huisheng, FANG Zefeng 2004. Effects of fly ash on
Figure 4. fly ash-saturation in concrete including UFA hydration and pore structure of cement at early age,
with a w/b of 0.28. Journal Chinese Ceramic Society (in Chinese), 32
(1):95–98
LONG Guangcheng, XIE Youjun & WANG Peiming 2005.
is noted that addition of fly ash into concrete improved Strength-effect of fly ash in mortar and concrete, Journal
significantly the compressive strength. This is so Railway Science and Engineering (in Chinese),
2(1):19–24
called improvement of steam curing adaptability of
Babu K G & Rao G S N 1996. Efficiency of fly ash in con-
concrete by addition of fly ash[LIU Baoju et al 2005] crete with age. Cement Concrete Research,
This will also result in a high unit strength factor of fly 26(3):465–474
ash when fly ash was added into concrete system under LIU Baoju, XIE Youjun & ZHANG Yanqing 2003. Effects of
investigated heat curing condition (see Figure4b). fineness and amount of fly ash on properties of cement-
Figure4b shows that the unit strength factor of fly ash based materials, Journal Building Material (in Chinese),
is more than 2.0 within 20% replacement of cement by 6(4) 426–430
fly ash and then rapidly reduces after addition amount Liu Baoju, Xie Youjun & Li Jian 2005. Influence of steam-
of fly ash is more than 20%. curing on compressive strength of concrete containing
supplementary cementing materials, Cement and
Concrete Research, 35( 5): 994–998
Martin Cyr, Philippe Lawrence & Erick Ringot 2006.
4 CONCLUSIONS Efficiency of mineral admixtures in mortars: Quanti-
fication of the physical and chemical effects of fine
As mentioned above, fly ash-saturation in cementi- admixtures in relation with compressive strength, Cement
tious materials system is a very complicated issue, and Concrete Research, 36(2): 264–277

119
Sustainable Construction Materials and Technologies – Chun, Claisse, Naik & Ganjian (eds)
© 2007 Taylor & Francis Group, London, ISBN 978-0-415-44689-1

Ultra fine fly ash concrete

Bruce K.T. Kandie & Ewan A. Byars


CMRU, Department of Civil and Structural Engineering,University of Sheffield, UK

ABSTRACT: This paper reports on the use of Ultra-Fine Fly Ash (UFFA) used as up to 50% partial replace-
ment for cement in concrete. UFFA is a new generation fine coal fly ash, which is double-classified to obtain
the finer particles from the classified bulk. The influence of UFFA on fresh properties (flow, setting time and
air content), porosity of mid to high strength, medium workability concrete mixes (designed for equal 28-day
strength) are reported and compared with concrete mixes made with OPC, Micro-Silica (MS) and seven BS
3892 Part 1 fly ashes (PFA).
The study shows that UFFA has significantly higher pozzolanicity than all UK fly ashes tested and signifi-
cantly reduces the water demand and air content of concrete. The compressive strength results indicate that a
partial replacement of OPC with UFFA can not only reduce the total binder content required to obtain target
strength at specific ages irrespective of curing, but also increases the efficiency of the combination binder by
up to 50% at later ages.
The porosity of concrete made with UFFA all showed improvement compared to equal strength concrete
made with OPC and UK PFA, irrespective of curing. A high strength of 130 N/mm2 was attained at 28 days for
a blend of UFFA/MS/OPC concrete with a combination of selected aggregates sizes proportions.

1 INTRODUCTION 2 EXPERIMENTAL INVESTIGATION

Portland cement is the principle hydraulic binder used 2.1 Materials


in modern concrete practice and manufactured by
The cement was a Portland cement confirming to BS
energy intensive process that consuming up to
12 1996, class 42.5 N. Seven UK Class F fly ashes
5.29 GJ/t, mostly obtained from burning of fossil fuel,
confirming to BS 3892, Part 1: 1997. Micro silica
is consumed [Khurana et al. 2002]. The production of
was an aqueous slurry (50/50 by weight) and UFFA
every tonne of Portland cement emit 0.89 to 1.1 tonne
used was a commercially available class F fly ash
of carbon dioxide, this contribute to the greenhouse
confirming to BS 3892 Part 1: 1997. Their chemical
gas emission that is responsible for global warming
compositions are show in Table 1. The aggregate was
[Bouzoubaa et al 1998 and Turanli et al 2005].
20 and 10 mm river aggregates and sand are shown in
The current production of fly ash at UK power
Table 2. A naphthalene-based superplasticizer to BS
plants is in the range of 8–10 Mt per annum. Approx-
5075, Part 3 was used to achieve a concrete workabil-
imately 50% of this is used in industrial applications
ity level at 125 mm slump. The properties of the
and the rest requires disposal. The world situation is
aggregates are given in Table 2. Figure 1 show the
similar with an average of 40% usage [McCarthy et al
various types of fly ashes researched on.
1999].
Ultra fine fly ash (UFFA) is a new style of fly ash.
Which is double classified at source to produce a
2.2 Concrete mixes
product consisting at only the very finest fly ash par-
ticles, typically with a mean 3 µm and a specific A series of concrete mixes were prepared for grades
surface area of 30,000 cm2/g. 40–80 N/mm2, with w/b ratios of 0.21–0.56 and a
The aim of this investigation was to characterise 125 mm slump target. UFFA was used in the propor-
the fresh, engineering and durability performance of tion of 0–50% of the total cementitious materials. The
UFFA concrete in comparison to concrete made with cementitious materials tested included PC42.5N
OPC, a range of UK fly ashes and micro silica. [BS12:1992], commercially available UFFA to BS

121
Table 1. Chemical properties of the cementitious materials used.

PERCENTAGE COMPOSITION

Chemical composition UK BS 3892 Part 1: PFAs

Oxides OPC* UFFA 1 2 3 4 5 6 7 MS* GGBS*

Silica dioxide (SiO2) 20.7 53.4 55.1 53 54.3 55.6 48.6 51.2 50.6 92 35.84
Aluminum oxide (Al2O3) 5.7 32.3 25.1 25.1 23.1 25 24.6 26.1 26.1 1 13
Ferric oxide (Fe2O3) 2.3 4.09 10.7 10.2 9.2 10.4 13 7.8 9.4 1 0.55
Calcium oxide (CaO) 64.8 5.05 1.6 3.8 4.1 1.9 2.8 6.4 3.7 0.3 39.53
Magnesium oxide (MgO) 1.1 1.29 1.5 2 2 1.6 1.7 1.9 2.2 0.6 8.28
Sodium oxide (Na2O) 0.19 .05 0.4 0.2 0.2 0.4 0.4 0.4 0.5 0.3 0.35
Potassium oxide (K2O) 0.6 0.08 0.1 0.1 0.1 0.2 0.1 0.1 0.2 0.8 0.5
Sulphate (SO3) 3.21 0.32 1.2 0.9 1.4 1.1 1.3 1.4 1.3 0.3 0.1
Equivalent alkali 0.58 0.10 0.47 0.27 0.27 0.53 0.47 0.47 0.63 0.83 0.68
Titanium oxide (TiO2) – 1.97 1 1.2 1 1.1 1.1 1.6 1.2 – –
Loss of inginition (LIO) 0.92 0.23 3.1 4.9 5.8 2.5 6.1 3.3 4.7 – –

* Provided by the manufacturer.

Table 2. The properties of the aggregates.

Properties of aggregates

Sieve analisis Coarse aggregates

% Passing Sand 10 mm 20 mm

Sieve no. (µm) Passing % Sieve no. (mm) Passing % Passing %

4.75 98 37.5 100 100


2.36 86 20 100 98
1.18 76 14 100 57
600 62 10 95 12
300 20 5 7 5
150 6 2.36 0.65 –
75 0
FM 2.51
Specific Gravity 2.62 2.63 2.63
W. Abs. (%) 0.59 1.12 0.58

3892: Part 1, 7 UK fly ashes to BS 3892: Part 1 and a 2.5 Determination of loss on ignition
Micro silica in slurry form (Table 1). The fresh sam-
The loss of ignition was determined in accordance to
ples were covered with polyethylene sheet to prevent
BS EN 196-2: 1995 at a temperature of 950°C for
evaporation. All the specimens were cast in 100 mm
duration of 1 hour.
steel cube mould and were cured in water to air
environment after demoulding after 1 day.
2.6 Determination of the setting time
2.3 Curing conditions The setting time was determined in accordance to BS
The curing conditions used are listed in Table 2. EN 196-3.

2.4 Determination of particle distribution 2.7 Determination of water demand


A laser Malvern Mastersizer E was used to measure This test was undertaken in accordance to BS 3892:
the particle size and the surface area of the various Part 1: 1993. Fine, medium and coarse sand was
pozzolans and cementitious materials. mixed in accordance to BS EN 196: Part 1: 1987.

122
BS3892: Part 1 PFAs
3 4 5 6
2
1 7

UFFA

3 µm
Figure 1. Shows the comparison between UFFA and various types of UK PFAs.

Table 3. Curing environments.

Environment Conditions

E1 Water, 23°C
E2 3 days of water, 23°C; thereafter air, 23°C 55% RH
E3 Air, 23°C, 55% RH
E4 3 days of water, 38°C; thereafter air, 38°C 95% RH
E5 24 hours of air, 5°C, 95% RH; thereafter air, 23°C, 55% RH

2.8 Determination of porosity of concrete the particles were 5.25 µm, this was less than that
The porosity of all the mixes was determined using vac- obtained from BS 3892 Part 1 PFA and GGBS but sim-
uum saturation apparatus [RILEM Recommendations ilar to MS. The fineness of the various fly ashes
1984]. showed relationship with its content in respect particle
fineness (Table 4). Figure 2 (a) show there is a linear
relationship between the mean particle size and the
2.9 Determination of the compressive strength
fineness of fly ash and similarly with every increase in
The compressive strength in accordance to BS 1881: fineness there is an increase in the carbon content
Part 116: 1983 on three 100 mm cubes at 7 and 28 (Figure 2 (b)). The relationship between the specific
days of full water immersion samples. surface area and the mean particle size was not linear
but a curve, which was decreasing with the increase in
the mean particle size due to the fly ash particle being
3 RESULTS AND DISCUSSIONS more coarser in it morphology.
A global fly ash characteristic may be prediction
3.1 Particle size distribution from figure 2 by knowing one of the elements of any
Table 4 shows the particle size distribution for the var- type of fly ash. The mathematical for the curve or lin-
ious materials analysed. From this table, it is clear that ear relationships for the fly ashes particles character-
UFFA has higher specific surface area than the UK. BS istics: AMD verses Sp. Surface Area is given by
3892 Part 1 PFA and GGBS which was in the range of equation y  7503.8x0.95 (R2  0.97), AMD verses
340 to 715 m2/kg and 1,448 m2/kg respectively, but SM Fineness by equation y  0.7232x2.9 (R2  0.95)
had the highest surface area. UFFA had a fineness of and Carbon content verse Sp. Surface Area by
0% with a mean particle size of 2.32 µm and 90% of equation y  1169x0.61 (R2  0.92).

123
3.2 Water demand
demand and 29% was the maximum water reduction
Figure 3 shows the water demand for cement, various at 95% replacement level of PC42.5N. The seven UK
pazzolans and the cementitious materials that were fly ashes had a variation of water demand and these
used in this investigation. UFFA had the lowers water were between the upper and lower bound zone. GGBS

Table 4. Mineral admixture laser particle properties.

Particle diameter
Cementitious Sp. surface Carbon Fineness
material area m2/Kg content (%) 45(µm) (%) D[v,0.1] D[v,0.5] D[v,0.9] Span

UFFA 2,893 0.23 0 0.4 2.32 5.28 2.1


PFA1 715 3.1 6.5 1.5 8.47 36.81 4.17
PFA2 359 4.9 11.1 3.37 15.82 46.33 2.72
PFA3 509 5.8 10.1 2.14 12.18 44.56 3.48
PFA4 681 2.5 6.3 1.58 9.2 36.5 3.8
PFA5 448 6.1 14.3 2.43 14.97 52.1 3.32
PFA6 499 3.3 9.3 2.24 12.79 42.91 3.18
PFA7 340 4.7 14.2 3.65 15.28 52.19 23.05
MS* 4,952 – 0 0.25 1.03 22.27 21.36
GGBS* 1,448 – 0.5 0.9 6.64 19.52 2.8

* for comparison.

3500 16
Sp. S. Area Fineness
Specific Surface Area m2/kg

3000 14

Fineness >45 microns (%)


2500 12
10
2000
8
1500
6
1000
4
500 2
0 0
0 5 10 15 20 25
Mean Particle Size (ADM)
(a)

3500

3000
m2/kg

2500
Specific Surface Area

2000

1500

1000

500

0
0 2 4 6
Carbon content %
(b)

Figure 2. Fly ash physical characteristics.

124
showed a slight reduction in the water demand up to a
maximum reduction of 4% while MS increased the
120 water demand as its partial replacement level of PC
42.5 N was increased, with an increase of 20 and 71
UFFA for 10% and 30% replacement level. Figure 4 (a) and
BS 3892: Part 1. Fly Ash (b) shows that the specific surface area, unburned
110 GGBS carbon content and the replacement level were the
MS factor responsible for the high and low water dement
for the UFFA, seven UK fly ashes, GGBS and MS.
We note that as the specific surface area for the fly
% Water required of OPC

ashes increased, there was a low water demand, simi-


100
larly as the replacement of cement was increased there
was a low water demand. This was directly opposite by
the increase in carbon content increasing the water
UK PFA Water demand. This clearly shows that the spherical particle
90 demand zone shape, the low level of carbon and the fineness of
UFFA may be the influencing factors to this reduction
in water. This was not similar to SM despite it having
a high surface area and its irregular surface texture
80 resulted to this high water demand. GGBS having a
high surface area did not show any significant water
reduction.

70
0 20 40 60 80 100 3.3 Workability
Pozzolan replacement (%) All the concrete mixes were designed for a slump of
120 mm for an equal 28 days compressive strength.
Figure 3. The water demand. The workability was measured at different rates using

100 100
10% 30% 35%
50% 70% 95%
95 95

90 90
Water Demand %
Water Demand %

85 85

80 80

75 75

70 70

65 65
0 1000 2000 3000 4000 0 2 4 6

Specific surface area m2/kg Carbon content %


(a) (b)

Figure 4. The effect of specific surface area and carbon content of fly ash water.

125
the Tattersall two-point workability test and the flow MS irregular shape, high surface area and its high
table. From table 5 and figure 5, we note that as the reactivity, resulting in a high g and h value due to MS
percentage of UFFA replacement of cement increased, reacting with the mixing water right from the moment
there was a reduction in yield value (g) and plastic vis- it comes in contact with water and a little of the mix-
cosity (h). This reduction of g and h due to UFFA ing water is left for lubricating the concrete despite the
replacement levels is as a result of an UFFA supplying application of the superplasticizer.
additional lubricant round the grains of aggregates, Figure 6 (a) Shows the workability of concrete in
due to the “ball bearing effect” of the ultra fine parti- terms of flow due to UFFA application. It can be
cle size, spherical shape and low carbon content of noted that as the UFFA content is increased from 0%
UFFA. The application of superplasticizers also aided to 50% by weight of OPC, the flowability increases,
the decrease in both g and h value for all the cementi- this may be attributed to the ultra fineness of this fly
tious materials. The workability of concrete contain- ash compared to the UK BS 3892 Part 1 PFA and MS.
ing UFFA was enhanced compared to BS 3892 Part 1 Similarly, there was a significant reduction in the air
PFA and that of MS. Despite the fineness of MS, the content as compared to the control mixes. But there
workability was low, this may be as a resulted due to was a variation in the air content for mixes cast for

Table 5. The fresh properties of concrete.

Mixes Two-Point Test Results


% Air
Grade/Type g h R2 Std Error Flow Content

Grade 40 N/mm2
OPC 2.96 0.48 0.964 0.069 429 2.2
UFFA-05 1.95 0.393 0.983 0.048 488 1.8
UFFA-10 1.59 0.383 0.987 0.042 527 1.6
UPPA-30 1.22 0.38 0.982 0.049 603 1.4
UFFA-50 0.71 0.336 0.977 0.055 653 0.8
BS 3892 Part 1 PFA-30 1.4 0.395 0.963 0.07 578 1.7
MS-10 2.03 0.392 0.94 0.088 490 1.5
Grade 80 N/mm2
OPC 3.34 0.465 0.966 0.068 463 4.6
UFFA-05 0.72 0.276 0.937 0.091 629 2.8
UFFA-10 0.65 0.275 0.943 0.087 633 2.4
UFFA-30 0.29 0.274 0.966 0.067 745 2
BS 3892 Part 1 PFA-30 0.42 0.294 0.986 0.043 668 2.5
MS-10 1.25 0.418 0.954 0.078 589 2.3

OPC40
UFFA 40/30
2
UFFA 40/50
BS 3892 Part 1. PFA 1 40/30
MS10
Impeller speed (rev/s)

1.5

0.5

0
2 3 4 5 6 7 8 9 10 11 12
Torque (Nm)

Figure 5. Workability of fresh concrete.

126
low and high strength, high strength concrete attain- exhibited the air-entraining phenomena for high
ing higher air content than the low strength. This is strength concrete as shown on Figure 6 (b).
due to the different superplasticizers used for low and
high strength concrete. Complast 111 superplasticizer
was applied at 0.2% by weight of the cementitious 3.4 Pozzolanicity
material for high strength concrete. This superplas- The pozzolanic activity of the fly ashes was determined
ticizer aided the workability of concrete but also in terms of strength activity index shown on Figure 6.
UFFA pozzolanicity was higher than UK BS 3892 Part
1 and OPC. The seven UK fly ashes pozzolanic indexes
800 are between the lower and upper bound zone.
Concrete flow (mm)

UFFA pozzolanic activity was enhanced by the


700 ultra-fine particle size, high content of CaO, the low
carbon content and it high reactivity compared to those
600 of the seven UK fly ashes (as shown in Table 1 and 3).
500 Grade 40 N/mm2
Grade 80 N/mm2 3.5 Porosity
400
The porosity of the concrete specimens was determined
0 20 40 60
after 28 days and 6 months of curing for the three dif-
UFFA % content
ferent curing environments: E1, E2 and E3. The results
(a)
are shown on Table 6. Porosity was factored with
respect to the porosity attaint by OPC concrete at 28
5 days of water cured (E1) samples for both low and high
strength concrete. From the results we can deduce that
Air content (%)

4 Grade 40 N/mm2
the curing environment had a significant effect on the
3 Grade 80 N/mm2
porosity of the cementation concrete. Water cured (E1)
2 samples had the lowest porosity compared to both par-
tially water cured then air cured samples (E2) and air
1 cured samples (E3). The order of porosity improve-
0 ment was E1  E2  E3.
0 20 40 The application of fly ash and MS lowered the
UFFA % content porosity of the concrete compared to the control mixes.
(b) UFFA concrete had a lower porosity than both the UK
BS 3892 Part I PFA and MS concrete. This may be
Figure 6. The effect of UFFA on fresh concrete (a) flow & due to the physical and chemical properties of UFFA
(b) Air content. over these other cementitious material.

Table 6. The typical factored porosity with respect to 28 days water cured OPC.

Porosity of Concrete (%)

Curing Environment

28 days 6 months
UK Fly ash
Mix Upper bound E1 E2 E3 E1 E2 E3

OPC 1.00 1.09 1.27 0.88 1.00 1.09


UFFA05 0.96 1.07 1.16 0.83 0.85 0.94
UFFA10 0.92 0.97 1.07 0.75 0.81 0.87
UFFA30 UK Fly ash 0.62 0.75 0.86 0.57 0.72 0.74
UFFA50 Lower bound 0.59 0.70 0.76 0.48 0.64 0.71
UK BS 3892 Part 1 PFA 1 30 0.79 0.81 0.88 0.65 0.75 0.84
UK BS 3892 Part 1 PFA 2 30 0.89 0.91 0.96 0.73 0.81 0.94
MS05 0.90 0.95 1.01 0.81 0.88 0.93
MS10 0.87 0.90 0.90 0.74 0.82 0.88

E1: Water curing; E2: 3 days Water curing then Air curing and E3: Air curing.

127
Table 4 shows the improvement of concrete poros- of the concrete with the increasing content of UFFA
ity due to the application of this cementation material. replacement level of OPC. 10% replacement level of
UFFA concrete improved the permeation of the over- OPC was in the same domain in improvement of the
all concrete compared to the control. This improve- permeability of concrete as compared to 30% UK BS
ment was indicated by the further reduction in porosity 3892 Part 1 PFA. Period of curing (from 28 to 6
months) also reduced the porosity of the concrete
over the 3 curing environments. This improvement of
200 concrete permeability due to the application of UFFA
over both UK BS 3892 Part 1 PFA and MS. May be
due to the due to the considerable pore refinement as
a result of the addition of UFFA content and the for-
180
mation of pozzolanic reaction products with the
progress of cement hydration. The application of
UFFA being more reactive than the UK BS 3892 Part
160 1 PFA would react with the calcium hydroxide in the
water filled capillary channel to produce calcium sil-
icate and aluminate hydrates of the same or similar
type that are formed in normal hydration on cement.
140 UFFA consumes more of the calcium hydroxide in
Pozzolanic Index %

the pozzolanic reaction compared to UK fly ash and


10% MS. The calcium hydroxide is converted to
water insoluble hydration product, filling the capillar-
120 ies, thereby reducing the permeability on the cemen-
titious concrete and this is further reduced at 6
months of curing compared to 28 days of curing.
UFFA at 30% replacement level concrete cured in
100
E2 environment at 28 days was better than the UK fly
ashes cures in E1. The porosity of this concrete was
exactly the same as that of 10% UFFA and both 5%
80 and 10% MS concretes cured in E1 environment at 6
OPC months.
Improvement in concrete porosity by UFFA com-
Log. (SPFA) pared to MS concretes may be said to be at the same
60 range at 6 months at 5–10% replacement levels of
Log. (UK BS3892 Part 1: OPC from the results in Table 4 in all the three curing
PFAs) environment.
40
0 100 200 300 400 4 CONCRETE COMPRESSIVE STRENGTH
Age (days)
The water contents for the mixes are given in Table 7.
Figure 7. Pozzolanicity of the pozzolans. The incorporation of cementitious material resulted in

Table 7. Composition and the compressive strength of concretes.

Compressive
strength (Mpa)
Mix composition kg/m3
Age of testing
Aggregates (days)
Cement
MIX CODE OPC UFFA MS Save w w/b 20 mm 15 mm 10 mm 5 mm Sand 7 28

OPC 522 120 0.23 770 0 340 0 778 84.6 95.1


UFFA/MS 1* 368 79 79 153 100 0.19 770 0 340 0 702 97 111.3
UFFA/MS 2* 368 79 79 153 100 0.19 0 770 340 0 702 98.4 116.6
UFFA/MS 3* 368 79 79 153 100 0.19 0 1110 0 156 546 102.5 129.5

128
a reduction in water-to-binder ratio of the UFFA/MS ACKNOWLEDGEMENT
concrete mixes. The results of strength are shown in
the same table. The strength of UFFA/MS concrete is I dedicate this paper to the late Dr Ewan A. Byars, for
higher than those of OPC concrete. This strength his helpful comments during the investigation. A vote
development showed that crushed gravel is better that of thanks goes to my parents, Sheffield University
river gravel. Due to the river gravel shearing faster department of Civil and Structural Engineering and
than the crushed gravels. A combination of 15 mm Kenya government for their moral support and spon-
crushed gravel and 5 mm of sub sand resulted in the sorships.
highest strength which was 129.5 N/mm2 at 526 kg/m3
binder at 28 days of testing. This was higher than
118.5 N/mm2 attained by Domone and Soutsos [1995)] REFERENCES
and Tsartsari [2002] at 28 days. The 5 mm coarse
aggregates seemed to fill the voids between the coarse British Standards Institution. BS 12 [1996].
aggregates, a view that is supported by Kaplan in 1959 British Standards Institution. BS 3892, Part 1 [1997].
[Goltermann et al. 1997] who stated that compressive British Standards Institution. BS 1881, Part 5 [1970].
strength of concrete is higher than that of mortar and British Standards Institution. BS EN 196-2 [1995].
indicated that the mechanical interlocking of the British Standards Institution. BS EN 196-3 [1995].
coarse aggregate contributes to this. The binder of Bouzoubaâ,N., Zhang, M.H., Bilodeau, A. and Malhotra, V. M.
1998. Laboratory-produced high-volume fly ash blended
UFFA/MS had 153 kg/m3 cement saving. cements: physical properties and compressive strength of
mortars. Cement and Concrete Research, Volume 28,
Issue 11, Pages 1555–1569.
5 CONCLUSION Bouzoubaâ, N. Zhang, M. H. and Malhotra, V. M. 1998.
Laboratory-produced high-volume fly ash blended
This article dealt with the detailed study on UFFA cements: compressive strength and resistance to the
compared to UK BS 3892 Part 1 PFA and MS, the chloride-ion penetration of concrete. Cement and Concrete
finding of which may be summarized as follows. Research, Volume 28, Issue 7, Pages 1037–1046.
UFFA has significantly higher specific surface and Domone, P. L. and Soutsos, M. N. 1995. Properties of high-
strength concrete mixes containing PFA and GGBS,
fineness than a range of UK PFAs tested. Magazine of Cement Research, Volume 47, No 173.
UFFA improved the workability of concrete more Goltermann, P., Johansen, V. and Palbol, L. 1997. Parking of
than conventional PFAS tested and this effect tended aggregates: an alternative tool to determine the optimum
to increase with the increasing replacement of cement aggregate mix, ACI Journal, Volume 94, Issue 5, Pages
with UFFA. 435–443.
At the upper limits of conventional replacement level Khurana, S., Banerjee, R. and Gaitonde, U. 2002. Energy
(40%) UFFA reduced water content by 23% whilst the balance and cogeneration for a cement plant. Applied
best UK PFA tested reduced water demand by 11%. Thermal Engineering, Volume 22, Issue 5, Pages
The pozzolanicity of UFFA was higher when 485–494.
McCarthy, M. J. and Dhir, R. K. 1999. Towards maximising
measured using standard mixes to BS3892 at all ages the use of fly ash as a binder. Fuel, Volume 78, Issue 2,
tested and the difference increased with time. Pages 121–132.
The application of UFFA reduced the porosity of Tsartsari, A. 2002. Super-classified pfa and microsilica
concrete significantly, particularly with extended blend, Civil and Structural Engineering, Dissertation.
water curing. Turanli, L., Uzal, B. and Bektas, F. 2005. Effect of large
The highest strength achieved was 129.5 N/mm2 by amounts of natural pozzolan addition on properties of
a blend of UFFA and MS at a cement replacement level blended cements. Cement and Concrete Research,
of 15%. The w/b ratio was 0.19 and the aggregates Volume 35, Issue 6, June 2005, Pages 1106–111.
used were crushed gravel of maximum size 15 mm.

129
Sustainable Construction Materials and Technologies – Chun, Claisse, Naik & Ganjian (eds)
© 2007 Taylor & Francis Group, London, ISBN 978-0-415-44689-1

Achieving sustainable construction through use of fly ash in concrete – An


Indian experience

Manish Mokal
Hindustan Construction Co. Ltd., Hincon House, Vikhroli (W), L.B.S. Marg, Mumbai

ABSTRACT: Manufacturing of normal portland cement, a major ingredient in concrete industry contributes
significantly to the CO2 emissions. The paper mentions briefly the efforts on part of Hindustan Construction
Company Ltd, the leading Indian construction company; to advocate and maximize the use of fly ash as a sup-
plementary cementitious material in concrete. The paper includes case study on use of High Volume Fly Ash
Concrete incorporating 55% fly ash at Bandra Worli Sea Link Project in Mumbai and Self Compacting
Concrete incorporating 45% fly ash at Rajasthan Atomic Power Project near Kota.
Of the many technical benefits, the most significant benefit of use of fly ash in concrete is enhancement of
durability of concrete, due to almost nil permeability, which in turn increases the service life of the concrete.
The other technical benefits associated with use of fly ash in concrete are contribution to increase in workabil-
ity, reduction in heat of hydration and better sulphate/chloride resistance. The utilization of fly ash also reduces
the consumption of cement in concrete thereby reducing its production to that amount.
Fly Ash concrete is a classic example for attaining sustainability in concrete construction alongwith the benefits
of increasing the durability and service life of the structure.

1 INTRODUCTION Traditionally, construction activities have relied on


using normal portland cement. Production of one
Construction is a major economic activity. In India, it tonne of normal portland cement releases approxi-
accounts for over 6% of Gross Domestic Product mately one tonne of CO2 into the atmosphere. India is
(GDP). It covers a wide range of activities from mak- the second largest producer of cement in the world.
ing simple dwelling units to construction of highly With the high emphasis given to cover the backlog in
complex power stations, dams, bridges, roads & high- infrastructure construction by the government, the
ways and so on. Inevitably, a construction project demand for cement is likely to rise sharply in coming
has to deal with environmental aspects. The threat of years.
global warming is real. According to a report by Using only normal portland cement in concrete has
Environmental Protection Agency (EPA) of the U.S.A. many problems in itself. Further, current demand of
Green house gases are accumulating in the earth’s sustainable construction by reducing the environ-
atmosphere as a result of human activities, causing mental impact and increasing the durability of the
global mean surface temperatures and sub-surface structure cannot be achieved.
ocean temperatures to rise. The challenge for the civil There are many supplementary cementitious
engineering community in the near future will be to materials (SCM) used in producing concrete, like, Fly
realize projects in harmony with the concept of sus- Ash, Ground Granulated Blast Furnace Slag, Silica
tainable development. This involves the use of high- Fume, Rice-husk Ash. A conscious use of these mate-
performance materials produced at reasonable cost rials, especially the abundantly available fly ash in
with the lowest possible environmental impact. India, would help conserve natural resources. It would
With the cost of construction increasing rapidly, also save energy required for producing normal
today the industry demands that the concrete used for portland cement, help the cause of environment, pro-
building structures should not only have high strength vide superior concrete structures and benefit the
but also have high durability and the structure has a rel- clients.
atively higher service life compared to previously built This paper discusses three cases studies on utilisa-
structures. tion of fly ash in concrete.

131
2 CASE STUDY 1 – USE OF FLY ASH FOR Table 1. Mixture proportioning of conventional concrete &
TREMIE SEAL CONCRETE AT BANDRA- Fly Ash Concrete for Tremie Seal (BWSL).
WORLI SEA LINK PROJECT
Conventional Fly ash
Ingredients (kg/m3) concrete concrete
2.1 Project description
Bandra-Worli Sea Link Project is a prestigious project Cement (OPC 53 Gr) 396 180
that envisages construction of 5.86 km long eight-lane Fly Ash (Dahanu) 0 220 (55%)
freeway to be built across the sea. Most of the concrete Total Cementitious 396 400
material
specified is high strength, high performance type.
Water 178 135
The distinctive features of the Bandra-Worli Sea W/cm ratio 0.45 0.34
Link Project are: Coarse Aggregate 905 1000
Fine Aggregate 835 930
• Out of 5.86 km length, the length of bridge portion
Admixture (HRWR) 5.5 10
is 4.0 km including 500 m cable stayed portion.
• Two independent 4 lane Cable stayed bridge of
500 m length on single pylon of 126 m height.
2.3.3 Aggregate
• Two independent 4 lane Cable stayed bridge of
Crushed basalt rock with a maximum size of 20 mm
350 m length at Worli end.
was used as coarse aggregate. Fine aggregate con-
• Bridge will be supported on friction piles. The piles
sisted of crushed sand manufactured from basalt rock
will be drilled and concreted in the sea-bed, 8–10 m
below the depth of water. and natural sand from River Ambika. The individual
aggregates were blended to get the desired combined
• Two curves on the sea link, for which different types
grading.
of trapezoidal segments (in plan) are necessary.
2.3.4 Chemical admixture
2.2 Requirement of Tremie seal concrete Sulfonated Naphthalene Formaldehyde based high-
For concreting of the pile cap, a cofferdam was driven range water-reducing Admixture confirming to ASTM
into the ground and the depth was filled with sand up C494-99 Type G was used.
to a level of 2 metres below the bottom of the pile cap.
These 2 metres were filled with Tremie seal concrete 2.4 Mixture proportions
of M30 grade. The basic purpose of this tremie con-
crete was to provide an impermeable working plat- The calculated quantities per cubic metre of concrete
form for the pile cap construction. for conventional mixture with normal portland cement
As per the project specification, the compressive only and mixture with fly ash are given in Table 1.
strength requirement is 30 MPa at 28 days. As the con-
crete was required to be placed underwater, it necessi- 2.5 Field application
tates the concrete to be cohesive enough with required
workability to be placed with Tremie pipe/pump. The Concrete was produced in 90 m3/hr capacity batching
location of the placing point was in deep sea and the & mixing plants situated onshore. The concrete after
placing procedure for tremie seal concrete required a mixing at batching plant was discharged through con-
slump of 170  10 mm after 3 hours. Initially the veyor into the transit mixers mounted on barges,
tremie seal concrete was designed with OPC only. which then hauled it to the placing point. The concrete
Subsequently, use of fly ash concrete was proposed and after arrival at placing point was taken in buckets,
after conducting lab and field trials, the mix was which discharged them into concrete pumps located
adopted in field. on jack up platform. The concrete was finally placed
by means of a pump. A total 2000 cubic metre of
tremie seal concrete was placed for the construction of
2.3 Materials this tremie seal under the pylon pile cap. Figure 1
2.3.1 Normal portland cement shows the view of completed tremie seal concrete.
Normal portland cement of 53 Grade conforming to
IS 12269-1987 was selected for use in concrete.
2.6 Field test results
2.3.2 Fly Ash The workability of concrete at placement point was
ASTM Class F Fly Ash conforming to requirement of determined using slump cone and flow table. At plac-
ASTM C-618-00 from field 3 of Dahanu Thermal ing point the slump was 150 mm and flow was 150%.
Power Plant was utilized after conducting necessary Required numbers of 150 mm cubes were cast for
physical and chemicals tests. testing at various ages in order to study the strength

132
Table 2. Hardened concrete properties of conventional
concrete & Fly Ash Concrete for Tremie Seal (BWSL).

Conventional Fly ash


Properties concrete concrete

Compressive Strength (MPa)


3 days 20.8 10.2
7 days 27.4 18.5
14 days 37.2 20.3
28 days 45.1 36.5
Figure 1. Completed view of Tremie Seal Concrete with 56 days 46.2 47.2
55% fly ash. 91 days 47.1 63.9
180 days – 64.8
70 Equivalent cube strength
Compressive Strength (MPa)

of core @ 365 days – 69.9


60 Durability Properties
50 Water Permeability 60 42.5
@ 28 D
40
Water Permeability 32 0
30 @ 91 D
20 RCPT @ 28 D 5500 2000
coulombs coulombs
10 RCPT @ 91 D 3000 972
0 coulombs coulombs
3 days 7 days 14 days 28 days 56 days 91 days RCPT of cores
Age of concrete @ 365 D – 423
coulombs
Conv. Mix FAC Mix

Figure 2. Rate of gain of strength of conventional & Fly


Ash concrete (FAC) for tremie seal. The permeability of fly ash concrete tested as per
DIN 1048 indicated penetration of 42.5 mm after 28
development behavior of this concrete. Samples were days & was reduced to 0 mm penetration after 91 days
also cast to determine water permeability of concrete as against 60 mm and 32 mm for OPC concrete.
as per DIN 1048 & resistance to chloride ion penetra- Production of additional C-S-H gel due to secondary
tion as per ASTM C1202. The test results are listed in hydration makes the concrete denser. This reduces the
Table 2. The rate of development of strength at different inter pore connectivity thereby reducing the perme-
ages is shown in Figure 2. ability of concrete.
Specimens tested for chloride ion penetration as
per ASTM C 1202 after 28 & 91 days indicated values
2.7 Interpretation of test results of 2000 & 972 coulombs. These values indicate “low” &
Table 2 shows the properties of hardened concrete for “very low” penetrability respectively. The RCPT val-
tremie seal concrete for only normal portland cement ues obtained for OPC concrete indicate 5500 & 3000
mixture and mixture with fly ash. Though the con- coulombs at 28 & 91 days which lie in high and mod-
crete was required to fulfill the 28 days criteria, study erate penetrability. The result obtained from the core
was conducted on both concrete mixes to judge the extracted from the actual structure is 423 coulombs
improvement of the performance in later ages. The after 365 days. This indicates that concrete becomes
following points confirm the beneficial effect of fly progressively resistant to chloride ion penetration i.e.
ash usage in concrete. more durable with passage of time.
The fly ash concrete achieving 36.5 MPa at 28 days
attained strength of 63.9 MPa after 91 days. Whereas
2.8 Conclusion
the strength of normal portland cement concrete which
achieved 45.1 MPa at 28 days increased only to The tremie seal requires to withstand an uplift pressure
47.1 MPa in 91 days. Equivalent cube strength of of approx. 5 metres head. This requires the concrete to
cores extracted after 1 year from the actual structure be impermeable to allow it to be used as a working
indicated strength of 69.9 MPa. The calcium hydrox- platform for pile cap concrete. The tremie seal concrete
ide produced during the initial cement hydration later made showed that the concrete was impermeable and it
reacts with the silica in fly ash to produce more C-S-H gave a virtually dry working platform as shown in Fig. 1
gel resulting in continuous gain in strength with time. due to incorporation of Fly Ash.

133
3. CASE STUDY 2 – USE OF FLY ASH FOR Table 3. Mixture proportioning of conventional concrete &
STRUCTURAL MEMBERS AT RAJASTHAN Fly Ash Concrete for structural members (RAPP).
ATOMIC POWER PROJECT
Mix with Mix with Mix with
Ingredients 0% Fly 25% Fly 40% Fly
3.1 Project description
(kg/m3) Ash Ash Ash
The project consists of two reactor units intended to
generate 2  220 MW of electricity. The scope of Cement 320 260 204
work for HCC covers construction of Main plant (OPC 43 Gr)
Fly Ash (Kota) 0 80 136 (40%)
buildings comprising of reactor building, reactor aux-
W/Cm 0.5 0.47 0.45
iliary, turbine and control buildings, tunnels and Superplasticiser 5.2 4.0 4.0
trenches and miscellaneous works. Slump (mm) 120 120 120
The construction activities for above-mentioned Compressive strength (MPa)
structures involved are: 7 days 31.77 26.29 19.7
28 days 43.91 41.12 37.8
• Reinforced concrete works in raft, isolated foot- 56 days 44.57 43.10 48.6
ings, concrete blocks, equipment foundations, slab, 91 days – – 53.5
beams, walls, hatches, hatch covers, pre-cast plank 180 days – – 66.2
and trenches with M25 grade of concrete Permeability (mm) 33 22 13
• Prestressed concrete work in inner and outer con- RCPT @ 28 days – – 1958
tainment wall and dome with M45 grade of con- RCPT @ 91 days – – 855
crete
• Heavy concrete work in calandria vault with inte-
gral carbon steel liner, fuelling machine service
area, heavy concrete blocks and heavy grout The individual aggregates were blended to get the
• Miscellaneous works. desired combined grading.

3.3.4 Chemical admixture


3.2 Requirements of structural concrete Sulfonated Naphthalene Formaldehyde based high-
Use of fly ash was proposed in structural concrete. The range water-reducing Admixture confirming to ASTM
grade of concrete was M25 and the target strength to be C494-99 Type G was used.
achieved was 32 MPa. Several trials were conducted
with different percentages of fly ash replacements to 3.4 Mixture proportions field results
check the suitability of use of fly ash in structural con-
crete. Initially concrete with 25% fly ash was approved. The calculated quantities per cubic metre of concrete
After checking the performance of 25% fly ash con- along with fresh and hardened concrete properties are
crete, the concrete mix with 40% fly ash was approved as given in Table 3.
and is being used at site. The mix with 40% fly ash
indicated better long-term strength and water perme- 3.5 Interpretation of results
ability results that led to taking decision for its use.
It was observed that the strength of 40% fly ash mix-
ture increased from 37.8 MPa at 28 days to 48.6 MPa
3.3 Materials at 56 days. The rate of increase in strength for 40% fly
3.3.1 Normal portland cement ash mixture was quite appreciable with compressive
Normal portland cement of 43 Grade conforming to strength values as high as 53.5 MPa at 91 days and
IS 8112-1989 was selected for use in concrete. 66.2 MPa at 180 days. The mixture with 0% fly ash
had no appreciable increase in strength from 28 to 56
3.3.2 Fly ash days. The permeability of mixture with 40% fly ash
ASTM Class F Fly Ash conforming to requirement of was 13 mm against 33 mm for mixture with 0% fly
ASTM C-618-99 from field 3 of Kota Thermal Power ash at 28 days. Progressive reduction in the RCPT
Plant was utilized after conducting necessary physical value of 40% fly ash mixture was observed. Both the
and chemicals tests. findings indicate that the fly ash concrete was more
durable than the concrete without any fly ash.
3.3.3 Aggregate
Crushed quartzite rock with a maximum size of 3.6 Conclusion
20 mm was used as coarse aggregate. Fine aggregate
consisted of crushed sand manufactured from The strength achieved with 0% fly ash mixture was
quartzite rock and natural sand from River Jhalawar. 43.91 MPa against the required target strength of

134
32 MPa. Though there was a scope to economise the
mix, the same could not be done due to the restriction
of minimum cement content and maximum water
cement ratio. The mix with 40% fly ash not only sat-
isfied the required target strength but also indicated
better durability. Using fly ash as replacement of
cement helps in economizing the concrete mixture
and achieving better durability.

4 CASE STUDY 3 – USE OF FLY ASH FOR


SELF-COMPACTING CONCRETE (SCC) FOR
COLUMNS, BEAMS AND OTHER
STRUCTURAL ELEMENTS IN RAJASTHAN
ATOMIC POWER PROJECT

4.1 Requirements of SCC


The columns, beams and other structural elements in
the nuclear power plant have dense reinforcement.
Due to this lot of honeycombing was being observed
after deshuttering. SCC was proposed as a solution to
rectify the problem. The grade of concrete was M25
and target strength to be achieved was 32 MPa. The
concreting methodology required concrete to satisfy
self-compacting properties after 1 hour.
Figure 3. Column of 10 m ht done in single lift with SCC.
4.2 Material
The raw material used was same as that for structural
Table 4. Mixture proportioning of Self Compacting con-
concrete except for the admixtures. For achieving self- crete (RAPP).
compacting properties in fresh state a combination of
three different types of admixtures were used. A poly- Ingredients (kg/m3) Mixture proportions
carboxylate ether based admixture was used to achieve
the workability, retarder to achieve the required reten- Cement 250
tion and a viscosity-modifying agent to achieve the Fly Ash 200
required viscosity. Total Water 180
W/cm 0.4
20 mm 250
4.3 Mixture proportions and test results 10 mm 374
Natural Sand 426
Initial mixture proportions were taken as recommended Crushed Sand 562
in the Guidelines for Self Compacting Concrete as Superplasticiser 3.8
given in EFNARC. Slight modifications were made to Retarder 0.45
incorporate available local materials. Accordingly, vari- VMA 0.45
ous laboratory trials were conducted to arrive at an opti- Compressive strength (MPa)
3 days 11.5
mum combination of materials for achieving desired 7 days 19.5
fresh and hardened state properties. The details of the 28 days 35
final mixture proportions are as given in table 4. 56 days 41.5

4.4 Conclusion
The columns and beams in the nuclear power plant the rheology of concrete making it more cohesive and
are heavily congested with reinforcement making it flowable. With conventional concrete the normal lift of
difficult to vibrate the concrete properly. Use of SCC column is 3 m. With the use of SCC it was able to do
worked as an ideal solution to build a structure free of concrete of 10 m height in single lift. This increases the
honeycombing. Use of fly ash in concrete enhanced progress of work.

135
5 GENERAL REMARKS REFERENCES

The above case studies prove the utility of fly ash for ACI 211.1-97, Standard Practice for selecting Proportion of
different types of concrete applications. If the same Normal, heavy weight and Mass Concrete
concrete had been done with only OPC, amount of ACI 304.2 R-96, Placing concrete by pumping methods
ACI 211.3 R, Guide for selecting proportions for No Slump
cement consumption would have been much higher. Concrete
For the above applications HCC has reduced cement V. M. Malhotra, High Volume Fly Ash Concrete
consumption by 7500 MT. Using fly ash in concrete EFNARC, Specification and Guidelines for Self-
not only improves the durability of the structure in a Compacting Concrete
cost effective manner but also helps in conserving the
natural resources and reduces the green house gases.

136
Sustainable Construction Materials and Technologies – Chun, Claisse, Naik & Ganjian (eds)
© 2007 Taylor & Francis Group, London, ISBN 978-0-415-44689-1

“Eco-pad” in-situ mixed concrete pavement with a 93–100%


total recycled content

B.W. Ramme, T. Jansen & A. Tawil


We Energies, Milwaukee, WI, USA

D.B. Anderson
Midwest Engineering Services Inc., Waukesha, WI, USA

ABSTRACT: This paper presents research performed to identify mixture proportions and develop an in-situ
mixed concrete for a 1.416 hectare [3.5 acre] storage pad for bottom ash and synthetic gypsum produced at We
Energies’ Pleasant Prairie Power Plant, which is located in Kenosha County, Wisconsin. Ingredients of the concrete
produced consisted of recycled concrete coarse aggregate, bottom ash fine aggregate, Class C fly ash and either
portland cement or slag cement yielding a 93% or 100% recycled content, respectively. Compressive strengths
attained 21 MPa [3,100 psi] for the portland cement/Class C fly ash blend at an age of 1 year and 12–14 MPa
[1,700–2,000 psi] for the Slag cement/Class C fly ash blend.

1 INTRODUCTION area was graded and a 12 in [305 mm] thick layer of


bottom ash was compacted as the base for the eco-pad.
The fundamental objective of this research project The term “eco” was selected because of the economic
was to develop mixture proportioning information and environmentally friendly nature of this construc-
and field construction experience with a high recy- tion process. The eco-pad was designed for a 203 mm
cled content in-situ mixed roller compacted concrete [8 in] pavement thickness with an expected one year
for a 1.416 hectare [3.5 acre] bottom ash and syn- strength of 21 MPa [3000 psi]. An in-situ mixing and
thetic gypsum outdoor storage pad (Figure. 1). The compaction process was used for construction of the
Class C fly ash and bottom ash used in this project pavement. The eco-pad pavement was constructed by
were produced at We Energies’ Pleasant Prairie Power placing a specified thickness of the recycled concrete
Plant located in Kenosha County, Wisconsin, and is a and bottom ash, premixing the two (2) aggregate mate-
by-product of Western USA sub-bituminous coal rials with an asphalt reclaimer. A specified amount of
combustion. The power plant is also equipped with the blended cementitous binder is then placed with a
We Energies patented ash fuel reburn systems where vein feeder spreading truck and the cementitous and
high carbon bituminous coal ash is introduced in aggregate materials are mixed with the reclaimer.
direct proportion to the coal being consumed, thus Water content can be added through the reclaimer if
producing a blended fly ash that meets ASTM C-618 needed for moisture conditioning and the mixture is
class C requirements. The fly ash is captured by elec- then compacted to the specified level of compaction.
trostatic precipitators from flue gas prior to discharge The pavement was saw-cut on 6 m [20 ft] grid in
through a chimney. The plant is presently equipped 24 hours and a curing compound was also applied. Saw
with an SCR (selective catalytic reduction) for reduc- cut joints were sealed with an elastomeric filler. A 0.6 m
tion of NOx emissions and wet scrubbers are being [2 ft] layer of bottom ash was placed on the slab to
constructed for SOx emission reductions. The bottom facilitate curing and provide some freezing and thaw-
ash was collected from a wet bottom tangentially ing protection for the eco-pad since it was constructed
fired boiler. The 38 mm [11⁄2 in] recycled concrete in late October and November.
coarse aggregate was supplied from a crushed and Owners, constructors, engineers and architects are
screened stockpile managed by an asphaltic concrete demanding “green” materials and construction alter-
producer in Racine County, Wisconsin. natives to meet sustainability requirements by meet-
Most of the pavement area had been previously ing the human infrastructure needs of today while
used as a bottom ash storage pad on a clay base. The preserving natural materials for future generations.

137
Figure 1. Eco-pad construction at Pleasant Prairie Power Plant, Kenosha County, Wisconsin.

The eco-pad will be monitored for performance 1.2 Relevant publications


to determine if it is a long term solution for large stor-
A literature search was conducted and rather than
age areas such as manufacturing and commercial
compiling an exhaustive review of roller compacted
warehousing storage yards, terminals, dockyards,
concrete and high volume concrete literature, some
and other large pavements that do not require a hard
important publications were reviewed and are listed
troweled finish.
in the references.

1.1 Objectives and scope


The primary objective of this research project was to 2 LABORATORY TESTING
develop a “green” alternative paving material and
construction process for environmentally friendly A laboratory mix analysis was performed to determine
large outdoor storage area pavements. Ninety Three the mixture proportioning. For this particular mix
to 100% recycled content was achieved for the pave- analysis, the effectiveness of the proposed cementituous
ment and long term performance is being evaluated of (portland cement and Class C fly ash mixture) and
this potentially sustainable process. The project was aggregate (recycled concrete and bottom ash) materials
changed during construction where slag cement was were assessed by evaluating the materials grainsize
substituted in place of the portland cement after the analysis, aggregate blending, moisture-density relation-
first day of paving due to a shortage of available port- ship, and moisture-strength relationships.
land cement and the late time of the Wisconsin con- Representative samples of the proposed materials
struction season. This field change provided the which included recycled concrete from Racine County
additional 100% recycled content dimension of this (which is located in southeast Wisconsin), bottom ash
research study. and Class C fly ash from We Energies Pleasant Prairie

138
Power Plant, and portland cement from LaFarge were 3 LABORATORY TESTING RESULTS
obtained. Laboratory testing of the samples included
moisture content testing (ASTM D2216), grainsize Evaluation of the proposed in-situ mixed roller com-
analysis (ASTM D422), moisture density relationship pacted recycled concrete mixture was performed based
by modified proctor method (ASTM D1557), and com- on coarse and fine aggregate consisting of 38 mm
pressive strength analysis (ASTM D1633). The mois- [11⁄2 in] top size recycled concrete from Payne and
ture density relationship for each mixture was Dolan in Racine, Wisconsin and bottom ash from We
performed in general accordance with ASTM D1557, Energies Pleasant Prairie Power Plant (P4). The
except that the five lift requirement was replaced with blended cementitous material consisted of 50% port-
three lifts. A 102 mm [4 in] diameter split mold was land cement from LaFarge and 50% Class C fly ash
used for compressive strength determination per ASTM from We Energies P4.
D1633 to facilitate the removal of each specimen with Based on the grainsize analysis of the proposed
minimal disturbance to the samples. Upon completion, recycled aggregate, the coarse aggregate is described
the specimens were sealed in plastic bags and cured for as a poorly to well-graded crushed concrete with about
seven (7) days at 100°F in accordance with ASTM 48–67% gravel, 31–45% sand, and 2.6–6.6% silt/clay
C-593 to approximate conditions of 28-day cure peri- sized particles. The initial sample of recycled concrete
ods. Following curing, the samples were capped with a was somewhat more open graded with limited fines
gypsum cap and the compressive strength was deter- compared to the more densely graded samples sup-
mined using a constant drive calibrated load frame. The plied during the second phase of the laboratory and
test specimens have a height to diameter ratio of field test. This was also evident in the aggregate
1.15:1; therefore, the strengths obtained provide a rel- blends, Moisture Density, and Moisture Strength test
ative measure of strength rather than the measure of results. The fine aggregate is described as a bottom
compressive strength such as would be obtained for ash with about 4–6% gravel, 77–85% sand, and
specimens having a height to diameter ratio of 2:1. In 13–17% silt/clay sized particles. Results of the unit
general 1.15 height to diameter ratio samples will weight tests on the coarse and fine aggregate indi-
produce a slightly higher strength than that achieved cated loose unit weights of 1584 to 1682 kg/m3 [99 to
with a height to diameter ratio of 2. 105 pcf] and 1041 kg/m3 [65 pcf], respectively. Grain
The preliminary mixture proportioning testing was size analysis test results are shown on Table 1 and
performed in two (2) phases. Initially, samples of the Figure 2.
proposed recycled concrete (coarse aggregate) and Results of the coarse/fine aggregate blends 50/50,
the bottom ash (fine aggregate) were tested to deter- 60/40, 70/30, and 80/20 generally indicate a poorly
mine their optimum blend for grainsize distribution graded aggregate with about 35–54% gravel, 41–57%
and density. The second phase consisted of mixing sand, and 5–8% silt/clay blends producing the higher
the selected aggregate blend with varying amounts of densities. Based on the blended aggregate test results
the blended cementituous binder material for deter- the 60/40 sized particles. The compacted unit weights
mination of the mixture’s optimum density and of the blends ranged from 1646.9 to 1747.8 kg/m3
strength characteristics. recycled concrete/bottom ash blend was selected for

Table 1. Summary of grainsize analysis tests recycled aggregates Eco-pad pavement


MES Project No. 7-45151.

Bottom ash Recycled concrete

Sample no. BA1 BA2 RC1 RC2 RC3 (field)

Grainsize analysis,
mm [in/ sieve #]
38.1 [11⁄2] – – 100 – –
25.4 [1] – – 95.7 100 100
19.05 [3⁄4] 100 100 85.0 93.4 94.2
12.7 [1⁄2] 99.0 98.5 65.2 75.5 79.1
9.5 [3/8] 98.1 96.7 54.6 66.1 69.4
4.76 [#4] 95.6 94.0 33.5 48.4 51.8
2.0 [#10] 92.3 91.2 20.3 37.1 35.8
0.84 [#20] 83.5 83.8 12.1 27.9 24.2
0.42 [#40] 67.0 70.1 7.5 20.6 17.1
0.147 [#100] 26.7 36.1 3.5 9.4 8.7
0.074 [#200] 12.6 16.7 2.6 6.6 6.6

139
the moisture-density and moisture-[102.8 to 109.1 densities as shown on Table 1. Based on the blended
pcf] with the 60/40 and 70/30 strength relationship aggregate test results, the 60/40 recycled concrete/
testing. Table 2 provides a summary of the aggregate bottom ash blend was selected for the moisture-density
trial blending tests. and moisture-strength relationship testing.
Evaluation of the compression strength potential
4 CEMENTITIOUS MATERIALS of the preliminary selected aggregate blend 60/40
included performing moisture-density and moisture-
Chemical and physical data available on the cementi- strength relationship testing by modified Proctor
tious materials used on this project are shown on Table method as previously described. Results of the
3. The Class C fly ash was supplied from We Energies moisture-density and moisture-strength test results
Pleasant Prairie Power Plant which is also the site of are summarized in Table 4.
the eco-pad construction project. The slag cement and The test results indicated that the 18% cementi-
portland cement were both provided by Lafarge NA. tious blend content exhibited the highest compressive
The cementitious materials were preblended at strength. However, since the increase in strength from
Lafarge’s terminal located in Milwaukee, Wisconsin. the 15–18% specimen was less than 0.03 MPa [5 psi],
The 1646.9 to 1747.8 kg/m3 [102.8 to 109.1 pcf] the 15% cementitious blend content was selected for
with the 60/40 and 70/30 blends produced the higher economic and sustainability reasons on the project.
Additional tests were also performed with varying
aggregate blends when the second sample of recycled
120
concrete showed a somewhat denser gradation.
100 Therefore, aggregate blends of 50/50, 60/40 and
BA1 70/30 recycled concrete/bottom ash were mixed with
Distributions

80
BA2 a constant 15% cementitious blend content to deter-
60 RC1 mine their moisture-density and moisture-strength
RC2
40 relationship. Results of the tests are summarized in
RC3
Tables 5 and 6.
20
Results of the moisture-density and moisture-
0 strength tests indicate the 70/30 aggregate blend with
0 10 20 30 40 50
Sample No. (mm)
15% blended cementitious content exhibited the
higher strength and density. This is likely due to the
Figure 2. Grainsize distribution for bottom ash and recy- material’s denser graded nature which allows for a
cled concrete (x-axis: GrainSize (mm); y-axis: % Finer). more compact arrangement of particles which also
Table 2. Summary of aggregate trial blending tests.

Sample no.
grainsize analysis,
mm [in/sieve #] BA1 RC1 50/50 60/40 70/30 80/20

38.1 [11⁄2] – 100 100 100 100 100


25.4 [1] – 95.7 97.6 97.4 97.0 96.6
19.05 [3⁄4] 100 85.0 92.5 91.0 89.5 88.0
12.7 [1⁄2] 99.0 65.2 82.1 78.7 75.3 72.0
9.5 [3/8] 98.1 54.6 76.4 72.0 67.7 63.3
4.76 [#4] 95.6 33.5 64.6 58.3 52.1 45.9
2.0 [#10] 92.3 20.3 56.3 49.1 41.9 74.7
0.84 [#20] 83.5 12.1 47.8 40.7 33.5 26.4
0.42 [#40] 67.0 7.5 37.3 31.3 25.4 19.4
0.147 [#100] 26.7 3.5 15.1 12.8 10.5 8.1
0.074 [#200] 12.6 2.6 7.6 6.6 5.6 4.6
USCS SM GW SP-SM SP-SM GP-GM GP
Unit Weight 1041.3 1586 – – – –
(Loose), kg/m3 [pcf] [65] [99]
Unit Weight – – 1646.9 1744.6 1747.8 1733.4
(Compacted), kg/m3 [pcf] [102.8] [108.9] [109.1] [108.2]

• Compacted unit weight is based on modified proctor method (ASTM D1557) at moisture content of 15%.
• Loose unit weight is based on as received moisture content.
• Aggregate blends are based on initial bottom ash and recycled concrete samples submitted.

140
Table 3. Selected chemicals and physical composition of cementitious materials.

Chemical data Class C fly ash Slag cement Portland cement

SiO2 (silicon dioxide)% 40.35 35.68 20.7


Al2O3 (aluminum oxide)% 18.94 10.00 4.8
Fe2o3 (iron oxide)% 5.18 0.58 2.7
SiO2 Al2O3 Fe2o3% 64.47 46.26 28.2
CaO (calcium oxide)% 21.65 38.62 65.4
MgO (magnesium oxide)% 3.81 11.2 2.5
SO3 (sulfur trioxide)% 1.93 2.41 2.4
LOI (loss on ignition)% 0.45 – 1.61
Na2O (sodium oxide)% 1.78 0.35 –
K2O (potassium oxide)% 1.25 0.42 –
Available Alkalis (as
equivalent Na2O%) 1.3 – 0.53
Physical data
Fineness, amount retained 13.6 1.0 5.3
on #325 sieve%
Specific gravity 2.52 2.95 3.15

Table 4. Summary of density/strength tests of 60/40 RC/BA aggregate blend with varying cement contents.

Moisture-density relationship Moisture-strength relationship

Optimum Maximum dry Optimum Maximum


Mixture ID moisture % density, kg/m3 [pcf] moisture % strength, MPa [psi]

60/40 RC/BA @12% PC/FA 15.5 1762.2 [110.0] 16.6 11 [1640]


60/40 RC/BA @15% PC/FA 16.5 1762.2 [110.0] 16.6 12.5 [1820]
60/40 RC/BA @18% PC/FA 14.5 1778.2 [111.0] 14.2 12.6 [1825]

Table 5. Summary of aggregate trial blending tests.

Sample no.
grainsize, mm
[in/sieve #] BA2 RC2 50/50 60/40 70/30

38.1 [11⁄2] – – – – –
25.4 [1] – 100 100 100 100
19.05 [3⁄4] 100 94.2 96.7 96.0 95.4
12.7 [1⁄2] 98.5 79.1 87.0 84.7 82.4
9.5 [3/8] 96.7 69.4 81.4 78.3 75.3
4.76 [#4] 94.0 51.8 71.2 66.6 62.1
2.0 [#10] 91.2 35.8 64.2 58.7 53.3
0.84 [#20] 83.8 24.2 55.9 50.3 44.7
0.42 [#40] 70.1 17.1 45.4 40.4 35.5
0.147 [#100] 36.1 8.7 22.8 20.1 17.4
0.074 [#200] 16.7 6.6 11.7 10.6 9.6
USCS SM 6P-6M SP- SP- SP-
SM SM SM
Unit Weight 1041.3 1682.1 – – –
(Loose), kg/m3 [65] [105]
[pcf]

• Loose unit weight is based on as received moisture content.


• Aggregate blends are based on second set of Bottom Ash and
Recycled Concrete samples submitted.

141
Table 6. Summary of the moisture density and moisture/strength tests with varying aggregate blends.

Moisture-density relationship Moisture-strength relationship

Optimum Maximum dry Optimum Maximum


Mixture Id moisture % density, kg/m3 [pcf] moisture % strength, MPa [psi]

60/40 RC/BA @12% PC/FA 13.5 1770 [110.5] 12.6 10 [1460]


60/40 RC/BA @15% PC/FA 12.5 1842 [115.0] 12.4 13 [1880]
60/40 RC/BA @18% PC/FA 10.5 1922 [120.0] 11.2 13.2 [1920]

produce a higher density. Higher density also gener- delay period from mixing of the cementitious mate-
ally produces higher strengths. rial to compaction. Compaction of the in-situ mixture
Subsequently, it was elected to construct the field was specified at 95 percent of the maximum dry den-
test pavement with a 127 mm [5 in] and 76 mm [3 in] sity as determined by the modified Proctor method.
thick recycled concrete/bottom ash aggregate blend and Climate conditions during the in-situ mixing were
a 15% blended cementitious content. Construction of challenging during construction. Due to a regional
the pavement would consist of placing 76 mm [3 in] of cement shortage, construction was delayed into late
bottom ash and 127 mm [5 in] of recycled concrete October and early November when temperatures were
prior to pre blending. This ratio by volume was cold in Wisconsin. This was complicated by a rainy
expected to be similar to the 70/30 ratio by weight period that made obtaining optimum moisture content
performed in the preliminary lab testing phase and for compaction a challenge at the beginning of the
also reflected the practical level of precision in con- project. A bottle neck in construction operation was
struction. the rate at which the cementitious material could be
blended at the terminal and delivered to the project.
An operating issue at the cement terminal also threat-
5 TEST PAVEMENT CONSTRUCTION ened to delay the project because cement could not be
OVERVIEW unloaded. However, ground granulated slag cement
was available at the terminal and substituted for port-
Based on the laboratory test data, an in-situ mixing land cement, thus adding another interesting dimen-
process was developed and a test pavement con- sion to this project.
structed. A 305 mm [12 in] thick compacted bottom
ash base grade was established for the proposed eco-
5.1 Concrete mixing and construction process
pad test pavement. The in-situ mixing phase consisted
of placing 76 mm [3 in] thickness of bottom ash across In summary, an in-situ mixing process was developed
the proposed pavement area. Then 127 mm [5 in] of for use on this project. Once the 305 mm [12 in] thick
recycled concrete was placed over the bottom ash. The bottom ash base grade was established, an additional
recycled concrete and bottom ash were then pre-mixed 76 mm [3 in] thick layer of bottom ash was spread
to a depth of 203 mm [8 in] with an asphalt reclaimer. with dump trucks and a road grader over the pad.
The cementitiuos materials supplier provided a 50/50 Next, a 127 mm [5 in] thick layer of recycled concrete
blend of portland cement and Class C fly ash that was coarse aggregate was placed over the bottom ash. An
placed dry with a vane feeder spreading truck over the asphalt reclaimer was used to mix the aggregates in
previously mixed aggregate blend. The cementitious place, followed by a road grader and compacted.
material blend was spread at a rate of 59.7 kg/m2 [110 Due to a rainy period, additional moisture was not
pounds per square yard]. This rate was based on a 15% required. The cementitious materials supplier pro-
dry unit weight basis of the maximum dry density of vided a pre-blended 50/50 class C fly ash and port-
the laboratory blended mixture. Moisture conditioning land cement mixture that was placed dry with a vane
(addition of water) was not generally required on this feeder spreader truck over the compacted aggregate
project due to relatively wet site conditions experi- surface. An asphalt reclaimer followed to mix the
enced due to a rainy period prior to mixing. After mix- cementitious and aggregate materials. Water can be
ing, the aggregate and cementitious materials mixture added through the reclaimer, if needed, to obtain opti-
was compacted with a large vibratory sheepsfoot com- mum moisture conditions for compaction. 95% mod-
pactor, graded, and final rolling was accomplished ified proctor densities were then achieved with the
with a smooth drum roller. A recommended mixture use of a sheepsfoot compactor followed by a vibra-
moisture content of 2% for optimum strength (9 to tory smooth drum roller and an asphalt-like finish
13%) was recommended along with a maximum texture was obtained. Saw cuts on a 6 m [20 ft] grid

142
followed the next day. A curing compound was subsequently air dried for 7 days, capped with a gyp-
applied following the saw cuts and finally an elas- sum capping compound and compressive strengths
tomeric joint filler was applied to seal the saw cut were determined in accordance with ASTM C39.
joints. Climate conditions were challenging during
construction. Due to a regional cement shortage, con-
struction was delayed into late October and early 7 RESULTS OF FIELD TESTING
November, when temperatures are beginning to get
cold in Wisconsin. This was complicated by a rainy Evaluation of the in-situ recycled concrete mixture con-
period that made attaining an optimum moisture con- structed in the eco-pad pavement was based on the
tent for compaction a challenge at the beginning of 127 mm [5 in] recycled concrete to a 76 mm [3 in] bot-
the project. The bottleneck in the construction opera- tom ash aggregate blend and 15% blended cementitious
tion was the rate at which the cementitious materials (50% portland cement/50% Class C fly ash) material or
could be blended at the terminal and delivered to the 15% blended (50% slag cement/50% Class C flyash)
project. An operating issue at the cement terminal material.
also threatened to further delay the project because Results of the grainsize analysis of the individual
cement could not be unloaded. However, ground bottom ash and recycled concrete samples used on-
granulated blast furnace slag cement was available at site indicated gradations similar to the results
the terminal and substituted for the portland cement obtained in the laboratory testing phase. Results of
thus adding another interesting dimension to this the field blended aggregate samples also are similar
research project. A call to the slag cement association to those obtained in the laboratory test phase. Results
indicated that they were not aware of a prior use of a of the grainsize analysis of the lab and field aggregate
50/50 fly ash/slag cementitious blend without port- blends are summarized in Table 7.
land cement being used in construction. The slag and Results of the moisture density relationship testing
class C fly ash binder pavement combined with the indicated a higher maximum dry density at about the
recycled aggregates provided a 100% recycled mate- same optimum moisture content as in the preliminary
rial content in approximately two thirds of the pave- laboratory mix proportioning phase. This is likely due
ment area. to a well-graded sample resulting in a more densely
compacted mixture. The higher result in the compres-
sive strength may also be due to the higher density
6 FIELD TESTING characteristics and lower optimum moisture contents.
Subsequently, two (2) additional samples of the previ-
Field testing of the materials used in the construction ously sampled and combined field blended aggregate
of the eco-pad test pavement were performed in three were mixed in the lab, one (1) with 15% PC/FA and
stages. The initial stage consisted of performing grain- the other with 15% SC/FA cementitious blend to fur-
size analysis on samples of the field blended aggre- ther assess the moisture-density and moisture-
gates. A laboratory mixture analysis of the field strength relationships. Results of the tests on the
aggregate blend with 15% of the blended cementitious PC/FA blend showed similar results to those of the
material was also performed to establish laboratory PC/FA blend of the first aggregate field blend mixture.
moisture-density and moisture-strength relationships. Results of the SC/FA cementitious blend also provided
The second stage of the testing was performed dur- results that were similar to those of the first aggregate
ing the field mixing of the blended aggregate and field blend mixture. Results of the SC/FA cementitious
cementitious materials. The field testing consisted of blend resulted with similar moisture density relation-
performing field density testing by nuclear gauge ships but with lower strengths, 11 MPa [1600 psi] vs.
method (ASTM D2922) during the compaction phase 15.3 and 18.6 MPa [2225 and 2700 psi]. This is likely
to assess the in-situ moisture content and percent due to the fact that the slag cement contained less CaO
compaction achieved. In addition, samples of the in- and also generally develops its strength at a slower rate
situ mixture were obtained and compacted in the field than portland cement. The second phase of the field
by the modified Proctor method. The field molded testing included performing field moisture and density
specimens were delivered to the laboratory and cured testing during the placement and compaction phase of
for a period of 7 to 365 days to assess the compressive the construction. In summary, the field blended aggre-
strength development of the mixture. gate had moisture contents initially of 14 to 19 percent,
The final phase of the testing included obtaining in- which was 0 to 5 percent above their recommended
situ core specimens after approximately one year to mixing range of 9 to 13.
assess the in-place strength of the in-situ recycled con- However, during the mixing process the moisture
crete mixture. The cores were obtained with a rotary contents were generally found to range from 10 to 16
type drill with a diamond impregnated core barrel in percent based on the in-place field density testing.
general accordance with ASTM D42. Samples were The field density testing also indicated an in-place

143
Table 7. Comparison of aggregate blend gradations.

60/40 blend 70/30 blend Field blend

Aggregate Sample 1 Sample 2 Sample 1 Sample 2 Sample 1 Sample 2


blend RC/BA 60/40-1 60/40-2 70/30-1 70/30-2 Field 1 Field 2

Grainsize analysis,
mm [in/sieve#]
38.1 [11⁄2] 100 100 – – – –
25.4 [1] 97.4 97 100 100 100 100
19.05 [3⁄4] 91.0 89.5 96 95.4 95.1 95.1
12.7 [1⁄2] 78.7 75.3 84.7 82.4 84.2 84.0
9.5 [3/8] 72.0 67.7 78.3 75.3 77.6 79.1
4.76 [#4] 58.3 52.1 66.6 62.1 63.6 65.0
2.0 [#10] 49.1 41.9 58.7 53.3 51.8 53.0
0.84 [#20] 40.7 33.5 50.3 44.7 40.7 39.1
0.42 [#40] 31.3 25.4 40.4 35.5 30.4 26.8
0.147 [#100] 12.8 10.5 20.1 17.4 14.2 13.0
0.074 [#200] 6.6 5.6 10.6 9.6 9.7 8.9

Table 8. Summary of density/strength tests based on field blended aggregate samples.

Moisture-density relationship Moisture-strength relationship

Optimum Maximum dry Optimum Maximum


Mixture ID moisture % density, kg/m3 [pcf] moisture % strength, MPa [psi]

60/40 RC/BA @12% PC/FA 10.5 1986.5 [124.0] 10.3 19 [2700]


60/40 RC/BA @15% PC/FA 10.0 1986.5 [124.0] 10.6 15 [2225]
60/40 RC/BA @18% PC/FA 11.0 1954.4 [122.0] 10.3 13 [1920]

Table 9. Summary of field compressive strength test results.

Sample no. FS-1 FS-2 FS-3

Sample date 11-04-04 11-05-04 11-08-04


Continuous blend PC/FA SC/FA SC/FA
Field molded samples
Moisture content, % 13.6 14.9 13.1
Dry Density, kg/m3 1941.6–1956 1919.2–1948 1933.6–1954.4
[pcf] [121.2–122.1] [119.8–121.6] [120.7–122]
Compaction, % 99–100 96–98 97–98
Compressive strength,
MPa [psi]
7 day (air) 11.1 [1620] 1.3 [185] 1.0 [145]
7 day (oven)
28 day (air) 16.8 [2440] 1.3 [195] 1.2 [175]
56 day (air) 17.4 [2525] 1.8 [265] 1.7 [240]
180 day (air) 22.6 [3280] 6.8 [985] 6.2 [900]
365 day (air) 29.9 [4325] 18.4 [2675] 6.9 [2455]
365 day (corrected)* 27.1 [3930] 16.8 [2435] 15.4 [2235]
Field core samples
365-day (air) 21.7 [3150] 13.6 [1970] 12.0 [1735]

Note: The molded field samples have a height to diameter ratio of 1.15:1 compared to the length to diameter ratio of 2:1 for
the field core samples. The 1.15 H/D samples therefore result in a somewhat higher strength than would be achieved with the
2 H/D core samples. A correction factor of 0.91 was therefore applied to obtain a corrected strength value on the molded 365
day sample for comparison purposes.

144
35 27.1 MPa [3930 psi] and 16.1 MPa [2334 psi], respec-
30 tively. The test results for the field molded and cored
25
samples are summarized in Table 9.
Strength (MPa)

20 FS-1
FS-2
15 FS-3 8 CONCLUSIONS
10

5 1) Based on the results of the analysis, when the


recycled concrete and bottom ash selected are
0
0 100 200 300 400 blended from 127 mm [5 in] and 76 mm [3 in]
Time (days) thick layers respectively and mixed with a 15%
blended (50% portland cement/50% Class C Fly
Figure 3. Eco-pad compressive strength. ash) cementitious material by dry weight, properly
mixed, moisture conditioned and compacted, a
compressive strength on the order of 21.4 MPa
compaction ranging from 92 to 99 percent with an [3100 psi] in one year was attainable.
average of 96.5 percent. 2) When the aggregate blend is mixed using slag
Results of the field molded compressive strength cement in lieu of portland cement in the cementi-
specimens are summarized in Table 9 and Figure 3. In tious material blend, a compressive strength on the
summary, the field molded samples of the PC/FA order of 11.7 to 13.8 MPa [1700 to 2000 psi] in
cementitious blend indicated compressive strengths one year was attainable.
(16.8 MPa [2440 psi] at 28 days and 17.4 MPa 3) Some variability in the test data due to variations
[2525 psi] at 56 days) that are similar to those of the of the individual materials was observed and sub-
laboratory mixtures with the field blend aggregates sequently showed some variability in the results
(15.3 MPa [2225 psi] and 18.6 MPa [2700 psi]) and obtained. Therefore, a mixture analysis for the
somewhat higher than these with the laboratory specific ingredients of each mixture should be
blended aggregates (13.0 MPa [1880 psi] and undertaken for each project.
13.2 MPa [1920 psi]). The field molded samples with 4) A “green” alternative paving material and con-
the SC/FA cementitious blend indicated compressive struction process for environmentally friendly and
strengths on the order of 1.3 MPa [195 psi] and economic large outdoor storage area pavements
1.2 MPa [175 psi] at 28 days which turned out to be has been developed with a 93 to 100% recycled
much less than the laboratory mixture which yielded content. Long term performance will be evaluated
a strength of 11 MPa [1600 psi] using the accelerated of this pavement that was produced in a sustain-
core method. This is probably due to the much lower able manner.
curing temperatures of the field samples and the fact
that slag cement generally develops strength at a
slower rate at lower temperatures.
The 365 days test results indicated compressive REFERENCES
strengths on the order of 30 MPa [4325 psi] and
Ramme, B. W., and Tharaniyil, M. P. 2004. Coal Combustion
18 MPa [2565 psi] for the PC/FA and SC/FA mix- Products Utilization Handbook. Second Edition, We
tures, respectively. Energies.
The final phase of the field testing included Ramme, B. W., Wen, H., Sohns, L., Naik, T. R., and
obtaining field core samples from the eco-pad pave- Kraus, R. N. 2004. Utilization of Self Cementing Class C
ment section after one year of field curing. Results of Fly Ash in Full-Depth Reclaimed Asphalt Concrete
the core strength tests indicated an average compres- Pavements. Eighth CANMET/ACI International
sive strength of 12.7 MPa [3150 psi] and 12.8 MPa Conference on Fly Ash, Silica Fume, Slag and Natural
[1852 psi] for the PC/FA and SC/FA mixtures. In Pozzolans in Concrete, Las Vegas, May 23–29, 2004.
Anderson, D. B. 2006. Report of High Recycled Content In-
comparing these results to the molded field samples,
Situ Mixed Concrete – Proposed “ECO-PAD” Pavement.
it must be recognized that the molded specimens have Midwest Engineering Services Inc. Project No. 7-45151-1,
a height to diameter ratio of 2. Therefore, the molded May 15, 2006.
samples will yield a somewhat higher strength value. Malhotra, V. M., and Mehta, P. K. 2002. High-Performance,
Correcting the shorter molded samples with a correc- High-Volume Fly Ash Concrete, Supplementary
tion factor of 0.91 as suggested in ASTM C42, Cementing Materials for Sustainable Development Inc.,
the molded samples would indicate strengths of Ottawa, Canada, 2002.

145
Sustainable Construction Materials and Technologies – Chun, Claisse, Naik & Ganjian (eds)
© 2007 Taylor & Francis Group, London, ISBN 978-0-415-44689-1

Properties of shotcrete with highly functional fly ash used as


dust-reducing agent

K. Sasaki, M. Ishii & Y. Butou


Coal Ash Recycle Project Group, Shikoku Electric Power Co., Inc., Japan

K. Yuno
Yonden Business Co., Inc., Japan

ABSTRACT: Shikoku Electric Power Co., Inc., has developed the technology to manufacture a brand name
“FINASH” about 10 years ago, by sorting and classifying coal ash generated in coal fired power plants.
“FINASH” is highly functional fly ash which is produced by removing irregular coarse particles, a key factor
causing variation in quality of coal ash, with sophisticated classification technique and extracting good quality
spherical fine particles. It is now utilized as concrete admixture for civil engineering structures and buildings.
The concrete with highly functional fly ash has some advantages of enhancing long-term strength development
and improving durability and workability. Thus, it has been used in many construction works executed by
Ministry of Land, Infrastructure and Transport and West Nippon Expressway Company Limited (the old Japan
Highway Public Corp) and so on. In this paper, properties (workability, strength development and durability) of
concrete with highly functional fly ash used as dust-reducing agent are described.

1 INTRODUCTION management for workers in tunnel construction, the


Welfare, Health and Labor Ministry has tightened dust
Coal thermal power largely depends on coal, one of regulations on spraying shotcrete, giving a boost to
fuel resources, which has a worldwide distribution development of many dust reducing materials.
centering on the Pacific Region, contributing to sta- Under these circumstances, the Shikoku Electric
ble supply. Because it excels other fossil fuels such as Power group has succeeded in developing high-
LNG economically as well, coal is expected to play a performance shotcrete in order to improve workability,
significant role as a basic supplier of energy next to namely less dust and less rebound, to develop strength
nuclear power and also as an intermediate supplier. and to enhance durability, by producing the highly
Thus, the development of coal thermal power plant functional fly ash (here after, HFA) by sorting and
is underway throughout Japan. Consequently, more extracting round and fine particles from raw particles
coal ash has been released from power plants year by of coal ash with windpower-utilized advanced classi-
year. In the year of 2004, the amount of the coal ash fication technique and mixing HFA in shotcrete.
from power plants reached 7.13 million tons, of which
approximately 12% has been thrown away in ash dumps
and the rest of it, approximately 88%, has been recycled 2 CHARACTERISTICS OF HFA
in portland cement/concrete area and civil engineering/
construction area. Raw material for portland cement, One of the main factors to change quality of fly ash is
however, occupies a high rate approximately 68% of the increase of poor shaped fly ash particles due to the
the overall recycled, showing distorted proportion in mixture of coals from different foreign countries or the
recycling. In addition, the difficulty to secure ash change in combustion conditions resulted from coun-
dumps midst recent growing awareness of environmen- termeasures for environmental preservation [Kanatsu
tal preservation and the increasing tendency to build et al. 1998]. Removal of these irregular coarse parti-
recycle-oriented society makes it more important cles causing quality change with wind-power-utilized
to develop further techniques to make the most of sophisticated classification technique to sort and
coal ash. extract high-quality round and fine particles less than
On the other hand, due to the growing tendency 20 µm can bring highly functional fly ash, which has
toward improvement of work environment and sanitary much higher quality and function than original fly ash

147
Table 1. Characteristic of HFA.

Chemical property Physical property

Wet Loss on Specific Flow value Activity index* (%)


SiO2 percentage ignition Density surface ratio*
Classification (%) (%) (%) (g/cm3) (cm2/g) (%) 28-days 91-days

HFA 57.0 0.09 1.5 2.40 5570 112 91 103


JIS A 6201 (Class I)
45 1.0 3.0
1.95
5000
105
90
100

* The ratio with standard mortar.

Table 2. Mixture proportions of shotcrete test at model tunnel.

Unit content (kg/m3)

Mixture Water cement Sand percentage Fine coarse Set accelerating


no. ratio (%) (%) Water Cement HFA aggregate aggregate agent

1 61.7 60.0 222 360 – 1031 708 21.6


2 56.4 203 360 100 953 726 21.6

Note: Max. size of coarse aggregate: 15 mm. Slump: 120  10 mm. Accelerator: 6% by mass of cement.

[Ukita et al. 1988, Ishii et al. 1988, Fukute et al. 1995]. Table 3. Materials used.
The HFA is approved as Class I of JIS A 6201
“Concrete Fly Ash” revised in February 1999 (Table 1). Materials Specification
The HFA has much better characteristics than orig-
Portland cement Normal Portland cement, Density:
inal particles before classification such as smaller
3.16 g/cm3
quality change, more round particles and higher poz- HFA Density: 2.40 g/cm3, Specific surface
zolanic reaction. Mixing the HFA into general con- area: 5570 cm2/g
crete, quality of concrete, such as decrease of water Fine aggregate Inland sand, Density: 2.59 g/cm3,
content, improvement of long age strength, and FM: 2.73
improvement of water-tightness, is improvable by the Coarse aggregate Crushed stone, Density: 2.66 g/cm3,
effects of ball bearing and fine particles. About these FM: 6.19
properties, the HFA has obtained technical evaluation Accelerator Cement mineral, Density: 2.80 g/cm3
from the authorities [A Concrete Admixture
“FINASH”. 1994] and at present around 10,000 tons
of HFA has been used in public works mainly in the at all and the mixture No. 2 contains 100 kg/m3 HFA
Shikoku region in Japan. in place of fine aggregate. Mixing of 100 kg/m3 HFA
contributes to moderate increase in viscosity as well
as reduction in water content. The specification of
3 MODEL TUNNEL SPRAY TESTS concrete materials is shown in Table 3. In addition,
HFA has high density in comparison with general fly
Prior to spray tests at the actual road tunnel, tests at ash so that there become few ratios of hollow particle
the model tunnel are conducted in order to verify the with classification.
effects of the shotcrete using HFA to improve worka-
bility and to develop strength. 3.1.2 Spray tests
The spray tests are conducted at the model tunnel set
up outside which is 3.5 m in height, 3.5 m in width
3.1 Outline of spray tests [Ishii et al. 2001,
and 7.0 m in length. A piston-pump-system SUPREMA
Fukami et al. 2000]
(Max. discharge: 14 m3/h) is used for a spraying gun
3.1.1 Mixture and materials and a powder accelerator compressor (Max. discharge:
The mixture of shotcrete used in the model tunnel 3.2 kg/min) is adopted for adding accelerator. In
spray tests consists of two types as shown in Table 2; terms of piping, a 3-inch flexible hose is attached at
plain standard mixture No. 1 which contains no HFA the pump outlet piping, which extends approximately

148
30 m to the end of the nozzle considering the length in 2000
21. 9
25
actual tunnels. 1800
(100)
Amount of dust
1600 Rebound rate 20
Prior to the spray tests, two types of shotcrete mix-

Amount of dust (c.p.m.)*

Rebound ate (%)


1400
ture selected is produced in a ready-mixed concrete 1200 15
10.4
factory and transported to the test site by agitator 1000 118 0
(47)
truck. Here, the properties of fresh concrete are meas- 800 (100 ) 10
600
ured and, at the same time, samples for base concrete 747
400 5
strength tests are prepared. 200
(63)

In the spray tests, at first samples are prepared by 0 0


No. 1 No. 2
spraying the disc container and the panel frame Plain HFA
(50  50  20 cm) set in the model tunnel. The for- * Count per minute.
mer is for initial compressive strength tests (3 h and (The value in the brackets is the ratio when plain is 100.)
4 h) and the latter is for preparing samples for com-
pressive strength tests. Next, after a vinyl sheet is Figure 1. Amount of dust and rebound rate in model tun-
spread in the model tunnel, spraying is conducted nel tests.
manually to the arch part circumferentially in the rage
of 2 m and toward the tunnel inside in the range of 4 m 30
at an spray angle 45° with keeping the distance of

Initial compressive strength (MPa)


Age: 24 hours
1.5 m from the nozzle tip for 8 minutes (Spray: 1 m3), 25
Age: 3 hours
and the amount of dust is measured with a digital dust 20 17.5
meter. At measurement, both mouths of the tunnel are (137)
covered with sheets to prevent rebound materials and 15
12.8
dust from splashing out of the tunnel. The rebound 10
(100)
rate is evaluated, after the completion of spray, by col-
lecting rebound materials fallen down on the vinyl 5 2.1 3.4
sheets and measuring the weight. (100) (162)
0
After the completion of spray tests, measurement No. 1 No. 2
Plain HFA
of initial compressive strength is carried out in 3 and
(The value in the brackets is the ratio when plain is 100.)
24 hours with pull-out test method. At the same time,
strength tests at the proper age are performed after a Figure 2. Initial compressive strength in model tunnel tests.
core sample (φ10 cm  20 cm) is cut off from the
panel frame for strength tests.

from the panel frame and cured at the temperature 20°C


3.2 Results and discussion
and the relative humidity 80% till the proper age. In
The results of the model tunnel spray tests are pre- addition, density of mixture No. 1 is 2.31 g/cm3, and
sented in Figure 1–3. the density of mixture No. 2 is 2.27 g/cm3.
The mixture No. 2, compared with the standard
3.2.1 Workability (amount of dust and mixture No. 1, obtains 62% increased strength in 3
rebound rate) hours and 37% increased strength in 24 hours, which
The amount of dust and the rebound rate are reduced shows an excellent property to develop initial strength
to 63% and 47% respectively in the mixture No. 2 (Fig. 2). Since initial strength of shotcrete is propor-
containing HFA 100 kg/m3 in place of fine aggregate, tional to the amount of accelerator added in general, a
compared with the plain standard mixture No. 1 (Fig. 1). certain amount of accelerator (6% by mass of cement)
The results reveal that the workability of shotcrete is is added to each mixture in these spray tests. It is con-
remarkably improved with less dust and less rebound sidered that the excellent initial strength gained above
by the mixture of HFA. This possibly shows that mix- is caused by further acceleration of hydration of port-
ing HFA in shotcrete increases viscosity of concrete land cement by accelerator by the effect of fine parti-
properly and the cohesion gained by the viscosity cles of HFA.
reduces separation and splash of fine particles as well The results of compressive strength tests at the
as improves adhesion of concrete. medium and long age find that the strength of the
mixture No. 2 at the age of 7, 28 and 91 days is
3.2.2 Strength development property increased 10%, 24% and 37% respectively compared
Initial compressive strength is measured in compli- with the mixture No. 1, which shows an excellent prop-
ance with the test method of JSCE-G561, whereas erty to develop strength (Fig. 3). Thus, it is considered
compressive strength tests are conducted in accor- that the use of HFA causes densification of hardened
dance with JIS A 1107 after a core sample is cut off concrete with the aid of gap-filling and pozzolanic

149
effects as well as decrease of water content, and even- with which conventional dust-reducing agent equiva-
tually contributes to the improvement of strength lent to 0.1% mass of portland cement is added. The
development. mixture No. 3 contains 100 kg/m3 HFA in place of fine
aggregate. The mixture No. 3 makes it possible to
increase viscosity of concrete properly and to decrease
4 ACTUAL ROAD TUNNEL SPRAYTESTS the water content by 9 kg/m3 compared with the stan-
dard mixture.
The model tunnel spray test results reveal that the use
of HFA as an admixture of shotcrete made it possible 4.1.2 Spray tests
to decrease the amount of dust and the rebound rate, The spray tests are performed using the on-site spray
and consequently to improve the strength development gun and equipment on the above three types of mix-
of shotcrete. Thus, the particular shotcrete is applied ture. Review is made on workability by the measure-
to actual road tunnel works in order to identify and ment of the amount of dust and rebound weight
verify the dust reducing effect, the strength develop- during spraying, and also on the strength develop-
ment property and durability. ment property and the durability.
Prior to the spray tests, the necessary concrete is
made at the on-site concrete plant and the fresh prop-
4.1 Outline of in-situ spray tests
erties of slump and air content are measured. Then the
4.1.1 Mixture and materials concrete is transported to the working place in the
The mixture of concrete and the specification of the underground by agitator truck.
concrete materials used in the actual road tunnel spray The spray tests are conducted with an integral piston-
tests are shown in Table 4 and Table 5 respectively. pump-system spray gun (Max. discharge: 20 m3/h) by
The in-situ spray tests are conducted on three types spraying 2 m3 concrete on the arch and side-wall parts
of mixture. The plain standard mixture No. 1 is the of the half section of the tunnel at the speed of
unit portland cement 360 kg/m3 which contains no