(Cement and Concrete Research 114 (2018) 65-78 Contents lists available at ScienceDisect Cement and Concrete Research journal homepage: www.clsevier.comflocate/cemconres Fillers in cementitious materials — Experience, recent advances and future potential as Vanderley M. John’, Bruno L. Damineli’’, Marco Quattrone’, Rafael G. Pileggi” eso 8 a,c St, A Pf Ani Pr, 5508-070 Sen Pal SP, Bas * onwoaty of Sa Pa, oe of Areca Urbana A Tah SCs, 1356690 So Cra SP, Bal ABSTRACT "The paper dscuses the potential fillers fn CO, mitigation nthe cement industry. A historical overview of the ‘of fillers presented as wll a the limits ffir ase given in ement stondards. Globally, limestone filer currently represents only 7% of average worldwide cement compotion, The Himits of the Curent route to ‘adding flr in cement by means of intergrinding are discussed. An inpovatve technology, that compensates binder dition by reduction ofthe water ried! for good rologeal behavior, s presented hallows linker replacement rates of up 70% The theory that enables the design of sich multimodal particle size ‘istibutions with high parle packing and low-water demand i presente, and examples of i aplication in ‘concrete production are given. The efficiency in terms of COs mitigation is demonstrated by comparing concrete formilttons designed wit his innovative approach with global benchmark of curen echnology. New filler ‘mineral swell asthe effets of high ler content on produeton processes and on dai ae also diseased 1. Introduetion ‘The traditional mitigation strategies for CO, emissions in the ce- ment instry are not sufficient to ensure the necessary mitigation in a scenario of inereasing cement demand. Therefore, the adoption of x pensive and environmentally risky carbon capture and storage (CCS) has been considered an unavokdable solution by cement industry le ders [1 The limited availability of ly ash and blast-furnace slag, which will represent < 20% of global cement demand by 2050 [2), is an important component of this problem. ‘The use of limestone filler as a patil replacement has been stan ‘dardized since the 1980s (3,4). The substitution of elinker reduces the ‘CO, emissions in cement production, almost proportionally to the re placement rate, because fillers do not require calcination. Limestone filler influences early hydration rates and reacts forming calcium carbo- silicate and earbo-aluminate hydrates [5,6]. However, the major effect, ‘of limestone filer is a physical dilution of the binder. Due to that, it tends to decrease strength if water content remains unchanged. In ‘consequence, the global average replacement rate of clinker by lime stone filler has remained low at approximately 7% (7) ‘This paper presents a summary ofthe current knowledge regarding the use of fillers in cementitious materials, including a historical review and recent advances in cement production technology. 2, Technology presentation ‘The technology consist of replacing clinker and other scarce re active supplementary cementitious materials (SCM) by “inert” mineral fillers. There is no single, universal definition fr fillers. Inthe context Of this paper, fillers are defined as fine particulate materials that are inert or almost chemically inert when mixed with cement, produced b grinding with or without surface treatment. They are used asa parti replacement for clinker or other reactive SCMs. The definition of inert mineral fillers includes particles in the same size range as cement, as well a5 particles that are finer than cement. Our definition is broader than the usual one adopted by the cement industry, because it includes fillers made from other minerals beside ealeum-tieh limestone, which 's currently the filler prescribed by cement standards. “The mixing of fillers with cement is dilution strategy that increases the volume and mass of the product by reducing the concentration of the reactive ingredients inthe cement paste matrix, Fillers are used for economic, technical, and environmental reasons (7,8) in the cement industry a well asin other industries. For the cement industry, the wse of filles helps to reduce thermal energy and COs emissions and is creases the expected productive life of limestone quarries, because bound CO; becomes part of the commercial product and allows the use of Tow-grade limestone or other minerals Emo adie mishnusp be CEM, John), brn daminl ub (A. Dame), mre aiotronswine gcse OM. Quattene), ibe! ieseu br CR Pkg p/n 101016 cemeone= 201708019, Received 9 December 2015; Reine in reve frm 22 September 2017; Acre 2 Sepleribe 2017 ‘Available online 37 March 2018 (0008-8546/ © 2017 Fever Ld. Alright reserved‘The global market for cement fillers estimated tobe around 280 Mt per year in 2014 (7), the majority of which is produced by intergrinding with clinker and other SCMs. However, there are other markets for fillers in construction, including selFeompacting coneretes,fiberce ment production, asphalt pavements, and soil modification. State-of-the-art technology allows much higher levels of clinker substitution with fillers than intergrinding, by using separate grinding of filer, clinker and other supplementary cementitious materials. All fines are blended with optimized proportions, resulting in a multimodal (non-continuous or gap-graded) particle size distribution cement (9), ‘and with a dispersant, a combination that allows for @ steep reduction in water demand for adequate rheological behavior in the final product. ‘The magnitude of water eduction achieved can be more than enough to ‘compensate for the effcts of binder dition. 2. Market experiences with filler in coment LL. Beginning ofthe 20th century: fst experiences “The frst recorded use of filles a binder replacements was in the Elephant Butte and Arrowrock Dams (ig. 1), built by the US Bureau of Reclamation between 1912 and 1916 {10}. For economic reasons, 45-48% of the cement was replaced with ground granite or sandston that was excavated during construction. The materials were ground to pass the 850 jm sieve, then mixed with coarse cement, and interground to 90% passing the 75 ym sieve. The concrete produced had the same ‘compressive strength at one year of age asthe concrete that used the ‘original coarse cement alone; this is because dilution was compensated by an inerease in clinker fineness during the second grinding (6). The ‘downstream face and spillway channel of the Arrowrock Dam were repaired duc to frost damage degradation in 1995 (11. No major repair has been reported in the Elephant Butte Dam located in Texas (3) ‘These 100 years-old dams ate still in use, ‘Another landmark achievement was the very thorough 10-year long. Investigation conducted in 1930s by a team from the Givil Engineering Department (12,13) of the University of California, Berkeley, on ce ments containing various fillers and artificial pozzolans, such as cal- ‘ined clay and mixtures of both, Interground replacement in cement with 20% limestone filler and 45% granite filler (LF and GF respectively in Fig. 2) was part of the experiment. As Fig. 2 shows, despite the f- reness of the cement arid the water content being almost constant, a 20% filler replacement surpassed the original cement compressive ‘strength in the long term, in both wet and dry curing. According to the authors, good results were obtained for blends of limestone filler and amon and Concrete esr 14 (2018 65-78 eative Strength to OPC ee (dow) CG ~ arnt ier comet, 9) onthe elatve compre stent of andard 1:3 Dat rm Dai ta (12, Une Cts, ee various pazzolans, such as calcined Monterey Shale and siliceous cays, as well as pumieite [12], ‘The substitution of clinker with inert materials, or with slag and imestone, was considered ‘cement adulteration’ in the USA in the early 1900s (14), and itis still considered a problem today in the Eurasian region [15,16]. Fr Mayfield (1, this fact introduced an ethical bias to technical diseussion and mos likely negatively influenced the public view of fillers in many cement markets 3.2, Standardization period: 19805-2016 “The use of limestone as a replacement for elinker was most likely Introduced into cement standards as an answer to the oil ersis (14) during the 1970s, Canada adopted a 59% limestone limit in normal Portland cement by 1983 (CAN3-A5-MS3), and by 1988, the Europeans wore already drafting proposals to allow 20% of filer in Portland: composite or Porland-filer cements [14]. Currently, several national tnd international standards include filers, and the EN 197-1 cement composition standard allows up to 35% of limestone filer substitution in cements (17) (ig. 3) Despite the maximum amount of limestone replacement being smaller than that allowed to fly ash and slag, lime- stone filler is 7% of global average of cement, a ate higher than slag (8%) oF fly ash (496) [7]. Morocco currently has the highest reported clinker substitution level with fille, with an average of above 20%. Recently, it is possible to observe a growing interest inthe combination ‘Menimam iets ler (x fin pation of the tnd 17-224.meso er yr) : Selected eons and worldwide Dat fo 7) of limestone with other SCM, inchuding calcined clay (18) ‘Almost all countries Hinit limestone Biller to a restricted range of| ‘compositions. However, the use of non-limestone filles is allowed lunder EN 197-1, This standard allows the addition of up to SIs of ‘minor mineral constituents,” including natural materials, whieh “., after appropriate preparation and because of their particle size dis. tribution, improve the physical properties of eement. They can be Inert ‘or have slightly hydraulic, latent hydraulic, or pozzolanie properties." “The practice of adding filers at the conercte mixing stage was most, likely introduced fo the market by the advances of sef-compacting concrete technology in the 1990s [19] and now has been extended t0 ‘other concretes (20] and may include fillers other than limestone. ‘The actual average replacement rates are much lower than the ‘maximum limits (Pig. 4), which clearly show the limitation of current technology and market segmentation. In Europe (the most technologi- ‘ally influential marked, the rate shows a very slow grovtth, approxi- mately 6.5%, which is close to the global average. The use of limestone in the USA is very low, 2.7% in 2013, despite the recent change in standards that allow up to 15% of limestone filler. The Indian limits for limestone filler are die the limited availablity of elinker-grade lime stone [24] 3.3, Limitations of current fller technology: simple dation of cements Considering that the ili almost inet, the replacement of binders ‘witha filler will result in dilution. This oecurs because a binder is de fined as a mineral that hydrates, sich as clinker, slag, and pozzolans. A lower binder concentration implies a lower rate of increase ofthe solid volume fraction filled by hydration produets, I'he waterto-olids ratio used to test cement strength is constant, as itis in most standard in ‘cluding EN197-1, it eauses an increase in the porosity of the system, Which reduces its strength. This ean be roughly estimated using a simplified Powers model by disregarding any influence of the filler in hiyatration (Pig. 5). Dilution can be compensated for by increasing clinker fineness ‘within certain limits. Limestone fillers have densities in che range of 2.6-2.7 g/em's therefore, their substitution on a mass replacement basis also increases paste volume (Fig. 5) and the separation distance be ‘oween aggregate particles. This partially explains the reported im: provements in rheological behavior [17], which may allow a reduction fof the water/cement ratio for constant workability, helping to com- pensate for the effets of dilution. At early stages, the dilution of clinker by filer is partially compensated for by an acceleration ofthe initial hydration rate [25,25] due to finer clinker particles andl the nucleation effect. in addition, some fillers may react with cement phases. amon and Concrete esr 14 (2018 65-78 g Past Porsty vi) g Flor Content (7/0) Fig. 5 Dion fect on pity an paste vokame cased by the ineoducton ofa ‘ompleey tne filer hen the watrslé rato wei) i ep cement. Dena Pothnd cement 2.1 9/em flr 269m coined woe: 0.24 9/4 Limestone filler partially reacts with aluminates, producing carboalu- sminate (25,27,28) and stabilizing etringite (5,29). Limestone filler can lo react with aluminate from slags or pozzolans in a synergistic ‘manner [29,30], allowing for greater porosity reduction However, most of the filler is introduced into cement by inter trinding limestone with clinker, normally resulting in cements with & lower strength class (17,31) than the original pure clinker cement, despite the limited reaction of limestone fille. In Europe, CEM 11/8 Portland-limestone filler cements typically fall in the lowestgrade strength class (82.5 MPa), while CEM I/A (Biller < 209) is mostly of the 42.5 MPa class [32]. In Brazil, approximately 654% of cement pro- ducers offer the 32 MPa cement CPI strength class, with only 10% ‘maximum limestone filler content; meanwhile, without the filler, the coment would be a 40 MPa strength clas. This isa result of non-com- pensated dilution. Dilution can be partially compensated for by in- creasing fineness through grinding or by reducing water/cement ratio. However, cement testing standards such as EN 197-1 do not allow the adjustment of mixing water content (0 keep workability constant Therefore, the standatd does not incentivize market exploitation of water-reducing strategies to compensate for dilution. This can partially explain why filled cement usually provides better in-use performance than what is suggested by ts standard classification [17,93). From the point of view of plastic concrete, filler substitutions of 15% (31 or betveen 10 and 20% [17.4] donot significantly affect the compressive strength, “Therefore, with current standards, increasing cement fineness isthe only industrial solution availabe to compensate for dilution. Limestone {s far easier to grind than clinker or slag therefore, intergrinding will result in limestone particles much finer than binder particles (17,35). ‘isis inefficient because increasing the finenes of limestone filer will only slightly affet its mechanical strength (36). The replacement of coarse clinker particles with incr fillers is much more effective [27 ‘he dilution of elinker or other SCMs by fillers beyond the limits where strength loss due to dilution can be compensated results in an Increase of the environmental impact of cement-based. materials However, environmental impact measured at the gate of the cement producer will show net reduction of CO, and energy. If we negloet eventual cheologieal improvements, it is possible to estimate (Fg. 6) that to make a 40 MPa conerete using a 32.5 MPa cement strength clas, the concrete requires approximately 40% more cement than is needed when a 52.5 MPa cement is selected. The lower the conerete design strength, the less important the effet is. However, when a 52.5 MPa strength cement becomes a 32.5MPa cement oving to dilution with 10% of filler, the environmental impact of cementitious materials in- creases by approximately 108%, But the CO, footprint of cement pro- ducers is reduced by slightly < 10% beeause of the binder dilution.i Ci ee Cemantstrengh clase (Ma) Fig, 6 txinaton ofthe effet of comet sent elas en cement consump for cancirie sens waning beneen 10 and SOMPa. Abrams curve CS = be" ie bese on PCA 39), whee k 8 costa aise far compressive stent eq 6 coment cl tenth when the watr/comen ao x= 0 ‘Tis effet is quite evident for industrial cement users however, Its not, perceived as relevant for self-help or small homebuilder companies that fend to use the same conerete formulations without considering the ‘cement strength clas. This may explain how Morocco, where most of the coment is sold in bags, ean have 20% average filler content while the European Union only has 78, despite having the same maximum standardized filler content (8), However, in regions where the only alae cement is a 32.5MPa strength class with fille, profession ‘users will be forced to use more cement than if they used @ CEM I with 42.5 MPa clas, and the environmental impact of the industry will in ‘rease despite the lower clinker factor. A similar effet may be expected when replacing filler with low-reactivity pozzolans or slags. 4, New developments: high filler, low-mixing water, with high mobility mixtures Recent research developments show that its posible to replace as much as 70% of clinker with filler without reducing. mechanic strength, This can be achieved iF dilution is compensated for by en fineering a reduction in the amount of mixing water required to achieve the desirable theological behavior. However, this Is not a ‘simple task because rheologieal behavior becomes increasingly difficult, to control with reduced water content 4.1, Packing and interparticle separation ‘The plain strategy for achieving a reduction in water demand isto Increase particle packing, which results in a lower volume of inter particle voids that needs to be filled with water. The packing max mization approach is not particularly innovative in the cement is ‘dustry (40), at leat for grading the aggregates, and guides researchers ‘even today. ‘The idea behind packing improvement i justified by a hypothetical increase in the critical solid content (gr) in the Krieger-Dougherty ‘model (4, whieh deseribes the viscosity of suspension asa function of| the volumetre solid content in suspension (Pq, (1). a) ® where n,~ relative viscosity, [yl ~ intrinsic viscosity, ~ sol con. tent, and gy = critical solid content. Despite its accuracy in describing. how viscosity is related to solid ‘concentration, this equation is not predictive; it fails to explicitly con sider the effects of the fundamental properties of particles (size, shape, surface area, density, ete.) and liquids (viscosity, density, ete) that amon and Concrete esr 14 (2018 65-78 compote the suspensions. The exaton requis an experimental de teoinaton ofthe enprcalprametr fo ach st of combined ma teria, Ect, the relation Bower teeta sod content and the pocng of parce ot asl ut als dependent on te nature oration de “Therefore, this approach is inset sae the maxinizaon of pecking dec not esr he minimization ef war quired for ade uate resegclBehavinUsl the acl water conten eed tDadoquaeeheslopeal Devo above tothe quity ruled for fil binder bycation, and this exces determine the Hal preity of the hardened cement past 42). The minimization of thi exo water ithe ey srategy to improve seength and perfomance of ow binder pewcoping ‘models capable of predicting the viscosity of suspen- sions fom basi ale td iid characters ala challenge Satacory rene ae achive sng the Funk and ings (4, ove whch creates the vison of sspersons wih the inte parle parton CS) (2) that desert the pce for pice Motion nel spre suspension The higher the 1 the oer te Shering energy dispaton de opie Ines, mee vc ws= 2 z-( 1 ) wa"|y ia o Where VSA = volumetric surface area (m?/em®), ealeulated by the product of specific surface area SSA (m/ and solid density p, (g/m), Y, = volumetric solid fraction in suspension, and Pac = pore feaetion in the maximum packing condition caleulated using the Westman and gill algorithm (425). The packing porosity is one of the variables fn the IPS equation, but it has a lower impact than the volumetric surface area (VSA). For concrete or mortars, a multiscale optimization of IPS canbe performed by considering a Muid as (a) water co the paste, ‘ona miero-sale, and (b) the paste (asa uid) to aggregates, on a macro scale ig. 7 illustrates the IPS concept from the dry powder (ef) to the distanced particles right). The ideal combination for reducing. the water demand in suspensions is achieved by reducing the packing porosity (water needed to fll the voids) and the surface area (water Aceded to cover the surfaces) because only the excess water will pro- mote spacing among particles. Although the IPS model describes the spatial distribution of sus pended particles which ean be comprehended as sort of degree of freedom regarding mobility, the model is not absolute since it does not consider other physical aspects linked to the energy dissipation during collisions among particles of various sizes in movement (including particle blockage by neighbors) and the propensity for phase separa tion, Literature confirms this finding 46, where different cement-filler suspensions exhibit distinct tendencies for visosity reduetion duc to WS increase. To improve particle mobility, the ratio between the par ticle size and IPS should be les than one (46). Another aspect to be considered is the energy dissipated by a par- ticle when moving inside a liquid This effect is described by the Stokes 3 [47] (Eq, (2) which ealelates the distance d that a particle with diameter D, aod density p, runs frely until stopping when projected horizontally ata speed vp in a liquid with viscosity 8 @ where dy = distance travelled until the stopping (um); ve = launching particle velocity (um; Dy = particle diameter ps = sold density (g/em") and ny = dynamic viscosity of the liquid (@/ tims) “The ratio between the maximum distance (4) that a particle laun- che ata certain velocity vp may wave uni immobility and the mean distance to oer parle CPS) results in a dimensionless parameter,Liquid content increase ) |: Particles Voids Voids filled in contact filled + Covered surface with liquid named the dynamic interference (INT,), that estimates the probability ‘of contacts among suspended particles in movement. The intr ‘characteristics of the suspensions can be identified through dividing INT by vo thus defining the natural interference (INT,) of the system by Eq. (4) (46). This equation allows comparisons among diferent suspensions, independent of their shearing conditions o ‘The mobility of particles with multimodal size distribution in sus pensions also follows the known Farris concept (48,49]. According to this, a particle moving inside a suspension made of particles smaller than about 1/10 of ts own diameter, behaves as if it was moving in a liquid with the same viscosity of a suspension. In other words, large particle kinetics is not affected by collisions with other partcts that is more than one order of magnitude smaller. But when it collides with particles that are larger than ~ 1/10 of is own diameter, the particle is ‘deviated. Therefore, a sub-set of particles of a given diameter can be ‘modeled as lowing ina (sub) suspension, comprised of particles with ‘diameters > 10 times smaller than those in the Hiquid phase. Fig. 8 «splays such a concept by plotting the effective particle size distribu ons defined within the 10 times diameter size intervals around some ‘exemplified diameters (125, 75, 45, 225, 11.25, 5.63, 2.37, 1.0, 0.5 and 0.25 um) for some Portland cement samples [46]. ‘The convergence between the predictive IPS model with the particle interaction concept of Farris arises by caleulating the IPS for each 20 diameter (ol) ° ° 10 100 1 Diameter (1m) Fig, 8. Una pare dsrbuton fo sone spcfe dames (125,75, 45, 25,1125, '363, 237,10, 05 and 025) of he eed cement onsen he Fs 10 da sete ato parle ern 1). amon and Concrete esr 14 (2018 65-78 Fig. 7 Schunate representation ofthe PS mol The vo ame of he ld pave woe cent hse mei) loess fom et oat Distant particles particle diameter Dy sub-suspension defined within its 10 times dia: meter interval, which allows the assessment of the effetive natural interference (INT) perceived by each partile diameter Dy. ‘The bulk interference (INT) for multimodal suspensions under shearing ean then be calculated using an algorithm that sums the in- dividual contribution of cach sub-suspension weighted by its volu metric contribution in suspension, thus converging to Fa. (5). As ob served, this last equation also includes a constant H, which was proven to be related to the total volumetric solid content in suspension | 6) “The physical meaning ofthe H constant involves the suspension capa: city of energy dissipation in terms of heat during the experimental measure of viscosity o where H = experimental dissipation parameter (Kunetion of the vol metric solid content), x; = volumetric content of particles with dis meter Dy INT = natural interference calculated for particle D, as- suming the IPS is calculated inside its sub-suspension interval, and 1m = number of size diameters ig. 9 demonstrates (46] the accuracy of the Interference Algorithm Jn predicting actual viscosity estimated by Casson's Model from c- Plame torres gre ler eke . a = y= 1,0479x + 0.0699 7 . INTp Fig. 9 nea relation terwcon expernenta ess of ait (Casson mote andthe Interne (IN, ented egy (3) (4).suspensions of various mineral compositions, surface area, and particle ‘ize distribution, from basie particle and liquid characteristics. ‘Therefore, the goal of minimizing the amount of water needed for the desired rheological behavior can be achieved by minimizing the interference in multimodal particle size packing. A suecessful approach to dovelop high-filer cements can be achieved by incorporating. @ ‘combination of optimized clinker particle size distributions (to ensure hhydration) and at least: (1) a dilution filler that has approximately the ‘same particle size a the elinker, (2) an ultrafine performance ile that reduces the interparticle volume of pores; and (3) a dispersant that prevents particle agglomeration to disrupt mobility (Fig. 10). This ap proach allows for a reduction in water of 30-50% (50-53) in com parison to standard mixtures, The effect of packing with low inter ference can be appreciated considering that the usual water eduction with dispersants is betwoen 1096 and 15% (54). Honever, when inereasing packing density, other problems arse Mixing energy needs to be controlled because good mixing is a pre ‘condition for dispersion. Another problem is that the compatibility between the binder and dispersant can interfere with the stability of «ispersion overtime, particulary at high temperatures, or ean itlead to ‘a dosage that retards hydration, 4.2, Practical application of flr substitution ‘There isa growing number of studies that portray the application of high-filler content in concrete from various groups, inchuding Sweden (KTH and CBN [55,56], Germany (U Darmstadt (50 57), U'T Karlsruhe [51,58], VBZ (59)), and Brazil (VU Sto Paulo) (46, 52,53). The results show that its posible to substitute up to 70-75% of the binder with a ‘combination of engineering fille, which produces concrete with com: pressive strengths of up to 90 MPa. Ths is achievable if the dilution ‘compensated for by a sharp reduction of mixing water, from typici values between 170 and 200 L/m? (liters of water per cule meter of concrete) to 90-165 L/an* range. The total binder content ~ clinker or ‘other reactive SEMS ~ ean be reduced to below 100 kg/m, Some con cretes with water content below 110 kg/m? have slump exceeding 22cm, {Asi LI shows, there is no correlation between stength and filler fraction or with water/eement (w/c) ratio, assuming, as usual, that ‘cement may contain not only binders such as clinker and reactive SCMS amon and Concrete esr 14 (2018 65-78 Fig, 10, Disc cement yrice sae scenarios) Cink price io “pine PSD and high ost clinker rine perfomance flr wih aspen ‘sty abd water demand, (esc of tne potermance filer reduces Phe td incrowes water dona (0 exc of “Un er and ek of elker and pe formance fle eas in high poston lower stent (e) witht admire, agglemerstion destroys poking ae cinter @ diaton titer ©) performance filler @ like blast furnace slag and pozzolans, but also ines filers. However, strength correlates well with the water/binder (11/9) ratio, which 8 @ proxy for the non-combined water, which comprises the bulk of the paste pore volume. The values of the w/% ratio are higher than the usual water/eement ratios for ordinary concrete. A w/b ratio of ap proximately 0.5 can result in concrete strengths from 65 MPa up to 90 MPa, whereas a 20 MPa strength can be produced with a w/b ratio between 1 and 1.5. Data also show that coneretes with different paste Porosities (estimated by w/b rato) can present the same strength. The w/c ratio merely describes the water concentration inthe cement paste, and varies between 0.22 kg/kg and 0.5 kg/kg which has no correlation ‘with porosity or strength. Water concentration in cement paste is loner than for typical coneretes, even though the density of the llr is lower and its volume is higher than that of the clinker. ‘A reduction of the mixing water content with no increase of the agaregate packing requires an inerease of the amount of “cement (fillers plus binders) 10 maintain the paste volume constant, a re ‘quirement for adequate theological behavior. Therefore, the reduction ofthe clinker (or binder) fraction in the cement is higher than the actual (004 footprint reduction ofthe conerete (Pig. 12) ‘The binder intensity (BD (60, defined as the amount (kg/m) of reactive binder for each MPa of compressive strength at 28 days, can be much lower than the best global benchmark whieh is around Skgm “MPa”! for concretes above 50 MPs, and increases respecting the minimum cement content of | 250kg/m*, reaching 12.5 kgm °MPa~ for 20 MPa coneretes (Fig. 12a) “The new technology, high filler content compensated by a reduction of mixing water demand by packing and dispersion, gives Bi reults as low as 2-4 kgm” °MPa~' at values 50% lower than for current con cote technology; a bi of Skgm MPa” is obtained using current technology for eoncretes above 50 MPa, The resulting CO» intensities (ig. 19 by, ranging between 2 and SkgCOsm- "MPa !, can be equivalent to those obtained by replacing clinker with other reactive SSCMs which are considered CO, neutral because they are wastes. The best formilations using pure clinker and high filler have a CO, footprint equivalent to coneretes produced using current technology, which use a clinker factor between 0.8 and 0.4 (Vig. L3e). However, not all for ‘mulations with high-fillr perform equally well in comparison with the benchmark, particularly with respect to binder intensity tis worth mentioning that an increase in aggregate packing cani : Le . eee : Conroe eg Gm and Cor sare 142018) 85-78 b ‘Fig 1, (Lat Filer econ income as leo no cotdaion with ogre eompesive tena. (Rt) Wata/ement binder +e) aia abd watering ata ite vera compres eng, Number represen ler faction €or Ierpretaton ofthe ferences nou mh gure ged the ede eee the wed version of tsar) Dat fm (19525557 5 pl wea our om pid dat ‘reduce the amount of paste (binders fillers, water and ait) required to fll the space. The theological behavior ofthe resulting conerete isn negatively affected, and an inerease in such aggregate packing wi further improve the environmental performance. 43, Additional filler minerals In general, industry standards limit filer additions to limestone (carbonate) materials within a specified range of chemical compost ons, EN 197-1 requires a minimum of 75% of CaCO,, and the Brazilian standard, NBR 11578-1991, requires strieter 85% minimum of CaCO. ‘This requirement seems to be primarily a reflection of the excelent performance of limestone as a fille. In addition, having limestone available at all cement plants makes its use economically convenient. However, any inorganic mineral product that has compatible strength and no deleterious chemical reetion with clinker can be used a a filler. The century-old USA experience with the Arrowsock and Elephant Butte Dams (sce Section 3.1) shows that certain types of ‘granite and sandstone can be used safely. There Is additional Iterature supporting the use of quartz (25,26,55,61-63], dolomite (25,46), ‘granite (12,46,52), eristobalite [52,55], nepheline syenite [52,55), and wollastonite (55), Damineli (52) replaced 50% wL/wt. of CEM 1 with filles of di: ferent mineralogy. The filler densities ranged feom 2.35 (ristobalite) to 2.82 (dolomite). The water/binder (or clinker) ratio was a constant 0.5 (wt/wt), which implies a 50% solid concentration (wt/wt) increase ‘when filler is added. The reduetion of paste porosity due to the lower volumetric concentration of water i fille-containing formulations ame on) aba E s resulted in compressive strengths S1-144% higher than the original CEM I cement paste (Pig. 14a). Despite thermogravimetre results re- vealing the chemical reaction of filles, particularly cristobalite and rnepheline syenite a 28 days, the great majority ofthe variation in the strength between filler-containing formulations (Fig. 14b) could be explained by the simple variation in filler density. The filler influence ‘on the inital volumetric water concentration is refleted in the porosity of the hardened paste ‘When replacing clinker with filer on a mass basis, which is typical in cement standards, filler density matters. 1 also matters for users because the lower the density of the filler, the larger isthe resulting paste volume, Volume replacement will cieumvent this problem (oohich is present in cements with high fractions of ly ash and slag), but ‘will al an adltonal step tothe conerete and cement quality ontrol process 4.4, Hligh-MgO limestone and dolomite as filers ‘The use of carbonate filler with chemical composition that results in ‘more than the maximum allowed MgO in the clinker by the standards, which is usually around 4-5% [64], is of interest because they are availabe in many cement plants. Even if their performance is inferior to pure limestone, it would be beter than no filler at al Dolomite fillers have been used in selécompacting concrete for rmulations for at least 15years {19,65,65), They have been re- commended by the European Federation of National Associations Re- presenting Concrete (EFNARC) since 2002 (67). The European Geaealonforelecompcing concrete ciel in 2008" by - $6 == 7 ef ermine i. — . Fig. 12. (2) Campion of cement pnt with or witha fier for once wih 20 MPs, © MPa, of 70 MP 28 compressve strength. The Figures epeet the sme ofeach pase in erm’ () Ganprson betwee formulations with and without Her, presenting kr fein on es, CO aa, an cent (e+ ode conte Dt om Poke (5710 » so 70 0 Compressive Sent (Pa ® content tan) = ° 2, 8 A Lee 1 oale PS 7 z oe . amon and Concrete esr 14 (2018 65-78 Fig. 12. Comparion of high er, lower demand concrete Ferman with 2 tel beach et by Dai ea (60) High ile tecnologia eset Sank ors (2) Binder ime (b) CD intensity versus emp stents (0) for convertion ences. The geen ln in) Metis he Inferno 0; Fenpit of concees made ith pe linker. (Foe iteretstin ofthe rele colar in ths wegen, he ede ef othe web version of sate) CEMBUREAU, EFNARC, ERMCO, BIBM, and EFCA (63) also re- commends dolomitic filers. In the USA, dolomitic fillers have been recommended since 2007 [69] by the Genter for Advanced Cement Based Materials (ACBM). Many other organizations, such as the US Transportation Research Board [70] and the Portland Cement Ass0- ciation (71) recommend “limestone” filers, which they define as a technical term that covers all mineral carbonates, including dolomite [72]. No reports of expansion problems have been detected in the lit erature. A recent, fairly comprehensive study conducted by the cement ‘manufacturers in Heidelberg (73) shows that the chemical reaction between dolomite filler and clinker mainly results in hydrotaite, with ‘no report of any expansion. Justnes [74) considers dolomite 1 be better than calcite. The so called “alkalt-carbonate” expansion has been lately associated withthe presence of reactive quartz [75,76] ‘The accumulated practical experience and recent research results, show that there Is no technical justification to exclude dolomites and high-Atg limestone as filles in cement by current standards 45. Scope of application ofhih filer cements Filler materials can be used as binder replacements in all markets, Including mortar, prelabricated concrete components, fiber-cement (inhere they already have been in use in high amounts fora long time), and even to high strength structural and mass coneretes. Eventually, demanding performance requirements for specific applications or ag gressive environments will be more casly achieved with low-fller content materials or by barring some reactive minerals, Fille-cements can also be formulated to be used by non-professional builders Aside from direct substitution during cement manufacturing, filles can and often are used in the partial substitution of eement during the mixing process by industrial facilites when producing ready-mixed concrete, dry-mix mortar and conerete, and building products. This will certainly enable a more rapid increase in the average filler content in ‘cementitious materials, even in an improbable scenario where cement standards remain unchanged. In this case, the filler may be supplied by other companies, including the largest multinational filler producers, and the cement sales will decrease accordingly. ‘This also allows for a compromised solution, wherein the cement Industry increases the average filler content to a limit that allows in- dustrial users to adel more fillers if they wish. This may limit the po- tential mitigation of the technology, as it will require much better ‘communication regarding cement composition than exists today. Fillers can potentially be used with all new binders, including copolymers, carbonation-hardening cements, and cement made with ew clinkers such as BYF (belite-yeclimite-ferrte) and CSA (calcium sulfoaluminate, Fillers can inerease the market competitiveness of these new cements 4.6, Robustness ofthe technology Thisty years of industelal experience in various counties has de- rmonstrated the robustness of replacing up to 35 wt.s of clinker by Icerground limestone filer (31) with no dispersant. Robustness of the technology for higher amounts of filler ~ High Filler Law Water CHFLWY) = that rely on dispersion to reduce water demand and compensate di lution, is yet to be demonstrated in various market and climatic con- ditions. Table 1 presents the main aspects that can become problems for robustness.Ccompcesive strength MPa) eeeeeaeeé amon and Concrete esr 14 (2018 65-78 Mining water Pe) oar Filer Density (g/cm) w Fig. 14 nese of filer mineaogy a he camprenive strength of cement peat 28s), with water binder ato eq DS. Fler deny inoence on uma Water ‘ooceaaton and estimate hydrate pst pores neletng canal vat Dat om 2 ‘The production of cements with controlled and stable particle size listibution by using a separate grinding process followed by dry Powder mixing is not technologically a problem. Particle segregation ‘during transportation of bulk volumes may be a problem. However, the idry-mix mortar industry has been able to formulate camposites where ‘segregation isnot a problem despite the much larger range of particle size distributions ‘A challenge for robustness is both the compatibility between cement ‘and admixture, and the time stability ofits dispersing effect, especially ‘at high temperatures. A low intial workability ora premature lose of workability will encourage the untrained user to add more water than specified, which will reduce the mechanical strength ofthe system. The presence of fines or clay contamination in aggregates in amounts that significantly increase the total surface and the demand for dispersant also introduces a risk of increasing water demand, which affects por: ‘sity, strength, and durability. This problem will be more relevant to the bagged cement market than forthe bulk market, where aggregate ‘quality control can be implemented. These may make bagged dry-mix ‘concrete desirable because the compatibility ofthe cement-admixture ‘and aggregate quality can be implemented by the proiacer. '5. Durability of HFLW cementitious materials ‘A major durability problem in cement-based materials is the cor: rosion of steel reinforcement. Carbonation and chloride exposure can ‘cause reinforcement depassivation, allowing corrosion to initiate. ‘Therefore, the major problem is confined to seel-reinforced concrete, ‘which is estimated to consume only approximately 25% of world ce: ment produetion and < 359% in countries with the highest consumption rate (Fig. 15). Therefore, the majority of cement used in construction ‘does not need to protect steel. ‘rable Cement in Reinforced Concrete (t/t) Fig. 15, Maton af ements in elo coer pret. Data fe (77:78) ‘The replacement of clinker with fillers reduces the alkaline reserve of cementitious materials. The carbonation depth (,) overtime (0 can be described as d; = kt", The k (Bq, (6) is directly proportional to ‘mass transport properties or the permeability (p), which is elated to the tonerete porosity, paste volume, and IPS [79), and itis inversely po portional to the alkaline reserve (q). The alkaline reserve depends on the chemical compesition and the amount of hydrated phases. ef oe (6) “Therefore, by replacing binder with filler and holding all other variables constant, the carbonation depth wil increase Beease a de- creases. However, when a high binder replacement ratio with fle ‘on 30% Kenly the unl hoy neg lr. nthe col stable? sao Proved pile Neel ether delet ot posible Sky of ory th temperate a3 haw High renga eat oge (res 5 LK‘compensated for by a reduetion in mixing water, the concrete porosity is also reduced, which ten to reduce p and k. Consequently, the effects ‘of filler on carbonation will depen! on the balance between the var on of a and p. Data from VDZ. (59) show that increasing the Aller ‘content from 17% to 50% (+ 290%) while reducing the water/(binder + fille) ratio from 0.5 to 0:3 (~ 40%), while keeping the paste volume ‘constant, results ina reduetion in the mortar porsity of approximately 25%, and in an equivalent carbonation ate. ‘Therefore, carbonation isnot controlled solely by the filler content Because it is possible to adjust binder and water content, ic. the IPS (79) of aggregates, while maintaining strength almost constant (see Fig. 10 and item 4, it will be feasible to design concrete formulations that comply simultaneously not only with rheological and mechanical performance specifications but also with certain durability parameters ‘such a8 carbonation resistance leis also desirable to maximize carbonation asa strategy for “carbon ‘capture and storage” (CCS) in all applications where stee] protection is not an isu. This ig the ease with mortars and plasters and small tn reinforced concrete blacks and pavers, which comprise a significant portion of the cement market in developing countries, This strategy also ‘applies to indoor reinforced steel elements in dry environments. Models will be needed to allow for quantitative estimation of CO, mitigation {801 by considering the actual formations to beter estimate CO. cap: ‘The effect of filler replacement on chloride penetration resistance, {as given by VDZ [59], showsa similar trend to carbonation phenomena, ‘A 50% binder replacement with fillers requires 30% reduction in water/(binder + filler) ratio to maintain the same chloride migration coefficient. The results in a 23% increase in the 28 day-compressive strength [81] Steel corrosion is triggered when chloride concentration is greater than a certain eritical chloride content, typically taken as 04% by mass ‘of cement. Therefore, replacing binder with filler will reduce the maximum amount of chlorides needed to initiate corrsion, Chlorides may be present as contaminants in the raw materials (castin blorides) ‘or be transported from the environment. Coastal regions are rich in airborne salt, and roads and bridges in cold countries are subject co de icing sats (82,83), urther, most reinforced concrete elements exposed to dry of indoor ‘lements have a much lower corrosion rsk than those exposed to outdoor ‘elements. Carbonated reinforeed concrete elements in dey environments (RH < 65%) protected from water have a eotrosion rate that poses no Fisk to service life (84). However, reinforcement corrosion rates in 30 yeas However, there are significant differences in maximum limits between countries, and the average replacement rate remains low. ‘The new lowbinder, high-filler method (hich combines dis persants to reduce the water and compensate dilution) has already been {ested in relevant environments such as ready-mix conerete and precast concrete. The addition of filles during concrete mixing is already standardized in the USA [20,89), This will have limited benefits be- cause minimum cement content remains in most of the standards, despite the abundant literature questioning its technical need (86,87), to ensure durability. The equivalent performance approach, described by De Schutter (90, introduces a possibility to overcome this imitation Anon-exausive search of Google Patents shows that the number of, patents in the cement field has been growing and that they are mostly foncentrated in the USA. There is currently a total of 20 patents (ig, 16). The first patents reated to the basic technology of packing and dispersion to allow flowability are > 20 years old. Authored by Ronin and Haggstrim (91-93), the patents seek to protect mechan- chemically activated cements, a mixture between quartz other SCMs, Alispersants, and the clinker and gypsum associated with a specific process involving pre-grindng of fillers followed by an intergrinding of all materials. This patent doesnot allow for strict control ofthe particle size distibution in the individual phases as seen in the technology patent by LafargeHoleim (then Lafarge) [94] in 2007. The patent de scribes a multimodal composition of particles, incuding ultrafine fillers (elow 1m), clinker, and other SCM as binder, with total clinker consumptions between 25 and 160 kg/m? (94). Markets include a “binder premix” with Portland cement content between 59% and 35%. Other patent-ovners ineide Roman Cement LLC. and Omiya [95 COmya is one ofthe largest specialty filler producers in the world, and has protected the concept of “functionalized file” for use in cement. [appears that patents have quite large overlap in terms of particle size distribution and technical concepts. Patents tend to ignore theln lence of important aspects such as shape and mineralogy of the fillers and clinker, aswell a efficiency ofthe superplastcizers. None of these patents seem to have been commercially explored to date, at least not ona large scale. In addition, we found no patent disputes on record in this subject. Experience with patents in other economic areas su ‘gests that the primary goal for at least some of those patents was (0 block possible competitors (96) from the market, 7. Potential of sealablity, 2.1. Raw materials ‘Almost any inert natural rock can be used as filler, including mine tailings and other wastes (see Section 4.2) i they are free of deleterious minerals such as sulfates, Therefore, there 4s n0 limit on the raw ma: terials that can be used to produce fillers, specifically because cement applications donot demand strict chemical composition, colour, oF refractive index, common fo the specialty filler market. However, fille mineralogy and particle shape may impose practical limitations on the ‘maximum amount of substitution for some minerals (53) ‘Another issue is the world production of dispersants admixtures, ‘The total dispersant content is very low, typically varying fom 0.5 t0 196 (L/w, of total fines. Therefore, if dispersamts become par of al ‘cements produced, the admixture consumption will be approximately 25-50 MU year, which is a rather modest amount. 7.2. Production process Filler production is an established technology, and companies supply equipment because there are other markets for filler aside from the cement industry, including cosmetics, pharmaceuticals, hygiene products, papet, food, adhesives, plasties, sealants, andl paints [97]. The ‘global production of specialty fillers was approximately 100 ML in 2012 {98}. Calcium carbonate fillers, ground and precipitated, ar estimated a being from 66 (97) to 90% (88) ofthe total market. ‘The raw materials used in fillers may require drying before pro cessing. Most fillers are produced by milling, which fs cheapest for products above 5 ym [99] in size. The ultrafine filler elas is perhaps a more challenging aspect of producing fillers on a large scale Different from current intergrinding technology, multimodal dis- tribution with high filler formulated for low-water demand will require ‘an individualized control of particle size distribution and specific su face area of each mineral component. Therefore, separate grinding, dedicated storage for each phase, and blending (ary mix) equipment will be mandatory. A dispersant must be applied at the grinding, blending or mixing steps. The dispersant must have along shelf life and readily dissolve in water, becoming effective in a very short period to prevent water aver-dosage. Filler production and blending can be completed at different sites, loser to market or filler sources, making logisties cheaper, and al: Towing for the exploitation of local aw materials and the easing of ‘adaptation to loeal market particularities. However, this also has a Potential to increase competition between producers. 7.3, Health and safety ‘The amount of inhalable and respirable low-solubility dust particles, in air inthe work environment is undesirable and already subject to strict regulations in many counties (100). Therefore, the use of fillers ‘composed by minerals with low solubility and with particles diameters that faitate inhalation (< ~7 um) may requite workers to use add tional personal protective equipment when manipulating cement or ‘cement-based prociicts. Examples of potentially problematic filers in ‘luce crystalline sila (quartz, tidymite, and cristobaite), which i ‘lasified by IARC [101 as eareinogenic to humans (Group 1) and also ‘causes silicosis [102] when inhaled, Quartz may be present as a amon and Concrete esr 14 (2018 65-78 secondary mineral in limestone, dolomite, and granite, as well as in SSCMSs such as metakaolin and calcined clays. I isnot clear if anti-dust admixtures ean be used to reduce occupational risk. Therefore, fille selection must include occupational health considerations. 8, Potential impacts on investment and production costs {An inerease in filler content will allow increasing cement production With lower oF no investment in new kilns. in markets where kilns are ready in operation, fillers will reduce kiln use and value, which may be an economic problem. Thermal energy consumption will decrease with filler content. In some markets, where alternative fuels are a source of revenue, a reduction of thermal energy demand can be pro blomatie. On the other hand, the consumption of electricity, an ex pensive supply, will be inereased due to finer and more sophisticated frinding and classification, as well as blending steps ‘The IEA GHG model cement plant (103) allowed us to roughly es- timate that, without considering the cost of the dry dispersant ad- mixture, additional silos, and blending equipment, filler production cost i approximately 37% ofthe total cost of pure Portland cement. IF ro special grinding equipment is required, which is not yet clear, C [APEX and operational costs are reduced by approximately the same value. Despite the uncertainty of our estimates, itis safe to assume that filler do not increase cement prociction costs 9. CO, mitigation potential ‘The technology will result in substantial reduction of 003 emis: sions and encegy use over the life eyele of cement-based materials, at a Tow investment and operational costs, especially if compared with ex- pected carbon capture and storage (CCS) costs Filler production may require thermal energy for drying raw ma terials, Eleetsieal energy demand will probably be 50-70% of the Portland cement — which is typically around 104 kWhyt for the CSI participants (104), roughly 10% ofthe total energy bill. COs emissions of filler wil depend also on the electricity emision factor, which varies between 50 and 800 g/KWh. For the scenario from TEA GHG (103), With an electricity emission factor of 520 2 004/kWh, the authors es timate an emission of 42kg CO,/t of filler, without considering the extraction associated emissions. This value is consistent with the LCA reported data from the literature, ranging from 26 [105] to 75 [106) kg COs/kg, ‘The global warming potential of dispersants is reported to be 1.88 kg COpay/kg. However, the consumption will be as low as 5-10 kg/tof fines and the contribution to emissions will be low. 10. Market penetration scenarios, barriers, and incentives Considering the eurrent low limits for filer established by standards of countries like India, Breil, the USA and Canada, and despite > 30 years of sucessful European experience with replacement ratios as high 8 35%, itis obvious tha there sill exists considerable resistance in the ‘market to filles, This resistance includes same cement producers, de spite the significant reduction in costs offered by fillers. Certainly, this resistance will be reduced by eventual increase of CO> and energy re lated costs and the perspective of mandatory carbon capture and sto- rage. Construction isa conservative, lw-tech marke, with highly regu: lated and standardized products. The market requirements for service life are also exceptionally long, which makes durability an intrinsically dificult research tope. Innovation in construction is slow and mostly introduced by construction suppliers [107]. However, cement is a standardized commodity and producers have limited experience in using product innovation to gain competitiveness. “The environmental market estill small n the construction business, but is growing and fueling innovation [108]. Therefore, there is &market for low-carbon cement solutions with proven tecanical perfor ‘mance and durability. The lack of reference standards for high-fller ‘cement can be overcome by petformance-based technical approval Honever, standardization is a pre-requisite to large-scale market penetration. It can also bea time-consuming activity, especialy if part ‘of the technical community remains skeptical. The acceleration of the standardization process will require substantial investments in research ‘and development. These investments will be capable of delivering se ‘entific evidences that will be validated by the worldwide community of ‘experts. Demonstration projects and technical approvals may also help to demonstrate the validity of te technology. A progressive increase of the maximum filler content may help to accumulate practical expe fence and public confidence, reducing the resistance t0 necessary ‘changes. Market segmentation of cement pragicts or the introduction of fillers in industrialized cement-based products may allow for higher filler substitution in markets where it poses no durability problems. Because fillers are mostly inert materials, they potentially carry the perception of being a low-quality product for the average consumer. In ‘markets [15,16] whore low-quality counterfeit cement made with fillers are stilla problem, this perception will be even stronger. One option for the industry is to develop products that work better and have better ‘environmental performances than ordinary cement, 10 shift the per- ‘ception from a low quality toa cost/benefit analysis. A clearer com rinication ofthe cement composition and its technical and environ mental performances is a precondition for gaining trust from Aggregate quality (especially regarding clay contamination (1091) ‘an variable fines content affet dispersant efficiency. Therefore, it may 10 be a barrier, especially in developing countries. Industrialized products, including dry-mix concrete and mortar, canbe a solution particularly in urbanized areas If the cement industry fils to raise the average filler content in the ‘cement, other companies will certainly capture the Aller market, raking it possible for industries producing cementitious materials to replace binder with filler during the mixing process. Ths trend is al ready perceptible in Brazil as well inthe USA, which have adequate standards in place [20,89) ‘Therefore, itis necessary to acknowledge thatthe increase in filler ‘content will proceed ata relatively slow pace. However, the pace will accelerate as science and technology advances and environmental pressure, CO>, and energy cost increase. There is also a learning eurve from both industry and users, which takes time. Considering that (a) > 70% of cement isnot used in stee-reinforced ‘conerete, an application that is durabiity-criieal; (b) it has been proven that replacing up to 70% of binder with filler is technically Possible; () the fact that in up to 10% of interground filler, the dilution effect is usually compensated for by grinding; and (d) that in some markets such as Morocco the market already operates with a 20% filler replacement using simple interground dilution technology, with the new technology a global average of 30% filler replacement cement is ‘considered possible to be reached in the year 2050. 111, Further research priorities ‘The success ofthe high-filler, low-binder, low-water technology wi ‘depend on extensive research and development efforts, because the sharp reduction in binder content and material porosity may have un forescen implications. An intemationally coordinated research effort will reduce the costs and speed up the development, Urgent needs in- clude: ‘© Longiterm durability, including aspects such as carbonation, chloride diffusion, abrasion resistance, alkalisilica reaction and frostaction and the risk of chemical reaction of varios filler mi erals with environmental contamination; ‘© Bffect on corrosion kinetics of carbonated and chloride amon and Concrete esr 14 (2018 65-78 contaminated concrete at various relevant enviconments, including dry indoor environments; ‘© Models to design mixes with the desirable rheologieal behavior as well as better and afferdable tools to measure different aspects of rheology in cementitious suspensions; ‘ Dry-based dispersans, with higher robustness to cement and ag- sgregate variability, with longer stability time in high temperatures, Of the topical developing world; + Performance of high-iller, low-water systems on the do-it market, 1 Mixing science and equipment suitable for systems with high eon- centration of solids; ‘ Mechanical behavior over the ong term, including adhesion toste!, fracture energy, fatigue, shrinkage, ercep of the clikerfiller, and fie resistance of strctires considering diferent filers; 1 Biller processing technologies and new filler mineralogy: ‘Better processing and quality methods for aggregates; ‘© Models to estimate and optimize earbon-capture of cement-based materials, « Integrated model to allow for the design optimization of concretes with low-emission and advanced performance over the entire ser Viee life, including rheological behavior, strength, durability, and CO, capture. yourselt 12, Conclusions A newly developed technology allows for up to 70% of binders to be substituted by inert fillers, which compensates for the binder dilution effect. Ths technology has the potential to raise the worldwide average filler content in cement from the curreat 7% to 30% by the year 2050. “This technology has the potential to diminish CO; emissions in the coment industry ata low cost, because files require thermal energy only if raw-material drying fs needed and the dispersant is used in low Packing optimization can be achieved simultaneously with low: water demand for adequate rheological behavior by using a combina ‘don of suffiefent IPS wih low interparticle interference. This concept enables the formulation to be engineered to allow for the control of binder content and paste porosity, independently of the mechar strength, It aso has a potential to control durability in ferent sce- ratios and even o optimize the amount of CO, captured during the wse phase. Consequently, it wil allow cementitious material formulations tobe engineered ta have low-earbon and advanced performance, = rultancously. ‘The data show that there is no technical reason to limit cement fillers to Tow-Mg high-purity Limestone. Dolomites and other minerals have a potential to be explored by the industry, preserving valuable clinker grade limestone quarries and facilitating logistics ‘he robustness of dispersants regarding the variability of cement and aggregate quality, as well as its stability at high environmental temperatures are critical aspects that ned to be addressed, ‘The degree of the success ofthis technology in the market, and is farure contribution to CO: mitigation, will pend on the advancement of scientific knowledge and degree of success of industry technological development. An intemationally coordinated research and develop- ‘ment effort will reduce the costs and speed up its development. Acknowledgments ‘This research has financial support from The Sio Paulo Research Foundation (FAPESP), Grant no 2016/05278-5 and InterCement. MQ work was partally supported by FAPESP (grant no. 2012/15195-9) and (CNPq (grant no, 136635/2016-4). VMJ and RGP acknowledge the support of CNPq (810705/2014-2 and 308716/2016-7). The authors wish to ac- knowledge with thanks the comments of Hlis Gartner and Karen Scrivener, a5 well sal participants ofthe UNEP/SBCT working group.References (1 1, wacso, Comet Tesbley Ramen: aon miss Redon wo aso, Orca CSO, 201, wr oe rye enen ‘Spon er dns op 0, (a SA il Va lin $A. asa, Heh Cat eee poten Inte gal enon irs by 20, Com, car Re (2017 t be pie {31 Nuyel, metone aw o Fetus cement ol owe re Nise, nF Reger, Howto dk) cabs Aa Co AST Intertal,100 ar Harbor brie, PO Box COD, Wet Conshohocken, PA {Sea ne 9-10 bwin cat, (9 Peg, eco Cs), Cabo Aas i Gen, ATE ob ar ato rive, PO ox 70, Wet Cosbohcken, PA 19282598, 190, Intp7wewanin tytn StPi00+ 8 ecwed ate 27 Bach 2018 (3) Letetbach 5 ey Gtk Sener inte of inno ey ‘lsc a tan come, Com Canc Re 28 (208) a, Srg/101016/.cnconres 2008.02 (6155 Ho, alte of ony ond Kt on cet idan, Gem: Coc, Campo 21,0998) 9-108, hi eetcony On ‘Shoo sas (7 St We, “ting he mbes ight” ENR, Cem, Sx. aii C2019, Tip wenden! inde ens eine tection dubs 181 US Breau of Recs. 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(rnaber, Eber na, Ras, Lowering he bal warming impact of gestion by ning Ulta High Porn bre Refored ct, Cam Ger Camps 203), hy Ser 0016) Mineral Pros Asin, tbe Ose of UK Comet dons ond ements Matera, MPA, 203, hs manson nye” Faabect 16 FINAL pe Taso, Let A Ne Mode fr Systemic Inmovation Dion a Project ‘asd tna, stir nae 2%, 2000, Pe Dewick M. Mine, Stsaiabeeeholgies andthe novain-reguton Para, Ftres 343008) 823-84 doo 10 1010/S0016 525702) LTE ao. ALL Teer MLA. Ande, SM Crane, Dectin of agree cy “tng and ing en amet, ACL ater 107 (2010) 387-395