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Construction and Building Materials 25 (2011) 3583–3590

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Construction and Building Materials


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How sulfates and increased temperature affect delayed ettringite formation (DEF)
in white cement mortars
E. Adamopoulou a, P. Pipilikaki b, M.S. Katsiotis a, M. Chaniotakis b, M. Katsioti a,⇑
a
School of Chemical Engineering, Laboratory of Inorganic and Analytical chemistry, National Technical University of Athens, 9 Heroon Polytecniou St. Zografou, Athens 15780, Greece
b
TITAN Cement Co. S.A., Group R&D and Quality Department, 18-19200 Eleusina, Greece

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

Article history: In this study, white cement CEM I and white limestone cement CEM II-LL A and D with 15%, 25% and 35%
Received 20 August 2010 limestone substitution were studied. The way delayed ettringite is forming due to exposure to increased
Received in revised form 2 January 2011 temperature (50 °C) and external sulfate attack was examined in mortar samples which were immersed
Accepted 1 March 2011
for 90 days in three different solutions: (a) saturated solution Ca(OH)2 at 50 °C, (b) saturated solution of
Available online 25 March 2011
Ca(OH)2 at 20 °C and (c) 5% w/w Na2SO4 solution at 50 °C. During this period mortar samples were visually
observed regularly while their expansion was estimated on a weekly basis by measuring the change of
Keywords:
length with a micrometer. At the end of the 90-days period the compressive strength of the mortars was
DEF
Limestone
determined and the deterioration products were identified through means of X-ray diffraction (XRD), Scan-
Sulfates ning Electron Microscopy (SEM) and thermogravimetric analysis (DTG). The results of this study show that
White cement DEF occurred in two forms. Samples cured at increased temperature contained DEF type I, which caused
Mortar mediocre expansion and damage. Samples cured at increased temperature in the presence of sulfates pro-
duced DEF type II, which caused significant damage on the surface and exhibited high expansion.
Ó 2011 Elsevier Ltd. All rights reserved.

1. Introduction which at large quantities can cause expansion effects through


water adsorption [6].
Delayed ettringite formation (DEF) is the ettringite-related The way ettringite formation and damage mechanism is initi-
deterioration of concrete regardless of whether or not the concrete ated in the cement matrix has been the point of controversy for
member has been subjected to steam curing [1]. It is a phenome- the past years. After carrying extensive investigations, different
non in which ettringite is generated by accumulating in the con- hypotheses were developed by many authors on the matter. It is
crete after hardening, eventually leading to its expansion and said that the formation mechanism and ettringite modification
thus, ultimately to the destruction of the concrete or mortar. DEF play an important role. It has been found that heat treatment at
is promoted by high-temperature steam curing, while normal higher temperatures, frost or freeze–thaw, carbonation, moisture
ettringite is formed as a consequence of the setting regulation dur- effects and with it natural occurring changes in moisture and tem-
ing the plastic stage of fresh concrete and is destroyed by steam perature can cause ettringite formation [6].
curing [2–5]. Furthermore, ettringite appears in two crystalliza- Finally, most researchers agree that DEF is created when the fol-
tions, different in habit and size. The first one (type I) of long lowing three conditions coincide and apply: excessive sulfates,
lath-like crystals which range from 10 to 100 lm and several lm high-temperature steam curing and sufficient water supply [7–
thick, formed at low hydroxyl ion concentrations (i.e. with low 12]. Delayed ettringite is formed into the pores or the cracks of
pH values in the pore solution). In the case of hydrated cements the cement paste due to high sulfate presence. The overall reac-
containing significant amounts of type I ettringite crystals, these tions characterizing the delayed ettringite formation process are
lead to high strengths and non-expansion, thus the classification described by following reactions.
of type I ettringite as ‘‘not expansive’’. The second type (type II)
of ettringite is rod-like crystals which range only from 1 to 2 lm CaðOHÞ2 þ Na2 SO4 þ H2 O ! CaSO4  2H2 O þ 2NaOH ð1Þ
long and 0.1 to 0.2 lm thick, which are formed at high hydroxyl
ion concentrations. These are present during the hydration of C3 A þ 3ðCaSO4  2H2 OÞ þ 36H2 O
Portland cements and are classified as type II ettringite crystals, ! 3C3 A  CaSO4  14H2 O ðmonosulfateÞ ð2Þ

2CaSO4 þ C3 A  CaSO4  14H2 O ! C3 A  3CaSO4


⇑ Corresponding author. Tel.: +30 2107723206; fax: +30 2106397771.
E-mail address: katsioti@central.ntua.gr (M. Katsioti).  32H2 O ðettringiteÞ ð3Þ

0950-0618/$ - see front matter Ó 2011 Elsevier Ltd. All rights reserved.
doi:10.1016/j.conbuildmat.2011.03.051
3584 E. Adamopoulou et al. / Construction and Building Materials 25 (2011) 3583–3590

C3 A  6H2 O þ 3ðCaSO4  2H2 OÞ þ 20H2 O 0.6 ratio proved to be the optimum regarding the rheology of the
! C3 A  3CaSO4  32H2 O ðettringiteÞ ð4Þ fresh mortar samples. The mortars were molded in prismatic moulds
with dimensions 4  4  16 cm. Nine specimens were created from
Pore distribution and shape, the transport of sulfates and external each mixture in order to achieve statistical repeatability and were
conditions such as temperature and pressure play a major role on de- preserved according to EN 196-1 instructions: for the first 2 days
layed ettringite formation. DEF may exist in different sizes (ranging all the samples were preserved in the moulds inside a wet chamber
from amorphous colloidal particles to well defined crystals) depend- (humidity >95%), then they were unmolded and preserved in a satu-
ing on the conditions of formation. Usually DEF is found in the shape rated Ca(OH)2 solution for 12 days (total of 14 days).
of crystals roughly 1–2 lm long and 0.1–0.2 lm wide. It must be After the initial preservation period the mortars were grouped
noted that DEF can occur as either types I or II ettringite (as described into three separate groups. Three specimens were taken from each
previously). According to existing literature, DEF created in high pH mixture for each group which corresponded to a different set of
environment (12.5–12.9) causes expansion and does not contribute condition, as explained below. First group was cured in a saturated
in strength development [13–16]. Ca(OH)2 solution at 20 ± 2 °C for 90 days. The second group was left
The External Sulfate Attack (ESA) induces damage which is to hydrate in a saturated Ca(OH)2 solution at 50 ± 2 °C for 90 days
mainly determined by the chemical interaction of a sulfate-rich in order to evaluate the effect of increased temperature. Finally, the
soil or water, with the cement paste. ESA is a generic name for a third group was left to hydrate in a 5% w/w Na2SO4 solution at
set of complex and overlapping chemical and physical processes 50 ± 2 °C for 90 days to emulate an environment with high external
caused by reactions of numerous cement components with sulfates sulphate presence and increased temperature – both perfect condi-
originating from external or internal sources. Soils containing so- tions for formation of type II ettringite (which causes expansion).
dium, potassium, magnesium and calcium sulfate are the main During this 90-days period the specimens were inspected and
sources of sulfate ions in groundwater. Additionally, solid indus- their expansion was determined by measuring their length with
trial waste, fertilizers, SO2 found in the atmosphere or in liquid a micrometer on a weekly basis. It must be noted that soon after
industrial wastes are also regarded high sulfate sources which pro- the initial exposure to increased temperature and high sulfate
mote ESA. For ESA to occur the following three conditions must be presence, deterioration was obvious on the surface of mortars. At
fulfilled at the same time: high permeability of concrete, sulfate- the end of the 90-days period, compressive strength of all mortars
rich environment and the presence of water [17–20]. As a result was measured according to EN 196-1. Additionally, samples were
of sulfates presence, different hydration products occur. These collected from the surface of all mortars and were studied using
products appear very rapidly, usually in few hours, and they are in- X-ray diffraction analysis (XRD), TG thermogravimetric analysis
volved in the expansion of concrete. and Scanning Electron Microscopy (SEM).
Aim of this work is to study the way cement pastes with high X-ray powder diffraction (XRD) was carried out in a Siemens D-
limestone content act when exposed to high sulfate environments 5000 Diffractometer using Cu Ka radiation (k = 1.5405 Å, 40 kV,
and increased temperature treatment. The study is mainly focused 30 mA). The diffraction spectra were collected in the range of 2–
on determining deterioration products and effects while also verify- 60° 2h scale, with a step size of 0.03°/s. Powder samples (1 g) were
ing the presence of DEF due to the aforementioned conditions. A sim- drilled from a layer of 2 mm thick (where damage from expansion
ilar study has been performed by the authors and has been recently was evident) from the surface and were consequently analyzed.
published [21]. The previous work is focused more on the time evo- Additional samples were also collected in order to determine the
lution of sulfate induced DEF expansion in white cement mortars. amount of ettringite on the surface of each sample, using the Rietv-
Based on the conclusions drawn from that work, the authors wish ield quantitative method. In this case the spectra were collected in
to give additional information regarding the expansion of mortar the range 2–26° 2h scale, with a step size of 0.005°/sec. It must be
due to sulfate attack, by including an additional mixture (35% lime- noted that ettringite appears in XRD at 2h angles 9.2° (main peak),
stone substitution) and an additional set of conditions (curing in 15.7° and 22.9°. Quantitative analysis was realized by measuring
20 °C). Accordingly, the effect of temperature on sulfate induced the integral area at the aforementioned 2h angles.
expansion is the main focus in this paper. It must be noted that these Thermogravimetric analysis (TG/DTG) was carried out in a Met-
papers are complementary and readers are advised to read both tler Toledo thermal analyzer, using a heating rate of 10 °C/min at
works in order to acquire a complete understanding of the sulfate in- the range of 25–1000 °C, in air atmosphere. Specimens (10 lg)
duced expansion mechanism. All in all, the authors believe that the were collected from a layer of 2 mm thick (where damage from
two papers offer a novel insight on sulfate induced DEF expansion, expansion was evident) from the surface and were consequently
thus assisting in the improvement process of the durability of white analyzed. The DTG analysis was conducted in order to verify the
cement mortars with high limestone content. presence of calcite and determine the remaining portlandite in
the surface of each samples.
2. Sample preparation and methods Finally, the microstructure of the surface as well as the forma-
tion and type of ettringite crystals of the treated mortars was stud-
Initially mortars were prepared by mixing white cement CEM ied under a FEI/Quanta 200 scanning electron microscope.
I-52,5 with limestone at three different ratios (15%, 25% and Specimens (1 ml) were collected from a layer of 2 mm thick
35%), thus creating white cement CEM II. Paste and mortar samples (where damage from expansion was evident) from the surface
were produced according to TN 196-1. A reference paste and mor- and were consequently cast in resin and polished in order to be
tar sample was also prepared. Initial and final setting times were examined under the microscope.
determined for paste samples along with normal plasticity water,
according to EN 196-1.
Consequently, the cement mixtures were mixed with standard- 3. Results and discussion
ised siliceous sand and water for the creation of mortar specimens.
The amount of sand used per specimen was 1350 g of standard sili- 3.1. Chemical analysis
ceous sand whose characteristics are described in EN 196-3. 450 g of
cement were added and all samples were formulated with a w/c ratio Mortar specimens were chemically analyzed as shown in Table
equal to 0.6. The standard w/c ratio of 0.5 was not applied as the addi- 1. The amount of C3A was determined according to Bogue’s equa-
tion of limestone caused the samples to be less workable, while the tions for each cement mixture and is shown in Table 1.
E. Adamopoulou et al. / Construction and Building Materials 25 (2011) 3583–3590 3585

From Table 1, the following observations can be made. Samples mated. The latter was expressed as the change in length in mi-
with limestone substitution exhibit a decreased amount of SiO2 cro-meters per meter of sample. Results are shown in Fig. 1 from
and Al2O3 due to decreased cement presence. Accordingly, C3A four specific ages (14, 28, 56 and 90 days). It is observed that spec-
was calculated to be in inverse proportion to limestone percentage imens cured in 50 °C and under external sulfate attack present
due to decreased Al2O3 presence. On the contrary, samples with higher expansion with a higher rate than specimens cured in dif-
limestone substitution exhibited higher LOI due to limestone calci- ferent conditions.
nation. Finally, it should be mentioned that sulfate presence seems Furthermore, mortars containing limestone expand with a high-
to be relatively high for all samples, which fulfils one of the funda- er rate (proportional to limestone substitution) under high temper-
mental conditions (mentioned in the Introduction) for delayed ature and sulfate presence. This is in accordance with the optical
ettringite formation. inspection results. Images of the treated samples are presented in
Fig. 2, where the deterioration is visible, especially for samples
3.2. Setting time and normal plasticity water treated with sulfates at 50 °C. On the other hand, the mortars im-
mersed in saturated Ca(OH)2 solution have low expansion. This
Initial and final setting time and normal plasticity water were means that heat induced ettringite formation is limited by the
determined for paste samples. In each case, 500 g of cement mix- amount of C3A and SO3 that exist in cement. Regarding the time
ture were mixed with the appropriate mass of water as determined evolution of expansion, it is shown in the authors’ previous work
from the Vicat testing method. Upon successful mixing with water, [21] that the expansion phenomena continue to apply even after
the pastes were left to hydrate in a wet chamber and initial and fi- the 90 days period, thus indicating that as long there is a constant
nal setting times were determined using the Vicat testing method. supply of sulfates expansion will occur.
The results are shown in Table 2. It is remarkable that in the case where high temperature and
external sulfate attack are applied the expansion increases while
C3A is decreased in the cement. This can be seen clearly in Fig. 3,
3.3. Expansion where expansion is plotted versus C3A content. This is attributed
to chemical reaction between calcite and Na2SO4 which promotes
The length of mortar specimens was determined during their formation of gypsum, as explained below.
curing with use of a micrometer and their expansion was esti-

Table 1
Chemical analysis of cement mixtures (before hydration). 3.4. Compressive strength

Sample Component
At the end of the 90-days period, compressive strength of all
SiO2 Al2O3 Fe2O3 CaO MgO SO3 LOI C3A mortars was determined. The results are shown in Fig. 4. It must
0% LL 20.82 4.98 0.23 66.98 0.60 2.91 3.05 12.8 be noted that due to limestone substitution, the cements are not
15% LL 18.56 4.41 0.22 65.54 0.60 2.77 7.12 11.3 considered to be of the same CEM type. Accordingly, strength is re-
25% LL 15.60 3.84 0.23 65.86 0.49 2.54 10.96 9.5
duced where limestone is present, and this reduction is propor-
35% LL 13.36 3.25 0.21 66.07 0.50 2.37 13.73 8.3
tional to cement substitution. Another important observation is
that samples cured in a solution of 5% Na2SO4 have lower strength
than those cured in a saturated solution of Ca(OH)2 as external sul-
Table 2
Setting time and normal plasticity water. fate attack in combination with increased temperature resulted in
significant surfacial damage. However, one should observe that
Sample Setting time (min) Normal plasticity
samples with limestone exhibit a lower loss of strength than the
Initial–final Water (g) reference sample. In specific, the reference sample lost 14.3% of
0% LL 100–140 140 its strength due to external sulfate attack and increased tempera-
15% LL 110–140 135 ture, while samples with 15%, 25% and 35% limestone lost 13.7%,
25% LL 100–120 130
12.7% and 13.5% of their strengths respectively. The authors have
35% LL 100–130 132
observed a similar behaviour in other cases where limestone was

Fig. 1. Expansion of mortar specimens under three different curing conditions.


3586 E. Adamopoulou et al. / Construction and Building Materials 25 (2011) 3583–3590

Fig. 2. Images of mortar samples with 35% LL after 90 days curing at (A) 20 °C in Ca(OH)2, (B) 50 °C in Ca(OH)2, (C) 50 °C in 5% Na2SO4.

80

70
Compressive Strength (MPa)

60

50

40

30
50 oC, Na2SO4

50 oC, Na2SO4

50 oC, Na2SO4

50 oC, Na2SO4
20
20 oC

20 oC
50 oC

20 oC
50 oC

50 oC

20 oC
50 oC

10

0
0% LL 15% LL 25% LL 35% LL

Fig. 3. Expansion plotted versus respective C3A percentage for each mortar sample. Fig. 4. Compressive strength after 90 days of curing at different conditions.

used as a substitute for cement [21]. This should be taken into ac-
count when designing a cementitious product containing be made regarding the presence of ettringite in each sample and
limestone. set of conditions. In specific, one observes that under sulfate and
Finally, it must be noted that samples exhibiting higher increased temperature curing conditions all samples exhibited
strengths also exhibited low expansion values when treated with high percentages of ettringite (9.2° 2h). More accurately, samples
sulfates at increased temperature. The authors have observed a with limestone contained higher percentages of ettringite in rele-
similar behaviour before [10,21] which shows that compressive vant proportion to limestone substitution, as the Rietvield method
strength must be regarded as a key factor for durability in high sul- has shown. In this case DEF formed was type II which caused the
fates environments. surfacial damage on the specimens. The fact that samples with
limestone contained less C3A (as shown previously) should not
3.5. X-ray diffraction confuse the readers, as the increase in ettringite was attributed
to the chemical reactions caused by limestone presence. In specific,
The XRD patterns of all mortars are presented in Fig. 5. Rietvield reaction (5) shows that calcite reacts with Na2SO4 and gypsum is
results are shown in Table 3. The most important observation can created:
E. Adamopoulou et al. / Construction and Building Materials 25 (2011) 3583–3590 3587

A B
E= ETTRINGITE E= ETTRINGITE
Q = QUARTZ
E PE Q Q PCE P Q QQQC QP CP Q Q Q Q = QUARTZ
E E PE Q E Q C P Q QQC QPC P Q Q Q
C = CALCITE 500 C = CALCITE 500
P = PORTLANDITE P = PORTLANDITE
450 450

400 400

350 350
Intensity [a.u.]

Intensity [a.u.]
300 300

250 O
250
0% LL-50 C- 15% LL-50 C-
O

200 Na2SO4 200 Na2SO4

150 150
O
0% LL-50 C
O 15% LL-50 C
100 100

50 50
O
0% LL-20 C
O 15% LL-20 C
0 0
5 10 15 20 25 30 35 40 45 50 55 60 65 5 10 15 20 25 30 35 40 45 50 55 60 65
ο
ο 2θ [ ]
2θ [ ]
C D
E= ETTRINGITE
E P Q C QE CE PEQQQQ P QPQCP Q P Q Q
E= ETTRINGITE
Q = QUARTZ
E EE E P Q E E Q C P Q QQQC QC CP Q Q Q
Q = QUARTZ E
C = CALCITE
500 C = CALCITE 500
P = PORTLANDITE P = PORTLANDITE
450 450

400 400

350 350

300 300
Intensity [a.u.]
Intensity [a.u.]

250 250
O
25% LL-50 C- O
35% LL-50 C-
200 Na 2SO4
200 Na 2SO4
150
25% LL-50 C
O 150
O
100 35% LL-50 C
100
50
50
O
25% LL-20 C O
0 35% LL-20 C
0
5 10 15 20 25 30 35 40 45 50 55 60 65
ο
5 10 15 20 25 30 35 40 45 50 55 60 65
2θ [ ] ο
2θ [ ]

Fig. 5. XRD patterns for mortars (A) 0% LL, (B) 15% LL, (C) 25% LL and (D) 35% LL in 90 days.

Table 3 i.e. expansion, which is caused by ettringite formation. Finally, it


Ettringite’s percentage according to Rietvield method in cured mortars after 90 days. should be observed that where ettringite was present, the portlan-
Sample Conditions dite peaks indicated a decrease in its amount, which verifies that
20 °C 50 °C 50 °C + Na2SO4
most of the Ca(OH)2 was consumed in the ettringite formation
reactions.
0% LL 1.07 4.2 5.99
In cases where only increased temperature was applied, DEF
15% LL 1.26 2.95 6.71
25% LL 1.24 2.66 7.36 type I was formed as all of the sulfates originated from the interior
35% LL 0.85 2.34 7.47 of the samples. It must be noted that in case of limestone substitu-
tion, DEF formation was limited in regard to the reference sample.
This must be attributed to decreased C3A presence due to cement
CaCO3 þ Na2 SO4 ! CaSO4 þ Na2 CO3 ð5Þ substitution as shown previously.

Reaction (5) takes place faster than (1) and the formed gypsum
reacts at an early stage with the unhydrated C3A resulting in 3.6. Thermogravimetric analysis
ettringite being formed according to reactions (3) and (4). Addi-
tionally, calcite turned into portlandite also contributes to reaction Differential thermogravimetry analysis (DTG) curves of the
(1). This ettringite formation takes place with a higher rate as gyp- damaged surfaces of the mortars treated with 5% Na2SO4 and
sum exists in the solution and thus has increased mobility and 50 °C are presented in Fig. 6. The peak near 130 °C is attributed
reactivity. Similar observations have been made by Kawaura et to the dehydration (water loss) of ettringite. The peak at 450 °C
al. [22], who have showed that sulfate presence along with in- is attributed to Ca(OH)2 and the peak near 700 °C is attributed to
creased calcite and portlandite presence result in volume change, the loss of CO2 and is related to the existence of calcite. The DTG
3588 E. Adamopoulou et al. / Construction and Building Materials 25 (2011) 3583–3590

-0,009

-0,018

-0,027
400 440 480

Fig. 6. DTG results of mortar samples cured for 90 days at 50 °C, immersed in sulfate solution.

A 10 μm B 10 μm

Fig. 7. SEM image of mortar sample 0% LL cured at 50 °C for 90 days with sulfates (A) and without sulfates (B).

A 20 μm B 20 μm

Fig. 8. SEM image of mortar sample 15% LL cured at 50 °C for 90 days with sulfates (A) and without sulfates (B).

results furthermore support the observations made with XRD, as damage and expansion occurred. A series of images were collected
portlandite is decreased for samples with limestone (see also the in order to ensure that a representative and statistically sound
inlayed plot). depiction of the damaged structure was obtained. Selected images
are shown in Figs. 7–10.
3.7. Scanning Electron Microscopy (SEM) By observing the images one can see the form of ettringite
which causes the expansion problems. In all cases where limestone
The surface of damaged mortars was examined with SEM. In was present, ettringite formed due to sulfates and increased tem-
specific, samples cured at 50 °C and samples cured at 50 °C in pres- perature (depicted as A in each sample) is found to be needle-like
ence of sulfates were studied, as these were the samples where and less than 10 lm in length. This verifies that under the afore-
E. Adamopoulou et al. / Construction and Building Materials 25 (2011) 3583–3590 3589

A 10 μm B 10 μm

Fig. 9. SEM image of mortar sample 25% LL cured at 50 °C for 90 days with sulfates (A) and without sulfates (B).

A 10 μm B 10 μm

Fig. 10. SEM image of mortar sample 35% LL cured at 50 °C for 90 days with sulfates (A) and without sulfates (B).

mentioned conditions, DEF formed is type II which is known to containing limestone exhibited higher concentration of ettringite
cause expansion in mortars [6]. On the contrary, DEF formed due under 50 °C and sulfate attack due to increased calcite content.
to increased temperature is shown to be increased in size Regarding ettringite in all, this work showed how the curing
(20 lm), however retaining its needle-like shape. As the expan- conditions result in the formation of two different forms of the
sion results showed previously, type I DEF can also be responsible crystal. In specific, type I DEF was created when increased temper-
for the damaging of mortar samples but in a limited degree rele- ature was applied, while type II DEF was found when increased
vant to the external sulfate attack effect. temperature was applied and sulfate solution was present. Both
forms of ettringite resulted in externally damaged mortars and
4. Conclusions had a similar shape. However, it was the type II ettringite that
caused higher expansion and greater damage, something that is
This study has showed how curing conditions can result in sur- owed to its small size and – in this case – higher rate of formation.
facial damage to white cement mortars containing limestone after The study of sulfate induced DEF and its effect on expansion of
90 days. It is shown that increased temperature (50 °C) can result white cement mortars containing limestone continues, as the
in formation of DEF type I which causes mediocre expansion. In authors plan to investigate these phenomena in mortar samples
the case of cements containing similar amounts of SO3, the amount of the same strength class.
of DEF created is related to C3A amount, which, in the case of lime-
stone substitution, is limited. As SEM analysis showed, DEF created
under increased temperature was needle-like in shape and near References
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