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Article history: The phosphate industry produces great amounts of waste-rocks during their mining activities in extrac-
Received 28 June 2020 tion and beneficiation steps. Waste-rocks are stored immediately on extraction sites or in the vicinity of
Received in revised form 23 July 2020 treatment facilities. Different types of waste-rocks are generated, yet this paper discusses the use of
Accepted 14 August 2020
stone-removal waste-rocks as aggregates for concrete. Starting from the chemical and mineralogical
Available online xxxx
composition, those waste-rocks were characterized by different techniques. Common geotechnical tests
were performed to assess the aggregates properties. Then, those aggregates were used in concrete formu-
Keywords:
lation as a full replacement of natural aggregates in order to test their mechanical behavior in comparison
Phosphate waste rocks
Valorization
to a reference concrete, using compressive, flexural and splitting tensile strengths as parameters to eval-
Construction aggregates, concrete uate the concrete performance according to the required standards.
Circular economy Those aggregates indicated a 41% Los Angeles coefficient, 43% Micro Deval coefficient and 5.20% Water
Absorption coefficient. The WRAM concrete has indicated an average of 12 MPa of compressive strength,
1.3 MPa of flexural strength and 2.65 MPa of splitting tensile strength at 28 days.
Ó 2020 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of The International Confer-
ence on Water Depollution and Green Energy 2019.
1. Introduction of mine sites [16]. These waste rocks represent mainly the interca-
lation layers which host the phosphate-rich layers and the over-
The development of infrastructures and civil engineering con- burden; they are characterized by a mix of wide variety of
tinue to increase every year making concrete the most used con- lithological formations. Phosphate waste rocks are confirmed to
struction material in the world compared to steel, wood, plastics have never undergo any chemical treatment; and it is proven that
and aluminium [1]. Every year, the use of concrete is estimated they don’t pollute surface or underground water, but they reduce
>11 billion metric tons [2]. Coarse aggregates occupied 60%–80% arable lands, modify topography and disfigure landscapes [17].
of concrete volume, playing a crucial role in the development of Therefore, it should be considered as natural resource of aggregate,
concrete mechanical properties [3–5]. Beshr et al. stated that fail- and to enhance the idea of aggregates from Moroccan phosphate
ure planes of high resistant concrete cross the coarse aggregates, mines are co-products and not waste rocks.
confirming that compressive and splitting tensile strengths were Many solutions have been sought for this major issue in phos-
deeply affected by the nature of these aggregate [6]. The demand phate mining, and the recycling as construction material is the
of aggregates for concrete industry is continuously increasing lead- most interesting option to be investigated. Clays composed of paly-
ing to the depletion of natural resources. To reduce the dependence gorskite phase as a clayey mineral from phosphate rocks were used
on natural aggregates, much researchers studied the substitution to elaborate fired bricks, revealing that a pressure of 5 MPa and
of natural aggregates by industrial by-products as an alternative heating temperature at 1050 °C for 2.5 h allowed the maximum
way for the construction industry [7-15]. mechanical characteristics [16]. While, clays containing montmo-
Large quantities of waste rocks, generated during the open pit rillonite mineral could successfully be used as an aluminosilicate
mining of the Moroccan phosphate mines, are considered as solid precursor to synthesize geopolymers materials with a compressive
wastes and deposited without sorting in stockpiles in the vicinity strength of 25 MPa for curing at ambient temperature [18]. In addi-
tion, phosphate waste rocks showed promising geotechnical prop-
erties as material for road constructions [19].
⇑ Corresponding author.
E-mail address: aiman.elmachi@ced.uca.ma (A. El Machi).
https://doi.org/10.1016/j.matpr.2020.08.404
2214-7853/Ó 2020 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of The International Conference on Water Depollution and Green Energy 2019.
Please cite this article as: A. El Machi, S. Mabroum, Y. Taha et al., Valorization of phosphate mine waste rocks as aggregates for concrete, Materials Today:
Proceedings, https://doi.org/10.1016/j.matpr.2020.08.404
A. El Machi et al. Materials Today: Proceedings xxx (xxxx) xxx
None researches could be found related to the use of Moroccan the NM 10.1.061 standard [21]. A maximum cement content of
phosphate waste rocks as aggregates for producing concrete. In 310 kg/m3 was adopted to obtain the necessary paste volume, in
this concept, the vision of this paper is to study the feasibility of addition to a total of 1.2% per m3 of superplasticizer to achieve
using phosphate waste rocks as aggregates in the concrete indus- the desired workability settings.
try, which will reduce the environmental impact due to the accu- Fig. 2 is a summary of the WRAM vs reference concrete mix
mulation of these wastes and minimize the consumption of designs used in the experimental work. During this study, the set-
natural sources by providing a new source of aggregates for tings (Workability, mixing and curing) were selected to meet those
concrete. of reference concrete manufacturing in order to have a better view
with the comparison.
2. Materials and methods
2.3. Tests and methods
2.1. Raw materials
The chemical composition of the waste rocks aggregates
The waste rocks were sampled from the stone-removal waste (WRAM) was defined by X-ray fluorescence analysis method using
rocks stockpile in Benguerir mine located in Gantour basin, Mor- Epsilon 4 Model, Malvern Panalytical equipment. In addition, crys-
occo. Fig. 1 sums up the followed processing protocol of phos- talline phases present in this sample were identified using X-ray
phates. This sample is mainly composed of different lithologies of diffraction (XRD) analysis by a Bruker-AXS D8 powder diffractome-
rocks such as limestones, marls and flintstone which present the ter with Cu Ka radiation (kKa = 0.154186 nm) operating in the
non-exploited layers extracted during phosphate mining opera- range of 10° and 80° (2h). QXRD analysis was carried out using Dif-
tions. Multiple samples was taken from a large stockpile and fracPlus EVA and TOPAS software to identify phases and to quan-
crushed eventually, while the crushing output product was sam- tify the abundance of these phases, respectively. Also, the
pled progressively. The samples at this step was mixed together microstructure of hardened specimens after mechanical tests at
to achieve homogeneity and obtain waste rocks aggregates mix- 28 days of curing was studied using a Scanning Electron Micro-
ture (WRAM) sample of 10–20 mm size caliber. scope (SEM) by TESCAN VEGA3 Emission.
The crushed sand used in the WRAM and reference (RC) con- The geotechnical tests such as Los Angeles (LA), Micro Deval
crete preparation are extracted from a quarry near Marrakesh, (MDE), water absorption (WA) and surface cleanliness, were per-
Morocco. Table 1 summarizes the physical properties of the used formed on aggregates using common geotechnical apparatus.
sands in this study. Los Angeles abrasion test on aggregates is the measure of aggre-
The reference concrete was prepared using normal coarse gate toughness and abrasion resistance such as crushing, degrada-
aggregates of two different size calibers of 4–12.5 mm and 12.5– tion and disintegration. The principle of LA abrasion test is to
20 mm (G1 and G2 respectively). produce abrasive action by use of standard steel balls which when
Different properties of those coarse aggregates are summed up mixed with aggregates and rotated in a drum for specific number
in Table 2. Both concrete mixtures were prepared using superplas- of revolutions also causes impact on aggregates. The percentage
ticizer to adjust the workability, and Portland cement. wear of the aggregates due to rubbing with steel balls is deter-
mined and is known as LA Abrasion Value. The Micro-Deval abra-
2.2. Concrete design and preparation sion test is a test of fine aggregate to determine abrasion loss in
the presence of water and an abrasive charge. This test is suitable
The preparation of both WRAM and reference concrete were for measuring the amount of weak and soft material in aggregates.
performed according to Dreux-Gorisse method [20]. The water/ce- After demolding, concrete cylinders were cured in the moist
ment ratio (W/C) and slump were fixed at 0.5 and 140 mm, respec- chamber equipped according to the NM 10.1.068 standard [22]
tively, which were often used in B25 concrete to insure good with 20 °C ± 2 °C, Relative Humidity = 95%. The mechanical tests
workability settings. More water was added in the case of non- were performed using a hydraulic press with the aim of assessing
obtaining the desired slump in order to assess the weakness of the strength of concrete in terms of compressive, flexural and split-
those aggregates which is the high-water absorption ratio in the ting tensile strengths following the requirements described in the
vision of producing concrete with good workability settings. The NM 10.1.051, NM 10.1.050 and NM 10.1.052 standards [23-25], at
slump test was performed by pouring fresh concrete in a 3, 7 and 28 days.
300 mm slump cone, after removing the cone, the fresh concrete
tends to subside. The difference between the cone height and the
subsiding fresh concrete is the value of the slump according to 3. Results and discussion
Table 1
Physical properties of fine and crushed sand used in the WRAM and reference concrete mix designs.
Caliber (mm) Finesse modulus Sand equivalent (%) Bulk density (T/m3) Water absorption (%)
Fine sand <1 2.75 71 2.69 1.11
Crushed sand <4 1.9 69 2.71 1.10
Table 2
Geotechnical properties of the GI and GII coarse aggregates used in the reference concrete mix.
Los Angeles (%) Flakiness index (%) Surface cleanliness (%) Bulk density (T/m3) Specific density (T/m3)
G1 20 13 0.6 1.44 2.64
G2 20 7 0.5 1.43 2.64
Table 3
Chemical and mineralogical composition of WRAM.
Chemical Composition wt. (%) LOI SiO2 Al2O3 CaO MgO Fe2O3 P2O5 K2O TiO2 MnO
27.11 32.23 0.58 23.20 9.20 0.21 7.26 0.10 0.05 0.06
3
A. El Machi et al. Materials Today: Proceedings xxx (xxxx) xxx
Table 4
All carried out test according to standards, requirements values and corresponding measured property.
4
A. El Machi et al. Materials Today: Proceedings xxx (xxxx) xxx
Table 5
Geotechnical properties of the bulk WRAM concrete and its three components separately (Limestone, Marls, Flintstone).
Los Angeles (%) Micro Deval (%) Flakiness index (%) Water absorption (%) Water content (%) Surface cleanliness (%)
Limestone 52 56 – 7.4 – –
Marls 49 51 – 6.1 – –
Flintstone 18 9 – 0.1 – –
WRAM 41 43 9.8 5.2 0.1 2.6
4. Conclusion
Fig. 7. SEM images of (A) WRAM concrete, (B) reference concrete, after 3 days, (C) WRAM concrete, (D) reference concrete, after 28 days.
Fig. 8. WRAM vs reference concrete crushing results showing performances in terms of compressive, flexural and splitting tensile strengths.
6
A. El Machi et al. Materials Today: Proceedings xxx (xxxx) xxx
CRediT authorship contribution statement [15] A. Modarres, Z. Hosseini, Mater. Des. 64 (2014) 227–236.
[16] M. Loutou, Y. Taha, M. Benzaazoua, Y. Daafi, R. Hakkou, J. Cleaner Prod. 229
(2019) 169–179.
A. El Machi: Conceptualization, Methodology, Software, Data [17] R. Hakkou, M. Benzaazoua, B. Bussière, Procedia Eng. 138 (2016) 110–118.
curation, Formal analysis, Visualization, Writing - original draft. [18] S. Mabroum, A. Aboulayt, Y. Taha, M. Benzaazoua, N. Semlal, R. Hakkou, J.
Cleaner Prod. (2020) 121317.
S. Mabroum: Formal analysis, Writing - review & editing. Y. Taha:
[19] M. Amrani, Y. Taha, A. Kchikach, M. Benzaazoua, R. Hakkou, Minerals. 9 (2019)
Supervision, Writing - review & editing. A. Tagnit-Hamou: Super- 237.
vision, Methodology, Writing - review & editing. M. Benzaazoua: [20] G. Dreux, J. Festa, Eyrolles (1998).
[21] NM 10.1.061, Essai pour béton frais – Essai d’affaissement, Service de
Writing - review & editing. R. Hakkou: Supervision, Writing -
Normalisation Industrielle Marocaine, 2008.
review & editing, Project administration, Funding acquisition. [22] NM 10.1.068, Essai pour béton durci – Confection et conservation des
éprouvettes pour essais de résistance, Service de Normalisation Industrielle
Declaration of Competing Interest Marocaine, 2008.
[23] NM 10.1.051, Bétons – Essai de compression; Service de Normalisation
Industrielle Marocaine, 2008.
The authors declare that they have no known competing finan- [24] NM 10.1.050, Bétons – Essai de flexion; Service de Normalisation Industrielle
cial interests or personal relationships that could have appeared Marocaine, 2008.
[25] NM 10.1.052, Bétons – Essai de fondage; Service de Normalisation Industrielle
to influence the work reported in this paper. Marocaine, 2008.
[26] NM 10.1.155, Essais pour déterminer les caractéristiques géométriques des
Acknowledgments granulats – Détermination de la forme des granulats – Coefficient
d’applatissement, Service de Normalisation Industrielle Marocaine, 2008.
[27] NM 10.1.138, Essais pour déterminer les caractéristiques mécaniques et
The authors would like to acknowledge the support through the physiques des granulats – Essai Los Angeles, Service de Normalisation
R&D Initiative – Appel à projets autour des phosphates APPHOS – Industrielle Marocaine, 2008.
[28] NM10.1.148, Essais pour déterminer les caractéristiques mécaniques et
sponsored by Cherifian Office of Phosphate OCP (OCP Foundation,
physiques des granulats – Détermination de la résistance à l’usure (Micro-
R&D OCP, Mohammed VI Polytechnic University, National Center Deval), Service de Normalisation Industrielle Marocaine, 2008.
of Scientific and technical Research CNRST, Ministry of Higher Edu- [29] F.P. Torgal, J.P. Castro-Gomes, Constr. Build. Mater. 20 (2006) 1079–1088.
[30] NM 10.1.273, Essais pour déterminer les caractéristiques mécaniques et
cation, Scientific Research and Professional Training of Morocco
physiques des granulats-Détermination de la masse volumique réelle et du
MESRSFC) under the project APPHOS, MAT-HAK-01/2017. coefficient d’absorption d’eau, Service de Normalisation Industrielle
Marocaine, 2008.
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