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ABSTRACT
The aim of this study is to understand the dimensional stability of two expansive systems based on calcium
aluminate cement (CAC) and calcium sulfoaluminate cement (CSA). These alternative cements are
interesting for their performances and the lower CO2 emissions related to the manufacturing process.
Expansive and non-expansive compositions have been selected as a function of gypsum content for both
systems in order to compare the hydration kinetics, the microstructure and the dimensional stability. There is
a substantial difference in the expansion of the CAC and CSA systems when gypsum is added. The CSA
system has faster hydration reactions, a finer microstructure and the magnitude of expansion is lower. The
critical amount of calcium sulfate leading to high expansion has been optimized. However, the microstructure
(studied by XRD, TGA, SEM, MIP) between the low expansion and the high expansion system remains
comparable in terms of phases quantities. The only difference is the distribution of ettringite and aluminium
hydroxide much more finely intermixed in the CSA systems. The difference in the magnitude of expansion
could be explained by the crystallization pressure of ettringite and the supersaturation of the solution in the
nanopores formed few hours after the hydration of these cements.
3. Materials
Figure 1. Ettringite coating around an expansive
particle (CSA cement grain) (Cohen, 1983) 3.1 CAC+C$H2 systems
In the swelling theory, the expansion is due to the The hydration of CAC systems with calcium sulfate
water adsorption or swelling of ettringite which is leads to the formation of ettringite and amorphous
formed by a through-solution mechanism, i.e. by aluminium hydroxide, see reaction (1). For this
the hydrates precipitation into the pore solution. study, gypsum (G) will be used and the respective
This leads to ettringite formation into the bulk, reaction is (2).
away from the anhydrous particles. Water
adsorption is possible because ettringite is 3CA+3C$Hx+(38-3x)HC3A.3C$.H32+2AH3 (1)
microcrystalline (has a colloidal size). The 3CA +3C$H2+32HC3A.3C$.H32+2AH3 (2)
formation of this type of ettringite occurs only if
calcium hydroxide (CH) is present in the solution. If The calcium aluminate cement (CAC) used for this
calcium hydroxide is absent, ettringite crystals will project was supplied by Kerneos in France.
be larger and swelling will not occur. These compositions were measured by XRD and
quantified by the Rietveld refinement.
Scherer studied the expansion with a
thermodynamic approach and developed the Table 1. Mineralogical composition of CAC cement
crystallization pressure theory. In porous materials, Anhydrous phase Cement notation [%wt]
cement paste, mortar, concrete and stone, there Calcium aluminate CA 70
can be a damage caused by the precipitation of Gehlenite C2AS 20
crystals from the liquid present in the pores. When Ferrites C3FT ~10
the supersaturation level of a given salt in the Perovskite CT
liquid is reached, there is a precipitation of this salt. Spinel MgAl2O4
Supersaturation depends on the concentration, on
the temperature and on the size of the pores. So a 3.2 CSA+C$H2 systems
crystal growing in a pore will encounter the pore
wall and exert pressure on it (Scherer, 2004). The main reaction occurring in CSA systems is
When a crystal is surrounded by a film of solution between the ye’elimite phase (C4A3$) and calcium
and there are small pores, high stresses appear. sulfate. This reaction (3) leads to the formation of
High crystallization pressures require a high ettringite and amorphous aluminium hydroxide.
supersaturation of the pore solution.
Supersaturation is given by the ratio between the C4A3$+2C$H2+34HC3A.3C$.H32+2AH3 (3)
Ion Activity Product (IAP) and the solubility product
(Ksp) of the given phase. The species forming The calcium sulfoaluminate cement (CSA) used for
ettringite are: this project was supplied by Buzzi Unicem SPA in
6 2 4 3 26 Italy.
→ .3 . 26
Table 2. Mineralogical composition of CSA cement
The resulting IAP for this phase is: Anhydrous phase Cement notation [%wt]
IAP= Ye’elimite C4A3$ 50
. . . .
Belite -C2A 20
Anhydrite + Gypsum C$ + C$H2 22
Calcite C
And the solubility product of ettringite is given by Aluminates C3A
(Warren and Reardon,1994): Brownmillerite C4AF
2
4. Methods 5. Results
All the experiments were carried out at 20°C. 5.1 Expansion tests
Cement pastes were prepared with water/binder
ratio of 0.4. Figure 2 shows the expansion in function of the
All the mixes were prepared under the same time for different compositions of CAC with
conditions. Additional gypsum (if present in the gypsum. The number on the right of the system
mix) was added in water. Then cement was added name (e.g. B-G1.0) is the molar ratio between C$
and mixed for 2 minutes using a paddle mixer and CA. With the increase of the calcium sulfate
(1100rpm). content there is an increase in expansion. For a C$
content below 0.7 the expansion seems to be
For expansion tests, the cement paste was cast in really low and above this ratio the expansion
special steel moulds of 1x1x4 cm3. The samples continues on over time.
were then cured for one day at high humidity Figure 3 shows the expansion for the systems with
environment and demoulded after 24 hours. The CSA and gypsum. Here again the expansion
first measure of the length (~4 cm) was done with increases with the calcium sulfate content and
an extensometer having a precision of ±1μm. The there is a critical behaviour. The composition with
samples were conserved into demineralized water. the higher amount of gypsum broke after 4 days.
There is not a soft transition between low and high
Hydration kinetics were studied by isothermal expansion for CSA systems. The range of
calorimetry with a TAM Air (3114/3236) from expansion of these systems is lower than for CAC
Thermometric. systems.
5.0%
B‐G1.2
For SEM, XRD and MIP the samples were cast in
High expansion
polystyrene cylinders of 30mm of diameter and B‐G1.1
4.0%
50mm high. After 24hours they were demoulded B‐G1.0
and placed in recipients containing demineralized B‐G0.92
water. For each age of curing (1,3,7,14 and 28
Expansion [%]
3.0% B‐G0.85
days) three slices were cut from the cylinders and crack threshold B‐G0.82
then introduced into isopropanol to stop hydration.
2.0% B‐G0.67
Low expansion
B‐G0.54
X-ray diffraction (XRD) analysis were done with a
Philips X’Pert Pro PANalytical (CuKα, λ=1. 54 Å) 1.0%
B‐G0.43
C‐G0.96
Mercury intrusion porosimetry (MIP) was done on a
Low expansion
1.5%
Porotec machine with pressure capacity of 400 C‐G0.92
MPa. Massive samples of about 1.5 grams were
Expansion [%]
C‐G0.82
4 days: sample broken
used for the analysis.
1.0% C‐G0.75
3
4.E+07 0.8%
5.2 Isothermal calorimetry
0.7%
Expansion [%]
Intensity [cts]
Gypsum
and Figure 5 show that CSA systems have faster 2.E+07 0.4%
Ettringite
kinetics than CAC systems. Both systems show a 0.3%
Expansion
similar behavior: the second peak is delayed when 1.E+07 0.2%
0.E+00 0.0%
35 0 10 20 30 40 50 60
B‐G‐0.25 Time [days]
B‐G0.82
B‐G1.1 0.7%
20 3.E+07 0.6%
0.5% CA
Expansion [%]
Intensity [cts]
15
2.E+07 0.4% Gypsum
Ettringite
10 0.3%
Expansion
1.E+07 0.2%
5
0.1%
0.E+00 0.0%
0
0 10 20 30 40 50 60
0 10 20 30 40 Time [days]
Time [h]
Figure 7. High expansion system (B-G0.82).
Figure 4. Hydration kinetics of CAC with gypsum.
5.4 SEM BSE images of CAC systems
35
C‐G0.5_ref
Figure 8 and Figure 9 show the microstructure of
30 C‐G0.54 low expansive and high expansive CAC systems
Normalized heat flow [mW/g of binder]
4
5.5 MIP, comparison of CAC with CSA systems With the presented results it is possible to discuss
the different expansion theories. The crystal growth
Figure 10 shows the cumulative pore size theory seems to not apply to these systems
distribution of the 4 studied systems. CAC systems because there are no expansive particles and the
have a bigger cumulative porosity than CSA ettringite is formed through-solution. The swelling
systems. The pore size distribution is comparable theory seems also to be not so accurate because
for all the systems with a pore size of the in the studied systems there is expansion even if
nanometric range (around 4 nm). no lime is present.
25
14 days Finally the crystallization pressure theory seems to
be in accordance with the present results because
20
with an increase of the supersaturation index of
ettringite, which is the expansive phase, there is an
15
increase in expansion. It has to be noted that not
all the ettringite participate to the expansion. Only
Porosity [%]
0 7.0 Conclusions
0.001 0.01 0.1 1 10 100
Pore Radius [µm]
Figure 10. Cumulative pore size distribution of CAC There is a threshold between low and high
and CSA systems. expansion at C$/CA molar ratio of 0.7 (40 to 50
%mol of C$).
5.6 Pore solution analysis There is a comparable behaviour for CAC and
CSA systems.
Figure 11 shows that with the increase of gypsum There is no noticeable difference in hydrates
content there is a strong increase of the content, microstructure and porosity between
supersaturation which leads to an increase in the low expansion and high expansion systems.
crystallization pressure at 7 days of hydration. There is a higher supersaturation in the high
There is a threshold of crystallization pressure at expansion systems, which causes high
around 70 MPa above which there is uncontrolled crystallization pressures.
and high expansion.
8.0 References
7days
12
CAC+Gypsum 90 Cohen, M.D.,1983. Theories of Expansion in
10
CSA+Gypsum
80
Sulfoaluminate-Type Expansive Cements -
Schools of Thought. Cement and Concrete
Crystallization pressure [MPa]
Ettringite saturation index [‐]
70 Research, 13(6):809-818.
8
60 Cohen, M.D.,1983. Modeling of Expansive
Cements. Cement and Concrete Research,
50
6 13(4):519-528.
40 Mehta P.K. ,1973. Mechanism of expansion
4 30
associated with ettringite formation, Cement and
Concrete Research, 3(1):1-6.
2
20 Scherer, G.W.,2002 Factors affecting crystallization
10 pressure. In Internal Sulfate Attack and Delayed
Ettringite Formation (K.L. Scrivener and J.P.
0 0
0 0.2 0.4 0.6 0.8 1
Skalny, eds.),RILEM:Villars, Switzerland,139-
C$/CA [mol/mol] 153.
Scherer, G.W.,2004. Stress from crystallization of
Figure 11. Supersaturation of ettringite in function of
salt. Cement and Concrete Research,
the gypsum content.
34(9):1613-1624.
Warren, C.J. and Reardon, E.J.,1994. The
6.0 Discussion solubility of ettringite at 25°C. Cement and
Concrete Research,24(8):1515-1524.
The previous results show that there is no
Correns, C.W.,1949. Growth and Dissolution of
substantial difference between low expansive and
Crystals under Linear Pressure. Discussions of
high expansive systems in the phase assemblage,
the Faraday Society, (5):267-271.
in the microstructure and in the pore size
distribution. However, the supersaturation index of
ettringite indicates a difference between the low
expansion and high expansion systems.