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Procedia Manufacturing 00 (2019) 000–000
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Procedia Manufacturing38
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29th International Conference

29th International Conference on
on Flexible
Flexible Automation
Automation and
and Intelligent Manufacturing
Intelligent Manufacturing
(FAIM2019), June 24-28, 2019, Limerick, Ireland.
(FAIM2019), June 24-28, 2019, Limerick, Ireland.

Study
Study of
of reactive
reactive powder
powder concrete
concrete using
using quartzite
quartzite tailings
tailings from
from the
the
state of Minas Gerais - Brazil
state of Minas Gerais - Brazil

Ivan Francklin
Ivan Junioraa,, Rogério
Francklin Junior Rogério Pinto
Pinto Ribeiro
Ribeiro
b
, Maurício H. da Silva
c
b, Maurício H. da Silvac, Filipe S.
, Filipe S.
a a c
Aureliano a, Ariellen A. F. Costaa, Vinicius L. G. Garciac
Aureliano , Ariellen A. F. Costa , Vinicius L. G. Garcia

aUniversity Center of Southern Minas - UNIS, Varginha-MG, Brazil;

a
University Center of Southern Minas - UNIS, Varginha-MG, Brazil;
b
University of São Paulo at São Carlos School of Engineering - USP, Brazil;
b
University
c of São Paulo at São Carlos School of Engineering - USP, Brazil;
cUniversity of Minas Gerais - UEMG, Passos-MG, Brazil.
University of Minas Gerais - UEMG, Passos-MG, Brazil.
.
.

Abstract
Abstract
Quartzite mining in Minas Gerais, Brazil, represents an important part of the state's economy, however, the difficulties of miners
Quartzite mining in Minas Gerais, Brazil, represents an important part of the state's economy, however, the difficulties of miners
in complying with environmental requirements have led to the closure of activity in many places, reflecting a social problem,
in complying with environmental requirements have led to the closure of activity in many places, reflecting a social problem,
increasing the class unemployment, and in an environmental problem, caused by large environmental liabilities by the tailings
increasing the class unemployment, and in an environmental problem, caused by large environmental liabilities by the tailings
waste resulting from the activity. This article approaches the search for alternatives to this problem and sees in the reuse of these
waste resulting from the activity. This article approaches the search for alternatives to this problem and sees in the reuse of these
wastes as aggregates in construction a path for the promotion of social and environmental sustainability of the region, in addition
wastes as aggregates in construction a path for the promotion of social and environmental sustainability of the region, in addition
to enabling the development of new technologies in the class of special concretes, in this case the production of Reactive Powder
to enabling the development of new technologies in the class of special concretes, in this case the production of Reactive Powder
Concrete – RPC, considered innovator in the world scene of the civil construction by presenting high compressive strength. RPC
Concrete – RPC, considered innovator in the world scene of the civil construction by presenting high compressive strength. RPC
are made using the fine fraction of the aggregate and powder reactive materials. This technology allows the incorporation of rock
are made using the fine fraction of the aggregate and powder reactive materials. This technology allows the incorporation of rock
residues, in this case, the quartzite powder could manifest positively in view of the high percentage of silica (Si). Based on these
residues, in this case, the quartzite powder could manifest positively in view of the high percentage of silica (Si). Based on these
premises, the objective of this research is to perform experimental studies with the fine fraction and quartzite powder for the
premises, the objective of this research is to perform experimental studies with the fine fraction and quartzite powder for the
production of RPC. The research was divided into the following stages: identification and collection of different types of quartzite;
production of RPC. The research was divided into the following stages: identification and collection of different types of quartzite;
petrographic appreciation; production of fine fractions and powders of quartzites; calculations and production of RPC in the
petrographic appreciation; production of fine fractions and powders of quartzites; calculations and production of RPC in the
laboratory; technological characterization of concretes. In general, the results presented to date showed a good behavior of the
laboratory; technological characterization of concretes. In general, the results presented to date showed a good behavior of the
quartzites, with results of compressive strength between 85 MPa and 143 MPa. In view of the above, it is worth highlighting the
quartzites, with results of compressive strength between 85 MPa and 143 MPa. In view of the above, it is worth highlighting the
possibility of a noble destination for the quartzite tailings from Minas Gerais for the production of reactive powders and as a
possibility of a noble destination for the quartzite tailings from Minas Gerais for the production of reactive powders and as a
consequence contribute to the minimization of negative environmental impacts in mining.
consequence contribute to the minimization of negative environmental impacts in mining.
© 2019
© 2019 The
The Authors.
Authors, Published
Published by
by Elsevier
Elsevier B.V.
B.V.
© 2019
This The
is an Authors,
open accessPublished by Elsevier
article under B.V.
the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/)
Peer review under the responsibility of the scientific committee of the Flexible Automation and Intelligent Manufacturing 2019
Peer-review
Peer review under
underresponsibility of theof
the responsibility scientific committee
the scientific of the Flexible
committee Automation
of the Flexible and Intelligent
Automation Manufacturing
and Intelligent 2019 (FAIM2019
Manufacturing 2019)
Keywords: Reactive powder concrete, quartzite tailing, environmental impact.
Keywords: Reactive powder concrete, quartzite tailing, environmental impact.

2351-9789 © 2019 The Authors, Published by Elsevier B.V.

2351-9789 © 2019 The Authors, Published by Elsevier B.V.
Peer review under the responsibility of the scientific committee of the Flexible Automation and Intelligent Manufacturing 2019
Peer review under the responsibility of the scientific committee of the Flexible Automation and Intelligent Manufacturing 2019
2351-9789 © 2019 The Authors. Published by Elsevier B.V.
This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/)
Peer-review under responsibility of the scientific committee of the Flexible Automation and Intelligent Manufacturing 2019 (FAIM 2019)
10.1016/j.promfg.2020.01.091
Ivan Francklin Junior; Rogério P. Ribeiro; Maurício H. da Silva; Filipe d´S Aureliano; Ariellen A. F. Costa; Vinicius L. G. Garcia/ Procedia
Ivan Francklin Junior et al. / Procedia Manufacturing 38 (2019) 1758–1765 1759
Manufacturing 00 (2019) 000–000

1. Introduction

Minas Gerais is recognized as a relevant Brazilian state in quartzite production, used as coating rock in civil
construction. The quartzite, also known as “pedra mineira” is used as decorative element in the construction industry
and are produced in many shapes, such as plates, fillets and small prismatic fragments, used in the mosaic creation.
The producer regions of quartzite are located in the southwest and southeast of the state of Minas Gerais. The
biggest production center in the southeast region of the state is located in the city of São Thomé das Letras.
During the explosion of quartzite in the mining operations, a large amount of residues is generated, up to 90% of
the total extracted material. The reason for the high amounts of rejects once the quartzite is used, fundamentally, as
coating rock and, thus, it must be extracted as a plate, complying with thickness and length standards. The residue
generated in the processing of the “pedra mineira” are a significant problem to the entrepreneurs since it occupies a
large volume. The environmental problems include the deconfiguration of the natural terrain and landscape, siltation
of nearby water streams, native vegetation supply and can destabilize slopes containing mining residues.
On the other hand, if the rejected material comply with standards for the use of rocky materials on civil construction,
it can arise as a feasible option to different applications. One of these alternative options is the use of the rejected
quartzite as a concrete component.
Late studies by Collares et al (2012) [1], Reis (2016) [2] and Russo (2011) [3] with quartzites from the State of
Minas Gerais for use in civil construction were mostly using the large fraction of the tailings, leaving open the need
for the use integral of the quartzites, mainly with the fine fraction and powders. Data indicate that these fractions (fines
and powders) are of the order of 50% after quartzite crushing.
In this way, it is being proposed in this research, as an alternative to the solution of the problems with the tailings,
to perform a study with the fine fraction and powder of the quartzites as materials in ultra high performance concretes,
in this case the reactive powders (RPC).
This concrete is a great innovation with regard to technological development in the civil construction scenario,
since the materials used are of fine particle size with a maximum characteristic size of 2 mm and post (filler). The use
of state-of-the-art chemical additives and additions of micro and nano silica to RPC are necessary to minimize the
internal porosity of the concrete. In addition, grain packaging studies are carried out in order to obtain the best possible
compactness in the blend. These conditions give RPC compressive strengths greater than 150 MPa, and in some cases
up to 800 MPa, resistance compatible with metallic materials such as steel [4].
This new technology is incorporated in the industry era, as it will impact the entire productive and executive chain
of construction, promoting the reduction of construction costs, increasing the durability and life of structures, reducing
steel consumption and minimizing environmental impacts in quartzite mining.
The RPC (Reactive Powder Concrete) is a revolutionary material classified as UHPC (Ultra-High Performance
Concrete). It is composed basically of sand, quartz, cement, quartz powder, active silica, small dimension steel fibres,
superplasticizer, and a reduced water/binder relation, between 0,15 and 0,20. These measures have the objective to
improve the concrete transition zone (reduction in the thickness and a lower interface porosity). With a finer
granulometry it is possible to obtain an homogeneous mass, an increase in the compactness, higher ductility (due to
the steel fibres addition) and an improvement in the paste-binder interface properties [5].
However, the RPC still needs more studies and practical applications. This is because there is not yet a complete
mastery of this new material in the face of the difficulties presented in the fresh state, especially with regard to the
changes in the consistency and viscosity aspect of RPC, since they hamper the workability times for transportation,
launching and densification [6].
In addition to the contribution of this research regarding the dosage, aiming to achieve good properties of RPC in
the fresh state, it is also worth noting the incorporation of new materials, in this case the quartzite wastes from Minas
Gerais, which have not yet been studied with this purpose. Quartzites, if they are positively manifested as a component
of RPC, will be contributing not only to the environment (minimizing tailings), but also to the civil construction sector
with an alternative material for the production of ultra-high performance concrete (UHPC).
The objective of the work is the proposition of an alternative solution for the rejected quartzite material through the
study of the fine fraction and the powder originated from the quartzite mined in the southeast region (São Thomé das
Letras). The study will evaluate the feasibility of the material in the fabrication of ultra-high performance concrete,
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enabling the rejected material to be used in a noble application, reducing the negative environmental impacts of the
mining and processing of the quartzite.

2. Materials an Methods

2.1. Description of field of work

In the southeast of Minas Gerais the quartzite from the Carrancas/São João del Rei group were studied.
The Carrancas/São João del Rei group, is divided in two lithostratigraphic units: the São Thomé das Letras and
Campestre formations, described Fig. 1. The first formation is constituted of quartzite containing green mica and the
latter is remarked by the alternance between quartzite and phyllite or graphite schist [7].

Fig. 1. quartzite mines around the urban area of São Thomé das Letras, coordinates: 21°42'39.67"S e 44°58'44.51"O.

2.2. Survey of the main active quartzite mines in southeast of Minas Gerais

During this survey, the mines where the samples would be collected were defined. The chosen mines were
geologically described and according to its environmental characteristics.
The chosen place is located in São Thomé das Letras, in the “Bico do Gavião” mine.

2.3. Quartzite sample collection

The field surveys, alongside with the empiric denomination of the quartzite miners for the classification of the
rejected material, displayed differences in the tonality and texture of the material, depending of the extraction point.
Three different geotechnical types of quartzite were categorized, being those the soft, hard and glaze material,
described in Table 1.
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Table 1. Identification of quartzite tailings from São Thomé das Letras.

Denominations used by miners Macroscopic Identification Image

Friable quartzite, foliated, lower apparent

Soft material
mechanical strength;

Quartzite with incipiente foliation and average

Hard material apparent mechanical resistance; widely used as
“cladding stone”

Silicified quartzite, massive structure, not plated;

Glass material
does not allow plaque formation .

The Fig. 2 presents the panoramic image of the Bico do Gavião mine, located in São Thomé das Letras, where the
samples were collected.

Fig. 2. Bico do Gavião mine, located in São Thomé das Letras.

The samples were identified and prepared for the different essays. Quartzite tailings were processed in the
laboratory using Abrasão Los Ângeles equipment. The fractions of the aggregates produced are presented in Table 2.

Table 2 - Granulometric dimensions of quartzite dust and sand fractions.

Sieve mesh in (µm) Percentage retained in the sieve
600 µm 0,86%
Small fraction(sand) 300 µm 6,91%
150 µm 65,52%
74 µm 13,48%
Fraction powder
45 µm 6,52%
(powdery)
Sieve bottom 6,71%
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Subsequently, the dosage study was carried out using ELKEM's EMMA software to obtain the best grain packaging
curve. The materials and the respective traces obtained are shown in Table 3.

Table 3 - Description of the traits studied and respective consumption of cement per m3 of concrete.
Additivies and fibers in% (in relation
Cement
Mass proportions (kg) to the mass of cement)
Samples (kg/m3
Active Powder Quartz nano Superplasticizer
Cement a/c fibers concrete)
silica of quartz sand silica (Glenium 51)
STL 2 1,00 0,145 0,183 1,20 0,25 2% 3% 0,18% 847,68
STL 3 1,00 0,145 0,183 1,20 0,25 2% 3% 0,18% 852,85
JUNDU 1,00 0,145 0,183 1,20 0,25 2% 3% 0,18% 854,91

The sample "JUNDU" refers to the industrialized aggregate coming from the Jundú Mining located in the
city of Descalvado - São Paulo - Brazil. The RPC produced with this aggregate was used as a comparative element in
this research.

2.4. Laboratory concrete fabrication

During this step, different types of concrete were fabricated, the behaviour of the sample was analysed in the fresh
and hardened states [10].
The production of the concrete was conducted in the Construction Materials Laboratory of UEMG (University of
Minas Gerais) – Passos unit. An electric mortar mixer was used in the fabrication of the concrete.
The samples defined for the accomplishment of the studies were: JUNDU; STL 2 and STL 3. For each of the 3
different levels of RPC, 22 concrete samples were produced (50 mm X 100 mm), totalling 66 samples, as shown in
Fig. 3.

Fig. 3. test bodies produced, totalling 66 samples.

2.5. Technological characterization of the post reactive concretes

The technological characterization studies of the post reactive concretes were conducted in the Geotechnics and
Structures Laboratory of EESC-USP (University of São Paulo at São Carlos School of Engineering). The studies
conducted were: axial compression strength in cylindrical samples [8]; static modulus of elasticity, according to ABNT
NBR 8522:2017 [9].

2.6. Uniaxial compression strength and static modulus of elasticity

For the determination of the axial compressive strength and the static modulus of elasticity and deformation, the
controlled servo press of the Geotechnics laboratory of the USP (University of São Paulo - São Carlos) was used.
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The duly rectified specimens were instrumented with electronic extensometers in Fig. 4, and the forces applied at
a rate of 0.45 MPa per second. Samples were assayed at 54 days of age.

Fig. 4. instrumentation of RPC specimens for determination of modulus of elasticity.

3. Results and Discussion

In this section, the results of axial compressive strength and static modulus of RPC samples are presented, following
the standards ABNT NBR 5739: 2007 [10]; ABNT NBR 8522: 2017 [9].

3.1 Axial compression strength

The Fig. 5 presents the maximum strength values (in MPa) and Fig. 6 shows the results of the normal distribution,
obtained for each of the RPC samples, being thos JUNDÚ (reference aggregate – industrialized sand from the
Descalvado – SP region), STL 2 (soft material) and STL 3 (glaze material).

Fig.5 The maximum compressive strength values (in MPa)

obtained for each of the RPC samples. Fig. 6 Normal distribution of axial compression strength, in MPa.

In general, the results presented to date showed a good behavior of the quartzites, with results of compressive
strength between 85 MPa and 143 MPa
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The average of the compression strength results from the three samples presented in Table 4. show values relatively
close to each other, especially STL 3, with the lowest standard deviation, of 8,4.

Table 4. Average of the compression strength results from the three samples presented.
JUNDU STL 2 STL 3
Average (MPa) 111,0 118,5 107,4
Standard deviation (MPa) 12,5 13,9 8,4

Coefficient of variation (%) 11,2% 11,7% 7,8%

Maximum result (MPa) 122,6 143,6 116,0
Minimum result (MPa) 83,8 101,3 85,2

3.2 Static modulus of elasticity

In the fig. 7, the elastic modulus means of the concrete of RPC and in fig. 8, are presented. The normal distributions
of the results of the specimens are presented.

Fig.7 - Average of Elasticity Module results

Fig.8 - normal distribution of static modulus of elasticity

As can be seen, the largest dispersions among the static modulus results were observed in the STL 2 and STL 3
samples.
The modulus elasticity results showed high RPC stiffness with values higher than 50 GPa. This is due to the study
of the packaging carried out by promoting a concrete with low porosity index and consequent increase of compactness.
Table 5, shows the means, standard deviations and coefficient of variation of the samples analyzed by the static
method.

Table 5 - Averages, standard deviation and coefficient of variation corresponding to the results of the static modulus
of RPC samples.
Average (GPa) Standard deviation (GPa) Coefficient of variation (%)
JUNDÚ 52,49 2,88 5%
STL 2 50,28 5,97 12%
STL 3 56,36 4,18 7%
The JUNDU sample obtained the lowest standard deviation at 2.88 GPa, while the STL 2 sample obtained the
highest standard deviation at 5.97 GPa.
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3. 4. Final Considerations

Based on the conducted studies, the quartzite rejected materials from São Thomé das Letras enabled a broad
characterization of these rocky types. The technological characterization of the quartzite samples (physical indexes)
showed little variation between the types of rejected material and the petrographic analysis showed small differences
regarding granulation, cohesion and mineralogical composition of the samples from STL, whereas these small
variations had little effect in the calculations for the concrete type obtaining.
The granulometric analysis of the powdery fraction obtained via sedimentation were similar to the analysed rocky
types and the granulometric distribution of the of the other materials used for the production of the RPC (mortar and
active silica), obtained directly with the manufacturers, were used for the packing calculation, using the software
EMMA, from ELKEM. The adjustment was very close to a reference curve.
In general, the technological studies carried out on quartzite samples from São Thomé das Letras obtained
satisfactory results as aggregates in the production of very high performance concrete. However, in view of the high
silica rate present in quartzites, future studies will be carried out on Alkali-Aggregate Potential Reactivity to verify
the deleterious potential of this material combined with Na and K present in Portland cement.
With the realization of these studies and subsequent support from institutions that contribute to the regional
economy movement, the commercialization of this product is economically viable and contributes to the solution of
social, economic and environmental problems that affect the mining sector of the state of Minas Gerais - Brazil, in
addition to providing on the market alternative revolutionary material that will meet the innovative demand of the
construction industry.

References

[1] Collares, E.; Francklin Junior, I., Castro, L. A. Evaluation of the Aggregate Produced From Wastes of Quartzite Mining Sites to Use in
Concrete. Soils & Rocks, v.35, p.27 - 36, 2012.
[2] Reis, M. J. Avaliação tecnológica de rejeitos de minerações de quartzito do Sudoeste Mineiro como agregados em blocos para pavimentação.
2016 198 p. Dissertação (Mestrado) - Desenvolvimento Regional e Meio Ambiente, Universidade do Estado de Minas Gerais, Passos, 2016.
[3] Russo, M. L. C. Reciclagem de Resíduo Gerado na Extração de Quartzito. Tese de Doutorado, Universidade Federal de Minas Gerais, 2011.
[4] Mehta, P. K. E Monteiro, P. J. M. Concreto: estrutura, propriedades e materiais. São Paulo: Ibracon, 2014.
[5] Richard, P.; Cheyrezy, M. Composition of Reactive Powder Concretes. Cement and Concrete Research. 1995;25:1501-1511.
[6] Tutikian, B. F.; Isaia, G.C.; Helene, P. Concreto de Alto e Ultra-Alto Desempenho. Isaia, G.C. (Ed.). Concreto: ciência e tecnologia. 1 ed. São
Paulo: Ibracon, 2011.
[7] Chiodi F, C.; Artur, A. C.; Rodrigues, E. P. Aspectos geológicos, petrográficos e químicos de interesse para o aproveitamento econômico dos
quartzitos foliados de São Thomé das Letras – Minas Gerais. Geociências. 2005; 24(2):163-171.
[8] ASSOCIAÇÃO BRASILEIRA DE NORMAS TECNICAS (ABNT), NBR 15845-5: Rocha para Revestimento: Determinação da Resistencia à
compressão uniaxial, Rio de Janeiro, 2015.
[9] ASSOCIAÇÃO BRASILEIRA DE NORMAS TÉCNICAS (ABNT). NBR 8522: Concreto - determinação dos módulos estáticos de elasticidade
e de deformação e da curva tensão-deformação. Rio de Janeiro, 2017.
[10] ASSOCIAÇÃO BRASILEIRA DE NORMAS TECNICAS (ABNT), NBR 5739: Concreto – Ensaio de compressão de corpos de prova
cilíndrocos, Rio de Janeiro, 2018.