Lecture 11 - Natural Materials and Industrial Byproducts

CE 601 (211)
CE 601 (211)
LECTURE
LECTURE11 11
USE
USEOF
OFNATURAL
NATURALAND
ANDINDUSTRIAL
INDUSTRIALBY-
BY-
PRODUCTS
PRODUCTSININCONCRETE
CONCRETE
COMMONLY USED NATURAL AND
INDUSTRIAL BYPRODUCTS
Natural pozzolans – pozzolanic reaction
Fly ash –pozzolanic reaction
Silica fume – pozzolanic reaction and/or filler
Blast furnace slag – cement in itself
Rice husk ash – pozzolanic reaction
Metakaolin – pozzolanic reaction and/or filler
Oil ash -filler
2
Cement kiln dust – cement in itself or filler
COMMONLY USED NATURAL AND
INDUSTRIAL BYPRODUCTS (Contd.)
 Baghouse dust – filler/retarder

 Silico manganese fume – cementititous/filler
 Limestone powder – filler/alkaline medium
 Other materials, metallic slags, etc. – mostly act as
fillers
3
DESCRIPTION OF SOME
LOCAL WASTE MATERIALS
Cement Kiln Dust (CKD)

 By-product of the cement manufacturing process.
4
DESCRIPTION OF SOME LOCAL
WASTE MATERIALS
Cement Kiln Dust
 Production of cement clinker typically generates around 6

to 7% of CKD by weight of clinker.
 Generation of CKD in the Kingdom is approximately 3.5

million tons per year.
 Arabian Cement Company Ltd. (ACCL), Jeddah,

produces 1000 tons per day.
 The concentration of alkalies, chloride and sulfate is

considerably higher in the CKD.
5
Cement Kiln Dust
Chemical composition
Constituent Weight %
CaO 49.3
SiO2 17.1
Al2O3 4.24
Fe2O3 2.89
K2O 2.18
MgO 1.14
Na2O 3.84
P2O5 0.12
Equivalent alkalis (Na2O + 0.658K2O) 5.27
SO3 3.56
Chloride 6.9
Loss on ignition 15.8
BaO (µg/g (ppm)) 78.2
Cr2O3 0.011
CuO 0.029
NiO 0.012
SrO 0.37
TiO2 0.34
6 V2O5 0.013
DESCRIPTION OF SOME
Limestone Powder
 Obtained during the crushing of carbonate rocks
7
DESCRIPTION OF LOCAL
WASTE MATERIALS USED
 Limestone quarry filtration system (circulated area).

 Disposal of waste quarry limestone powder to the ground (rectangle
8 area).
Limestone Powder
Constituent Weight %
SiO2 11.79
CaO 45.7
Al2O3 2.17
Fe2O3 0.68
MgO 1.8
K2 O 0.84
Na2O 1.72
Na2O+(0.658K2O) 2.27
Loss on Ignition 35.1
Moisture 0.2
9
DESCRIPTION OF SOME
Electric Arc Furnace
Dust
 EAFD is generated as a by-
product during the electric
arc furnace steel making
process.
10
DESCRIPTION OF SOME
Electric Arc Furnace Dust
 Dust emanating from an electric furnace is collected into bag filters during the
steel making process.
 This fine dust consists mostly of iron oxide and zinc oxide.
 The annual steel production in Saudi Arabia is 471,000 tons.
 1 ton of steel generates 1.5 to 2% of EAFD.
 Approximately, the annual production of EAFD in Kingdom is 8,242 tons.
 The world steel Industry spends approximately $50-250 per ton to stabilize
EAFD for landfill or for zinc recovery.
11
Constituent Weight, %
Aluminium 0.7
Calcium 9.39
Cadmium 0.0004
Copper 0.06
Iron 33.6
Potassium 1.7
Magnesium 2.3
Manganese 1.8
Sodium 2.6
Nickel 0.01
Lead 1.31
Phosphorous 0.13
Silicon 2.38
Tin 0.03
Sulphur 0.57
Titanium 0.09
Zinc 10
12
DESCRIPTION OF SOME
Oil Ash
 OA is a by-product of the
burning of oil to produce
energy in power
generation/desalination
plants.
13
DESCRIPTION OF SOME
Oil Ash
 Very fine ash and most of its passes # 200 sieve.
 Main constituents are carbon and sulfur.
Constituents Weight, %
SiO2 1.65
CaO 0.45
Chemical Al2O3 < 0.10
composition Fe2O3 0.47
MgO 0.48
K2O 0.03
Na2O 0.53
V2O5 2.65
Sulfur 9.6
Na2O + (0.658K2O), % 0.55
14
DESCRIPTION OF SOME
Natural Pozzolan
 Natural raw material.
 Sources: Volcanic ash, shales, etc.
 Pozzolanic material meets ASTM C 618.
 In Kingdom NP is available in basalt plateaus (Harrat)

 Plateaus are spread across an area of 90,000 km2 in the east of
the escarpment onwards to the coast of the Red Sea.
15
Natural Pozzolan
Constituent Weight, %
SiO2 42.13
Al2O3 15.33
Fe2O3 12.21
MgO 8.5
K2O 0.84
Na2O 2.99
16
Natural Pozzolan
Physical properties
Material retained ASTM C 618
on # 325 sieve, % requirements
15 < 34
Mix details Average Strength activity ASTM C618

compressive index, % requirements, %
strength, MPa
OPC 28.18
Natural 88.86 75
pozzolan cement 25.05
concrete
Natural Pozzolan
Setting time and consistency
Consistency by Time of setting, ASTM C 150
weight of minutes requirements
Cement cement, % Initial Final Initial Final
OPC 26.2 200 212

Pozzolan Should not Should not
20% 27.2 215 250
be less be more
Pozzolan 25.9 205 217
30% than 45 than 600
Pozzolan 25.1 215 229 minutes minutes
50%
Metakaolin
Pulverized steel slag
Silico-Managanese fume
SABAYEK, Jubail, Saudi Arabia
• Ferro alloys production

(a) (b)
capacity 230,000 mt/year (a) (b)
• 100 kg of SiMn fume is

generated per ton of alloy
(c) (d) (c) (d)
• Approximately 32 to 33
metric ton (mt) of fumes
are generated per day
(a) (b)
(a) (b)
• Approximately 11,680-
12,045 mt/year
21 (c) (d)
(c) (d)
Silico-Manganese fume
Disposal
Disposal is
is aa major
major
environmental
environmental problem
problem
22
Silico-manganese fume
Comparison of by products production
Source material Material Production By-Product
By-Product
Production Quantity Quantity
Silico Manganese Fumes (SiMn) SiMn Alloys 1 ton 100 kg
Ground Granulated Blast Furnace Steel 1 ton 350 – 500 kg
Slag (GGBFS)
Electric Arc Furnace Dust (EAFD) Steel 1 ton 15 to 20 kg
Cement Kiln Dust (CKD) Cement 1 ton 60 to 70 kg
Production of Ferro alloys in the world

Reference Company Ferro alloys production
Annual conference, 2018 Pertama Ferroalloys Sdn. Bhd (Malaysia) 230,000 mt/year
Annual conference, 2018 Sakura Ferroalloys Sdn Bhd(Malaysia) 174,000 mt/year
OM Materials (Sarawak) Sdn Bhd
Annual conference, 2018 250-300,000 mt/year
(Malaysia)
SABAYEK SABAYEK
120-135,000 mt/year
(Saudi Arabia)
Skopski Leguri
Skopski Leguri 98,000 mt/year
(Macedonia)
Zhdanov et al., (2015) Russia 1,109,000 mt/year
23
http://news.steel-360.com/steel/the-slag-the-steel-industry/
Chemical and physical properties of SiMn
Fume and Silica Fume
SiMn Fume Property SiMn Fume Silica Fume Silica Fume

Reddish Gray to off
Appearance
brown white
Shape Spherical Spherical
Specific gravity 0.98 g/cc 2.2 g/cc
BET surface area 8.1 m2/g 23 m2/g
Average particle size 0.491 µm 0.37 μm
1: Mn Fe2 O4, 2: Quartz (SiO2), 3: Sylvite (KCl)
Chemical
SiO2 Al2O3 Fe2O3 CaO MgO K2O SO3 MnO Na2O Cl ZnO P2O5 LOI
Composition
SiMn Fume 14.47 1.24 2.37 4.61 4.78 27.25 6.16 33.13 1.64 3.28 0.73 5.7
Weight (%)
Silica Fume 93.62 0.73 0.24 0.76 1.8 1.24 0.51 1.07 1.55
24
EVALUATION OF NATURAL
POZZOLAN
Compressive Strength
60
50
Compressive strength, MPa
40
30
0% Pozzolan
20
20% Pozzolan
30% Pozzolan
10
40% Pozzolan
50% Pozzolan
0
0 20 40 60 80 100
Period of exposure, days
Compressive Strength
100
80
60
40 OPC
Pre-blended cement
SF-7%
20 FA-30%
Pozzolan 15% +SF 5%
Pozzolan 18% +SF 2%
0
0 20 40 60 80 100 120 140 160 180 200
Present trend in the use of natural
pozzolan
 Improvement in the activity of pozzolan

by using mechanical (grinding to a finer
size) and chemical (adding alkaline
materials, such as NaOH, calcium
hydroxide, etc.) techniques.
 Used as an precursor in the alkali-
activated binders.
Utilization of CKD
 Earlier studies were conducted mostly on

cement paste or mortars.
 Durability, particularly reinforcement
corrosion, of CKD concrete need to be
assessed due to the high chloride
concentration in CKD.
Materials
 Cement
 Type I
 Type V
 CKD
 0, 5, 10, and 15%
Main Constituents
Constituent, CKD Type I Type V
wt. % cement cement
CaO 49.3 64.4 64.1
SiO2 17.1 22.0 20.5
Chloride 6.90 -- --
SO3 3.56 2.10 1.96
Alkalis 5.27 0.33 0.41
Loss on 15.8 0.7 0.8
ignition
Specimens & Tests
 Specimens
 Cylinders (75 mm x 150 mm)
 Tests
 Compressive strength (3, 7, 14, 28, 56, and 90 days)
 Chloride permeability (After 28 days of curing)
 Electrical resistivity (After 28 days of curing)
Compressive Strength Development (Type
I cement)
65
60
55
50
45
0% CKD
40 5% CKD
35 10% CKD
15% CKD
30
0 20 40 60 80 100
Age, days
Compressive Strength Development (Type
V cement)
65
60
55
50
45
0% CKD
40 5% CKD
35 10% CKD
15% CKD
30
0 20 40 60 80 100
Age, days
Chloride permeability
(Type I cement)
Cement Chloride Classification
permeability,
C
I (100%) 1,697 Low
I (95%) + 1,794 Low

CKD(5%)
I (90%) + 1,969 Low
CKD(10%)
I (85%) + 2,744 Moderate
CKD(15%)
(Type V cement)
Cement Chloride Classification
permeability,
C
V (100%) 2,675 Moderate
V (95%) + 2,492 Moderate

CKD(5%)
V (90%) + 3,036 Moderate
CKD(10%)
V (85%) + 3,301 Moderate
CKD(15%)
Electrical Resistivity
(Type I Cement)
70.00
M1-CKD (Type I 100% ) M2-CKD (Type I 95% +CKD 5% )
60.00 M3-CKD (Type I 90% +CKD 10% ) M4-CKD (Type I 85% +CKD 15% )
Electrica l R esisticity , K -O hm -cm
50.00
40.00
30.00
20.00
10.00
0.00
2.50 3.00 3.50 4.00 4.50 5.00
Moi sture C onte nt, %
Electrical Resistivity
(Type V Cement)
90.00
M5-CKD (Type V 100% ) M6-CKD (Type V 95% +CKD 5% )
80.00
M7-CKD (Type V 90% +CKD 10% ) M8-CKD (Type V 85% +CKD 15% )
70.00
Electrica l Resisticity , K -O hm-cm
60.00
50.00
40.00
30.00
20.00
10.00
0.00
2.50 3.00 3.50 4.00 4.50 5.00
Moi sture C onte nt, %
Conclusions
 Compressive strength of both Type I and Type V

cement concretes decreased due to the
incorporation of CKD.
 There was no significant difference in the
compressive strength of 0% and 5% CKD cement
concretes.
 The chloride permeability increased with an
increase in the quantity of CKD.
 There was no significant difference in the chloride
permeability of 0% and 5% CKD cement concretes.
Conclusions (contd.)
 The electrical resistivity of concrete decreased

due to the incorporation of CKD.
 For normal range of moisture contents the
risk of corrosion was moderate in all the
concretes.
Conclusions (contd.)
 Increase in the chloride permeability and

decrease in electrical resistivity in CKD
concrete is due to the high chloride
concentration in the CKD.
 Type I cement binds more chlorides than
Type V cement, resulting in improved
corrosion resistance of the former cement.
Recommendation
The quantity of CKD in concrete should be

restricted to 5%, as a replacement of cement, from
strength and durability perspectives.
LOW TO MEDIUM STRENGTH
CONCRETE USING WASTE
MATERIALS
Low to Medium Strength
CKD CEMENT CONCRETE
C o mpressive streng th, M Pa

70 HIGH
70 STRENGTH
CKD-0 CKD-5
65
HIGH 65
CKD-10 CKD-20 STRENGTH CKD-0 CKD-50
60
60
55 CKD-60
55
50 50
MEDIUM
45 MEDIUM 45 STRENGTH
STRENGTH
40 40
35 35
30 LOW 30 LOW
STRENGTH STRENGTH
25 25
20 20
15 15
VERY LOW
10 VERY LOW 10 STRENGTH
STRENGTH
5
5
0
0 0 20 40 60 80 100
0 20 40 60 80 100
Period of Curing, days Period of Curing, days
Cementitious material: 370 kg/m3 Cementitious material: 300 kg/m3

44 w/cm: 0.45 w/cm: 0.55
WATER ABSORPTION
CKD CEMENT CONCRETE
W ater absorption, %
W ater absorption, %
7.00 7.00
6.21
6.00 6.00 5.58

5.34
4.76
5.00 4.58 5.00
4.11 4.17
4.00 4.00
3.00 3.00
2.00 2.00
1.00 1.00
0.00 0.00
CKD-0 CKD-5 CKD-10 CKD-20 CKD-0 CKD-50 CKD-60

45 w/cm: 0.45 w/cm: 0.55
DRYING SHRINKAGE
CKD CEMENT CONCRETE
Shrinkage strain, microns

700
700
600
600 Threshold
Threshold
500
500
400
400
300
300
CKD-50
CKD-0 CKD-5 200
200 CKD-60
CKD-10 CKD-20
100
100
0
0
0 20 40 60 80 100 120 140 160 180 200
0 20 40 60 80 100 120 140 160 180 200


46 w/cm: 0.45 w/cm: 0.55
ELECTRICAL RESISTIVITY
CKD CEMENT CONCRETE
Electrical R esistivity, k.O hm.cm
Electrica l R esistivity, k.O hm.cm

100 350
CKD-0 CKD-5 300 CKD-50 CKD-60

CKD-10 CKD-20
Electrical Electrical Risk of
Mix resistivity at Risk of Mix resistivity at reinforcement
reinforcemen
250
designation 3% moisture designation 3% moisture corrosion
t corrosion k.Ohm.cm
k.Ohm.cm
CONTROL 34.2 Moderate 200
CKD-50 17.7 Moderate
CKD-5 33.3 Moderate
CKD-10 28.9 Moderate 150 CKD-60 15.2 Moderate
CKD-20 21.2 Moderate

100
50
0 0
1.00 2.00 3.00 4.00 5.00 6.00
0.50 1.50 2.50 3.50 4.50
Moisture content, % Moisture content, %

47 w/cm: 0.45 w/cm: 0.55
CORROSION POTENTIALS
CKD CEMENT CONCRETE
C o rro sion Potentials, mV SC E

-800 -800
-750 -750
-700 -700
-650 -650
-600 -600
-550 -550
-500 -500
-450 -450
-400 -400
-350 -350 ASTM C 876 Threshold Value
-300 ASTM C 876 Threshold Value -300
-250 -250
-200 -200
-150 CKD-0 CKD-5 -150
CKD-50
-100 CKD-10 CKD-20 -100
CKD-60
-50 -50
0 0
0 20 40 60 80 100 120 140 160 180 200 220 240 0 20 40 60 80 100 120 140 160 180 200 220 240
Period of Exposure, Days Period of Exposure, Days

48 w/cm: 0.45 w/cm: 0.55
CORROSION CURRENT DENSITY
CKD CEMENT CONCRETE
C o r r o s io n c u r r e n t d e n sity , m A /c m 2
C o r r o s io n c ur r e n t d e nsity , µ A /c m 2
1.00 1.00
CKD-0 CKD-5 CKD-50
CKD-10 CKD-20 CKD-60
0.80 0.80
0.60 0.60
Threshold Value Threshold Value

0.40 0.40
0.20 0.20
0.00 0.00
0 50 0 50 100 150 200 250 300 350 400 450 500
Period of exposure, days Period of exposure, days

49 w/cm: 0.45 w/cm: 0.55
THERMAL CONDUCTIVITY
CKD CEMENT CONCRETE
T h erm a l C o n d u ctiv ity , W /m K

ACI range for concrete: 1.98–2.94 W/mK
2.56 2.59 2.60

2.46
2.40
2.50 2.50
2.09
2.00 2.00
1.50 1.50
1.00 1.00
0.50 0.50
0.00 0.00
CKD-0 CKD-5 CKD-10 CKD-20 CKD-50 CKD-60

50 w/cm: 0.45 w/cm: 0.55
COMPRESSIVE STRENGTH
LSP CEMENT CONCRETE
C ompressive streng th, M Pa

65.00
60.00
55.00 HIGH
65 HIGH
STRENGTH LSP-0 LSP-50 STRENGTH
60
50.00 LSP-60
55
45.00
50
40.00 LSP-0 LSP-5
45
LSP-10 LSP-15
35.00 MEDIUM 40 MEDIUM
STRENGTH
STRENGTH
30.00 35
LOW
STRENGTH
25.00 30
LOW
STRENGTH
25
20.00
20
15.00
15
10.00
VERY LOW 10 VERY LOW
STRENGTH STRENGTH
5.00 5
0 10 20 30 40 50 60 70 80 90 100 0 20 40 60 80 100
Period of curing, days Period of curing, days

51 w/cm: 0.45 w/cm: 0.55
WATER ABSORPTION
LSP CEMENT CONCRETE
Water absorption, %
Water absorption, %
6.33
5.98
6.00 6.00
5.34
5.00 4.71 4.72 5.00
4.11 4.21
4.00 4.00
3.00 3.00
2.00 2.00
1.00 1.00
0.00 0.00
LSP-0 LSP-5 LSP-10 LSP-15 LSP-0 LSP-50 LSP-60

52 w/cm: 0.45 w/cm: 0.55
DRYING SHRINKAGE
LSP CEMENT CONCRETE

800 800
700 700
600 Threshold 600 Threshold
500 500
400 400
300 300
LSP-0 LSP-5 LSP-50

200 200
LSP-10 LSP-15 LSP-60
100 100
0 0
0 20 40 60 80 100 120 140 160 180 200 0 20 40 60 80 100 120 140 160 180 200

53 w/cm: 0.45 w/cm: 0.55
LSP CEMENT CONCRETE
Electrica l R esistiv ity , k.O hm .cm
Electrica l R esistiv ity , k.O hm.cm

2400 3200
2200 3000
LSP-50 LSP-60
LSP-0 LSP-5 2800
2000
LSP-10 LSP-15 2600 Electrical
Electrical Risk of
Mix resistivity at
1800 resistivity Risk of 2400 reinforcement
Mix designation 3% moisture
at 3% reinforcement corrosion
designation 2200 k.Ohm.cm
1600 moisture corrosion
LSP-50 102.4 Negligible
k.Ohm.cm 2000 LSP-60 76.2 Low
1400 CONTROL 34.2 Moderate
1800
LSP-05 63.2 Low
1200 1600
LSP-10 65.9 Low
1000 LSP-15 63.7 Low 1400
1200
800
1000
600 800
400 600
400
200
200
0
0

54 w/cm: 0.45 w/cm: 0.55
LSP CEMENT CONCRETE
C o rro sio n Po tentia ls, mV SC E

C o rrosio n Potentia ls, mV SC E
-800 -800
-750 LSP-50
LSP-0 LSP-5 -750
LSP-60
-700 LSP-10 LSP-15 -700
-650 -650
-600 -600
-550 -550
-500 -500
-450 -450
-400 -400
-350 ASTM C 876 Threshold Value -350 ASTM C 876 Threshold Value
-300 -300
-250 -250
-200 -200
-150 -150
-100 -100
0 20 40 60 80 100 120 140 160 180 200 220 240 0 20 40 60 80 100 120 140 160 180 200 220 240

55 w/cm: 0.45 w/cm: 0.55
LSP CEMENT CONCRETE
C o r r o s io n c u r r e n t d e n s ity , µ A /c m 2
LSP-0 LSP-5
0.80 0.80
LSP-10 LSP-15
LSP-50 LSP-60
0.60 0.60
0.40 0.40
0.20 0.20
0.00 0.00
0 50 100 150 200 250 300 350 0 50 100 150 200 250

56 w/cm: 0.45 w/cm: 0.55
LSP CEMENT CONCRETE

2.96
3.00 3.00 2.77
2.69 2.67 2.64
2.40
2.50 2.50
2.00 2.00
1.50 1.50
1.00 1.00
0.50 0.50
0.00 0.00
LSP-0 LSP-5 LSP-10 LSP-15 LSP-50 LSP-60

57 w/cm: 0.45 w/cm: 0.55
USE OF LIMESTONE POWER IN
SELF COMPACTING CONCRETE
OBJECTIVE
 Study the possibility of utilizing LSP in SCC.

 Assess the durability of the developed in SCC
in severe exposure conditions.
 Determine the life-cycle cost of the developed
SCC compared to the normal concrete.
Constituents of trial mixtures
Admixture,
Effective Weights of Constituents, kg/m3 liter/100 kg
Mix # Cement
w/c ratio Limestone Silica Coarse Fine Glenium- Stream
Cement Fly Ash
Powder Fume Aggregate Aggregate 51 -2
1 0.40 400 246.7 0 0 822.4 575.7 1.5 0.50
2 0.45 400 239.8 0 0 799.4 559.6 1.5 0.50
3 0.50 400 232.9 0 0 776.3 543.4 1.5 0.50
4 0.55 400 226.0 0 0 753.2 527.3 1.5 0.50
5 0.40 400 139.2 0 0 870.2 731.0 1.0 0.50
6 0.38 400 140.8 0 0 880.0 739.2 1.4 0.50
7 0.40 400 171.2 0 0 842.3 684.8 1.2 0.50
8 0.40 400 171.2 0 0 856.0 684.8 1.4 0.50
9 0.40 400 171.2 0 0 856.0 684.8 0.8 0.50
10 0.40 400 173.1 0 0 842.3 640.1 1.6 0.50
11 0.38 400 173.1 0 0 856.0 684.8 1.6 0.50
12 0.40 400 171.2 0 0 856.0 684.8 1.0 0.50
13 0.40 400 171.2 0 0 856.0 684.8 1.5 0.50
14 0.40 380 140.3 20 0 876.9 736.6 1.8 0.50
15 0.40 280 0 0 120 974.9 974.9 1.1 0.50
Flow properties of the trial
mixtures
Slump L-box U-Box V-Funnel
Mix # Diameter (mm) (seconds) Remarks
(mm)
1 No slump - - - Rejected
2 No slump - - - Rejected
3 480 - - - Rejected
4 775 0.8 35 30 Rejected
5 743 1.0 5 11 Accepted
6 863 1.0 0 10 Accepted
7 820 1.0 20 13 Accepted
8 500 - - - Rejected
9 750 0.8 48 35 Rejected
10 600 0.65 - - Rejected
11 700 0.7 - - Rejected
12 450 - - - Rejected
13 785 1.0 0 10 Rejected
14 820 0.80 30 12 Accepted
15 825 0.9 10 7 Accepted
Selected mixtures
 Mix #5 (M5): Prepared with 8% LSP and w/c

ratio of 0.4.
ratio of 0.38.
ratio of 0.4.
 Mix #14 (M14): Prepared with 8% LSP plus
5% silica fume and w/c ratio of 0.4.
 Mix #15 (M15): Prepared with 30% fly ash and
w/c ratio of 0.4.
Properties evaluated
 Compressive strength
 Split tensile strength
 Shrinkage
 Plastic
 Drying
 Pulse velocity
 Performance under thermal variation
 Corrosion resistance
 Corrosion potentials
 Corrosion current density
 Chloride diffusion
 Rapid chloride permeability
 Sulfate resistance
Compressive strength
90
M5 M6 M7 M14 M15
80
Compressive Strength, MPa
70
60
50
40
30
0 10 20 30 40 50 60 70 80 90 100
Age, days
M5: 8% LSP w/c: 0.40; M6: 8% LSP w/c: 0.38;

M7: 10% LSP w/c: 0.40 ; M14: 8% LSP+5% SF w/c: 0.40
M15: 30% FA w/c: 0.40
Pulse velocity
5100
M5 M6 M7 M14 M15
5000
Pulse velocity, m/s
4900
4800
4700
4600
4500
4400
0 10 20 30 40 50 60 70 80 90 100
Age, days
M5: 8% LSP w/c: 0.40; M6: 8% LSP w/c: 0.38;

M7: 10% LSP w/c: 0.40 ; M14: 8% LSP+5% SF w/c: 0.40
M15: 30% FA w/c: 0.40
Split tensile strength
8.0
7.5
7.0
Split tensile strength, MPa
6.5
6.5 6.4
6.0
5.8
5.5
5.5
4.9
5.0
4.5
4.0
M5 M6 M7 M14 M15
Mix
Plastic shrinkage strain
1400
M5
1400
M5
M6 M6 1185
1200 1185
M7
1200
M7 1096 1096
Maximum Shrinkage Strain, microns
M14
M14
Maximum Shrinkage Strain, microns
1000 M15
1000 M15 888
833
888 800 774
833
800 774
600
400
600
200
400
0
M5 M6 M7 M14 M15
200
0
M5 M6 M7 M14 M15
Drying shrinkage strain
600
500
Shrinkage, microns
400
300
M5
200
M6
M7
100 M14
M15
0
0 50 100 150 200 250 300 350 400
Period of Exposure, days
Corrosion potentials
-700
M5
M6
-600
M7
M14
Corrosion Potentials, mV SCE
-500 M15
-400
-300
-200
-100
0
0 50 100 150 200 250 300 350 400
Period of Exposure, Days
Time to corrosion initiation
Time to
Mix designation and composition corrosion
initiation, days
M5 (8% LSP & w/c = 0.4) 35
M6 (8% LSP & w/c = 0.38) 230
M7 (10% LSP & w/c = 0.4) 130
M14 (8% LSP, 5% SF & w/c = 0.4) Passive
M15 (30% FA & w/c = 0.4) 20

Corrosion current density
0.80
M5
0.70 M6
2
Corrosion Current Density,m A/cm
M7
0.60 M14
M15
0.50
0.40
0.30
0.20
0.10
0.00
0 50 100 150 200 250 300 350 400 450 500
M5: 8% LSP w/c: 0.40; M6: 8% LSP w/c: 0.38;

M7: 10% LSP w/c: 0.40 ; M14: 8% LSP+5% SF w/c: 0.40
M15: 30% FA w/c: 0.40
Sulfate resistance
Reduction in compressive strength
due to sulfate attack
30
3 Months
6 Months 25.83
25 12 Months
R eduction in C ompressive Strength, %
19.51
20
16.13
14.75 14.63
15
11.18
10 8.89
7.48
6.64
6.05
5.36
5 4.42
3.43
2.72
1.94
0
Mix 5 Mix 6 Mix 7 M14 M15
M5: 8% LSP w/c: 0.40; M6: 8% LSP w/c: 0.38;

M7: 10% LSP w/c: 0.40 ; M14: 8% LSP+5% SF w/c: 0.40
M15: 30% FA w/c: 0.40
Cost of material
Mix # and composition Total cost ,

SAR
M5 (8% LSP; w/c: 0.4) 270
M6 (8% LSP; w/c: 0.38) 289
M7 (10% LSP; w/c: 0.40) 278
M14 (7% SF; 8% LSP; w/c: 0.40) 321
M15 (30% FA; w/c: 0.40) 340
ELECTRIC ARC FURNACE DUST
Cement Kiln Dust
Limestone Powder
Oil Ash
Natural Pozzolan
75
EAFD CEMENT CONCRETE
C ompressive strength, M Pa
HIGH
STRENGTH
70
70 HIGH
EAFD-0 EAFD-5 STRENGTH
65 EAFD-0 EAFD-50
65
EAFD-10 EAFD-15
60
60 EAFD-60
55
55
50
50
MEDIUM MEDIUM
45
STRENGTH 45 STRENGTH
40 40
35 35 LOW
STRENGTH
30 LOW
30
STRENGTH
25 25
20 20
15 15
VERY LOW
VERY LOW
10 STRENGTH 10 STRENGTH
5 5
0 0
0 20 40 60 80 100 0 20 40 60 80 100

76 w/cm: 0.45 w/cm: 0.55
WATER ABSORPTION
Water absorption, %
Water absorption, %
6.00 6.00
5.46 5.51
5.34
4.91
5.00 4.61 5.00
4.31
4.11
4.00 4.00
3.00 3.00
2.00 2.00
1.00 1.00
0.00 0.00
EAFD-0 EAFD-5 EAFD-10 EAFD-15 EAFD-0 EAFD-50 EAFD-60

77 w/cm: 0.45 w/cm: 0.55
DRYING SHRINKAGE

800 800
700 700
500 500
400 400
EAFD-0 EAFD-5 EAFD-50

300 300
EAFD-60
EAFD-10 EAFD-15
200 200
100 100
0 0
0 20 40 60 80 100 120 140 160 180 0 20 40 60 80 100 120 140 160 180

78 w/cm: 0.45 w/cm: 0.55
Electrical R esistivity, k.O hm.cm
Electrical Resistivity, k.O hm.cm

500
1200 EAFD-50
450
EAFD-0 EAFD-5 EAFD-60
1100
EAFD-10
Electrical
EAFD-15 400
1000 Risk of Electrical Risk of
Mix resistivity at
reinforcement Mix resistivity at reinforcement
900 designation 3% moisture 350
corrosion designation 3% moisture corrosion
k.Ohm.cm
k.Ohm.cm
300 EAFD-50 32.0 Moderate
Moderate
EAFD-05 38.8 EAFD-60 26.8 Moderate
700
Moderate 250
EAFD-10 39.2
600
Moderate
EAFD-15 39.2 200
500
400 150
300
100
200
50
100
0 0
1.00 6.00 11.00 16.00 21.00 26.00 0.00 5.00 10.00 15.00 20.00 25.00

79 w/cm: 0.45 w/cm: 0.55
C o rro sio n Po tentia ls, mV SC E

Co rro sion Potentials, mV SC E
-650
-650
-600
-600
-550
-550
-500
-500
-450
-450
-400 -400
-350 ASTM C 876 Threshold Value -350 ASTM C 876 Threshold Value
-300 -300
-250 -250
-200 -200
-150 EAFD-0 EAFD-5
-150
EAFD-50
-100 EAFD-10 EAFD-15 -100
EAFD-60
-50 -50
0 0
0 20 40 60 80 100 120 140 160 180 200 220 240 0 20 40 60 80 100 120 140 160 180 200 220 240

80 w/cm: 0.45 w/cm: 0.55
C o r r o s io n c u r r e n t d e n s ity , m A /c m 2
C o r r o sio n c u r r e n t d e n s ity , µ A /c m 2
1.00
1.00
EAFD-0 EAFD-5
EAFD-50
EAFD-10 EAFD-15
0.80 EAFD-60
0.80
0.60
0.60

0.40
0.40
0.20
0.20
0.00 0.00
0 50 100 150 200 250 300 350 0 20 40 60 80 100 120 140 160

81 w/cm: 0.45 w/cm: 0.55

3.00
3.00
2.52 2.57
2.40 2.43 2.45
2.50
2.50 2.34
2.00
2.00
1.50
1.50
1.00 1.00
0.50 0.50
0.00 0.00
EAFD-0 EAFD-5 EAFD-10 EAFD-15 EAFD-50 EAFD-60

82 w/cm: 0.45 w/cm: 0.55
SETTING TIME
Normal EAFD
Mix Consistency, % Setting time, minutes

Initial Final
OPC 25.7 200 265
ASTM C 150
EAFD (5%) 26.6 325 415 Initial Final
EAFD (10%) 24.8 525 615 setting setting
time time
EAFD (15%) 31.6 776 1123
45 600
EAFD (50%) 28 1230 1470 min min
EAFD (60%) 27.2 1423 1672
Thermally Treated EAFD

Time of setting, minutes
Mix Consistency
Initial Final
EAFD (50%) 38.6 325 415
EAFD (60%) 35.3 525 615
83
LEACHING OF HEAVY METALS
Heavy EAFD EAFD EAFD EAFD EAFD TCLP
metals 5% 10% 15% 50% 60% limits
mg/kg mg/kg mg/kg mg/kg mg/kg mg/kg
Ag <0.010 <0.010 <0.010 <0.010 <0.010 < 5.0
Al <0.003 <0.003 <0.003 <0.003 <0.003 --
As <0.006 <0.006 <0.006 <0.006 <0.006 < 5.0
Ba 0.117 0.123 0.119 0.114 0.103 < 100.0
Cd <0.001 <0.001 <0.001 <0.001 <0.001 < 1.0
Co <0.001 <0.001 <0.001 <0.001 <0.001 --
Cr 0.271 0.308 0.359 1.38 1.86 < 5.0
Fe <0.050 <0.050 <0.050 <0.050 <0.050 --
Hg <0.050 <0.050 <0.050 <0.050 <0.050 < 0.1
Mn <0.002 <0.002 <0.002 0.020 0.010 --
Ni <0.002 <0.002 <0.002 0.010 0.013 < 25
Pb <0.010 <0.010 <0.010 <0.010 <0.010 5.0
V 0.091 0.074 0.063 0.069 0.064 25
Zn <0.003 <0.003 <0.003 0.712 0.650 250
84
OIL ASH
Cement Kiln Dust
Limestone Powder
Oil Ash
Natural Pozzolan
85
OA CEMENT CONCRETE
70
HIGH
60 STRENGTH
50
40
MEDIUM
STRENGTH
30
LOW
STRENGTH
OA-0 OA-5
20
OA-10
10
VERY LOW
STRENGTH
0
0 20 40 60 80 100
Period of curing, days
Cementitious material: 370 kg/m3

86 w/cm: 0.45
WATER ABSORPTION
Water absorption, %
OA CEMENT CONCRETE
6.00
5.23
5.00 4.42
4.11
4.00
3.00
2.00
1.00
0.00
OA-0 OA-5 0A-10

87 w/cm: 0.45
DRYING SHRINKAGE
Shrinkage strain, microns OA CEMENT CONCRETE
700
OA-0 OA-5 OA-10
600 Threshold
500
400
300
200
100
0
0 20 40 60 80 100 120 140 160 180 200 220 240

88 w/cm: 0.45
OA CEMENT CONCRETE
T h erm al C on du ctivity, W /m K
3.00
2.51
2.40 2.37
2.50
2.00
1.50
1.00
0.50
0.00
OA-0 OA-5 OA-10

89 w/cm: 0.45
E lectrica l R esistiv ity , k.O hm .cm
OA CEMENT CONCRETE
1200
1100
OA-0 OA-5 OA-10
1000 Electrical
Risk of
Mix resistivity at
reinforcement
900 designation 3% moisture
corrosion
k.Ohm.cm
OA-05 103.4 Negligible
700
OA-10 120.1 Negligible
600
500
400
300
200
100
0
1.00 2.00 3.00 4.00 5.00
Moisture content, %

90 w/cm: 0.45
C o rro sio n Po tentia ls, m V SC E
OA CEMENT CONCRETE
-850
-800 OA-0 OA-5 OA-10
-750
-700
-650
-600
-550
-500
-450
-400
ASTM C 876 Threshold Value
-350
-300
-250
-200
-150
-100
-50
0
0 20 40 60 80 100 120 140 160 180 200 220 240

91 w/cm: 0.45
OA CEMENT CONCRETE
OA-0 OA-5 OA-10

0.80
0.60
Threshold Value
0.40
0.20
0.00
0 50 100 150 200 250 300 350

92 w/cm: 0.45
LEACHING OF HEAVY METALS
OA CEMENT CONCRETE
TCLP-
OA 5% OA 10% TCLP limits
Elements
mg/kg mg/kg mg/kg
Ag <0.010 <0.010 5.0
Al <0.003 <0.003 --
As <0.006 <0.006 5.0
Ba 0.089 0.062 100.0
Cd <0.001 <0.001 1.0
Co <0.001 <0.001 --
Cr 0.227 0.191 5.0
Fe <0.050 <0.050 --
Hg <0.050 <0.050 0.1
Mn <0.002 <0.002 --
Ni 0.032 <0.002 25
Pb <0.010 <0.010 5.0
V 2.27 4.70 25
Zn <0.003 <0.003 250
93
NATURAL POZZOLAN
Cement Kiln Dust
Limestone Powder
Oil Ash
Natural Pozzolan
94
NP CEMENT CONCRETE
C o mpressiv e streng th, M Pa

HIGH
STRENGTH
80
NP-0 NP-10 80
70 NP-15 NP-20 NP-0 NP-50 HIGH
70 STRENGTH
NP-60
60
60
50
50
40 MEDIUM MEDIUM
STRENGTH 40 STRENGTH
LOW
30 STRENGTH
LOW 30
STRENGTH
20
20
10 10
VERY LOW VERY LOW
STRENGTH STRENGTH
0 0
0 20 40 60 80 100 0 20 40 60 80 100

95 w/cm: 0.45 w/cm: 0.55
WATER ABSORPTION
NP CEMENT CONCRETE
Water absorption, %
Water absorption, %
6.00 6.00
5.50
5.34
5.15 5.18
4.98
5.00 5.00
4.35
4.11
4.00 4.00
3.00 3.00
2.00 2.00
1.00 1.00
0.00 0.00
NP-0 NP-10 NP-15 NP-20 NP-0 NP-50 NP-60

96 w/cm: 0.45 w/cm: 0.55
DRYING SHRINKAGE
NP CEMENT CONCRETE

700 700
500 500
400 400
300 300
NP-
50
200 200 NP-
NP-0 NP-10 60
100 NP-15 NP-20 100
0 0
0 20 40 60 80 100 120 140 160 180 0 20 40 60 80 100 120 140 160 180

97 w/cm: 0.45 w/cm: 0.55
NP CEMENT CONCRETE
E le c tr ic a l R e sistiv ity , k.O hm .c m
Electrica l R esistiv ity , k.O hm.cm

2400
2400
NP-0 NP-10 2200
2200 NP-50 NP-60
Electrical
NP-15 NP-20 2000 Electrical
Risk of Risk of
2000 Mix resistivity at Mix resistivity at
reinforcement reinforcement
designation 3% moisture designation 3% moisture
corrosion 1800 corrosion
1800 k.Ohm.cm k.Ohm.cm
CONTROL 34.2 Moderate 1600 NP-50 87.0 Low
1600
NP-10 36.9 Moderate 1400 NP-60 87.7 Low
1400
1200 NP-15 55.2 Moderate 1200
1000 NP-20 39.6 Moderate 1000
800 800
600 600
400 400
200 200
0 0
1.00 6.00 11.00 16.00 21.00 26.00
1.00 6.00 11.00 16.00 21.00 26.00

98 w/cm: 0.45 w/cm: 0.55
NP CEMENT CONCRETE
C orrosio n Potentials, mV SCE

-850
-850 NP-50 NP-60
NP-0 NP-10 -800
-800
-750 NP-15 NP-20 -750
-700 -700
-650 -650
-600 -600
-550 -550
-500 -500
-450 -450
-400 -400
-350 ASTM C 876 Threshold Value
-350
-300 ASTM C 876 Threshold Value -300
-250 -250
-200 -200
-150 -150
-100 -100
-50 -50
0 0
0 20 40 60 80 100 120 140 160 180 200 220 240 0 20 40 60 80 100 120 140 160 180 200 220 240

99 w/cm: 0.45 w/cm: 0.55
NP CEMENT CONCRETE
C o r r o sio n c u r r e n t d e n s ity , µ A /c m 2
1.00
NP-0 NP-10 1.00
NP-15 NP-20 NP-50 NP-60

0.80
0.80
0.60
0.60
Threshold Value
0.40 Threshold Value 0.40

0.20 0.20
0.00 0.00
0 50 100 150 200 250 300 350 400 450 500 0 50 100 150 200 250 300 350 400 450 500

100 w/cm: 0.45 w/cm: 0.55
NP CEMENT CONCRETE

2.50 2.40
2.33 2.29 2.34 2.39
2.50
2.15
2.00
2.00
1.50
1.50
1.00 1.00
0.50 0.50
0.00 0.00
NP-0 NP-10 NP-15 NP-20 NP-50 NP-60

101 w/cm: 0.45 w/cm: 0.55
RECOMMENDATIONS
Concrete Applications
High strength structural concrete with
CKD 0 – 20% moderate durability for beams, columns,
footings, slabs, etc.,
Non-structural concrete with moderate
CKD 50 – 60% durability as blinding concrete, pavements,
insulation material, trench fill, etc.,
High strength structural concrete with high
LSP 5 - 10% durability for beams, columns, footings,
slab, etc.,
Medium strength structural concrete with
LSP 15% moderate durability requirements for
beams, columns, slab, footings, etc.,
Non-structural concrete with moderate
LSP 50 - 60% durability as blinding concrete, electric
trench material, etc.,
102
RECOMMENDATIONS
Concrete Applications
High strength structural concrete with high durabity
EAFD 5%
for beams, columns, footings, slab, etc.,
Medium strength structural concrete with moderate
EAFD 10 - 15%
durability for beams, columns, slabs, footings, etc.,
Non-structural concrete with low durability for
EAFD 50 - 60%
blinding concrete, pavements, and blocks etc.,
OA 5%
durability for beams, columns, footings, slab, etc.,
Medium strength structural with moderate
OA 10% durability applications for beams, columns, slab,
footings, etc.,
NP 10%
durability for beams, columns, footings, slab, etc.,
Medium strength structural applications with
NP 15 -20% moderate durability for beams, columns, footings
and slab etc.,
Non-structural strength concrete with low durability
NP 50 and 60%
103 for blocks, blinding concrete, pavements, etc.,
Silico-Managanese fume
SABAYEK, Jubail, Saudi Arabia
• Ferro alloys production

(a) (b)
capacity 230,000 mt/year (a) (b)
• 100 kg of SiMn fume is

generated per ton of alloy
(c) (d) (c) (d)
• Approximately 32 to 33
metric ton (mt) of fumes
are generated per day
(a) (b)
(a) (b)
• Approximately 11,680-
12,045 mt/year
104 (c) (d)
(c) (d)
Silico-Manganese fume
Disposal
Disposal is
is aa major
major
environmental
environmental problem
problem
105
Silico-manganese fume
Comparison of by products production
Source material Material Production By-Product
By-Product
Production Quantity Quantity
Silico Manganese Fumes (SiMn) SiMn Alloys 1 ton 100 kg
Ground Granulated Blast Furnace Steel 1 ton 350 – 500 kg
Slag (GGBFS)
Electric Arc Furnace Dust (EAFD) Steel 1 ton 15 to 20 kg
Cement Kiln Dust (CKD) Cement 1 ton 60 to 70 kg
Production of Ferro alloys in the world

Reference Company Ferro alloys production
Annual conference, 2018 Pertama Ferroalloys Sdn. Bhd (Malaysia) 230,000 mt/year
Annual conference, 2018 Sakura Ferroalloys Sdn Bhd(Malaysia) 174,000 mt/year
OM Materials (Sarawak) Sdn Bhd
Annual conference, 2018 250-300,000 mt/year
(Malaysia)
SABAYEK SABAYEK
120-135,000 mt/year
(Saudi Arabia)
Skopski Leguri
Skopski Leguri 98,000 mt/year
(Macedonia)
Zhdanov et al., (2015) Russia 1,109,000 mt/year
106
http://news.steel-360.com/steel/the-slag-the-steel-industry/
Chemical and physical properties of SiMn
Fume and Silica Fume
SiMn Fume Property SiMn Fume Silica Fume Silica Fume

Reddish Gray to off
Appearance
brown white
Shape Spherical Spherical
Specific gravity 0.98 g/cc 2.2 g/cc
BET surface area 8.1 m2/g 23 m2/g
Average particle size 0.491 µm 0.37 μm
1: Mn Fe2 O4, 2: Quartz (SiO2), 3: Sylvite (KCl)
Chemical
SiO2 Al2O3 Fe2O3 CaO MgO K2O SO3 MnO Na2O Cl ZnO P2O5 LOI
Composition
SiMn Fume 14.47 1.24 2.37 4.61 4.78 27.25 6.16 33.13 1.64 3.28 0.73 5.7
Weight (%)
Silica Fume 93.62 0.73 0.24 0.76 1.8 1.24 0.51 1.07 1.55
107
Development of Self-Compacting Concrete
Utilizing Silico Manganese Fume
 Assess proportions of SMF that can be used to

produce SCC meeting flowability criteria.
 Assess the mechanical properties of SCC
incorporating SMF.
 Evaluate the technical and economic benefits of
using SMF in lieu of Portland cement and other
fillers in SCC.
 Carry out statistical analysis of data and develop
correlation models between the properties of
SCC developed using SMF.
 Provide recommendations regarding the use of
SMF for producing SCC.
Constituents
 Constituents
 Cement
 Silico-manganese fume
 Limestone powder
 Aggregates
 Superplaticizer
 Stabilizer
Mix proportions
Cement Content (0-500) kg/m3 (Variable)
Total mineral SMF (0-500) kg/m3 (Variable)
Total binder 500 kg/m3

Water/Cement 0.4
CA/total aggregate 0.5
SP (0.8-1.1)%
VMA (0-0.15)%
Limestone Powder/Total 0.1

aggregate
Tests
 Flow properties  Hardened properties

 Flow table  Compressive
 V-funnel strength
 U-tube  Tensile strength
 L-box  Flexural strength
 Sieve Segregation  Modulus of elasticity
resistance.  Drying shrinkage
 Slump retention
 Setting time
 Plastic shrinkage strain
Flow properties
T50 V-
S/N Flow table slump funnel U-Box L-Box Sieve SP (as % of VMA
ratio segregation binder) % Remarks
flow time
(650-800) (2-5) (6-12) (0-30) (0- 15)
Range mm (s) mm (0.8-1) - - -
(s) %
Control 670 4.5 11.5 18 0.81 12.8 0.8 0.15 Accepted
SMF10 675 4 11 15.5 0.83 14.5 0.8 - Accepted
SMF20 672 3.7 9.5 13.2 0.845 13.6 0.83 - Accepted
SMF30 680 3.3 9 11.1 0.86 13.2 0.87 - Accepted
SMF40 677 3 7.5 9 0.885 14.1 0.9 - Accepted
SMF50 670 2.8 7 7.6 0.9 12.8 0.92 - Accepted
SMF60 676 2.4 6.5 6.1 0.915 13.4 0.96 - Accepted
SMF70 672 2 6 4.2 0.925 12.9 0.98 - Accepted
SMF80 677 1.5 4.5 3 0.94 13.9 1.03 - Not selected
SMF90 671 1.5 4 1.5 0.951 13.4 1.06 - Not selected
SMF100 675 1.5 3.5 1.5 0.96 13.9 1.1 - Not selected
C o m p r e ssiv e S tr e n g th (M P a )
28-days compressive strength
60.0
50.0
40.0
30.0
20.0
10.0
0.0
0 10 20 30 40 50 60 70
SMF %
Split tensile strength (M Pa)
28-day split tensile strength
6.0
5.0
4.0
3.0
2.0
1.0
0.0
0 10 20 30 40 50 60 70 80 90 100
SMF %
F lexu ral S tren gth (M P a)
28-day flexural strength
7.0
6.0
5.0
4.0
3.0
2.0
1.0
0.0
0 10 20 30 40 50 60 70 80 90 100
SMF%
Plastic shrinkage strain
Cost analysis
100.0
Cost ($/m3)
81.2
75.0
75.4
70.7
66.1
61.4
56.6
50.0 52.0
47.2
25.0
0.0
SMF0 SMF10 SMF20 SMF30 SMF40 SMF50 SMF60 SMF70
SMF %
CO2 emission
Recommendation
Parameter Value
FA/TA 0.5
SMF Up to 350 kg/m3 as per the
strength requirement
Superplasticizer 0.8 – 1.1% by weight of powder
Water/powder ratio 0.40

Cement Up to 150 kg/m3 as per the
strength requirement
Total powder 500 kg/m3
Stabilizer Not required
USE OF RED MUD FOR THE
PRODUCTION OF GREEN CONCRETE
 Red mud (RM) is a solid waste residue produced during the

digestion of bauxite ore with caustic soda during the production of
alumina.
 Its disposal remains a worldwide issue due to environmental
concerns. RM poses a wide range of environmental problems due
its disposal in open ponds.
 Underground water resources, such as wells and aquifers, may be
polluted due to improper disposal of RM.
 Also, alkaline airborne dust is carried by air, affecting the
transpiration process of plants. Disposal of RM in landfills changes
the property of soil and results in partial or complete loss of
fertility.
 Vast areas of land are used for the disposal of RM and other
industrial byproducts. The incorporation of RM in Portland cement
or asphalt concrete may offer a much sought after opportunity to
mitigate today’s waste management problems
Objectives
 Evaluate the chemical composition and physical properties

of indigenous RM.
 Prepare trial mixtures and test to determine the optimum
proportions of RM that can be beneficially utilized to
produce green concrete.
 Determine the mechanical properties and durability
characteristics of concrete produced with the selected
proportions of RM.
 Assess the economic feasibility of the developed RM
concrete.
 Recommend avenues for use of the developed green
concrete produced using RM.
Properties of Red mud
Physical properties Value

Specific gravity 2.33
Apparent specific gravity 2.53
Saturated surface dry moisture content, % 3.88
Chemical composition Value
Al2O3, % 24.95
Fe2O3, % 16.73
SiO2, % 20.02
Na2O, % 9.57
TiO2, % 9.76
CaO, % 6.43
LOI, % 12.54
Setting time
Setting time, minutes ASTM C150 limits

Composition
Mix
(Cement + Red mud)
Initial Final Initial Final
CR-RM0 100% OPC + 0% red mud 96 285
CR-RM5 95% OPC + 5% red mud 109 300
CR-RM10 90% OPC + 10% red mud 112 300
More than Less than

CR-RM15 85% OPC + 15% red mud 128 300
45 minutes 600 minutes
CR-RM20 80% OPC + 20% red mud 137 300
CR-RM25 75% OPC + 25% red mud 141 320
CR-RM30 70% OPC + 30% red mud 149 320

Composition
Mixture Mix details Remarks
designation
CONTROL OPC 100% Control Mix
CR-RM-20 OPC 80% + RM 20% 20% cement replaced with

RM
CR-RM-25 OPC 75% + RM 25% 25% cement replaced with
RM
AR-RM-15 OPC 100% + RM 15% of 15% fine aggregate (sand)

FA replaced with RM

FA replaced with RM

FA replaced with RM
Shrinkage
Heat of hydration
Water absorption
Acid-resistance
Reinforcement corrosion
Recommendation
 Up to 25% fine RM can be used, as a replacement of cement, to

produce high strength and durable concrete. In view of considerable
strength gain of concrete prepared with 25% fine RM, it is suggested
to use RM after pulverizing it to save cement and produce high
quality concrete. The use of RM as a partial substitute for cement
leads to a decrease in the cost of concrete, conserves energy and
protects the environment by minimizing greenhouse gas emission
associated with cement production.
 Up to 15% RM can be used to replace fine aggregate. Such use
increases the compressive strength and enhances the durability of
standard cement concrete. Even though this type of concrete does
not decrease the cost of concrete, it enhances durability, thereby
resulting in an increase in the useful service-life of concrete
structures.
UTILIZATION OF FOAM AND PHOSPHOGYPSUM FOR THE
DEVELOPMENT OF THERMAL AND ACOUSTIC
INSULATION MATERIALS FOR BUILDINGS
 Objective
 Ascertain the proportions of PG to produce lightweight
concrete.
 Determine the mechanical, thermal and acoustic
properties of lightweight concrete produced with the
combination of optimum dosage of PG and foam.
 Provide recommendations on the mixture design
parameters for a lightweight concrete with efficient
thermal and acoustic properties.
Morphology and chemical
composition of phosphogypsum
Composition of phosphogypsum
mixtures
Weights of materials, kg/m3
w/
Mix# c
Proportion of Coarse Fine rati
phosphogypsum
Cement Phosphogypsum
aggregate aggregate
o
M0 0 400 0 1105 737 0.4
M10 10 360 20 1125 750 0.4
M20 20 320 80 1144 763 0.4
M40 40 240 160 1184 790 0.4

Evaluation
Property Specimen size and Test age Test method
geometry
Unit weight 50x50x50 mm cube 24 hours of casting ASTM C138 [2]
Compressive 50x50x50 mm cube 3, 7, 14, 28, 60, 90, 120, ASTM C39 [3]
strength and 180 days
Flexural strength 40x40x160 prism After 28 days of curing ASTM C78 [4]
Modulus of 75 x 150 mm cylinder After 28 days of curing ASTM C469 [5]
elasticity
Water absorption 75 x 150 mm cylinder After 28 days of curing ASTM C642 [6]
Rapid chloride 100 x 200 mm cylinder After 28 days of curing ASTM C1202 [7]
permeability
Drying shrinkage 25x25x285 prism Length change ASTM C157 [8]
Expansion of 25x25x285 prism Length change ASTM C1012 [9]
concrete
Acid resistance 50x50x50 mm cube After 3 and 6 months of Non-standard
exposure to 2% H2SO4
After 6 months of
Sulfate resistance 50x50x50 mm cube exposure to 5% Na2SO4 ASTM C1012 [9]
and 5% MgSO4
Unit weight
2400
2300
3
Unit weight of concrete, kg/m
2200
2100
2000
1900
1800
0 10 20 30 40 50 60 70 80
PG, % (Replacement of sand)
Detailed evaluation
Detailed evaluation
50 800
45.2 M0
700 M10
M20
40
600 M40
Drying Shrinkage, microstrain

33.4
Modulus of Elasticity, GPa
30.8
500
30
23.8 400
20 300
200
10
100
0
0
0 20 40 60 80 100 120
M0 M10 M20 M40
PG, % Replacement of cement Exposure period, days
Detailed evaluation
8 4000
3,752 3,799
3,477
6.90
3,343
6.46
6.12
6 3000
5.22
Chloride permeability, Coulombs

Water Absorption, %
4 2000
2 1000
0 0
0 10 20 40 M0 M10 M20 M40
PG, % (Replacement of cement) PG, % replacement of cement
Detailed evaluation
Sulfate exposure
Foam concrete
>2000 kg/m3 Normal >20 MPa Structural

weight high strength lightweight concrete
>1400 kg/m3 Lightweight 5-20 MPa Low strength

medium strength lightweight concrete
<1400 kg/m3
Lightweight low
strength <5 MPa Thermo-insulation
lightweight concrete
Density Compressive strength

Foam concrete
Normal
Lightweight high weight high
strength concrete strength
concrete
Normal weight
Lightweight medium
medium strength
strength concrete
concrete
Lightweight low strength

concrete Normal weight low
strength concrete
Concrete with foam and
Phosphogypsum
2500
4%-Foam 12%-Foam
2000
3
Unit weight, kg/m
1500
1000
500
0
M0 M10 M20 M40
PG, % replacement of cement
Phosphogypsum
12
4%-Foam 12%-Foam
10
Water absorption, %
0
M0 M10 M20 M40
PG, % replacement of cement
Phosphogypsum
Recommendations
 Concrete with more than 50% PG, replacing fine aggregate or cement,
can be used as a structural lightweight concrete (Unit weight less than
2,000 kg/m3 and 28-day compressive strength of 30 MPa or more). The
applications include, beams, columns, footings and other load bearing
structural elements. However, concrete with 70% and more PG can be
used as medium strength-lightweight concrete (Compressive strength
between 20 and 30 MPa and unit weight of less than 2,000 kg/m3).
 Appropriate precautions, such as the application of a coating is
necessary, in wet environments since the water absorption of
lightweight concrete is more than that of the control concrete. Also,
lightweight concrete should be used in conjunction with a protective
acid-resistant surface coating in acidic environments.
 Foam can be used to produce lightweight concrete. Concrete with
more than 7.5% foam satisfied the lightweight concrete criterion.
Recommendations
 The quantity of foam should be restricted to 1% to produce structural grade

concrete (compressive strength of more than 30 MPa). However, it should be
restricted to 7.5% to produce a concrete of 5 MPa compressive strength. This
foam concrete can be used as low strength thermal insulation concrete.
 Concrete with 40% PG and 12% foam can be used to produce a thermal insulating
lightweight material with low strength requirements. The PG foam concrete
cannot be used as a replacement of polystyrene board. However, it can be used
as a final layer of the roofing system, because of which the thickness of
polystyrene board can be reduced accordingly. Also, the developed lightweight
concrete can be used to produce partition walls and blocks.
 A similar composition can be used to produce a sound absorbing low strength
concrete, such as partition walls.
 Phosphogypsum from some sources is known to emit radiation. The average
radiation level of the used phosphogypsum was 0.05 µSv/h, which is within the
safe permissible limits. However, a detailed study on this aspect is recommended
prior to the use of phosphogypsum as a building material.
Thank You

Lecture 11 - Natural Materials and Industrial Byproducts

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CE 601 (211)

 Baghouse dust – filler/retarder

Cement Kiln Dust (CKD)

 Production of cement clinker typically generates around 6

 Generation of CKD in the Kingdom is approximately 3.5

 Arabian Cement Company Ltd. (ACCL), Jeddah,

 The concentration of alkalies, chloride and sulfate is

 Limestone quarry filtration system (circulated area).

 The annual steel production in Saudi Arabia is 471,000 tons.

 1 ton of steel generates 1.5 to 2% of EAFD.

 Approximately, the annual production of EAFD in Kingdom is 8,242 tons.

 Natural raw material.

 Sources: Volcanic ash, shales, etc.

 Pozzolanic material meets ASTM C 618.

 In Kingdom NP is available in basalt plateaus (Harrat)

Mix details Average Strength activity ASTM C618

OPC 26.2 200 212

SABAYEK, Jubail, Saudi Arabia

• Ferro alloys production

• 100 kg of SiMn fume is

Production of Ferro alloys in the world

SiMn Fume Property SiMn Fume Silica Fume Silica Fume

1: Mn Fe2 O4, 2: Quartz (SiO2), 3: Sylvite (KCl)

 Improvement in the activity of pozzolan

 Earlier studies were conducted mostly on

I (95%) + 1,794 Low

V (95%) + 2,492 Moderate

 Compressive strength of both Type I and Type V

 The electrical resistivity of concrete decreased

 Increase in the chloride permeability and

The quantity of CKD in concrete should be

C o mpressive streng th, M Pa

Cementitious material: 370 kg/m3 Cementitious material: 300 kg/m3

6.00 6.00 5.58

Cementitious material: 370 kg/m3 Cementitious material: 300 kg/m3

Shrinkage strain, microns

Period of exposure, days

Cementitious material: 370 kg/m3 Cementitious material: 300 kg/m3

Electrica l R esistivity, k.O hm.cm

CKD-0 CKD-5 300 CKD-50 CKD-60

CKD-10 28.9 Moderate 150 CKD-60 15.2 Moderate

CKD-20 21.2 Moderate

Cementitious material: 370 kg/m3 Cementitious material: 300 kg/m3

C o rro sion Potentials, mV SC E

Cementitious material: 370 kg/m3 Cementitious material: 300 kg/m3

Threshold Value Threshold Value

Cementitious material: 370 kg/m3 Cementitious material: 300 kg/m3

T h erm a l C o n d u ctiv ity , W /m K

2.56 2.59 2.60

Cementitious material: 370 kg/m3 Cementitious material: 300 kg/m3

C ompressive streng th, M Pa

Cementitious material: 370 kg/m3 Cementitious material: 300 kg/m3

5.00 4.71 4.72 5.00

Cementitious material: 370 kg/m3 Cementitious material: 300 kg/m3

Shrinkage strain, microns

600 Threshold 600 Threshold

LSP-0 LSP-5 LSP-50

Cementitious material: 370 kg/m3 Cementitious material: 300 kg/m3

Electrica l R esistiv ity , k.O hm.cm

Moisture content, % Moisture content, %

Cementitious material: 370 kg/m3 Cementitious material: 300 kg/m3

C o rro sio n Po tentia ls, mV SC E

Cementitious material: 370 kg/m3 Cementitious material: 300 kg/m3