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Cements with calcareous fly ash as component of low clinker eco-self compacting concrete

  • Jacek Gołaszewski EMAIL logo , Grzegorz Cygan , Tomasz Ponikiewski and Małgorzata Gołaszewska
Published/Copyright: July 11, 2019
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Open Engineering
From the journal Open Engineering Volume 9 Issue 1

Abstract

The main goal of the presented research was to verify the possibility of obtaining ecological self-compacting concrete of low hardening temperature, containing different types of cements with calcareous fly ash W as main component and the influence of these cements on basic properties of fresh and hardened concrete. Cements CEM II containing calcareous fly ash W make it possible to obtain self-compacting concrete (SCC) with similar initial flowability to analogous mixtures with reference cement CEM I and CEM III/B, and slightly higher, but still acceptable, flowability loss. Properties of hardened concretes with these cements are similar in comparison to CEM I and CEM III concretes. By using cement nonstandard, new generation multi-component cement CEM “X”/A (S-W), self-compacting concrete was obtained with good workability and properties in hardened state.

Keywords: calcareous fly ash; self-compacting concrete

1 Introduction

Eco-concrete is defined as a concrete which uses waste materials as at least one of its components, its production process does not lead to environmental destruction, and it has high performance and life cycle sustainability (Fib Bulletin No. 67: Guidelines for green concrete structures, 2012). The eco-concrete is characterised by the optimization of use of materials and mix design, which especially includes: minimization of cement and clinker content through its substitution with mineral additives; enhanced workabilityof fresh concrete, best by using self-compacting concrete (SCC), enhanced durability and service life, and last butnot least, acceptable cost, obtained by usage of commonly and locally available low cost materials and technologies. (Suhendro, 2014)

Thermal effects associated with cement hydration are of particular importance for concrete durability (Neville & Brooks, 2010). They can cause cracking in the whole volume of concrete element lowering its durability and shortening its service life-time. The problem is especially important in the case of SCC which is usually characterized by high cement content. Thus, composition concept of eco-SCC with low hydration heat was developed and presented in (Gołaszewski & Cygan, 2017a) (Gołaszewski & Cygan, 2017b).

One of mineral admixtures which could be used in eco-concrete is calcareous fly ash W (CFA-W). CFA-W can be the main constituent of cement (EN 197-1:2002, EN 2012-1:2012), however its use is limited due to significant changeability of its chemical composition and physical properties, a high content of free calcium and sulphur compounds which are potentially detrimental to the durability and shrinkage of concrete and its high water demand which negatively affects workability, as seen in (Dziuk et. al. 2013; Felekoǧlu, Türkel, & Kalyoncu, 2009; Giergiczny, Synowiec, & Żak, 2013; Gołaszewski, Kostrzanowska, Ponikiewski, & Antonowicz, 2013; Tsimas & Moutsatsou-Tsima, 2005). However, many studies such as (Czopowski, Łaźniewska - Piekarczyk, Rubińska-Jończy, & Szwabowski, 2013; Dąbrowska & Giergiczny, 2013; Gibas, Glinicki, & Nowowiejski, 2013) show no negative influence of CFA-Won properties of hardened concrete and that negative influence of CFA-W on the workability of fresh concrete may be lower when it is used as a main constituent of cement, as seen in (Czopowski i in., 2013; Dziuk i in., 2013; Gołaszewski i in., 2013). Moreover, CFA-W has pozzolanic and hydraulic properties, due to the high content of active silica, mostly in amorphous phase; hydration mechanisms of CFA-W were presented in (Giergiczny, Garbacik, & Ostrowski, 2013).

The main goal of the presented research was to verify the possibility of obtaining eco-SCC containing different types of cements with CFA-W as a main component. The scope of application of eco-SCC covers all types ofconstruction, but it is especially dedicated for to semi-massive and massive constructions. Therefore, the influence of CFA-W addition to cement for SCC was analysed, both in terms of possibility of obtaining SCC concrete, and its thermal characteristics.

2 Materials and methods

Influence of 7 types of cements containing CFA-W W as a main component on properties of fresh and hardened self-compacting concrete was investigated. Properties of these cements, produced by the Institute of Ceramics and Building Materials in Cracow, are presented in details in Table 1. Cements were obtained by intergrinding the constituents. As data in Table 1 indicate, properties of cements containing CFA-Wmeet the requirements for common cements according to EN 197-1. The properties of SCC with CFA-W cements were compared to concretes with CEM I and CEM III/B cements.

Table 1

Cement properties

ParametersCement
CEM ICEM III/BCEM II/AWCEM II/BM (V-W)CEM II/BM (S-W)CEM II/BM (LL-W)CEM IV/BWCEM IV/B (V-W)CEM „X”(S-W) 1
Constituent, % massClinker94.581.166.764.766.045.848.047.9
Fly ash W-14.314.315.314.050.024.023.9
Fly ash V-14.324.0
Slag S-7015.323.9
Limestone LL-14.0
Gypsum5.54.64.74.76.04.24.04.3
Components, % massLOI1.920.862.282.051.926.102.302.242.14
SiO220.3524.3726.4724.4919.6025.9729.5126.94
Al2O34.486.909.526.996.1511.5412.688.98
Fe2O32.062.463.282.442.303.764.162.93
CaO66.5658.2752.4257.9160.6850.2844.1052.02
MgO0.930.981.351.771.031.391.672.28
K2O0.540.530.610.190.140.150.940.53
Na2O0.240.700.260.340.300.220.280.440.26
SO32.821.953.013.163.113.303.193.33
Surface, cm2/g383052904190413042304430420041303810
Setting time, min152204173204197232213356252
Compressive strength, MPa2 d27.523.520.417.118.011.612.011.7
7 d48.726.940.935.634.536.022.323.2
28 d56.355.350.147.449.845.637.737.740.3
Water demand, %26,531.927.628.629.227.234.630.829.8
Flow diameter, cm18,016.414.912.917.016.015.6
Shrinkage after 28 days, %0,33-0.40-0.46-0.42-0.31-0.28-0.44-0.36
Hydration heat after 72 h, J/g287,3225287.8258.3276.5264.9239.6238.8222.1

Concrete composition is presented in Table 2. Concretes were designed according to the concept of eco-SCC with low hydration heat, first of all aiming at minimization of cement content, and thereby clinker content in concrete. Flowability of all eco-SCCs was designed for slump flow diameter 650 mm ± 40 mm (flow class SF1 - SF2, according to EN 12350-8:2010) by appropriately choosing the amount of superplasticizer (SP). Polycarboxylic-ether-based SP was selected on the basis of preliminary tests as giving optimal balance between high fluidity and stability of the fresh concrete. Natural aggregate was used with maximum grain diameter of 16 mm, with 45%of fine fraction (<2 mm).

Table 2

Composition of concrete

MaterialB0B1B2B3B4B5B6B7B8
CEM ICEM III/BCEM II/AWCEM II/BM (V-W)CEM II/BM (S-W)CEM II/BM (LL-W)CEM IV/BWCEM IV/B (V-W)CEM „X” (S-W) 1
Cement, kg/m3306
Sand 0-4 mm, kg/m3969969961932944935917938940
Coarse aggregates 4-11 mm, kg/m3363363360349354350343351352
Coarse aggregates 8-16 mm, kg/m3451451448434439436426436436
Water, kg/m3193
SP, kg/m32.902.904.694.395.754.688.074.814.47
SP, % of cement mass0.940.941.531.431.881.532.641.571.46
w/c0.63
w/ceff0.54
w/peff0.45
Volume of cement paste, dm3294294297294296299301297297
Clinker content, kg/m328992248204198202140147147

The scope of the research included the following properties and tests:

  • Consistency and flow time T500 of concrete was tested using slump-flow test (EN 12350-8). The stability of SCC was evaluated with the Visual Stability Index (VSI; ACI 237 R-07). Measurements were performed 5 and 60 min after the end of mixing. The air content in the concrete mix was determined according to EN 12350-7, 5 min after the end of mixing.

  • Development of concrete hardening temperature was tested using 250 mm cubic samples insulated using styrofoam coating of thickness 100 mm and thermal conduction coefficient 0.044W/m·K (Fig. 1). Temperature of concrete was measured in the middle of a cube, with a temperature probe inserted into concrete at the time of concreting. External temperature during the test was 20◦C.

  • Setting time of concrete was tested using Schleibinger Vikasonik ultrasonic system (Fig. 1). Transmitter and receiver were placed on the sides of cubic sample tested for of concrete hardening temperature development.

  • Hydration heat of cements was measured using isomeric calorimeter TamAir. Measurement was held during 72 hours at a temperature 20◦C.

  • Compressive strength after 1, 7 and 28 days was tested according to PN-EN 12390-3, samples were cured according to PN-EN 12390-2.

Figure 1 Methods of testing development of concrete hardening temperature and setting time.
Figure 1

Methods of testing development of concrete hardening temperature and setting time.

Six samples were tested for each concrete, and average value was used in the analysis.

3 Test results and discussion

Obtained results are compiled in Tables 3 and 4.

Table 3

Heat of hydration of cements with of SP (w/c = 0.54, SP content see Table 2)

SampleCementHydration heat (J/g) at time
1 h12 h24 h36 h48 h72 h
B0CEM I11.8149.92137.59193.30223.92261.30
B1CEM III/B3.219.3911.3522.732.5294.03
B2CEM II/A-W21.5032.0752.42135.75194.12250.65
B3CEM II/B-M (V-W)19.2727.2134.6262.04125.73220.16
B4CEM II/B-M (S-W)4.8610.4514.5622.2337.14102.31
B5CEM II/B-M (LL-W)12.8421.1935.4569.94136.11179.55
B6CEM IV/B-W14.0822.8825.9530.3737.7699.25
B7CEM IV/B (V-W)5.0814.8221.6033.0962.92132.88
B8CEM „X” (S-W)16.4220.9326.7453.5692.17158.96
Table 4

Propeties of SCC

PropertyB0B1B2B3B4B5B6B7B8
CEM ICEM III/BCEM II/A-WCEM II/B-M (V-W)CEM II/B-M (S-W)CEM II/B-M (LL-W)CEM IV/B-WCEM IV/B (V-W)CEM „X” (S-W)
Slump flow diameter, mmafter 5 min675680630665655640630620640
after 60 min640670560610620610540520570
Flow time T500, safter 5 min32.72.82.42.22.23.232.8
after 60 min2.42.92.93.233.1--3.4
VSI indexafter 5 minVSI0VSI0VSI0VSI0VSI0VSI0VSI0VSI0VSI0
after 60 minVSI0VSI0VSI0VSI0VSI0VSI0VSI0VSI0VSI0
Air content, %2,21.92.23.22.82.43.42.42.9
Setting time of concrete, h6.3310.079.7010.911.4316.6011.0719.0817.87
Maximal temperature, oC52,634,849,344,237,94238,639,240,0
Time of max. temperature, h17.9339.9224.529.932.1644.2532.434.436.37
Compressive strength, MPaafter 1 day6.92.274.33.52.92.73.22.42.4
after 7 days37.425.430.828.122.723.915.419.618
after 28 days54.241.443.142.339.842.633.234.833.1

Flowability loss increases with the increase of content of CFA-W in cement. Negative impact of CFA-W on consistency can be linked to its high water demand (Gołaszewski i in., 2013). If the content of CFA-W in cement is on level 15% (B2, B3, B4, B5) the flowability loss is clear, but the fresh SCC keeps fluidity within class SF1 limits. If the content of CFA-Wis between 24 - 50% (B6, B7) the fluidity loss is so high that fresh SCC fluidity is out of SF1 limits, however slump flow diameter remains over 520 mm. In case of fresh SCC with CEM „X”/A (S-W) (B8) slump flow after 60 min remains at the SF1 class limit. Obtained flowability allows to use all the cements with CFA-W for SCC for formation of horizontal and vertical elements with regular reinforcement.

All tested fresh SCCwere stable, segregation resistant, not exhibiting bleeding (VSI0), and were characterized by the air-content of 1,5 - 3,5%. Air content of fresh concretes with CFA-W cements is insignificantly higher (by about 1 - 1,5%) than of reference concretes B0 and B1. It is probably due to higher viscosity of fresh SCC with CFA-W cements, which impedes their ability to remove air from the fresh concrete.

The use of cements with CFA-W delays the setting time of concrete in relation to concrete with CEM I cement, and the delay amounts from 50% to even 200% (from 3H to 13h) (Table 4). The longest delay was observed for concretes B5, B7 and B8 (cements CEM II/B-M (LL-W),CEMIV/B (V-W) and CEM „X”/A (S-W) respectively). Due to higher specific surface, and despite a large amount of slag, that cement does not delay setting time of concrete as much as cements with CFA-W.

The highest amount of generated heat during the cement hydration process obviously characterized B0 samples (CEM I and SP). The other samples are characterized by lower hydration heat and kinetics of its generation, and the amount of generated heat is mainly dependent on the amount of clinker in cement and cement specific surface area. Obtained results clearly show the influence of CFA-W on the reduction of hydration heat of cement and thus maximal temperature of concrete (Fig. 3). However, the crucial factor seems to be the amount of SP content in concrete. It increases significantly in proportion to the amount of CFA-W in cement contributing significantly to slowing down of the process of hydration. Taking under consideration the resistance of concrete to thermal cracking, moment of maximum temperature should be as late as possible. In respect to concrete with CEM I, the moment of obtaining maximum temperature by concretes with cements with CFA-W is significantly delayed.

Figure 2 The influence of the cement type on slump flow and flow time of the fresh SCC.
Figure 2

The influence of the cement type on slump flow and flow time of the fresh SCC.

Figure 3 The influence of cement type on maximal temperature and time of obtaining maximal temperature of SCC.
Figure 3

The influence of cement type on maximal temperature and time of obtaining maximal temperature of SCC.

Results of compressive strength tests are shown in Fig. 4. As it could be expected after analysing the setting times results, the early compressive strength of cements with CFA-W is low. After 28 days, compressive strength of concretes with cements CEM II/A-W and CEM II/B-M (B2, B3, B4, B5) is comparable to compressive strength of reference concrete with CEM III/B (B1), while compressive strength of concretes with CEM IV/B and CEM „X”/A (SW) (B6, B7, B8) is visibly lower. All concretes with cements CEM II containing CFA-W have a class C30/37 or higher, concretes with cements CEM IV and CEM “X” have a class C25/30. Keeping in mind that clinker content in CEM II/B-M is ~200 kg/m3 and in cements CEM IV/B and CEM X is ~140 kg/m3 of clinker, obtained compressive strengths of concretes are satisfactory.

Figure 4 The influence of cement type on compressive strength of self-compacting concrete.
Figure 4

The influence of cement type on compressive strength of self-compacting concrete.

4 Conclusions

The conducted research allows to formulate the following conclusions:

  1. It was proven that by using CFA-W cements and by optimizing concrete composition it is possible to obtain SCC of acceptable flowability, low hydration heat, prolonged setting time and good 28 days strength.

  2. Cements CEM II/A-W, CEM II/B-M make it possible to obtain SCC with similar initial flowability to analogous mixtures with reference cement CEM I and CEM III/B, and slightly higher, but still acceptable, flowability loss. Properties of hardened concretes with those cements are at least not worse than those of concretes based on cements with CEM III/B of the same class but lower compressive strength in comparison to CEM I.

  3. SCC with CFA-W cements CEM IV/B-W and CEM IV/ B (V-W) are characterized by high flowability loss and their properties in hardened state are in general worse than CEM I, CEM III/B, CEM II/A-W and CEM II/B-M concretes. While it makes them more difficult to use, it does not exclude their use in eco-SCC.

  4. The results confirm the possibility of successfully using the new generation multi-component cement. By using cement CEM “X”/A (S-W), self-compacting concrete was obtained with acceptable workability, low hardening temperature and good properties in hardened state.

  5. Results indicate that cements with CFA-W can be used to obtain eco-SCC concrete.

Acknowledgement

Research was co-financed by the European Union from the European Regional Development Fund POIG 01.01.02.-24-005/09 Innovative cementitious materials and concretes made with high – calcium fly ashes.

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Received: 2019-02-10
Accepted: 2019-05-14
Published Online: 2019-07-11

© 2019 J. Gołaszewski et al., published by De Gruyter

This work is licensed under the Creative Commons Attribution 4.0 International License.

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https://doi.org/10.1515/eng-2019-0024
Keywords for this article
calcareous fly ash; self-compacting concrete
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  13. EFQM model implementation in a Portuguese Higher Education Institution
  14. Assessment of direct and indirect effects of building developments on the environment
  15. Accelerated Aging of WPCs Based on Polypropylene and Plywood Production Residues
  16. Analysis of the Cost of a Building’s Life Cycle in a Probabilistic Approach
  17. Implementation of Web Services for Data Integration to Improve Performance in The Processing Loan Approval
  18. Rehabilitation of buildings as an alternative to sustainability in Brazilian constructions
  19. Synthesis Conditions for LPV Controller with Input Covariance Constraints
  20. Procurement management in construction: study of Czech municipalities
  21. Contractor’s bid pricing strategy: a model with correlation among competitors’ prices
  22. Control of construction projects using the Earned Value Method - case study
  23. Model supporting decisions on renovation and modernization of public utility buildings
  24. Cements with calcareous fly ash as component of low clinker eco-self compacting concrete
  25. Failure Analysis of Super Hard End Mill HSS-Co
  26. Simulation model for resource-constrained construction project
  27. Getting efficient choices in buildings by using Genetic Algorithms: Assessment & validation
  28. Analysis of renewable energy use in single-family housing
  29. Modeling of the harmonization method for executing a multi-unit construction project
  30. Effect of foam glass granules fillers modification of lime-sand products on their microstructure
  31. Volume Optimization of Solid Waste Landfill Using Voronoi Diagram Geometry
  32. Analysis of occupational accidents in the construction industry with regards to selected time parameters
  33. Bill of quantities and quantity survey of construction works of renovated buildings - case study
  34. Cooperation of the PTFE sealing ring with the steel ball of the valve subjected to durability test
  35. Analytical model assessing the effect of increased traffic flow intensities on the road administration, maintenance and lifetime
  36. Quartz bentonite sandmix in sand-lime products
  37. The Issue of a Transport Mode Choice from the Perspective of Enterprise Logistics
  38. Analysis of workplace injuries in Slovakian state forestry enterprises
  39. Research into Customer Preferences of Potential Buyers of Simple Wood-based Houses for the Purpose of Using the Target Costing
  40. Proposal of the Inventory Management Automatic Identification System in the Manufacturing Enterprise Applying the Multi-criteria Analysis Methods
  41. Hyperboloid offset surface in the architecture and construction industry
  42. Analysis of the preparatory phase of a construction investment in the area covered by revitalization
  43. The selection of sealing technologies of the subsoil and hydrotechnical structures and quality assurance
  44. Impact of high temperature drying process on beech wood containing tension wood
  45. Prediction of Strength of Remixed Concrete by Application of Orthogonal Decomposition, Neural Analysis and Regression Analysis
  46. Modelling a production process using a Sankey diagram and Computerized Relative Allocation of Facilities Technique (CRAFT)
  47. The feasibility of using a low-cost depth camera for 3D scanning in mass customization
  48. Urban Water Infrastructure Asset Management Plan: Case Study
  49. Evaluation the effect of lime on the plastic and hardened properties of cement mortar and quantified using Vipulanandan model
  50. Uplift and Settlement Prediction Model of Marine Clay Soil e Integrated with Polyurethane Foam
  51. IoT Applications in Wind Energy Conversion Systems
  52. A new method for graph stream summarization based on both the structure and concepts
  53. “Zhores” — Petaflops supercomputer for data-driven modeling, machine learning and artificial intelligence installed in Skolkovo Institute of Science and Technology
  54. Economic Disposal Quantity of Leftovers kept in storage: a Monte Carlo simulation method
  55. Computer technology of the thermal stress state and fatigue life analysis of turbine engine exhaust support frames
  56. Statistical model used to assessment the sulphate resistance of mortars with fly ashes
  57. Application of organization goal-oriented requirement engineering (OGORE) methods in erp-based company business processes
  58. Influence of Sand Size on Mechanical Properties of Fiber Reinforced Polymer Concrete
  59. Architecture For Automation System Metrics Collection, Visualization and Data Engineering – HAMK Sheet Metal Center Building Automation Case Study
  60. Optimization of shape memory alloy braces for concentrically braced steel braced frames
  61. Topical Issue Modern Manufacturing Technologies
  62. Feasibility Study of Microneedle Fabrication from a thin Nitinol Wire Using a CW Single-Mode Fiber Laser
  63. Topical Issue: Progress in area of the flow machines and devices
  64. Analysis of the influence of a stator type modification on the performance of a pump with a hole impeller
  65. Investigations of drilled and multi-piped impellers cavitation performance
  66. The novel solution of ball valve with replaceable orifice. Numerical and field tests
  67. The flow deteriorations in course of the partial load operation of the middle specific speed Francis turbine
  68. Numerical analysis of temperature distribution in a brush seal with thermo-regulating bimetal elements
  69. A new solution of the semi-metallic gasket increasing tightness level
  70. Design and analysis of the flange-bolted joint with respect to required tightness and strength
  71. Special Issue: Actual trends in logistics and industrial engineering
  72. Intelligent programming of robotic flange production by means of CAM programming
  73. Static testing evaluation of pipe conveyor belt for different tensioning forces
  74. Design of clamping structure for material flow monitor of pipe conveyors
  75. Risk Minimisation in Integrated Supply Chains
  76. Use of simulation model for measurement of MilkRun system performance
  77. A simulation model for the need for intra-plant transport operation planning by AGV
  78. Operative production planning utilising quantitative forecasting and Monte Carlo simulations
  79. Monitoring bulk material pressure on bottom of storage using DEM
  80. Calibration of Transducers and of a Coil Compression Spring Constant on the Testing Equipment Simulating the Process of a Pallet Positioning in a Rack Cell
  81. Design of evaluation tool used to improve the production process
  82. Planning of Optimal Capacity for the Middle-Sized Storage Using a Mathematical Model
  83. Experimental assessment of the static stiffness of machine parts and structures by changing the magnitude of the hysteresis as a function of loading
  84. The evaluation of the production of the shaped part using the workshop programming method on the two-spindle multi-axis CTX alpha 500 lathe
  85. Numerical Modeling of p-v-T Rheological Equation Coefficients for Polypropylene with Variable Chalk Content
  86. Current options in the life cycle assessment of additive manufacturing products
  87. Ideal mathematical model of shock compression and shock expansion
  88. Use of simulation by modelling of conveyor belt contact forces
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