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22Magazine of Civil Engineering. 2022. 113(5). Article No. 11305
Magazine of Civil Engineering issn
2712-8172
journal homepage: http://engstroy.spbstu.ru/
Research article UDC 666.97
DOI: 10.34910/MCE.113.6
Blended binder based on Portland cement and recycled concrete powder
O. Larsen S. Samchenko , V. N a ruts
National Research Moscow State Civil Engineering University, Moscow, Russia M larsen. [email protected]
Keywords: construction and demolition waste, recycled concrete, recycled concrete powder, recycled screening waste, mechanochemical activation, blended binder
Abstract. The article investigates the properties of recycled concrete powder obtained by mechanochemical activation of recycled screening waste with organic plasticizer in vibrating mill. The waste concrete powder was considered as a part of blended binder based on Portland cement. The optimal powder ratio in blended binder was 30% by weight of cement with the maintenance of the strength properties. The laser diffraction method, X-ray analysis and IR spectroscopy, as well as standard methods were used to estimate the properties of activated powder. The activation of recycled screening waste in 150 min with 0.5% plasticizer allowed us to achieve the specific surface area of the powder at the range of 457.5 cm2/g with content of fine-grained particles in the size of 0-10 ^m (26.6%) and 0-20 ^m (31.2%). It was estimated that the increase of powder ratio in blended binder reduces the standard consistency of the paste and extends the setting time of the binder. The optimal content of the powder was 30% by weight of cement with standard consistency of 24.6%. The compressive strength at the age of 2, 7 and 28 days was 24.3, 37.4 and 50.5 MPa respectively. The structure change of recycled screening waste particles by mechanical destruction and surface amorphization of initial crystalline phases was confirmed by XRD method and IR spectroscopy.
Citation: Larsen, O., Samchenko, S., Naruts, V. Blended binder based on Portland cement and recycled concrete powder. Magazine of Civil Engineering. 2022. 113(5). Article No. 11306. DOI: 10.34910/MCE.113.6
1. Introduction
The growth of energy and resource-saving technologies has become one of the main goals of sustainable development. The construction industry accounts about 50% of the total use of natural raw materials, 40% of energy consumption and almost half of generated worldwide industrial waste. At the present time the increase of world population and the improvement of life quality have led the development of increased construction activity, which further entails certain negative environmental impact.
Concrete is the most widely used building material. Concrete production is considered to have high negative environmental and social costs. According to the data [1], it is about 75.7 million m2 residential buildings were built in 2018. At the same time, in 2018 global cement production amounted 53.7 million tons, and at the end of 2019, this value increased up to 57.8 million tons. Currently, all industries, including the construction sector, are trying to reduce their impact on the environment.
Construction and demolition waste reuse stay relevant not only for foreign countries, but also for Russia. The growth of concrete production causes the increase of waste of volume from old buildings. In European Union it is annually generated about 850 million tons of industrial waste [2], but only some of it obtained from concrete and demolition waste [3] are used as recycled concrete powder.
© Larsen, O., Samchenko, S., Naruts, V., 2022. Published by Peter the Great St. Petersburg Polytechnic University.
Large volume of concrete and demolition waste accumulates in large areas and represents a serious environmental problem [4]. Earlier dismantled concrete elements have not been widely used, they were dumped in landfills or used as sub-base material in road construction [5]. Several countries in Europe have accepted the mix of recycled concrete aggregate into concrete [6]. In recent decades many studies have shown their application as coarse and fine recycled concrete aggregates not only in ordinary concrete, but also in self-compacting concrete mixtures [7-10]. This approach aims to conserve natural resources, reduce construction cost related to aggregates supply and transport, decrease the consumption of non-renewable natural resources, minimize waste and associated emissions.
Recycled concrete aggregates have poor quality due to the presence of mortar in relation to natural aggregates. As a result, their use in load bearing concrete is limited [11].
The process of crashing and screening of demolished concrete forms a significant amount of waste. The maximum content of adhered mortar fraction 5-10 mm is up to 75% of the total mass of recycled concrete aggregate [12, 13].
The production of recycled aggregates is associated with generation of recycled screening waste, its content depends on the crushing method and can be from 30% to 70% of the crushed material [14, 15]. The use of recycled screening waste can be considered as supplementary cementitious materials in preparation of waste powder concrete [3, 16, 17], that can be considered as a part of blended binder based on Portland cement.
Various industrial waste is used as powder in concretes [18, 19]. Industrial waste should be activated due to their diverse chemical composition and properties. The activation increases the reactivity and uniformity of waste. It accelerates chemical reactions, both between solid-phase components and between solid and liquid. It changes the composition and structure of the crushed substance.
The pre-treatment of recycled screening waste is necessary for the preparation of recycled concrete powder with stable properties. Various grinding equipment can be used for preparing recycled screening waste, and the type of the mill significantly affect recycled concrete powder properties [20, 21].
It is known that recycled concrete powder can exhibit cementitious properties due to the content of unreacted particles of clinker minerals. The activation gives the ability to exhibit cementitious properties. It can be assumed that the use of such waste can be a valuable resource in production of the SCC mixture and it is aimed to reduce the consumption of cement.
Mechanochemical activation is considered as a joint grinding of recycled screening waste with a dry superplasticizer Melflux 5581F in vibrating mill. This is necessary to create an adsorptive layer on the surface of recycled screening waste particles, to reduce their strength, deformation and destruction due to the decrease in surface energy, as well as for the subsequent partial dispersion of the composite system
[22]. Mechanochemical activation is effective resource- and time-saving method of obtaining binders with low water to binder ratio and active powder for concretes. The method consists in joint grinding of cement or other disperse materials with dry superplasticizer in the mill to accelerate the process of activation. Mechanochemical activation of binders and powders with superplasticizers promotes the formation of polymer shell on the surface of grains, provides faster grinding due to the Rehbinder effect. The specific surface area of the material while mechanical activation increases and its chemical reactivity enhances
[23].
It is advisable to apply recycled screening waste in self-compacting concrete in order to expand the range of supplementary cementitious materials (microsilica, ground blast furnace slag, fly ash). Therefore, the aim of this study is to obtain the high-fineness recycled concrete powder by the mechanochemical activation and evaluate its properties for use in self-compacting concrete. Thus, the efficiency of activating recycled screening waste can be evaluated by specific surface area on the recycled powder and its particle size distribution. It is necessary to establish the required amount of superplasticizer and activation time, to obtain the recycled powder with specified properties to measure the effect of recycled powder on properties of composite binder.
2.. Materials and Methods
2.1. Materials
The cement used in this study was Ordinary Portland Cement type CEM I 42.5 R Mordovcement in accordance with Russian standard 31108-2016. The mineralogical composition of the clinker is presented in Table 1. The specific surface area of cement was 344.5 m2/kg. The main physical properties and chemical composition of cement are presented in Table 2 and Table 3.
The choice of cement was due to the low content of C3A and its granulometric composition. The low content of C3A contributes the reduction of heat release of the concrete. Furthermore, the effect of superplasticizers is most evident in low-alumina Portland cement. The granulometric composition of the selected Portland cement contributes the uniform particle size distribution, which allows to get the structure of blended binder with dense packing of the particles when the powder is added.
Table 1. Mineralogical composition of the clinker.
_Mineral content (%)_
C3S C2S C3A C4AF
62.40 17.56 5.49 14.55
Table 2. Main physical properties of cement.
Compressive strength (MPa)
Standard water requirement (%)
Setting time (min)
2 days
28 days
initial
final
Expansion (mm)
26.5
185
245
23.3
54.4
Table 3. Chemical composition of the clinker.
Components (%)
Loss ignition 0.21 21.65
SiÜ2 AI2O3 Fe2Ü3 CaO SO3 MgO К2О 4.73 4.36 65.47 0.40 1.27 0.84
Na2O R2O 0.26 0.81
0
Superplasticizer Melflux 5581F as grinding aid for recycled concrete powder was used. The recommended dosage of superplasticizer is 0.1-0.5 % by mass of cement. At the same time, it was taken into account that the subsequent overdose of the plasticizer leads to segregation, retardation and lack of concrete mixture setting with reduction the mechanical characteristics of the concrete.
The recycled concrete powder was produced from the internal wall panel of a residential building in Moscow (Table 4). The chemical and phase composition of recycled screening waste are presented in Table 5 and Table 6.
Table 4. Particle size distribution of recycled screening waste.
Fractions (mm) 2.5 1.25 0.63 0.315 0.16 pallet
Partial sieve residue (%) 25.1 15.5 19.1 21.5 13.3 5.7
Total sieve residue (%) 25.1 40.5 59.6 81.1 94.3 100
Table 5. Chemical composition of recycled screening waste.
Oxide Content (%)
CaO 49.02
SiO2 39.45
AI2O3 3.74
Fe2O3 2.50
MgO 1.76
K2O 1.12
SO3 1.05
Na2O 0.587
TiO2 0.222
P2O5 0.153
ZnO 0.0917
MnO 0.0851
Oxide Content (%)
SrO 0.0742
BaO 0.0631
CuO 0.0222
Cl 0.0190
ZrO2 0.0152
Cr2O3 0.0139
C03O4 0.0072
V2O5 0.0064
Loss ignition 0.0139
Table 6. Phase composition of recycled screening waste.
Phase Content (%)
Quartz 53.5
Foshagite 11.0
Microcline 8.6
Muscovite 2.4
Chlorite 0.7
Calcite 11.2
Dolomite 3.3
Alite 0.6
Belite 1.3
Brownmillerite 1.0
portlandite 0.6
Ettringite 0.8
Amorphous phase 5.0
2.2. Methods
The main properties of the binder were determined in accordance with Russian standard 310. The laser diffraction analysis was used to determine the particle size distribution of Portland cement and recycled concrete powder. The X-ray diffractometer ARL X'tra was used to determine the phase composition of recycled screening waste. The ARL Optim'X X-ray fluorescence spectrometer was used to determine the chemical composition of the samples. The Vertex 70 Fourier spectrometer was used in IR spectroscopy.
3. Results and Discussion
The demolished internal wall panel was broken mechanically and cleaned from reinforcement. Recycled screening waste with fraction 0-2.5 mm was activated in a laboratory vibration mill during 150 min with dry superplasticizer Melflux 5581F content of 0.1-0.5 % by mass of recycled screening waste. The mode of activation was experimentally established with optimal operation of the equipment. The purpose of activation was to obtain the activated powder with specific surface area at the range of 450 m2/kg. The optimal dosage of Melflux 5581F was 0.5%. The specific surface area increases from 395.6 to 457.5 m2/kg (Table 6).
The influence of activated recycled concrete powder on properties of blended binder was estimated by the maximum change of main properties: standard consistency of the binder, setting time and compressive strength. It was found that the optimal content of the powder in blended binder is 30%. It was determined that standard consistency of blended binder has reduced from 26.5% up to 24.6%.
The Melflux 5581F superplasticizer acts as an activation intensifier to obtain the grain composition of the powder with increased number of fine particle fractions, which creates an adsorbed layer of polycarboxylate molecules on the grains of the powder.
The chemical reactions and initial hydration activity of the powder are accelerated due to application of mechanochemical activation. The mechanochemical activation is considered as a process of activation
of recycled concrete particles and dry polycarboxylate superplasticizer Melflux 5581F in vibrating mill. The formation, movement, and multiplication of various structural defects under high-intensity destructive action on solid state is theoretical background of activation [24]. The penetration of polycarboxylate molecules into microcracks occurs simultaneously and is accompanied by the Rebinder effect. The destruction of the material is facilitated and the newly formed surface is modified with a polymer modifier. Mechanochemical activation brings an increase of chemical activity of substance due to the accumulation of energy in structural defects [25]. When the mechanical action stops, it causes the stabilization of the solid body structure. The period of relaxation processes occurs, the activity of the substance decreases. In this case, the inculcation of polycarboxylate fragments on activated powder contributes to the consolidation of defects in its structure [26].
The results of mechanochemical activation of the powder are estimated by the change in particle size distribution and the specific surface area (Table 7).
Table 7. Particle size distribution of 150 min activation.
Dosage of Melflux 5581F in % by mass of recycled screening waste Specific surface area, m2/kg Fraction content (%)
0-5 |jm 5-10 jm 10-20 jm 0-10 jm 0-20 jm >80 jm
0 395.6 3.3 21.0 14.9 17.6 40.3 2.9
0.1 415.6 4.4 18.7 16.7 18.2 40.1 1.9
0.2 432.6 5.5 15.4 17.8 20.9 38.8 1.5
0.3 441.0 6.1 15.9 18.3 23.6 34.9 1.2
0.4 448.5 6.3 16.3 15.8 27.0 33.6 1.0
0.5 457.5 7.2 14.9 19.3 26.6 31.2 0.8
The use of the Melflux5581F has positive effect on fineness of activated powder which is directly proportional to its content. The specific surface area increases by 15.65% compared to the plain powder (from 395.6 to 457.5 m2/kg) with 0.5 % of Melflux 5581F in recycled screening waste and significantly reduces the energy consumption of activation (Figure 1).
In Fig. 1 the curve is linear within 60 min of activation in vibrating mill with different content of superplasticizer, and it corresponds with Rittinger law [26, 27]. The specific surface area of the powder increases with growth of Melflux 5581F dosage. Further activation does not lead to a significant specific surface area growth of the powder due to particles agglomeration, that observes in plain composition.
The superplasticizer as grinding intensifier provides less agglomeration of the particles due to the disjoining and electrostatic repulsion of the particles containing superplasticizer on their surface. The activation efficiency evaluated by degree of dispersion and size change of the powder particles. It depends on time of exposure in vibrating mill and dosage of Melflux 5581F. The granulometric composition of the powder and Portland cement showed in Figure 2.
The main properties of blended binder consisted of Portland cement and activated powder with content from 10 up to 70% was studied. The properties were compared with the properties of Portland cement in accordance with Russian standards. The results are shown in Table 8. It was found that the optimal content of the powder was 30% with uniform distribution of the powder by volume of cement matrix. The necessary properties were achieved with minimum change in setting time and compressive strength.
The obtained data corresponds with the data of other authors. Previous studies have shown [28] the effect of recycled concrete powder on properties of concrete at the age of 28 days with 0.35 water-cement ratio. It was determined that compressive strength with content of the powder 10, 20, 30, and 40% was 60.69, 59.19, 56.18, and 45.64 MPa respectively. It has been shown [29] that the strength of cement paste with water-cement ratio of 0.4 and mechanoactivated recycled screening waste in the amount of 0.1% at the age of 3, 28 days was 21.2 and 47.6 MPa; with content of 0.2% - 18.8 and 43.3 MPa respectively. In research [16] it was determined that adding of 5, 10, and 15% increases the strength of concrete by 167, 228 and 333 % in comparison with plain composition. Previous studies reported [28] that the initial setting time of cementitious materials containing 0, 15, 30 and 45% recycled concrete powder was approximately 273, 288, 298 and 309 min respectively, and the results for the final setting time were 469, 520, 539 and 590 min.
4700
4450
4200
m
■¿S
3950
es
1 3700
<D O
S
3450
O «
'13
<u a
3200
2950
2700
- —X —▲
—■
plain 0.1% by mass of :ement
* 0.2% by 0.3% by mass of mass of :ement :ement
0.4% by 0.5% by mass of mass of :ement ement
30 45 60 75 90 120 150 180
Time of activation (min) Figure 1. Effect of activation time on specific surface of recycled concrete powder.
Figure 2. Particle size distribution of recycled concrete powder (1) and Portland cement CEM I 42.5 R (2).
Table 8. Properties of blended binder based on recycled concrete powder and Portland cement.
Powder content in mixture (%)
Standard water requirement (%)
Setting time (min)
Compressive strength (MPa)
initial
final
2 days
7 days
28 days
0 26.5 185 245 23.3 38.3 51.4
10 25.5 217 255 23.5 38.0 54.5
20 25.0 226 275 24.1 37.9 54.2
30 24.6 233 305 24.3 37.4 50.5
40 24.0 265 345 18.6 30.2 42.5
50 23.5 275 365 16.5 26.5 39.5
60 23.5 300 380 14.5 25.2 35.6
70 23.0 315 415 13.8 24.9 34.2
The results of X-ray analysis of recycle concrete powder before and after activation are presented in Figure 3 and Figure 4. It was determined that the activation changes the structure of recycle concrete powder particles by mechanical destruction and amorphization of the initial constituent phase of calcium silicate hydrates. It is confirmed the XRD diffraction of unactivated recycle concrete powder (Figure 3) shows the presence of peaks: calcium silicate hydrates of foshagite type Ca4Si3O9(OH)2 (d = 0.4914; 0.2894; 0.2196), calcium carbonate CaCO3 (d = 0.3858; 0.3033) and silica SiO2 (d = 0.4260; 0.3345; 0.1821; 0.1604). During the life cycle, calcium silicate hydrate undergoes transformation. In the initial stage of concrete hardening, calcium silicate hydrates as foshagite contain a large amount of crystal and adsorbed water. In the late stage of hardening, when the concrete dries the adsorbed water disappears, and calcium silicate hydrates become dehydrated. The crystal water of calcium silicate hydrates as foshagite undergo their changes along with the structure. In long-term hardening concretes they are formed with a minimum amount of water (1.5-2)H2O. In hardened concrete foshagite is identified as Ca4Si3O9(OH)2 according to the international classification. Such calcium silicate hydrate is formed in lime-sand mixtures during synthesis in laboratory hydrothermal treatment.
The intensive mechanical impact on recycle concrete powder shows the absence of peaks of calcium silicate hydrates and the presence of intense lines of quartz and calcium carbonate at the X-ray diffraction diagram. It causes the surface amorphization with deep phase material change (Fig. 4) and transition to an amorphous state.
I if
•j - • • • | SiQ: ! CaCOis i
..... : : : _____i_____j;____: .... : : .....: :..... • : J._____■_____ : .....:....
\ : Г 1 : : : Г "Ï : : 3 Ш î r : j
: î ; : : : : ] : • : :
ill
! < h î
: : • • <► q * ..... • .....Г"
¡5 'fil..... 1 Î J % 5 ,-f £
?С|У I ; i : JU It Jl f4 fl: f! fiyl —
a : : E t —i-i-i-i- — - —i—i—i- -i-\- - —i- r
Figure 3. X-ray diffraction diagram of recycle concrete powder before activation.
2 1
Г
Figure 4. X-ray diffraction diagram of recycle concrete powder after 150 min activation with 0,5 %
Melflux 5581F.
The IR spectroscopy results of recycle concrete powder before and after activation are presented in Fig. 5, 6. They show the change in structure of the material before and after mechanochemical activation. IR reflectance spectrums have differences, which are expressed in changes in the intensity of absorption bands in the range of 3500-2500 cm-1, 1100-1000 cm-1 and 900-750 cm-1. The change in high-frequency absorption band at the range of 3000-2800 cm-1 after activation indicates the presence of carbonyl groups of superplasticizers that confirms its chemisorption by the surface of the powder. The appearance of organic
compound shows the increase of the peak at the range of 1100-1000 cm-1. The transformation of silicon component indicates the presence of an absorption line contour in frequency range of 900-750 cm-1 that explains the amorphization of the surface during mechanochemical activation.
0.32 0.30
h
0.26 0.34 0.22 ? 0.20 * O.fS d * 0.10 p 1 0.14 №
:
:
:
0.06 0.04 0.02 0,00 1
c <n v 1
t ?
-J
Î500 ¿COD 25» 3000 1500 1000 SCO uuintar (aa-1)
Figure 5. IR reflectance spectrum of recycle concrete powder before activation.
Figure 6. IR reflectance spectrum of recycle concrete powder after 150 min activation with 0.5 %
Melflux 5581F.
4. Conclusion
1. The results of experimental investigation showed the potential of recycled concrete powder that can be used as an alternative supplementary material with residual cementitious properties.
2. The obtained blended binder consisted of Portland cement and recycled concrete powder. The optimal content of recycled concrete powder in blended binder was 30%. The powder was obtained while activation of recycled screening waste in vibration mill during 150 min with 0.5 % of Melflux 5581F.
3. It was determined that the obtained recycled concrete powder while activation consisted of fine particles with size 0-10 ^m and 0-20 ^m in the range of 26.6% and 31.2% respectively.
4. The efficiency of mechanochemical activation was confirmed by XRD and IR spectroscopy. It was determined that activation of recycled screening waste and polycarboxylate superplasticizer Melflux 5581F in vibration mill leads to production the powder with hydraulic properties.
5. It was established that the standard consistency of blended binder was 24.6%. The recycled concrete powder in the amount of 30% provides the appropriate setting time (initial - 233 min; final - 305) and compressive strength of 50.5 MPa.
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Information about author:
Oksana Larsen
PhD in Technical Science
ORCID: https://orcid.ora/0000-0002-9612-7190
E-mail: [email protected]
Svetlana Samchenko
Doctor of Technical Science
ORCID: https://orcid.ora/0000-0002-3523-593X
E-mail: samchenko@list. ru
Vitali Naruts
ORCID: https://orcid. ora/0000-0001-6280-2541 E-mail: [email protected]
Received 25.01.2021. Approved after reviewing 20.12.2021. Accepted 21.12.2021.
