Optimizing Masonry Mortar: Experimental Insights into Physico-Mechanical Properties Using Recycled Aggregates and Natural Fibers
Abstract
:1. Introduction
Literature Review on Mortars with Natural Fibers: Coconut, Abaca and Toquilla
2. Materials and Methods
2.1. Materials
2.1.1. Cement
2.1.2. Water
2.1.3. Aggregates
2.1.4. Natural Fibers
2.2. Production Process
2.3. Experimental Programme
- Bulk density of mortars according to UNE-EN 1015-10 [77]. To determine this value, the average of three measurements taken on samples of dimension 4 × 4 × 16 cm3 is used. The bulk density is obtained by dividing the mass of the specimen previously dried in an oven for 24 h (65 ± 5 °C) by the apparent volume of the hardened mortar sample.
- Mortar thermal conductivity was determined according to the UNE-EN ISO 8990:1997 standard [78]. For this purpose, a mini thermal hot-box equipped with thermocouples and a datalogger for accumulating temperature data was used. A total of three samples were tested for each type of mortar, with dimensions of 24 × 24 × 3 cm3. The measurements were taken 24 h after the start of the test to obtain a stationary heat flux.
- Water absorption coefficient by capillarity according to UNE-EN 1015-18 [79]. In this way, six half-samples are obtained from 4 × 4 × 16 cm3 samples so that the fractured face with the open matrix is the one in contact with the water. Thus, these half-samples, previously dried for 24 h in an oven (65 ± 5 °C), are immersed vertically in water to a depth of 10 ± 1 mm. The capillary absorption coefficient is determined with the help of Equation (1):
- Open porosity determined according to UNE-EN 1396 [80]. It is defined as the ratio between the accessible pore volume and mortar apparent volume. To determine this index, a total of three samples of each type were used and Equation (2):
- Mortar shrinkage over time according to the recommendations of the UNE 80-112-89 standard [81]. For this test, three samples of each type of mortar of dimension 2.5 × 2.5 × 28.7 cm3 were used. This test allows the determination of the dimensional stability of the mortars over time and is expressed as the longitudinal variation in mm/m experienced by the samples over 120 days.
- Mortar bonding strength according to UNE-EN 1015-12 [82]. For this purpose, a layer of each mortar type of approximately one centimeter thickness is applied to a previously moistened ceramic block. The ceramic piece is moistened immersed in water for 24 h, in such a way that the suction of the water from the mortar mixing by the ceramic piece is avoided. Subsequently, with the help of adhesion equipment, metal discs with a diameter of 50 mm are glued with epoxy resin on the hardened sample. The tensile test determines the adhesion strength between the mortar and the application surface. A total of five samples were tested for each mortar type.
- Mortar surface hardness, determined by using a Shore D durometer (Smooth-On, Inc., Macungie, PA, USA), following the recommendations of UNE-EN-ISO 868 standard [83]. A total of three 4 × 4 × 16 cm3 samples were analyzed for each dosage, taking five measurements on the two plane-parallel faces that were in contact with the mold and separating each measurement by a minimum distance of 2 cm from each other.
- Mechanical resistance to bending and compression in standardized samples of 4 × 4 × 16 cm3 according to UNE-EN 196-1 [74]. The flexural strength test consists of a three-point breakage test, where the vertical load is applied perpendicular to the longitudinal axis of the sample and at the center of the span. Subsequently, each of the two pieces generated in this bending test is subjected to a compression breaking test using a uniform load on a surface of 4 × 4 cm2. For this test, an IBERTEST hydraulic press model AUTETEST 200-10SW has been used (Madrid, Spain).
- Interior microstructure analysis of the different mortars developed in the research using scanning electron microscopy (SEM). A Jeol JSM-820 (Mitaka, Tokyo) operating at 20 kV and equipped with Oxford EDX analysis was used to carry out this analysis. The test samples were extracted from the inner matrix of the 4 × 4 × 16 cm3 mortar samples. Additionally, to ensure a good surface conductivity of electrons, the test samples were coated with a thin gold foil using a Cressington 108 model metallizer (Watford, UK).
3. Results
3.1. Physical Properties
3.2. Mechanical Properties
3.3. Critical Discussion of the Potential Application of the Developed Mortars
4. Conclusions
- Mortars made with RCA have a lower bulk density than those made with natural aggregate. This decrease in density of close to 10% is even greater for those samples made with natural fibers. Thus, this lower density and the incorporation of fibers of vegetable origin have a positive effect on the thermal conductivity of the mortars. For the best case, with the incorporation of toquilla straw fibers, the RCA–1:3–1.5%(T) dosage obtained a thermal conductivity 37% lower than that of the reference mortar (NA–1:3).
- Capillary water absorption was much higher in those mortars made with RCA due to the nature of these sands. However, the incorporation of natural fibers managed to reduce the capillary water absorption, although without reaching the values obtained for the traditional mortar made with natural sand.
- The incorporation of natural fibers reduces shrinkage during the drying of mortars made with RCA, thus approaching the behavior experienced by traditional mortars. It has been observed that the mortars made with abaca fiber showed greater dimensional stability.
- Surface hardness was not affected by the type of aggregate used in the manufacture of the mortars, although it was slightly reduced by the incorporation of natural fibers.
- The production of mortars with RCA has a negative impact on bond strength. Thus, the adhesion of traditional mortar is superior to mortar with RCA and, in turn, the incorporation of natural fibers has an impact on the decrease in this mechanical property. Mortars with higher cement content showed higher bond strength.
- Flexural strength of mortars made with recycled aggregate is lower than that of traditional mortar and is reduced as the cement content in the mix decreases. Despite this, the incorporation of natural fibers has a positive impact on the improvement of the flexural strength of mortars made with RCA, with coconut and abaca fibers showing the best performance.
- The incorporation of fibers did not significantly improve the compressive strength of the mortars, the type of aggregate being the determining factor for this property. Thus, the traditional mortars showed a higher compressive strength than their counterparts made with RCA.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Ref. | Fiber Addition | Fiber Length [mm] | Main Results |
---|---|---|---|
[22] | 0, 4, 6, and 8% by weight of cement | 16.7 | In all cases the flexural strength was increased, however, for the compressive strength a decrease was observed from 4% added fiber. Capillary water absorption in the mortars is increased. Energy consumption and CO2 emissions during production decreased by more than 11% compared to the control mortar without coconut fiber. |
[23] | 0, 0.2, 0.4, and 0.6% mass fractions of cement and soil mix | 24.0 | The coconut fiber reinforcement increased mortar blocks’ residual strength under compression, as well as their ductility and energy absorption. In addition, a significant improvement in mortar durability against freeze–thaw and moisture–dryness cycles was obtained. |
[24] | 0.5, 1.0, 1.5, and 2.0% relative to the weight of cement | 30.0 | Properties of cement mortars with coconut fiber in masonry walls were evaluated. The best results were obtained for addition of 0.5% fiber, significantly improving flexural strength and slightly increasing diagonal compression in walls. |
[25] | 0, 0.25, 0.5, 0.75, 1.0, 1.25 and 1.5% by volume | Less than 3.0 | As the interface between added fibers and mortar matrix weakened, there was an improvement in the mortars’ cushioning properties. However, there was a compressive strength loss and an increase in porosity. |
[26] | 0.125, 0.25, 0.5 and 0.75 by weight of mortar mix | 24.0 | While there was no significant improvement in flexural and compressive mechanical strengths, post-cracking properties such as ductility, residual strength and toughness increased with a higher fraction of coconut fiber in the mortar matrix. |
[27] | 0, 1, 2.5, and 4% by volume | 17.0 | Coconut fiber addition positively influenced the first crack deflection, improving the toughness indices, plastic cracking and impact strength of the produced cementitious mortars. |
[28] | 0, 1, 2 and 3% by volume of mortar | 10.0–20.0 | The best results were obtained with additions of coconut fiber at 2% by volume of mortar, significantly increasing flexural strength compared to the reference, improving toughness, and preventing cracking. |
[29] | 0, 1, 2 and 3% by volume of mortar | 16.0–18.0 | The mortars were subjected to moisture–dryness cycles and an increase in wetting was observed in coconut fiber samples. Natural degradation of the fibers in the mortar matrix occurred, which decreased the mechanical strengths. |
[30] | 1.5% by volume of mortar | 15.0 | Higher flexural strengths, increased fracture energy and increased capillary water absorption were obtained compared to traditional mortar. |
[31] | 0, 5, 10, 15, and 20% by weight of cement | 60.0 | The potential use of coconut fiber reinforced mortars as a façade cladding material was analyzed. It was found that these mortars with plant fibers could reduce dwelling interior temperatures by 0.5–1.5 °C. |
[32] | 0.25 and 0.5% by weight of cement | More than 10 | The coconut fiber reinforced mortars significantly improved flexural and compressive mechanical strengths, satisfying the criteria for application as mortar in masonry walls according to Colombian standards. |
[33] | 0, 3, 6, 9, 12, and 15% by weight of cement | 10.0–30.0 | Composite with a combination of 10% silica fume, 10% metakaolin and 6% coconut fibers showed superior mechanical and physical properties to the reference mortar, with a compact microstructure, making it a sustainable and environmentally friendly alternative. |
Ref. | Fiber Addition | Fiber Length [mm] | Main Results |
---|---|---|---|
[34] | 0.2, 0.3 and 0.4% over the total solid weight | 20.0, 25.0, 30.0 and 35.0 | The best results were obtained in mortars made with treated fibers with a 3% NaOH solution, with a length of 30 mm and incorporated at 0.2% of the mortar weight. With this composition, it was possible to improve the mechanical resistance to bending and compression, with a good fiber integration in the matrix. |
[35] | 0.2% over the total solid weight | 30.0 | Flexural strength was improved by 20%, compressive strength by 28% and tensile strength by 26% compared to the reference mortars. In addition, the abaca fiber mortars improved their dimensional stability by reducing shrinkage. |
[36] | 0, 0.25, 0.5, 1 and 2% of the weight of cement | 4.5 | The good hygroscopic properties of abaca fibers reduce the autogenous shrinkage of mortars, improving their mechanical performance and mitigating cracking risk. In addition, the presence of these fibers delays mortar setting time. |
[37] | 1% over the total solid weight | 10.0, 30.0, 80.0, 100.0 and 300.0 | Abaca fibers showed great potential for application in rehabilitation mortars for masonry houses. The optimum fiber length for improving flexural strength and wall ductility was found to be 80 mm. |
CaO | SiO2 | SO3 | Al2O3 | Fe2O3 | K2O | TiO2 | MgO | SrO | BaO | MnO | P2O5 | I. Loss |
---|---|---|---|---|---|---|---|---|---|---|---|---|
67.11 | 16.98 | 4.56 | 4.38 | 3.56 | 0.71 | 0.23 | 0.25 | 0.09 | 0.07 | 0.09 | 0.04 | 1.93 |
Properties | NA | RCA | Normative |
---|---|---|---|
Fine Content (%) | 1.23 ± 0.06 | 3.87 ± 0.10 | UNE–EN 933-1 [59] |
Particle Form | Not relevant | Not relevant | UNE–EN 13139 [60] |
Fineness Modulus (%) | 2.56 ± 0.14 | 4.11 ± 0.08 | UNE–EN 13139 [60] |
Friability Coefficient (%) | 14.11 ± 0.25 | 24.15 ± 0.23 | UNE–EN 146404 [61] |
Bulk Density (kg/m3) | 1560 ± 17 | 1387 ± 14 | UNE–EN 1097-3 [62] |
Dry Density (kg/m3) | 2569 ± 3 | 2398 ± 16 | UNE–EN 1097-6 [63] |
Water Absorption (%) | 0.54 ± 0.04 | 5.87 ± 0.09 | UNE–EN 1097-6 [63] |
Aggregate | Al2O3 | CaO | Fe2O3 | K2O | MgO | SiO2 | MnO | TiO2 | SO3 | P2O5 | NaO2 | I. Loss |
---|---|---|---|---|---|---|---|---|---|---|---|---|
RCA | 10.81 | 12.03 | 1.56 | 2.41 | 0.98 | 57.92 | 0.43 | 0.65 | 1.03 | 0.09 | 0.41 | 11.68 |
Fiber | Bulk Density (kg/m3) | Young’s Modulus (GPa) | Diameter (mm) |
---|---|---|---|
Abaca | 1230 ± 8 | 22.7 ± 1.3 | 0.1–0.4 |
Coconut | 1340 ± 15 | 16.4 ± 0.9 | 0.1–1.2 |
Toquilla straw | 670 ± 12 | 11.5 ± 0.7 | 0.7–1.1 |
Type | Cement [g] | Sand [g] | Water [g] | Water/Cement Ratio | Natural Fiber Reinforcement [g] | ||
---|---|---|---|---|---|---|---|
Abaca | Coconut | Toquilla Straw | |||||
NA–1:3 | 450.0 | 1350 | 234.0 | 0.52 | — | — | — |
RCA–1:3 | 450.0 | 1350 | 328.5 | 0.73 | — | — | — |
RCA–1:3–1.5%(A) | 450.0 | 1350 | 328.5 | 0.73 | 6.75 | — | — |
RCA–1:3–1.5%(C) | 450.0 | 1350 | 328.5 | 0.73 | — | 6.75 | — |
RCA–1:3–1.5%(T) | 450.0 | 1350 | 328.5 | 0.73 | — | — | 6.75 |
NA–1:4 | 337.5 | 1350 | 183.0 | 0.54 | — | — | — |
RCA–1:4 | 337.5 | 1350 | 283.5 | 0.84 | — | — | — |
RCA–1:4–1.5%(A) | 337.5 | 1350 | 283.5 | 0.84 | 6.75 | — | — |
RCA–1:4–1.5%(C) | 337.5 | 1350 | 283.5 | 0.84 | — | 6.75 | — |
RCA–1:4–1.5%(T) | 337.5 | 1350 | 283.5 | 0.84 | — | — | 6.75 |
Sample | Capillarity Water Absorption (kg/m2·min0.5) | Open Porosity (%) | Sample | Capillarity Water Absorption (kg/m2·min0.5) | Open Porosity (%) |
---|---|---|---|---|---|
NA–1:3 | 0.41 ± 0.03 | 67.3 ± 0.9 | NA–1:4 | 0.39 ± 0.01 | 70.1 ± 0.3 |
RCA–1:3 | 0.63 ± 0.01 | 82.4 ± 1.2 | RCA–1:4 | 0.57 ± 0.03 | 83.3 ± 0.3 |
RCA–1:3–1.5%(A) | 0.50 ± 0.03 | 76.5 ± 0.7 | RCA–1:4–1.5%(A) | 0.44 ± 0.01 | 76.4 ± 1.3 |
RCA–1:3–1.5%(C) | 0.55 ± 0.02 | 77.1 ± 0.9 | RCA–1:4–1.5%(C) | 0.46 ± 0.03 | 78.8 ± 0.5 |
RCA–1:3–1.5%(T) | 0.57 ± 0.02 | 76.8 ± 0.4 | RCA–1:4–1.5%(T) | 0.50 ± 0.02 | 78.5 ± 0.5 |
Sample | Superficial Hardness (Shore D Units) | Bonding Strength (MPa) | Sample | Superficial Hardness (Shore D Units) | Bonding Strength (MPa) |
---|---|---|---|---|---|
NA–1:3 | 84.1 ± 0.7 | 0.53 ± 0.05 | NA–1:4 | 83.7 ± 0.6 | 0.42 ± 0.02 |
RCA–1:3 | 83.8 ± 0.4 | 0.41 ± 0.02 | RCA–1:4 | 83.9 ± 0.5 | 0.35 ± 0.01 |
RCA–1:3–1.5%(A) | 78.9 ± 0.4 | 0.35 ± 0.04 | RCA–1:4–1.5%(A) | 79.2 ± 0.8 | 0.29 ± 0.03 |
RCA–1:3–1.5%(C) | 78.1 ± 1.1 | 0.38 ± 0.01 | RCA–1:4–1.5%(C) | 78.5 ± 0.7 | 0.30 ± 0.03 |
RCA–1:3–1.5%(T) | 79.3 ± 0.6 | 0.30 ± 0.02 | RCA–1:4–1.5%(T) | 78.1 ± 0.4 | 0.26 ± 0.02 |
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Ferrández, D.; Zaragoza-Benzal, A.; Pastor Lamberto, R.; Santos, P.; Michalak, J. Optimizing Masonry Mortar: Experimental Insights into Physico-Mechanical Properties Using Recycled Aggregates and Natural Fibers. Appl. Sci. 2024, 14, 6226. https://doi.org/10.3390/app14146226
Ferrández D, Zaragoza-Benzal A, Pastor Lamberto R, Santos P, Michalak J. Optimizing Masonry Mortar: Experimental Insights into Physico-Mechanical Properties Using Recycled Aggregates and Natural Fibers. Applied Sciences. 2024; 14(14):6226. https://doi.org/10.3390/app14146226
Chicago/Turabian StyleFerrández, Daniel, Alicia Zaragoza-Benzal, Rocío Pastor Lamberto, Paulo Santos, and Jacek Michalak. 2024. "Optimizing Masonry Mortar: Experimental Insights into Physico-Mechanical Properties Using Recycled Aggregates and Natural Fibers" Applied Sciences 14, no. 14: 6226. https://doi.org/10.3390/app14146226
APA StyleFerrández, D., Zaragoza-Benzal, A., Pastor Lamberto, R., Santos, P., & Michalak, J. (2024). Optimizing Masonry Mortar: Experimental Insights into Physico-Mechanical Properties Using Recycled Aggregates and Natural Fibers. Applied Sciences, 14(14), 6226. https://doi.org/10.3390/app14146226