Search Results (18)

Extensive research has addressed concrete deterioration and its countermeasures; however, studies on responsive repair methods and materials remain comparatively limited and less systematic. In this study, six mixtures of repair mortars (RMs) were formulated using aluminate-based binders, specifically calcium sulfoaluminate (CSA) and amorphous calcium aluminate (ACA) cements. The experiment evaluated the mechanical properties and freeze–thaw resistance of these mortars. To accelerate hydration, a controlled amount of anhydrite gypsum was incorporated into each mixture. The fluidity and setting time of fresh RMs were measured, whereas the compressive strength, flexural strength, and ultrasonic pulse velocity (UPV) of hardened RMs were evaluated at 1, 7, and 28 days. In addition, freeze–thaw resistance was assessed as per ASTM C666 by determining the relative dynamic modulus of elasticity. Additionally, the hydration products and microstructural characteristics of paste specimens were qualitatively analyzed. The mechanical performance, including strength and UPV, and freeze–thaw resistance of RMs containing ACA were superior to those of RMs containing CSA. In particular, compared to the CSA-containing specimens exposed to freeze–thaw action were significantly deteriorated, the ACA-containing specimens showed excellent resistance with relatively less cracking and spalling. This may imply that ACA is effective as rapid repair materials for concrete structures in cold regions. Microstructural observations revealed variations in hydration products depending on the aluminate binder employed, which significantly influenced the mechanical and durability properties of the RMs. These results may aid the selection of optimal repair materials for deteriorated concrete structures. Full article

Using waste materials as replacements for sand in building materials helps reduce waste and improve the properties and sustainability of the construction materials. Authors proved the possibility of using imperial smelting furnace (ISF) slag granules as a 100% substitute for natural sand in self-compacting (SCC) cement-based mortars of calcium sulfoaluminates (CSA). The study proved that ISF slag’s radioactive properties meet this area’s requirements. CSA cement eliminates the noted problem in the case of concrete with Portland cement, which is the extended setting of the cement binder. The research findings indicate that using slag to replace sand up to 100% in mortars without grains smaller than 0.125 mm allows high flowability, compaction, low porosity and mechanical parameters. The compressive strength of the CSA cement mortars was about 110 MPa, and more than 140 MPa for geopolymer mortar. Unfortunately, the alkaline pH of a geopolymer causes high leachability of barium and sodium. Thus, the CSA cement is in a more favourable binder to achieve high strength, is environmentally friendly, and is a self-compacting mortar or concrete. Full article

Both the high CO₂ emissions associated with cement production and the increasing demand for concrete call for the use of binder types that can be produced in a more climate-friendly way than that of ordinary Portland cement. To ensure that these binders can also be used in reinforced concrete structures, their influence on the corrosion behavior of embedded steel reinforcement must be investigated. In the study presented here, the passivation behavior of steel in mortars made from various new types of binders is investigated. In addition to alkali-activated materials with high and low calcium contents, a calcium sulfoaluminate cement and a binder produced from calcium silicate hydrate (C-S-H) phases, synthesized in an autoclave, were investigated. While the steel clearly passivated in the alkali-activated slag and the C-S-H binder, the calcium sulfoaluminate cement showed the lowest open circuit potentials and polarization resistances, indicating a less effective level of passivation. The metakaolin geopolymer with a potassium-based activator showed an onset of passivation that was dependent on the environment of the specimens at an early age, whereas the alkali-activated fly ash with a sodium-based activator showed a delay in passivation that was not influenced by the environment of the specimens at an early age. Full article

This study determined how replacing sodium nitrate-based antifreeze admixture (AF) with belite-calcium sulfoaluminate (belite-CSA) cement affects the early age properties of ecological concretes based on ordinary Portland cement (OPC) and ground granulated blast-furnace slag (GGBFS). Concrete specimens were cured at −15 °C and treated in various ways before testing, i.e., no treatment, stored at 20 °C for 12 and 24 h. Generally, the addition of belite-CSA cement shortened the setting time due to the rapid formation of ettringite. The incorporation of 25 wt% of antifreeze admixture (AF) to the OPC-GGBFS concrete cured at −15 °C partially inhibited ice formation and enabled the continuation of hydration processes. This trend was observed for all samples, independent of the applied AF after freezing curing. On the contrary, the addition of 20 wt% of CSA failed to inhibit the ice formation and increased the risk of frost damage for concretes despite the treatment after freezing. These concrete specimens had lower hydration, lower strength, and a more porous binder matrix. The microstructure of the binder matrix was significantly affected by the amount of CSA and extreme negative curing, followed by no notable recovery post-curing at room temperature. Therefore, pre-curing at room temperature for at least 6 h has the potential to avoid frost damage. Concrete containing 25 wt% AF combined with 12 h and 24 h of curing at 20 °C after removal from freezing and prior to testing could enhance the compressive strengths of all concretes. The renewed hydration was indicated as the main influencing factor. Full article

Controlled low-strength materials (CLSMs) have been developed using various byproducts for backfilling or void-filling around pipelines or culvert boxes. However, these CLSMs have encountered issues related to their inadequate placement around underground facilities, despite satisfying the performance requirements, especially flowability, recommended by the American Concrete Institute (ACI) 229 committee. In this study, a new CLSM is developed to ensure a significantly higher flowability, lower segregation, and faster installation compared with previously developed CLSMs. This is achieved through a series of laboratory tests. To enhance the flowability and prevent segregation, a calcium-sulfoaluminate-based binder and fly ash are used in combination with two types of additives. The measured flowability of the new CLSM is 700 mm, while its compressive strength and bleeding satisfy the general criteria specified by the ACI 229R-13. In addition, the performance of the developed CLSM is compared with that of predeveloped CLSMs. The new CLSM was not only shown to exhibit the highest flowability, but also to satisfy the specified requirements for compressive strength and bleeding. Overall, it is anticipated that the developed CLSM can significantly reduce the costs related to the disposal of old pavements, the installation of new pavements, and other construction expenses compared to the costs related to the conventional method, even though the expenses for the backfill materials could increase due to the higher production costs of CLSMs than soil. In addition, there is a need to investigate its field applicability in order to evaluate the precise costs, maintenance, and long-term stabilities after installation. Full article

The associated effect of sodium chloride and dihydrate gypsum on the mechanical performance of a slag-based geopolymer activated by quicklime was investigated by compressive strength, shrinkage, and square circle anti-cracking tests of mortar with a 0.5 water–binder ratio and a 1:3 binder–sand ratio, as well as paste soundness, powder X-ray diffraction (XRD), thermogravimetric analysis (TGA), scanning electron microscopy with energy dispersive spectroscopy (SEM-EDS), and mercury intrusion porosimetry (MIP) of the paste. The results indicate that (1) when dihydrate gypsum is used alone, it combines with calcium aluminate hydrate (C-A-H) to form calcium sulfoaluminate hydrate (AFt), which encourages the hydration process of slag. A 7.5% addition can result in an increase of 97.33% and 36.92% in 3-day and 28-day compressive strengths, respectively. When NaCl is used by itself, it facilitates the condensation of the aluminum silicate tetrahedron unit and generates zeolite. A 2% dosage can lead to a 66.67% increase in the 3-day compressive strength, while causing a 15.89% reduction in the 28-day compressive strength. (2) The combined effect of 2% NaCl and 7.5% gypsum results in the formation of needle-like and rod-shaped AFt, Friedel’s salt, and plate-like Kuzel’s salt in the geopolymer. This leads to an increase in 3-day and 28-day compressive strengths by 148% and 37.85%, respectively. Furthermore, it reduces the porosity by 18.7%. (3) Both NaCl and gypsum enhance the paste soundness of the slag-based geopolymer, and they do no harm to the crack resistance of the geopolymer. The drying shrinkage of the geopolymer at 28 days is just 0.48 × 10⁻³, which is only 66.7% of OPC. This slag-based geopolymer has a simple preparation process, good volume stability, low raw material cost, low energy consumption, and low carbon emissions. It can be used instead of 32.5 slag Portland cement in plain concrete applications, and has high engineering, economic, and environmental values. Full article

The combined utilization of mineral accelerators and nano-seeding materials is a novel method to promote the early strength of cement-based materials. In this paper, the effects of nano-C-S-H seed (NCS) on the early compressive strength of the Portland cement (PC)– calcium sulfoaluminate cement (CSA) binder were investigated. The results showed that NCS and CSA synergistically contributed to the early strength of PC. In detail, a 326.3% increase in the 10 h compressive strength of PC paste was obtained through the addition of NCS (2 wt%) and CSA (5%) in common. This was higher than the sum of the increases observed with the single additions of CSA (157.9%) or NCS (87.6%), with the same above dosage, in PC. Meanwhile, the early strength enhancement effects of NCS and CSA, when used together in PC, lasted longer than the effects of either used alone. Moreover, the synergetic effect mechanism was analyzed by isothermal calorimeter, QXRD, TGA, MIP, and SEM techniques. The calorimetry, XRD, and TGA results demonstrated that the synergistic mechanism was associated with the synergistic promotion effects of CSA and NCS on the hydrates. The fast hydration of CSA produced large amounts of ettringite and also consumed partial free water to promote the performance of the seeding effect of NCS which, simultaneously, further accelerated the precipitation of C-S-H gel and CH. The high alkie environment was also beneficial for the continuous generation of ettringite. In addition, the results of MIP and SEM measurements showed that the micro-filling effect of NCS significantly optimized the pore structure of a PC-CSA blend-hardened paste. Thus, the synergistic strength enhancement effects of CSA and NCS on PC were attributed to the matching of the promotion of hydration generation and the optimization of pore structures in hardening cement paste. The results of this article provide a new approach to achieving the rapid development of the early strength of cementitious materials, with potential applications in precast concrete and low-temperature construction. Full article

To promote the sustainable development of eco-efficient calcium sulfoaluminate (CSA) cements through the partial replacement of the CSA clinker with supplementary cementitious waste products, the effects of coal fly ashes on the early-age and mature-age properties of a calcium sulfoaluminate (CSA)-based cement paste were investigated. The impacts of both Class C and Class F fly ashes on the rheological properties, hydration kinetics, and compressive strength development of CSA cement paste were studied. Rheology-based workability parameters, representing the rate of loss of flowability, the rate of hardening, and the placement limit, were characterized for the pastes prepared with fixed water-to-cement (w/c) and fixed water-to-binder (w/b) ratios. The results indicate a slight improvement in the workability of the CSA paste by fly ash addition at a fixed w/b ratio. The isothermal calorimetry studies show a higher heat of hydration for the Class C fly ash-modified systems compared to the Class F-modified systems. The results show that fly ash accelerates the hydration of the calcium sulfoaluminate cement pastes, chiefly due to the filler effects, rather than the pozzolanic effects. In general, ettringite is stabilized more by the addition of Class F fly ash than Class C fly ash. Both fly ashes reduced the 1-day compressive strength, but increased the 28-day strength of the CSA cement paste; meanwhile, the Class C modified pastes show a higher strength than Class F, which is attributed to the higher degree of reaction and potentially more cohesive binding C-S-H-based gels formed in the Class C fly ash modified systems. The results provide insights that support that fly ash can be employed to improve the performance of calcium sulfoaluminate cement pastes, while also enhancing cost effectiveness and sustainability. Full article

The objective of this research is to investigate the possible reuse of dredged sediments from the port of Cherbourg, France, as an alternative material in road engineering and as a backfill material. These dredged sediments contain high percentages of organic matter (OM), and the presence of OM in the sediment, even in small amounts, can affect the engineering properties of sediments. This research was carried out in two series: the sediment was treated with traditional hydraulic binders (ordinary Portland cement (OPC), calcium sulfo-aluminate (CSA) cement, quarry sand (QS), lime, and a combination of them) in the first series, and with pozzolanic binders in the second series (ground-granulated blast-furnace slag (GGBS) and fly ash (FA)), along with the introduction of an activator. According to French legislation, these two pozzolanic binders (GGBS and FA) have no carbon footprint as they are industrial by-products, and therefore, the second series of this research is considered to be highly eco-friendly and economical. Sediment treated with hydraulic binders yielded a maximum value of unconfined compressive strength (UCS) of 1 MPa at 28 days. Out of eight formulations made using traditional binders, only one formulation barely met the French criteria to be used in the sub-base layer of roads. The development of geopolymer using alkali-activated GGBS and then the incorporation of 30% sediments yielded a UCS value above 2 MPa at 28, 60, 90, and 180 days. Furthermore, the addition of 5% lime and 3% granular calcium carbonate in the same mixture (geopolymer + 30% sediments) increased the UCS by up to 60% and 90%, respectively. Full article

The early-age carbonation curing technique is an effective way to improve the performance of cement-based materials and reduce their carbon footprint. This work investigates the early mechanical properties and microstructure of calcium sulfoaluminate (CSA) cement specimens under early-age carbonation curing, considering five factors: briquetting pressure, water–binder (w/b) ratio, starting point of carbonation curing, carbonation curing time, and carbonation curing pressure. The carbonization process and performance enhancement mechanism of CSA cement are analyzed by mercury intrusion porosimetry (MIP), thermogravimetry and derivative thermogravimetry (TG-DTG) analysis, X-ray diffraction (XRD), and scanning electron microscope (SEM). The results show that early-age carbonation curing can accelerate the hardening speed of CSA cement paste, reduce the cumulative porosity of the cement paste, refine the pore diameter distribution, and make the pore diameter distribution more uniform, thus greatly improving the early compressive strength of the paste. The most favorable w/b ratio for the carbonization reaction of CSA cement paste is between 0.15 and 0.2; the most suitable carbonation curing starting time point is 4 h after initial hydration; the carbonation curing pressure should be between 3 and 4 bar; and the most appropriate time for carbonation curing is between 6 and 12 h. Full article

The purpose of this study is to optimize the composition of CSA (calcium sulfoaluminate) cement with sodium silicate (Na₂SiO₃) and gypsum for binder jetting 3D printing. The preliminary test was carried out with an applicator to decide the proper thickness of one layer before using the 3D printer. A liquid binder was then selected to maintain the shape of the particles. Based on the results, the optimal mixture of dry materials and a liquid activator was derived through various parametric studies. For dry materials, the optimum composition of CSA cement, gypsum, and sand was suggested, and the liquid activator made with sodium silicate solution and VMA (viscosity modified agent) were selected. The setting time with gypsum and sodium silicate was controlled within 30 s. In case of the delayed setting time and the rapid setting mixture, the jetting line was printed thicker or thinner and the accuracy of the printout was degraded. In order to adjust the viscosity of the liquid activator, 10% of the VMA was used in 35% of sodium silicate solution and the viscosity of 200–400 cP was suitable to be sprayed from the nozzle. With this optimal mixture, a prototype of atypical decorative wall was printed, and the compressive strength was measured at about 7 MPa. Full article

This is an experimental study on the development of a low-carbon, eco-friendly cement containing a calcium sulfoaluminate expansive agent (CSAe), slag, and silica fume (SF). The cement to be developed has a low water/binder ratio (w/b) of 0.5 and is designed to be used for structural purposes, with focus on its mechanical performance. CSAe, slag, and SF were mixed at various mixing ratios. The main hydration product of the slag-based CSAe cement in the experiment was ettringite. Substituting less than 30% of CSAe showed a sufficient level of mechanical performance; that is, the material could be used as structural cement. SF controlled the excessive expansion of CSAe. However, since the developed slag-CSAe-SF cement has low early age (1 d) strength, follow-up research is needed for improvement. Full article

Belite-calcium sulfoaluminate (BCSA) cements are special binders obtained from non-Portland clinkers; they have become increasingly more important due to their environmental impact during the manufacturing process compared to Portland cements, such as lower energy consumption and CO₂ emissions. The aim of this paper was to assess the possible use of titanogypsum (T) and water potabilization sludge (W) to reduce the amount of natural raw materials (natural gypsum and clay, respectively) used in the production of BCSA cements. Three BCSA clinker generating raw mixes, containing T and/or W, and a reference mix based only on natural materials (limestone, clay, bauxite and natural gypsum) were heated in an electric furnace at temperatures ranging from 1200 to 1350 °C. Quantitative X-ray diffraction (XRD) analysis of the burnt products showed high conversion of reactants towards the main hydraulically active BCSA clinkers components (C₂S and C₄A₃$), particularly at temperatures of 1300 and 1350 °C. Isothermal calorimetric measurements, differential thermal–thermogravimetric and XRD analyses as well as porosimetric measurements showed that all BCSA cements, from mixing the clinkers (at optimum temperatures) with commercial anhydrite, exhibited similar hydration behavior. Full article

In this study, experiments were performed on the applicability of mortars and concretes based on calcium sulfoaluminate (CSA) binders to facilitate the early strength development of ordinary Portland cement (OPC) under low-temperature conditions. An optimum mixture of CSA was evaluated to improve the early strength of OPC, and the effects of accelerators and retarders on this mixture were examined to demonstrate the applicability of the resulting concrete mixture. Furthermore, mixture applicability was validated by producing concrete at the Remicon Batcher plant and performing numerical simulations. As observed, the optimum CSA substitution rate for the realization of early strength was 17% of the total unit binder amount with CaO/SO₃ and SO₃/Al₂O₃ ratios of 1.9 and 1.25, respectively. Evidently, CSA in combination with Na₂SO₄ as an accelerator promoted the early strength of concrete with OPC and secured its constructability using additional retarders to control the quick setting of concrete. Additionally, the activation of initial hydration at low temperatures yielded a compressive strength of 5 MPa/12 h or higher for the resulting concrete mixture. Full article

In this study, a calcium sulfoaluminate-based expansive additive (0%, 2.5%, 5.0%, and 7.5% by the mass of the binder) was added to compensate for the shrinkage of alkali-activated material (AAM) mortar. Modulus of elasticity curves based on the ACI 209 model were derived for the AAM mortar mixed with the additive by measuring the compressive strength and modulus of elasticity. Moreover, autogenous shrinkage and total shrinkage were measured for 150 days, and drying shrinkage was calculated by excluding autogenous shrinkage from total shrinkage. For the autogenous and drying shrinkage of AAM mortar, shrinkage curves by age were obtained by deriving material constants using the exponential function model. Finally, shrinkage stress was calculated using the modulus of elasticity of the AAM mortar and the curves obtained using the shrinkage model. The results showed that the calcium sulfoaluminate-based expansive additive had an excellent compensation effect on the drying shrinkage of AAM mortar, but the effect was observed only at early ages when the modulus of elasticity was low. From a long-term perspective, the shrinkage compensation effect was low when the modulus of elasticity was high, and thus, shrinkage stress could not be reduced. Full article