Oxidation of pyrite (FeS2) and troilite (FeS) impurities in kaolinitic clays after calcination

Valorisation of locally available clays for producing blended cements is crucial for a widespread adoption of sustainable binders incorporating these materials. In some places, clays can be intermixed with small amounts of iron sulfides, which could eventually expand in the alkaline media of concrete and lead to cracking if clay particles are sufficiently fine. This study explored the stability of iron sulfides, namely troilite and pyrite, during calcination of clays and their influence in reactivity. It was found that both troilite and pyrite decompose and oxidize into hematite under typical calcination conditions for clays. Furthermore, there is no negative influence of the presence of iron sulfide phases on the reactivity of calcined clays. This shows that these clays are suitable for use in blended cements, provided that adequate quality control is conducted to ensure a complete decomposition of the iron sulfide phases.

Pozzolanic Efficiency of Calcined Clays in Blended Cements with Focus on the Early Hydration

The fundamental knowledge about the reaction mechanism of calcined clays in cement and the mutual interaction is important for their assessment as supplementary cementitious material and the resulting concrete properties. In this study, the hydration of two cements differing in alkali content and with the addition of a highly reactive, aluminum-rich metakaolin and one calcined common clay with low kaolinite content was investigated during the first 48 hours. For this purpose, four established methods that describe the early hydration were used: isothermal calorimetry, thermogravimetry, in-situ X-ray diffraction and chemical analysis of pore solution. This so far unique combination of methods enabled the understanding of the complex binder (cement-calcined clay) hydration behavior. The results showed considerable differences depending on type of calcined clay, its chemical-mineralogical composition, fineness and especially towards its reaction mechanism with aluminate clinker phases controlled by the composition of pore solution. The impact of calcined clay on the early clinker hydration exceeds significantly physical effects only.

From composition to the microstructure and durability of limestone ternary blended cements: A Systematic review

Limestone ternary cements have attracted significant research and commercial attention recently, for technical and environmental reasons. Standardization of these cements is imminent under BS EN197-5. Presently, detailed understanding of the hydration and microstructure evolution of limestone ternary cements from different alumina-rich supplementary cementitious materials (SCMs) exists in the scientific literature; improved reaction kinetics and additional phase assemblages refine the pore structure. However, understanding of the performance of these cements under exposure conditions is less prevalent. In this contribution, we review these data in a way that allows stakeholders to appreciate the capabilities of the different compositions and their performance. We focus our discussion on critically examining the interplay between the cement composition and the microstructure on durability. It is demonstrated that limestone ternary cements offer a pathway for reducing the embodied CO2 of concrete without compromising their performance. The resistance to chloride ingress, sulphate attack and ASR are significantly improved in a manner similar to binary cements. Carbonation and freeze-thaw resistance is generally lower than OPC but adequate air entrainment can offer improvement in freeze-thaw resistance. The challenge to widespread adoption of these cements is evidence of durability under field conditions. To this end, we recommend large-scale field trialling of these cements and understanding of the role of combined exposures on durability and mechanical properties.

Effect of Bogue Potential Phases of Clinker on the Mechanical Strength of Fly ash-Limestone Based Portland Composite Cement

Continuous rise in population coupled with infrastructural requirements leads to increasing demand of cement which is projected to be around 4.8 billion tons by 2030 and 6.0 billion tons annually by 2050 from current production level of more than 4.2 billion tons [1], and this further requires judicious use of natural resources, particularly limestone on one side and to mitigate carbon and energy footprints on other for sustainable development. Therefore, to bring down environmental impact during cement production, cement industries have been engaged over the years to substitute Portland cement with alternative cementitious materials; fly ash, granulated blast furnace slag, limestone etc individually or in combination of two-three mineral constituents in the manufacture of blended cements, which showed better durability characteristics in comparison to ordinary Portland cement. The formulation and commercialisation of these cements largely depends on the quality of Portland clinkers in terms of oxide constituents, potential as well as actual phase composition, morphology and granulometry of alite and belite grains, along with availability and quality of the cementing materials, prevalent standard norms and regulations. In view of above, present paper highlights the effect of different clinkers in terms of potential minerals as per Bogue calculations (CL-1:C3S-48.20%, C3A-6.30%; CL-2:C3S-54.20%, C3A-9.30% and CL-3: C3S-60.05%, C3A-9.0%) on mechanical strength of fly ash-limestone based ternary cement blends, Portland composite cements, similar to CEM-II/A, B-M as per EN-197-1, prepared with 15, 20, 25, 30 and 35% by weight fly ash and 5 & 10% by weight limestone, by inter-grinding of all cement constituents process, maintaining Blaine’s fineness at 370±10m2/kg, and the results of compressive strength at different curing ages showed optimum strength development in case of clinker CL-2 with potential phases, C3S-54.20% and C3A-9.30%, thus leading to better management of natural resources and extended mine life.

Assessment of Corrosion Performance of Steel Rebar in Snail Shell Ash Blended Cements under Marine Environments

An attempt has been made on a constructive approach to evaluate the performance of snail shell ash (SSA) for its corrosion performance under marine environments. Corrosion performance of steel rebar in chloride-contaminated SSA with (0% to 50%) replacement levels of cement extract medium was examined through electrochemical and weight loss techniques. Initially, snail shell powder (SSP) is made by pulverizing and subsequently SSA is by thermal decomposition methods. Both SSP and SSA were characterized by X-ray diffraction, Fourier transforms infrared spectroscopy, scanning electron microscopy, and energy dispersion X-ray spectroscopy. Concrete cubes with 0% to 50% replacement levels of cement by SSA were evaluated for their mechanical properties. A critical level of 20 to 30% SSA improved both corrosion resistance and strength of concrete. Extrapolation modeling for the strength and corrosion rate with respect to later age were made. SSA is a suitable replacement material for natural limestone in cement productions.

Assessment of the Sustainability of Concrete by Ensuring Performance During Structure Service Life

This article presents a method to assess the sustainability of concrete based on three elements: service life, performance and environmental impact. The method proposes - to achieve similar performance and service life times, regardless of the component materials used, so that the sustainability assessment ultimately depends on the environmental impact criterion. To this end, specific experimental methods are used to determine the performance of concrete in terms of compressive strength and carbonation resistance for concrete cast with two blended cement types. The procedure needed to classify the concrete through carbonation resistance is detailed, in relationship with the performance obtained for compressive strength. The obtained results highlight the concrete formulations to be used to ensure similar performances regardless of the cement type used. In conclusion, the simplicity in the application of the method, which is closely related to the performance approach on concrete durability in the revision proposals of the European standards, is highlighted. The method is also a useful tool to encourage the widespread use in concrete formulation of blended cements with low environmental impact, without reducing the performance or service life time of the constructions.