Concrete damage due to oxidation of pyrrhotite-bearing aggregate: a review

Oxidation of pyrrhotite-bearing aggregates is one of the major causes of concrete damage in numerous buildings in Trois-Rivières in Canada and Connecticut in the USA. In the presence of moisture and oxygen, pyrrhotite oxidizes to generate iron-and sulfate-rich secondary minerals that cause internal sulfate attack. Iron sulfides are accessory minerals of different rock types. The distribution of sulfides is often very heterogeneous in terms of aggregate particles, even at the level of the quarries in which some areas may contain copious amounts than others, which complicates the sampling method. Pyrrhotite is a complex mineral with varying chemical composition, crystallographic structure, and specific surface area. These factors influence the reactivity of pyrrhotite. Therefore, it is challenging to control the quality of the aggregate sources. In this study, recent advances in the identification and quantification of pyrrhotite to diagnose complicated cases are presented, and a performance-based approach for the quality control of new sources of aggregates is introduced. The performance-based approach is preferred because it eliminates the influence of the oxidation of pyrrhotite.

Deterioration Caused By Sulfide-Bearing Aggregates: Performance Test Development

Recently in Quebec Canada, concrete structures suffered very rapid deterioration within 3 to 5 years of construction. The deterioration was caused by an iron sulfide, namely pyrrhotite, in the coarse aggregate that suffered oxidation inside concrete and promoted sulfate attack; indicated by the presence of ferric oxyhydroxides (“rust”), gypsum, ettringite, and thaumasite. The goal of the current work was to reproduce this reaction under accelerated laboratory conditions, in progression of a performance test. Conditions to promote pyrrhotite oxidation and internal sulfate attack were provided; exposure cycles were tested with heating and cooling, and saturation in oxidizing agents or lime solution. Oxidation was induced in concrete samples, however, other mechanisms contributed to deterioration. The bleach was found to promote NaCl and Friedel’s salt formation, furthermore, it seemed to mitigate expansion from sulfate attack. Sulfoaluminate decomposition was also found to cause secondary ettringite formation. More optimization to the test methods was recommended.

Deterioration Caused By Sulfide-Bearing Aggregates: Performance Test Development

Recently in Quebec Canada, concrete structures suffered very rapid deterioration within 3 to 5 years of construction. The deterioration was caused by an iron sulfide, namely pyrrhotite, in the coarse aggregate that suffered oxidation inside concrete and promoted sulfate attack; indicated by the presence of ferric oxyhydroxides (“rust”), gypsum, ettringite, and thaumasite. The goal of the current work was to reproduce this reaction under accelerated laboratory conditions, in progression of a performance test. Conditions to promote pyrrhotite oxidation and internal sulfate attack were provided; exposure cycles were tested with heating and cooling, and saturation in oxidizing agents or lime solution. Oxidation was induced in concrete samples, however, other mechanisms contributed to deterioration. The bleach was found to promote NaCl and Friedel’s salt formation, furthermore, it seemed to mitigate expansion from sulfate attack. Sulfoaluminate decomposition was also found to cause secondary ettringite formation. More optimization to the test methods was recommended.

Influence of internal sulfate attack on cement paste properties: contamination by pyrite

abstract: The objective of this work was to evaluate the influence of the presence of sulfate in the microstructure and compressive strength of cement pastes. The lack of availability of more suitable aggregates, for reasons of distance or costs, sometimes leads to the use of materials that contain sulfate in their composition, which is harmful to cement mixtures. Currently, there are normative recommendations that limit the content of contaminants in the aggregates. However, there are still divergences as to the content that does not damage the concrete. In order to discuss the levels presented in the standards and the values above those allowed by them, tests were carried out on cementitious compounds contaminated by pyrite in different levels of sulfates (0.0%, 0.5%, 1.0% and 5.0% of SO3). SEM, XRD, compressive strength, ultrasonic pulse velocity and porosity analyses were performed in samples at different ages until 720 days of age. During early ages until the first year, the most contaminated samples presented an increase in their strength (1.0% and 5.0% of SO3). This behavior was explained by SEM, XRD and porosity analyses by filling the pores with products of sulfate attack, such as ettringite. At the end of the tests (720 days) the series that presented the lowest compressive strength, the presence of cracks and large amounts of ettringite was the one that had 5.0% SO3 contamination, proving the importance of a normative limit content.

Valorization of Fine Recycled Aggregates Contaminated with Gypsum Residues: Characterization and Evaluation of the Risk for Secondary Ettringite Formation

Fine recycled aggregates (FRA) (0/4 mm) are up to now not valorized on a high enough level because of characteristics like an elevated water absorption, higher fines content, and the presence of contaminations. Leftover gypsum residues from the construction site can cause internal sulfate attack when FRA are incorporated into new structures. Concern about this deteriorating reaction plays an important role in the rejection of FRA. In this study, samples of FRA from different recycling centers were characterized and incorporated into mortars. They were then subjected to swelling tests in order to evaluate the development of sulfate attack. Reference materials with different amounts of sulfates were used as a comparison. Results showed a variable sulfate content in industrial FRA, depending heavily on the source of the materials. In all but one case, the total amounts surpassed the acceptable sulfate contents specified in the European standard EN 206, meaning the FRA would be rejected for reuse in concrete. Nevertheless, swelling tests demonstrated that these contamination levels did not pose a risk for sulfate attack. These results indicated that the incorporation of FRA leads to acceptable mechanical performances and that the sulfate limit could be reviewed to be less strict.