Development of novel mortar using fine river sand and pretreated waste flue gas desulfurization gypsum powder and pond fly ash

Abstract

The objective of this study is to investigate the potential of combined pond fly ash (PFA) and flue gas desulfurization gypsum (FGDG) as a partial replacement for cement by mixing them with fine river sand for green mortar development. We studied the physical, mechanical, and microstructural properties of mortars by using techniques such as scanning electron microscopy equipped with energy-dispersive X-ray spectroscopy (SEM-EDXS) and X-ray diffraction (XRD) for chemical component identification of the hydrated phase. These experimental results show that mortar containing pond fly ash, FGDG, and cement concentrations of 5 wt%, 5 wt%, and 90 wt% yields the maximum compressive strength (8.9 MPa) and flexural strength (3.4 MPa) after 28 days. This mortar has 12.6% higher compressive strength and 48% lower shrinkage in comparison with control specimens. A reduction in shrinkage is attributed to the denser structure of the mortar, as the calcium silicate hydrate (C–S–H) gel is found to exist in the SEM image and also identified through XRD studies. It is also concluded that excessive ettringite formation causes expansion in the volume of mortar, voids formation, and results in the reduction of strength. The application of this mortar can be in the internal plaster, bricks, and masonry.