Partial Cement Replacement Material Research Articles

Agricultural Solid Waste as Source of Supplementary Cementitious Materials in Developing Countries.

Concrete production utilizes cement as its major ingredient. Cement production is an important consumer of natural resources and energy. Furthermore, the cement industry is a significant CO2 producer. To reduce the environmental impact of concrete production, supplementary cementitious materials such as fly ash, blast furnace slag, and silica fume are commonly used as (partial) cement replacement materials. However, these materials are industrial by-products and their availability is expected to decrease in the future due to, e.g., closing of coal power plants. In addition, these materials are not available everywhere, for example, in developing countries. In these countries, industrial and agricultural wastes with pozzolanic behavior offer opportunities for use in concrete production. This paper summarizes the engineering properties of concrete produced using widespread agricultural wastes such as palm oil fuel ash, rice husk ash, sugarcane bagasse ash, and bamboo leaf ash. Research on cement replacement containing agricultural wastes has shown that there is great potential for their utilization as partial replacement for cement and aggregates in concrete production. When properly designed, concretes containing these wastes have similar or slightly better mechanical and durability properties compared to ordinary Portland cement (OPC) concrete. Thus, successful use of these wastes in concrete offers novel sustainable materials and contributes to greener construction as it reduces the amount of waste, while also minimizing the use of virgin raw materials for cement production. This paper will help the concrete industry choose relevant waste products and their optimum content for concrete production. Furthermore, this study identifies research gaps which may help researchers in further studying concrete based on agricultural waste materials.

Pozzolanic Reactivity of Coal Bottom Ash after Chemically Pre-Treated with Sulfuric Acid

Current trend in construction industry has highlighted the use of silica-rich supplementary cementitious materials from industrial wastes in the production of concrete. Numerous studies have validated the pozzolanic properties of these materials, yet coal bottom ash received only infamous reputation as a pozzolanic material, owing to its low reactivity and heavy metals contaminants. Therefore this study was purposed to enhance the pozzolanic reactivity of coal bottom ash through chemical pre-treatment process. Different concentrations of acids and treatment period were studied to obtain optimum parameters for pre-treatment process. Treated ash was characterized for its chemical oxide composition. Its effect on the hydration of cement was studied through the inclusion as cement replacement material in mortar mixtures. From the chemical oxide compositions, a combination of 0.5 M of H2SO4 and 1 hour soaking duration presented the highest SiO2 proportion in the ash. Its inclusion at 5% (by weight of cement) to replace cement proportion in mortar mixtures was able to enhance the compressive strength of mortar at later age, regardless of its slower strength development in the early age. Utilizing treated coal bottom ash as partial cement replacement material has unlocked new achievement for greener future in construction industry.

Utilization of Bagasse Ash in Concrete and Curing it by Treated Hospital Wastewater

This study examined the potential use of sugarcane bagasse ash as a partial cement replacement material and treated domestic wastewater was made for the mixing and curing of concrete. The bagasse ash was collected from the Malaprabha sugar industry, Belagavi, and the treated wastewater was collected from Dr. Prabhakar Kore Hospital & MRC, Belagavi. The work involved the design of M20 grade concrete with w/c ratio of 0.40 and also chemical admixture was made used. The study evaluated the slump, compressive strength, and split tensile strength of concrete with different cement replacement ratios. An equal number of cubes and cylinders were casted and were cured in both tap water and treated wastewater separately for a curing period of 28 days and 56 days. The compressive and tensile strength results were obtained after 28 days of curing period for cubes and cylinders. Results show that replacement of cement with bagasse ash and curing them under treated wastewater obtained good results, which supports waste minimization and utilization. The blended concrete compressive strength results also indicate that the easing of sulphate attack will be drastically reduced when cured under treated wastewater.

Influences of fine waste foundry sand from the automobile engine-part casting process and water-cementitious ratio on the properties of concrete: A new approach to use of a partial cement replacement material

This research was conducted to study the utilization of fine waste foundry sand (FWFS) produced by the automobile engine-part casting process as a partial cement replacement material in the production of concrete. The tested contents of cementitious material (ordinary (Type I) Portland cement (OPC) plus FWFS) were 350 and 450 kg/m3, the tested water-cementitious material ratios (w/c) were 0.35, 0.45, and 0.55, and the percentage replacements of FWFS in the OPC were 10, 20, 30, and 40 wt%. The evaluated fresh properties included the unit weight, initial slump, late slump and setting times. Furthermore, the hardened properties were tested, including the compressive and splitting tensile strengths, modulus of elasticity, and the resistance of the concrete to chemical attack by a 5% sodium sulfate (Na2SO4) solution and a 1% sulfuric acid (H2SO4) solution. The experimental results indicated that, with an increase in the FWFS replacement percentage, the unit weight of fresh concrete and initial slump decreased, while the late slump, initial and final setting times increased. Importantly, increasing the FWFS replacement in OPC slightly decreased the compressive and splitting tensile strengths and the concrete's 28-day modulus of elasticity. The chemical resistance results indicated that, following immersion in Na2SO4 or H2SO4, the concrete mixed with FWFS exhibited less corrosion than the conventional concrete (0% FWFS replacement). Additionally, the mass loss was low when the w/c ratios decreased and the percentage replacement of FWFS increased.

Utilization of Palm Oil Fuel Ash and Eggshell Powder as Partial Cement Replacement - A Review

The increase in population leads to increase in construction of houses and other buildings to accommodate these people. The extensive use of concrete for constructional purposes leads to release of Carbon Dioxide (CO2) gas into the atmosphere which adds to the already increased global warming. The increase in urbanization has also lead to increased generation of waste materials. These waste materials are by-products, which are disposed in landfills causing environmental and health issues. The utilization of agricultural wastes as cement substitute is a great alternative for reducing the use and production of cement, which contributes to 5% to 7% of global CO2 emissions alone. Palm Oil Fuel Ash (POFA) Eggshells are two major agricultural wastes, which are generated in abundance in Malaysia. This paper reviews the combined utilization of Eggshells Powder (ESP) and POFA as potential partial cement replacement material and development of bio-concrete, which may help in reducing the environmental issues that are caused by the agricultural by-products. They have been used successfully but individually in concrete. The pozzolanic activity triggered by POFA requires Calcium Hydroxide which cement provides to a limit. Eggshells when grinded into Eggshells Powder (ESP) are rich in calcium oxide and can provide the required calcium hydride and enhance the pozzolanic reaction.

Effect of using glass powder as cement replacement on rheological and mechanical properties of cement paste

Glass powder (GP) is considered as a pozzolanic material, thus it can be used as a partial cement replacement material. Its effect on the microstructure and on the mechanical properties is controlled by its chemical composition, particle size distribution (PSD), the amount of replacement and the curing conditions. The effect of cement replacement by glass powder on the rheological and the mechanical properties of cement paste is studied. Two types of cements were used (CEMI and CEMII) at five different percentages of glass powder replacement (0, 10, 20, 25 and 30%). The results showed an increase in the cement paste flow using CEMI compared to CEMII. Also, the initial and final setting times were lower at CEMI than CEMII. Increasing the replacement percentages by higher glass powder resulted in a decrease in the linear and volume expansion of the mixes due to the reduction of the ASR. The 10 and 20% GP mixes showed a higher compressive strength at longer ages than the control mix which is related to the pozzolanic reactivity of the glass powder.Bottom Ash was added to the 20% GP mix, at different percentages (2.5, 5, 10 and 20%). The maximum compressive strength was obtained at 5% BA mix.

Potential use of brick waste as alternate concrete-making materials: A review

Abstract Solid waste produced from construction and demolition activities amount to several million tons globally, and one of the prominent wastes is brick waste. In recent years, there have been increasing number of researches carried out on recycling brick wastes to produce a more eco-friendly concrete. This review summarizes the usage of brick waste as potential partial cement and aggregate replacement materials whereby the performance in terms of the mechanical strengths and some durability-related properties of the concrete were discussed. It was found that the most feasible usage of recycled brick is in the form of brick dust, whereby up to 20% cement replacement could enhance the strength and some durability properties of the concrete due to the potential pozzolanic reactivity of the brick dust particles. On the other hand, the inclusion of recycled brick as aggregate does not give profound improvement of the properties of concrete as it is governed by the inherent porous nature of the aggregate. Hence, the use of recycled brick as partial aggregate substitute should be confined to low volume replacement levels and when environmental consideration necessitates its usage.

Study of Steel Scrap Reinforced Concrete with Partial Replacement ofCement with Bagasse Ash

According to the report published by United Nations Food and Agricultural Organization in 2017, it is estimated that India presently produces 341.2 million metric tonnes of sugarcane, proving the fact that India is the second largest sugarcane producer on the globe. Sugarcane bagasse is a fibrous waste product recovered from the Sugar milling industry. There is an increasing threat of disposing the bagasse ash, as it causes serious environmental hazards. Hence, there is an immediate need to find an alternative solution to use the waste product in the form of bagasse ash, in an effective manner. Thus, this paper dealt with the replacement of cement using the bash in concrete. Furthermore, there has been numerous research made, into using steel fibre in concrete. Similar to steel fibre is steel scrap, which is a waste material from Lathe machines. Thereby, this paper will also deal with addition of steel scrap to the concrete, as the latter is much cheaper than steel fibres, which are normally used. Hence, a comprehensive study is made in the research, where concrete is prepared by partially replacing cement by bagasse ash and adding steel scrap to the volume of concrete, as a whole. Here, cement is partially replaced by bagasse ash by 0%, 5%, 10% and 15% by weight of cement in concrete. Similarly, steel scrap is added at dosage of 0%, 1% and 2% to the volume of concrete. The studies were conducted on 12 different combinations of bagasse ash and steel scrap being used in M20 grade of concrete. The parameters studied include compressive strength, split tensile strength and flexural strength of concrete. The results are compared with conventional concrete and, the optimum combination of using both bagasse ash as a partial replacement material for cement and addition of steel scrap to the concrete, is determined.

Efficient method of producing clinker-free binding materials using electromagnetic vortex milling

Blast furnace slags are a by-product resulting from the production of pig iron that can be used as partial cement replacement materials. However, latent hydraulic properties and a low chemical activity of slags limit their wide application. Here, we demonstrate some methods for slag activation using electromagnetic vortex milling and alkaline activation. We show that slag powder with an average particle size of 8 μm and a specific surface area of 2.4 m2/g is achieved at “slag/ferromagnetic elements” ratio of 1:2 and the processing time of 5 min in the electromagnetic vortex mill. The using of a 5 M sodium hydroxide solution stimulates the dissolution of the slag and results in the average 28-days compressive strength of a cement of 45.8–59.8 MPa.

Engineering Properties of 1200 kg/m³ Lightweight Foamed Concrete with Egg Shell Powder as Partial Replacement Material of Cement

This study presents the effects of egg shell powder on lightweight foamed concrete when partially replace the cement. At 2017, 12235 million eggs were consumed and around 85 thousand tonnes of egg shell waste was the yield in Malaysia. The waste might result in an environmental problem if it is not reused properly. Besides, large cement production also results in carbon dioxide emission and depletion of natural limestone. Therefore, studies on effects of egg shell powder on properties of lightweight foamed concrete as partial replacement of cement is attractive to be carried out by aiming to promote the application of lightweight foamed concrete as well as to mitigate the environmental issue by reducing the number of eggshell wastes and pure cement production. The objective of this study is to investigate the effects on engineering properties of lightweight foamed concrete with a fresh density of 1200 ± 50 kg/m3when the cement is partially replaced by egg shell powder at replacement levels of 0%, 2.5%, 5%, 7.5%, and 10% by mass. The properties of the lightweight foamed concrete studied included workability, stability, compressive strength, flexural strength, water absorption, and sorptivity. The results show that the replacement of egg shell powder reduces the spread diameter, stability, and sorptivity, and improve the compressive and flexural strengths at replacement level of up to 5%. The eggshell powder is feasible to be used as partial cement replacement material for the production of the masonry unit.

Strength and Durability of Mortar Incorporating Roof Tile Powder as Partial Cement Replacement Material

Strength and Durability of Mortar Incorporating Roof Tile Powder as Partial Cement Replacement Material

Combined Effects of Metakaolin, Rice Husk Ash, and Polypropylene Fiber on the Engineering Properties and Microstructure of Mortar

AbstractThis paper reports an experimental study carried out to investigate the effects of using metakaolin (MK) and rice husk ash (RHA) as a partial replacement material for cement, and polypropyl...

Utilizing waste materials to enhance mechanical and durability characteristics of concrete incorporated with silica fume

Construction and demolition wastes are increasing significantly due to augmented boom of modern construction. Although the partial cement replacement materials do promote the idea of sustainable construction, the use of construction and demolition waste can also be considered to be viable option to advance the sustainability in modern construction practices. This paper investigates the use of industrial waste materials namely marble dust and crushed bricks as replacement of natural fine aggregates along with the use of silica fume as a partial cement replacement on the mechanical properties and durability characteristics of concrete. Partial replacement levels of waste materials were 10 and 20 percent by volume while the partial replacement level of silica fume was kept to 20 percent at all concrete samples. The results reported in this paper show that the use of marble dust as a replacement material to the natural fine aggregates resulted in an increase in the mechanical properties of concrete. However, the use of crushed bricks did not substantially contribute in the development of strength. Water permeability of concrete incorporated with both silica fume and waste materials (marble dust and crushed bricks) decreased significantly. The decrease in water permeability of concrete was attributed to the pozzolanic reaction of silica fume with calcium hydroxide of cement and the filler effect of the waste materials of marble dust and crushed bricks. The use of waste materials also enhance the freeze and thaw resistance of concrete. Authors strongly suggest that the pozzolanic reaction and the development of the microstructure of the concrete through the use of waste materials are largely responsible from the advances in the durability of concrete.

Material and structural properties of waste-oil palm shell concrete incorporating ground granulated blast-furnace slag reinforced with low-volume steel fibres

This paper presents the utilization of low-volume steel fibres to improve the performance of concrete containing waste oil palm shell as aggregate and ground granulated blast furnace slag (GGBS) as partial cement replacement material. The experimental results showed that although the increased GGBS replacement level caused a lowering of the concrete properties, the addition of low-volume steel fibres improved the material properties, such as the mechanical properties, stress–strain behaviour and flexural toughness of the oil palm shell concrete (OPSC). In terms of these properties, it was found that the combination of 20% GGBS as partial cement replacement and 0.6% steel fibres achieved the best results among the concrete mixtures tested. The mix was then used for the investigation of the structural behaviours (bond and flexural behaviours) in comparison with conventional concrete and plain OPSC. The results showed that the OPSC containing 0.6% steel fibres enhanced the structural performance compared to the corresponding OPSC without fibres as well as the ready-mixed grade 30 normal weight concrete.

Comparative environmental life-cycle analysis of concretes using biomass and coal fly ashes as partial cement replacement material

Nowadays, the concrete production sector is challenged by attempts to minimize the usage of raw materials and energy consumption, as well as by environmental concerns. Therefore, it is necessary to choose better options, e.g. new technologies or materials with improved life-cycle performance. One solution for using resources in an efficient manner is to close the materials' loop through the recycling of materials that result either from the end-of-life of products or from being the by-product of an industrial process. It is well known that the production of Portland cement, one of the materials most used in the construction sector, has a significant contribution to the environmental impacts, mainly related with carbon dioxide emission. Therefore, the study and utilization of by-products or wastes usable as cement replacement in concrete can supply more sustainable options, provided that these types of concrete produced has same durability and equivalent quality properties as standard concrete.This work studied the environmental benefits of incorporating different percentages of two types of fly ashes that can be used in concrete as cement replacement. These ashes are waste products of power and heat production sectors using coal or biomass as fuels. The results showed that both ashes provide a benefit for the concrete production both in terms of environmental impact minimization and a better environmental performance through an increase in cement replacement. It is possible to verify that the incorporation of fly ashes is a sustainable option for cement substitution and a possible path to improve the environmental performance of the concrete industry.

Blended Cement Containing High Volume Ground Dune Sand and Ground Granulated Blast Furnace Slag for Autoclave Concrete Industry

This paper presents the results of using ground dune sand (GDS) and ground granulated blast furnace slag (slag) as high volume cement replacement materials. In this study, plain and four blended mixtures were fabricated and cured under normal and autoclave conditions. For the blended mixtures, 40% GDS by weight of the total binder materials and different percentages of slag (15%, 30% and 45%) were incorporated as partial cement replacement materials. The effect of curing conditions (normal and autoclave) on the compressive strength of prepared mixtures was studied. The results showed that, for the autoclave cured mixture, up to 85% of cement can be replaced by GDS and slag without significant drop in the compressive strength. Microstructure analyses using scanning electron microscope (SEM) and X-ray diffraction analysis (XRD) were carried out to examine the microscale changes of the hydrated mixtures. The SEM revealed the formation of thin plate-like calcium silicate hydrate and compacted microstructure of autoclave cured mixture. XRD showed the elimination of calcium hydroxide and existence of residual crystalline silica of all blended mixtures.

The incorporation of wood waste ash as a partial cement replacement material for making structural grade concrete: An overview

With increasing industrialization, the industrial byproducts (wastes) are being accumulated to a large extent, leading to environmental and economic concerns related to their disposal (land filling). Wood ash is the residue produced from the incineration of wood and its products (chips, saw dust, bark) for power generation or other uses. Cement is an energy extensive industrial commodity and leads to the emission of a vast amount of greenhouse gases, forcing researchers to look for an alternative, such as a sustainable building practice. This paper presents an overview of the work and studies done on the incorporation of wood ash as partial replacement of cement in concrete from the year 1991 to 2012. The aspects of wood ash such as its physical, chemical, mineralogical and elemental characteristics as well as the influence of wood ash on properties such as workability, water absorption, compressive strength, flexural rigidity test, split tensile test, bulk density, chloride permeability, freeze thaw and acid resistance of concrete have been discussed in detail.

Evaluation of Mechanical Properties of BAGcrete

The usage of waste materials in making concrete gives a satisfactory solution to some of the problems related to waste management and environmental concerns. In the development of blended cements, some of the Agro wastes such as sugarcane bagasse ash, rice husk ash and wheat straw ash are used as pozzolanic materials. Few studies have been reported on the use of bagasse ash (BA) as partial cement replacement material. This research aims to study the physical and mechanical properties of hardened concrete prepared with bagasse ash as partial replacement material for cement are reported. The Portland cement was replaced with BA in the ratio of 0%, 5%, 10%, 15% and 20% of weight of cement. The compressive strength, splitting tensile strength and flexural strength of concrete at the age of 28 days were investigated. From the test results it was observed that bagasse ash is an effective mineral admixture, with 5% as optimal replacement ratio of cement.

Corrosion Resistance of High Strength Concrete Containing Palm Oil Fuel Ash as Partial Cement Replacement

This experimental work investigates the influence of POFA as partial cement replacement towards corrosion resistance of high strength concrete. Plain high strength concrete (P0) with 100% ordinary Portland cement (control specimen) and POFA high strength concrete containing POFA as partial cement replacement material were used. At the first stage, mix with 20% POFA (P20) has been identified as the best performing mix after cubes (150×150×150 mm) containing various content of POFA as partial cement replacement were prepared, continuously water cured and subjected to compressive strength test at 28 days. At the second stage of study, control specimen (P0) and high strength concrete mix containing 20% POFA (P20) were prepared in form of cylinders with reinforcement bar buried in the middle for corrosion resistance test. Specimens were subjected to half cell potential technique following the procedures outlined in ASTM C876 (1994). Incorporation of POFA as partial cement replacement has contributed to densification of microstructure making the concrete denser thus exhibit higher resistance towards corrosion as compared to plain concrete.

Effect of MIRHA and Fly Ash in Ductile Self-Compacting Concrete on Abrasion and Impact Performance

The benefits of Microwave Incinerated Rice Husk Ash (MIRHA) as partial cement replacement materials in DSCC mixes has led to the research on the possibilities of combining both MIRHA and fly ash as an addition in DSCC replacing up to 20% of cement volume whilst maintaining satisfactory properties. The addition of both materials can improve concrete properties and reduce the cost of DSCC production. These supplementary cementitious materials are expected to give positive effects on the concrete abrasion and impact resistance. The incorporations of both MIRHA and fly ash in DSCC as cement replacement materials are considered as a new type of concrete. Therefore, it is important to have a complete knowledge on the behaviour of the composite material when being subjected to repetitive dynamic loading. The test results showed that MIRHA and fly ash combination in DSCC improved both abrasion and impact resistance of DSCC compared to reference specimens.