Substitution Of Cement Research Articles

Substitution of cement by marine clay in spray-based 3D concrete printing

Spray-based 3D concrete printing (S-3DCP) is a type of 3D concrete printing specifically for automated constructions on vertical and overhanging surfaces, e.g. facades and ceilings. In this study, cement is partially substituted by calcined marine clay to develop a high-performance mixture for S-3DCP. Through setting, rheological, and tack tests, the fresh properties of the mixtures with marine clays calcined after different temperatures have been assessed. Considering pumping and deposition performance, tackiness, and sustainability, the optimum calcination temperature of marine clay is determined as 700 °C. The subsequent spray-based printing test shows that compared with the mixture without marine clay, the mixture with the marine clay calcined at 700 °C has a more uniform thickness distribution and 185% higher building capacity. The study contributes to the deeper understanding of the rheological and tack properties of the mixtures with calcined marine clay, which guides the future utilization of marine clay.

Using Waste-to-Energy Fine-Combined Ash as Sand or Cement Substitute in Cement Mortar

Using Waste-to-Energy Fine-Combined Ash as Sand or Cement Substitute in Cement Mortar

Eco-friendly concrete incorporating palm oil fuel ash: Fresh and mechanical properties with machine learning prediction, and sustainability assessment

Rising natural resource consumption leads to increased hazardous gas emissions, necessitating the concrete industry's focus on sustainable alternatives like palm oil fuel ash (POFA) to replace cement. Also, advanced machine learning (ML) techniques can uncover previously unreported insights about the effects of POFA that may be missing from the literature. Hence, this study investigates the influence of varying concentrations of POFA on fresh and mechanical characteristics with quantifying ML approaches and microstructural performance, as well as the environmental impact of structural concrete. For this, cement substitutions of 5 %, 15 %, 25 %, 35 %, and 45 % (by weight of cement) were utilized. POFA enhanced the overall concrete workability, with slump increments ranging from approximately 9 %–55 % and compacting factor increments of 4 %–12 %. Mechanical performance of POFA concrete improved up to 25 % replacement levels, with the highest enhancements observed in compressive (4.5 %), splitting tensile (36 %), and flexural (31 %) strength, for the mix containing 15 % POFA. The finer particle size of POFA improved microstructural performance by reducing porosity, aligning with the enhanced mechanical strength. The environmental impact of POFA was assessed by measuring eCO2 emissions, revealing a potential reduction of up to 44 %. Incorporating 5 %–15 % POFA yielded ideal mechanical performance results, significantly enhancing sustainability and cost-effectiveness. Regarding the ML approach, it can be observed that a low regression coefficient (R2) contrasts sharply with the higher R2 values for the random forest (RF) and the ensemble model, indicating satisfactory precision prediction with experimental results.

An Evaluative Review of Recycled Waste Material Utilization in High-Performance Concrete

The disposal of waste materials and their adverse effects on the environment have become a worldwide concern, disturbing the fragile ecological equilibrium. With growing awareness of sustainability in the construction industry, it is of great importance to recycle waste materials for producing high-performance concrete (HPC). This aligns with the twelfth Sustainable Development Goal (SDG) of the United Nations, emphasizing responsible production and consumption, especially concerning the production of HPC using waste materials and energy-efficient methods. The review evaluates the purposeful utilization of recycled waste materials to improve the engineering characteristics of HPC, taking into consideration pertinent literature. It encompasses a comparative evaluation of strength development, water absorption, microstructures, and x-ray diffraction (XRD) analyses of HPC manufactured with different types of recycled waste materials. The key result of the review showed that using incinerated bottom ash (IBA) below 25% and incorporating 40% copper slag can enhance HPC’s mechanical performance. Additionally, recycled coarse aggregate (RCA) can replace up to 50% of conventional aggregate in self-compacting HPC with minimal impact on durability properties. In HPC cement substitution research, fly ash, silica fume, and metakaolin are prominent due to their availability, with fly ash showing remarkable durability when used as a 15% cement replacement. This thorough review offers valuable insights for optimizing the utilization of recycled waste materials in the development of environmentally friendly HPC. Doi: 10.28991/CEJ-2023-09-11-020 Full Text: PDF

Utilization of Waste Bricks as a Cement Substitution Material in Concrete Mixture

Concrete is the main material in building construction. The use of Portland cement as a binder in concrete mixes causes high concrete production costs. Apart from that, cement production also produces high CO2 emissions. Therefore, this research aims to utilize brick waste discarded from the brick industry as a partial substitute for cement in the concrete mixture. The brick powder is sieved to 80 mesh size and then used to replace cement with variations of 0%, 5%, 10%, 15% and 20% based on the weight of the cement. The compressive strength of the concrete was tested at 7, 14 and 28 days. Test results show that the use of brick waste up to 10% can increase the compressive strength of concrete. At 15% and 20% substitution, there was a decrease in the compressive strength of the concrete due to incomplete pozzolanic reaction. So it is concluded that brick waste can be used as a substitute for cement up to 10% in the concrete mixture without reducing its compressive strength. This research can provide solutions for environmentally friendly waste utilization and reduce the use of cement in concrete mixtures.

Enhancing Reinforced Concrete Beams: Investigating Steel Dust as a Cement Substitute

This research undertook an extensive examination of the ramifications of integrating steel dust as a partial substitute for cement within reinforced concrete beams. The investigation encompassed an assessment of various facets, encompassing the workability of the concrete mixture, alongside crucial mechanical properties such as compressive strength, split tensile strength, flexural strength, ultrasonic pulse velocity (UPV), and elasticity modulus. The findings unveiled a notable reduction in workability as the proportion of steel dust increased within the mixture, with a consequential substantial impact on the elasticity modulus. Notably, compressive strength exhibited an enhancement at a 10% replacement of cement yet exhibited a decline with higher degrees of cement substitution. The inclusion of steel dust led to the formulation of adjusted equations pertaining to split tensile and flexural strength characteristics within the mixture. Remarkably, the incorporation of 10% steel dust yielded an increase in ductility. Conversely, at a 30% steel dust inclusion level, ductility diminished alongside a reduction in the maximum load-bearing capacity. In light of these findings, it is imperative to exercise prudence when considering the utilization of steel dust as a cement substitute, particularly when approaching or exceeding the 10% replacement level threshold. Further comprehensive research is imperative to acquire a comprehensive understanding of its implications and its susceptibility to potential corrosion concerns.

Performance of lightweight foamed concrete partially replacing cement with industrial and agricultural wastes: Microstructure characteristics, thermal conductivity, and hardened properties

The production of eco-friendly concrete has been made possible by reusing agricultural and industrial wastes. This paper presents an experimental investigation of the characteristics of lightweight foamed concrete (LWF) produced from a protein-based foaming agent and including granulated blast furnace slag (GGBS), fly ash (FA), rice husk ash (RHA) and palm oil fuel ash (POFA) at various substitution levels (0, 10 %, 20 %, 30 %, 40 %, 50 %, and 60 %) with cement. By executing a slump test, the fresh characteristics of mixes were assessed. In addition, a total of 25 different LWF mixtures were produced and tested for their porosity, bulk density, compressive strength, bending strength, splitting tensile strength, water absorption, ultrasonic pulse velocity (UPV), and thermal conductivity. To elucidate the causes for the experimental findings acquired, microstructural analysis was also performed. The findings indicate that the GGBS, FA, RHA, and POFA ratios of the LWFs increased due to a reduction in slump, porosity, water absorption, bulk density, and thermal conductivity up to 40 % GGBS, 30 % FA, 20 % RHA, and 30 % POFA. However, the compressive strength, bending strength, splitting tensile strength, UPV were raised up to 40 % GGBS, 30 % FA, 20 % RHA and 30 % POFA as substitution for cement. LWF containing 40 % GBS as a cement substitution also demonstrate larger compressive strength, bending strength, splitting tensile strength, and ultrasonic pulse velocity in comparison with the control, 30 % FA, 20 % RHA, and 30 % POFA LWF. The findings are promising and reveal a major opportunity for developing eco-friendly LWF by partially substituting cement with GGBS and FA industrial by-product material, RHA and POFA agricultural waste materials as well.

Impact of waste materials (glass powder and silica fume) on features of high-strength concrete

Abstract Pozzolanic materials, glass powder, and silica fume (SF) have all been used in concrete recently as a partial cement substitution to increase the strength of the concrete. The aim of this study is to analyze the impact of waste glass powder (WGP) and SF combination on high-strength concrete (HSC) characteristics. The working methodology of the current research consists of using SF passed through sieve No. 200, and WGP particles that passed through sieve No. 400 (particle size less than 38 µm), maximum size of aggregate (14, 20) mm and W/C + p (0.25, 0.35, and 0.45). The used waste materials were in three different amounts of SF and WGP (5, 10, and 15%) by weight of cement. HSC was tested for compressive strength, density, and ultrasonic pulse velocity (UPV) with various glass powder and SF contents. The obtained results show that after 7 and 28 days, concrete specimens containing 15% glass powder and SF demonstrated an increase in density, UPV, and compressive strength, depending on the test results. Conversely, concrete specimens with 5% SF and WGP had decreased compressive strength, UPV, and density. It was detected that WGP gave high mechanical (compressive strength) and physical properties (density and UPV) than SF with a ratio of 15% and lower properties with a ratio of 5%. In HSC manufacturing, glass powder may be used instead of SF.

A comprehensive investigation on the impacts of steel slag aggregate on characteristics of high-performance concrete incorporating industrial by-products

Steel slag (SS), an industrial by-product of the steel industry, has the potential to serve as a natural aggregate alternative in concrete production to not only mitigate the exploitation of natural resources but also minimize the environmental impact of its treatment and disposal. This study was designed to investigate comprehensively the impacts of using SS as a full replacement for coarse aggregate and of using fly ash (FA) and ground granulated blast-furnace slag (GGBFS) as partial replacements for Portland cement on the engineering properties (i.e., workability, fresh unit weight, porosity, compressive and flexural strengths, ultrasonic pulse velocity, and drying shrinkage), durability (i.e., water absorption, surface electrical resistivity, and rapid chloride ion penetration), and microstructure (i.e., scanning electron microscopy observation) of high-performance concrete (HPC). A comparative analysis of the economic and environmental benefits of SS concrete versus natural aggregate concrete was also performed. The test results revealed that SS, FA, and GGBFS all impacted the properties of HPC significantly. The HPC mixtures in which natural aggregate had been completely replaced with SS exhibited about 20.4–21.3% higher unit weight than the natural aggregate concrete. The HPC samples with added FA and GGBFS exhibited enhanced performance in terms of mechanical strength, durability, and microstructure. Moreover, total material cost, global warming potential (GWP), and ozone depletion potential (ODP) were all found to be significantly lower in the HPC samples produced using SS and either GGBFS or a combination of FA and GGBFS. As a result, after 210 days of normal curing, the 100% SS concrete containing 15% FA and 35% GGBFS as a Portland cement substitution (S100F15G35 specimen) exhibited compressive and flexural strength values of 110.3 and 11.1 MPa, which were approximately 9.0% higher than the corresponding values of the reference concrete. Also, the S100F15G35 specimen registered the respective ultrasonic pulse velocity, surface electrical resistivity, and rapid chloride ion penetration values of 5328 m/s, 113.3 kΩ.cm, and 203 Coulombs, indicating high-quality and durable concrete. Moreover, incorporating 15% FA and 35% GGBFS in SS concrete resulted in a reduction of 15.7% drying shrinkage and 24.4% total material cost, especially reduced environmental impacts with a significant reduction in GWP and ODP by 43.5% and 29.2%, respectively. These findings further demonstrate the potential of using SS in combination with FA and GGBFS to create high-quality HPC that is both more economical and significantly more sustainable than conventional HPC.

Use and effect of fly ash in concrete: A literature review

Concrete production is characterized by a significant demand for energy and raw materials. The construction, maintenance, and demolition of engineering works cause excessive polluting waste that requires costly disposal. For this reason, alternative reusable materials that improve the mechanical properties of concrete, such as fly ash, are currently being investigated as an effective solution to reduce problems related to environmental impact. This paper analyzed 80 articles indexed in different databases such as ScienceDirect, IOPscience, Scielo, Ebsco, Scopus, SpringerLink, ProQuest, Dialnet, and Semanticscholar, which were not older than seven years since publication, to conduct an updated systematic review of the use, effect, and influence of fly ash on concrete. The methodologies and designs used to obtain the optimum percentages of 5, 10, and 15% were reviewed, analyzing mainly the results obtained when fly ash is used in concrete. Finally, according to the review carried out, it was concluded that fly ashes improve the mechanical and physical characteristics of concrete, and that the optimum dosage is 10% in substitution of ordinary Portland cement applied in simple concrete.

An Anova-Based Numerical Analysis of WHA Partial Replacement Concrete

In this work, a study exploiting concretes made with a bio-plant using natural waste is presented. The study examined the effects of partial cement substitution with bio-plants on the mechanical characteristics of conventional concretes and assessed the discrepancy between actual and expected elasticity modulus values. The usage of and effects on the modulus of elasticity of the partial replacement of concrete with WHA have been the subject of extensive research. Research was conducted in the area using various water-cement ratios coupled with water hyacinth ash and replacement percentages of cement. One-way analysis of variance (ANOVA) is used as a practical approach to verify normality. The supplied experimental data sets are used to train and evaluate the reliability predicting model. Thus, the study effort provides an overview of the numerical analysis performed using statistical techniques and the examination of the resulting data. The model's dependability is provided by the linear relationship between the Concrete mix% and with & without WHA. The 90C+10%WHA mixture performs better than conventional concrete.

Influence of silane treated nano eggshell powder on mechanical and durability properties of concrete

In order to test concrete’s sustainability, this study substitutes nano eggshell powder (nESP) for cement in a silane-treated environment. The results showed that the silane-treated concrete mixtures outperformed the untreated ones in terms of performance. nESP was replaced by 5 to 20% with in cement of 5% along with constant replacement of 30% fly ash by weight of cement. It was found that partial cement substitution with nESP up to 10% produced a sample with greater strength than the control sample. The filling and reinforcing properties of the nESP and the pozzolanic effect of flyash after silane treatment produced favorable results when mechanical strength was evaluated. The increased electrical resistance with age may be caused by the increased hydration products and excess CSH gel formation induced by the pozzolanic action of the fly ash in concrete.

Multi-Response Optimization on Hydrated Calcium Aluminate Rich Ternary Binders Using Taguchi Design of Experiments and Principal Component Analysis

This study investigates the influence of various factors on the performance of ternary binders, utilizing statistical approaches. The research focuses on the influence of varying compositions of Portland Cement-Calcium Aluminate Cement-Calcium Sulphate (PC-CAC-CŜ), types and amounts of mineral powders, and chemical admixtures in ternary binders. Using the Taguchi design, the study required a limited number of experimental trials, utilizing a standard orthogonal array of seven factors across three levels. These factors encompassed binder composition (C1-C2-C3), mineral powder types (limestone, quartz, slag), replacement ratio (0%, 25%, 50%), retarder (0%, 0.1%, 0.2%), superplasticizer, viscosity modifying agent (stabilizer) and accelerator (0%, 0.05%, 0.1%). Measurements on hydration kinetics, dimensional stability, compressive strength, and microstructural analyses like X-ray diffraction were conducted. Principal Component Analysis (PCA) was employed to interpret the continuous data derived from heat of hydration curves, length change curves and X-ray diffraction (XRD) patterns. Results indicated that retarder quantity and binder type significantly impacted paste workability. Higher powder content led to reduced strength, whereas increased accelerator improved strength. A strong correlation was observed between accelerator content and the dimensional stability. The primary hydration product’s formation was predominantly influenced by the PC-CAC-CŜ ratio, accelerator, and cement substitutions.

Effect of Cement Substitution by both Perlite and Pozzolan Powders on the Mechanical Behavior and Water Absorption of Pozzolanic Mortar

This paper studies the effect of both perlite and pozzolan powders as cement substituents. First, it addresses the mechanical properties of pozzolanic mortar in the short term, i.e., with a schedule of 7, 14 and 28 days. Next, in order to extend the analysis related to the porosity of the designed mortars, the water absorption is studied. The provided results indicated that the compressive strengths of the pozzolanic mortars were lower than those of the reference mortar. However, among the tested pozzolanic mortars, those containing 10% of perlite displayed superior strengths. Additionally, while the water absorption values for pozzolanic mortars were higher than those of the reference mortar, the inclusion of 10% of perlite in the mortar resulted in lower water absorption compared to the other pozzolanic mortars.

Rheological, Mechanical, and Micro-Structural Property Assessment of Eco-Friendly Concrete Reinforced with Waste Areca Nut Husk Fiber

Fiber-reinforced concrete (FRC) has become one of the most promising construction techniques and repairing materials in recent times for the construction industry. Generally, plain concrete has a very low tensile strength and limited resistance to cracking prior to the ultimate load, which can be mitigated by the incorporation of fiber. Natural fibers have emerged as an appealing sustainable option in the last few decades due to their lower cost, energy savings, and minimized greenhouse effects. Areca fiber is one of the natural fibers that can be sourced from the waste-producing areca nut industry. Hence, this study aims to assess the mechanical, rheological, and micro-structural properties of areca fiber-reinforced concrete (AFRC). For this purpose, areca fiber was used in the concrete mix as a weight percentage of cement. In this regard, 1%, 2%, 3%, and 4% by weight of cement substitutions were investigated. As key findings, 2% areca fiber enhanced the compressive strength of concrete by 2.89% compared to the control specimen (fiber-free concrete). On the other hand, splitting tensile strength increased by 18.16%. In addition, scanning electron microscopy (SEM) images revealed that the cement matrix and fibers are adequately connected at the interfacial level. Energy dispersive X-ray spectroscopy (EDX) test results showed more biodegradable carbon elements in the areca fiber-mixed concrete as well as an effective pozzolanic reaction. The study also exhibited that adding natural areca fiber lowered the fabrication cost by almost 1.5% and eCO2 emissions by 3%. Overall, the findings of this study suggest that AFRC can be used as a possible building material from the standpoint of sustainable construction purposes.

Relationships between Mortar Spread and the Fresh Properties of SCC Containing Local Metakaolin

Self-compacting concrete (SCC) production is a complex operation that requires finding a good combination and suitable dosages for its constituents. Several formulation methods have been developed to meet the workability requirements of SCC. Mortar spread is used to estimate SCC’s rheological properties, but the use of supplementary cementitious materials, such as metakaolin, could affect the accuracy of the estimation. In this paper, the relationships between the fresh properties of local-metakaolin (MK)-based SCC and the spreading of its mortar portion were investigated. The results showed the existence of good correlations between the spreading of mortar portion of SCC and its fresh state properties. The partial substitution of cement with MK did not affect these correlations. The mortar flow should be chosen according to the required rheological properties of the SCC. This can be achieved by using an appropriate viscosity-enhancing agent (VEA).

Microstructure and Water Retention Kinetics in Autogenous Cured Self-Compacting Concrete Blends Using Super Absorbent Polymer.

This research aimed to determine how a super absorbent polymer affects the microstructural characteristics and water retention kinetics of a new composite made by substituting granite pulver (GP) and fly ash (FA) for cement. Understanding the mechanics of water movement is crucial for comprehending the effectiveness of autogenous curing. Several experiments were conducted to analyze the water mitigation kinetics of super absorbent polymer (SAP) in the hydrating cement paste of autogenous cured self-compacting concrete (GP-ACSSC) mixtures. In the first hours following casting, water sorptivity, water retention, and hydration tests were carried out. The effects of various concentrations of SAP and GP, which was utilized as an alternative cement for the production of sustainable concrete that leads to reduction in carbon footprint, on the autogenous cured self-compacting concrete with reference to the abovementioned properties were explored. The investigation showed that releasing the curing water at a young age, even around the beginning of hydration, allowed homogenous and almost immediate distribution of water across the full cured paste volume, which improved the water retention kinetics. Compared to the control mixtures, the addition of SAP up to 0.6% and the substitution of cement with GP up to 15% had favorable impacts on all water kinetics parameters.

Influence of partial cement substitution by ground blast furnace slag on the mechanical properties of phosphogypsum cemented backfill.

Phosphogypsum (PG) stockpiles occupied a large amount of land resources, and serious environmental pollution problems have attracted the attention of countries around the world. Cemented backfill can reduce the environmental problems caused by tailings stockpiles and is an important development trend in green mine construction. To investigate the effect of binder type on the performance of PG cemented backfill, this paper used ground granulated blast furnace slag (GGBFS) to substitute part of Portland cement (PC) as binder and studied the effect of different ratios of binder on the uniaxial compressive strength (UCS), surface crack extension, acoustic emission (AE) characteristics, and microstructure of PG cemented backfill. The results show that substituting part of PC with GGBFS is beneficial to improve the mechanical properties of PG cemented backfill. When PC was substituted by 50% of GGBFS, the 28d UCS of the backfill was increased from 1.535 to 4.539 MPa. Furthermore, the UCS of the backfill gradually increased as the GGBFS substitution level increased, and more AE signals could be monitored during uniaxial compression. Compared with PC, the sulfate in PG participates in the hydration reaction of GGBFS, more hydrated calcium-aluminum-silicate-hydrate (C-A-S-H) gels and ettringite (AFt) are formed, and the microstructure of the backfill is denser, and the required strength can be obtained with less binder. Thus, substituting part PC with GGBFS as a binder can provide an economical and environmentally friendly alternative for the consumption and reuse of large quantities of PG.

INOVASI LAPIS PONDASI ATAS CTB (CEMENT TREATED BASE) MENGGUNAKAN SUBTITUSI POFA DAN LIMBAH CANGKANG KERANG HIJAU

During the current administration, the construction sector, especially toll road infrastructure in Indonesia, has increased. This will increase the amount of cement production to meet construction needs. Even though the cement industry is one of the contributors to gas emissions. In addition, the plantation sector can be optimized as an alternative construction material. Such as palm shell waste (POFA), which contains the same content as cement. The fisheries sector can also be optimized as an alternative construction material. such as green mussel shells which have the same content as cement, which is pozzolanic. Based on these problems, the purpose of this research is to optimize palm oil shell waste and green mussel shells as cement substitution materials in CTB to reduce gas emissions. The method used is research and experimentation by partially substituting cement by 10% and 20% using POFA. 5% and 10% use green mussel shell waste which will later be compared with the CTB Job mix formula which complies with the general specifications by testing the compressive strength of concrete and analysis of CTB work unit prices per 1 m3. The results of this study revealed that the highest compressive strength of 5.5 MPa occurred in 20% POFA substituted CTB and 10% green mussel shells. This compressive strength is higher than Normal CTB. However, from the results of price analysis it can be seen that 20% POFA substitution CTB and 10% green mussel shells require a 3.7% higher cost than the Normal CTB price or a difference of Rp.19,792.22.

Enhancing eco-concrete performance through synergistic integration of sugarcane, metakaolin, and crumb rubber: Experimental investigation and response surface optimization

Sustainable construction has gained paramount importance due to the consideration of the devastating effects of construction activities on the environment. Researchers are exploring innovative approaches to mitigate the carbon footprint and enhance the durability of concrete. In order to regulate the demand and cost of concrete constituents, such as cement and sand, there is a need to invent alternative materials and utilize various industrial and agricultural wastes instead of concrete ingredients, either partially or completely. The experimental investigation and optimization of eco-concrete composites by integrating sugarcane bagasse ash (SCBA), metakaolin (MK), and crumb rubber (CR) are cutting-edge research areas that aim to develop environmentally friendly and high-performance concrete materials. The present research work has attempted to utilize SCBA up to 15% by weight of cement with an increment of 5%, MK as a fractional exchange of cement up to 15% with 5% intervals, and CR was utilized as fractional volumetric substitution of sand from 0% to 15% in concrete. Different sets of combinations were evaluated to identify effects on density, workability, compressive strength, split tensile strength, flexural strength, and microstructural properties. This study has obtained satisfactory results when compared to the control concrete for 10% substitution of cement with MK and 10% substitution of cement with SCBA, along with a 10% replacement of fine aggregate (i.e., sand) with CR. The results were analyzed and optimized using Response Surface Methodology (RSM), which illuminated a strong correlation between experimental findings and RSM models, with an R squared (R2) value of 0.9580. The experimental findings and RSM models showed a significant correlation. The increment in the substitution of sand with CR resulted in a decline in strength, and it can be controlled by adopting different effective pretreatment techniques for CR.