Mechanical and physical properties of cement blended with sewage sludge ash

The aim of this paper is to evaluate the compatibility of sewage sludge ash (SSA) with various types of commercially available cements (CEM I and CEM II types, cements with several proportions of clinker). The behaviour of mortars fabricated with various percentages (10-30% by weight) of the cement replaced by SSA has been analyzed in terms of workability, mechanical strength, porosity and shrinkage/expansion. SSA exhibits moderate pozzolanic activity; the highest compressive strengths were obtained with 10% of the cement replaced by SSA. The CEM II/B-M (V-LL) 42.5R cement is considered ideal for preparing mortars containing SSA. Shrinkage data demonstrate that sulphates present in SSA are not reactive towards cement.     

Influence of combustion temperature on the performance of sewage sludge ash as a supplementary cementitious material

The potential for using sewage sludge ash (SSA) as a supplementary cementitious material (SCM) has been investigated. Controlled combustion of sewage sludge collected in Croatia from two wastewater treatment plants produced SSA with different characteristics. These were used to substitute for cement in mortar samples. The chemical composition and physical properties of SSA depend on wastewater composition, the sludge treatment process and the combustion temperature. These factors influence the suitability of SSA to be used as a SCM. For three different combustion temperatures (800, 900 and 1000 °C), it was concluded that properties of fresh mortar were not affected while in the hardened state, the most favorable combustion temperature is 900 °C regarding mechanical properties. Regardless of combustion temperature, for all types of SSA used in mortars as cement replacement (up to 30%), the average decrease in both compressive and flexural strength values was less than 8% for every 10% of added SSA. The results presented indicate that using up to 20% replacement of cement by SSA produces mortars that meet the specific technical requirements analyzed in this work.     

Phosphate fertilizer from sewage sludge ash (SSA)

Ashes from sewage sludge incineration are rich in phosphorus content, ranging between 4% and 9%. Due to the current methods of disposal used for these ashes, phosphorus, which is a valuable plant nutrient, is removed from biological cycling. This article proposes the possible three-stage processing of SSA, whereby more than 90% of phosphorus can be extracted to make an adequate phosphate fertilizer. SSA from two Swiss sewage sludge incinerators was used for laboratory investigations. In an initial step, SSA was leached with sulfuric acid using a liquid-to-solid ratio of 2. The leaching time and pH required for high phosphorus dissolution were determined. Inevitably, dissolution of heavy metals takes place that would contaminate the fertilizer. Thus in a second step, leach solution has to be purified by having the heavy metals removed. Both ion exchange using chelating resins and sulfide precipitation turned out to be suitable for removing critical Cu, Ni and Cd. Thirdly, phosphates were precipitated as calcium phosphates with lime water. The resulting phosphate sludge was dewatered, dried and ground to get a powdery fertilizer whose efficacy was demonstrated by plant tests in a greenhouse. By measuring the weight of plants after 6 weeks of growth, fertilized in part with conventional phosphate fertilizer, fertilizer made from SSA was proven to be equal in its plant uptake efficiency.     

Metallic aluminum in MSWI fly ash: quantification and influence on the properties of cement-based products

This article focuses on the effects of metallic aluminum contained in municipal solid waste incineration (MSWI) fly ashes on cement-based materials in which they are added. The ash under study was treated by an industrial physicochemical process of neutralization. The paper also presents a method to quantify the metallic aluminum content of ash: it consists in measuring the amount of hydrogen gas produced by the oxidation reaction of metallic aluminum. This method is simple and fast. Results show that studied ash contains an appreciable amount of metallic aluminum. Investigations were carried out to study the incorporation of the ash in concrete: in this case, the presence of metallic aluminum is worrying because it could be responsible for disorders in concrete. In fact, swellings are observed on cement pastes and mortars containing ash during the first 24 h of hydration. A test based on hydrostatic weighing permits to quantify the swelling of fresh cement paste and to study the evolution of this swelling. Causes of swelling are analyzed. Results show that ettringite formation occurs after the end of the expansion reaction. So it can be concluded that metallic aluminum is the sole responsible for the observed swelling. Consequences of swelling are also analyzed by measuring compressive strength of ash-containing mortars: this swelling leads to cracks in the mortars and significant decrease of their compressive strength.     

Recycled sand in lime-based mortars

The increasing awareness of the society about safe guarding heritage buildings and at the same time protecting the environment promotes strategies of combining principles of restoration with environmentally friendly materials and techniques. Along these lines, an experimental program was carried out in order to investigate the possibility of producing repair, lime-based mortars used in historic buildings incorporating secondary materials. The alternative material tested was recycled fine aggregates originating from mixed construction and demolition waste. Extensive tests on the raw materials have been performed and mortar mixtures were produced using different binding systems with natural, standard and recycled sand in order to compare their mechanical, physical and microstructure properties. The study reveals the improved behavior of lime mortars, even at early ages, due to the reaction of lime with the Al and Si constituents of the fine recycled sand. The role of the recycled sand was more beneficial in lime mortars rather than the lime–pozzolan or lime–pozzolan–cement mortars as a decrease in their performance was recorded in the latter cases due to the mortars’ structure.     

Utilization of gold tailings as an additive in Portland cement.

Mine tailings are formed as an industrial waste during coal and ore mining and processing. In the investigated process, following the extraction of gold from the ore, the remaining tailings are subjected to a two-stage chemical treatment in order to destroy the free cyanide and to stabilize and coagulate heavy metals prior to discharge into the tailings pond. The aim of this study was the investigation of the feasibility of utilization of the tailings as an additive material in Portland cement production. For this purpose, the effects of the tailings on the compressive strength properties of the ordinary Portland cement were investigated. Chemical and physical properties, mineralogical composition, particle size distribution and microstructure of the tailings were determined by Fourier transform infrared spectroscopy (FTIR), X-ray diffractometry (XRD), particle size analyzer (Mastersizer) and scanning electron microscope (SEM). Following the characterization of the tailings, cement mortars were prepared by intergrinding Portland cement with dried tailings. Composition of the cement clinkers were adjusted to contain 5, 15, 25% (wt/wt) dried tailings and also silica fume and fly ash samples (C and F type) were added to clinker in different ratios. The mortars produced with different amounts of tailings, silica fume, fly ashes and also mixtures of them were tested for compressive strength values after 2, 7, 28 and 56 days according to the European Standard (EN 196-1). The results indicated that gold tailings up to 25% in clinker could be beneficially used as an additive in Portland cement production. It is suggested that the gold tailings used in the cement are blended with silica fume and C-type fly ash to obtain higher compressive strength values.     

A study of disposed fly ash from landfill to replace Portland cement

The landfills of fly ash are the problem of all power plants because this disposed fly ash is not used in any work. This research studies the potential of using disposed fly ashes which have disposal time of 6-24 months from the landfill of Mae Moh power plants in Thailand to replace Portland cement type I. Median particle sizes of disposed fly ashes between 55.4 and 99.3 microm were ground to reduce the sizes to about 7.1-8.4 microm. Both original and ground disposed fly ashes were investigated on physical and chemical properties. Compressive strengths of disposed fly ash mortars were determined when Portland cement type I was replaced by disposed fly ashes at the rate of 10%, 20%, and 30% by weight of cementitious material (Portland cement type I and disposed fly ash). The results presented that most particles of original disposed fly ashes were solid and sphere with some irregular shape while those of ground disposed fly ashes were solid and irregular shape. CaO and LOI contents of disposed fly ashes with different disposal times had high variation. The compressive strengths of original disposed fly ash mortars were low but those of ground disposed fly ash mortars at the age of 7 days were higher than 75% of the standard mortar and increased to be higher than 100% after 60 days. From the results, it could be concluded that ground disposed fly ashes were excellent pozzolanic materials and could be used as a partial replacement of cement in concrete, even though they were exposed to the weather for 24 months.     

Use of Pb blast furnace slag as a partial substitute for fine aggregate in cement mortar

The technical properties of cement mortars containing natural fine aggregate that is replaced by lead blast furnace slag at 25 and 35% level were assessed at fixed water-to-cement (W/C) ratio and at fixed flow table value. The leachabilities of some toxic elements from the cement mortars were also assessed to test the environmental suitability of the slag for use in preparation of cement mortar. At fixed W/C ratio, the strength of the mortar decreased with increase of the slag content. On the other hand, at fixed consistency, strength increased with increasing slag content in the mortar composition. The concentrations of some toxic elements in the leachates collected from the mortars containing slag were slightly higher than for the control mortar, but the concentrations in the leachates remained within the regulatory limits for recycling in construction applications. For most elements, leaching from a mortar containing 35% of slag was similar to that from a mortar containing 25% of slag. Therefore, 35% of natural sand can be beneficially replaced with Pb slag to produce cement mortar without affecting the mechanical and leaching properties studied in this work.     

Recycling municipal incinerator fly- and scrubber-ash into fused slag for the substantial replacement of cement in cement-mortars

Fly- and scrubber-ash (weight ratio of approximately 1:3) from municipal solid waste incinerators (MSWI) are a major land-fill disposal problem due to their leaching of heavy metals. We uniformly mixed both types of ash with optimal amounts of waste glass frit, which was then melted into a glassy slag. The glassy slag was then pulverized to a particle size smaller than 38 μm for use as a cement substitute (20–40% of total cement) and blended with sand and cement to produce slag-blended cement-mortar (SCM) specimens. The toxicity characteristics of the leaching procedure tests on the pulverized slag samples revealed that the amount of leached heavy metals was far below regulatory thresholds. The compressive strength of the 28-day cured SCM specimens was comparable to that of ordinary Portland cement mortars, while the compressive strength of specimens cured for 60 or 90 days were 3–11% greater. The observed enhanced strength is achieved by Pozzolanic reaction. Preliminary evaluation shows that the combination of MSWI fly- and scrubber-ash with waste glass yields a cost effective and environmentally friendly cement replacement in cement-mortars.     

Comparative study on the characteristics of fly ash and bottom ash geopolymers

This research was conducted to compare geopolymers made from fly ash and ground bottom ash. Sodium hydroxide (NaOH) and sodium silicate (Na(2)SiO(3)) solutions were used as activators. A mass ratio of 1.5 Na(2)SiO(3)/NaOH and three concentrations of NaOH (5, 10, and 15M) were used; the geopolymers were cured at 65 degrees C for 48 h. A Fourier transform infrared spectrometer (FT-IR), differential scanning calorimeter (DSC), and scanning electron microscope (SEM) were used on the geopolymer pastes. Geopolymer mortars were also prepared in order to investigate compressive strength. The results show that both fly ash and bottom ash can be utilized as source materials for the production of geopolymers. The properties of the geopolymers are dependent on source materials and the NaOH concentration. Fly ash is more reactive and produces a higher degree of geopolymerization in comparison with bottom ash. The moderate NaOH concentration of 10 M is found to be suitable and gives fly ash and bottom ash geopolymer mortars with compressive strengths of 35 and 18 MPa.     

Caesium sorption by hydrated cement as a function of degradation state: experiments and modelling

To provide reliable K(d) data for Cs required for the performance assessment of cement-based radioactive waste repositories, two complementary approaches were followed. First, Cs sorption was determined on a range of hydrated cement paste (HCP) and mortar samples of CEM I and CEM V for different degradation states and solution compositions, as well as on some single mineral phases. Second, a surface complexation-diffuse layer model previously developed by Pointeau et al. [Pointeau, I., Marmier, N., Fromage, F., Fedoroff, M., Giffaut, E., 2001. Cs and Pb uptake by CSH phases of hydrated cement. Material Research Society Symposium Proceedings, 663, 105-113] for Cs sorption on synthetic CSH phases was simplified to facilitate its application to whole HCP and mortars or concrete, following re-assessment of the model parameters. All measurements were compared with model predictions. The sorption data obtained on the different solid phases as a function of conditions corroborate that CSH minerals are the main sorbing phase for Cs in HCP. The data also clearly show the important influence of pH and the dissolved concentration of Na, K and Ca on K(d). It is further suggested that a decrease of pH is concomitant with a decrease of the Ca/Si ratio and a corresponding increase in surface sites with high affinity for Cs and, thus, K(d). Elevated concentrations of cations able to compete with Cs for these sites lead to a decrease of K(d), on the other hand. The simplified model was applied to the sorption measurements performed within this study as well as to a variety of literature data, mainly K(d) values for a variety of fresh HCP and mortar or concrete samples based on different samples of Ordinary Portland Cement as well as blended cements. The results show that the model can be applied reasonably well to a very large variety of conditions in terms of solid and solution compositions that cover a range of K(d) values from 10(-4) to ca. 3.2m(3)/kg. The large scatter typically observed for Cs sorption, especially on fresh HCP samples prepared from different formulations, can be explained quantitatively by the variable concentrations of Na and K in the respective solutions, which compete with Cs for fixation sites. On the other hand, the comparatively uniform conditions in degraded HCP typically render the prediction of K(d) values less uncertain than in case of fresh HCP.     

Influence of recycled aggregate quality and proportioning criteria on recycled concrete properties

This paper presents the results of experimental research using concrete produced by substituting part of the natural coarse aggregates with recycled aggregates from concrete demolition. The influence of the quality of the recycled aggregate (amount of declassified and source of aggregate), the percentage of replacement on the targeted quality of the concrete to be produced (strength and workability) has been evaluated. The granular structure of concrete and replacement criteria were analyzed in this study, factors which have not been analyzed in other studies. The following properties of recycled concretes were analyzed: density, absorption, compressive strength, elastic modulus, amount of occluded air, penetration of water under pressure and splitting tensile strength.A simplified test program was designed to control the costs of the testing while still producing sufficient data to develop reliable conclusions in order to make the number of tests viable whilst guaranteeing the reliability of the conclusions.Several factors were analyzed including the type of aggregate, the percentage of replacement, the type of sieve curve, the declassified content, the strength of concrete and workability of concrete and the replacement criteria. The type of aggregate and the percentage of replacement were the only factors that showed a clear influence on most of the properties.Compressive strength is clearly affected by the quality of recycled aggregates. If the water–cement ratio is kept constant and the loss of workability due to the effect of using recycled aggregate is compensated for with additives, the percentage of replacement of the recycled aggregate will not affect the compressive strength.The elastic modulus is affected by the percentage of replacement. If the percentage of replacement does not exceed 50%, the elastic modulus will only change slightly.     

Oyster shell as substitute for aggregate in mortar.

Enormous amounts of oyster shell waste have been illegally disposed of at oyster farm sites along the southern coast of Korea. In this study to evaluate the possibility of recycling this waste for use as a construction material, the mechanical characteristics of pulverized oyster shell were investigated in terms of its potential utilization as a substitute for the aggregates used in mortar. The unconfined compressive strengths of various soil mortar specimens, with varying blending ratios of cement, water and oyster shell, were evaluated by performing unconfined compression tests, and the results were compared with the strengths of normal cement mortar made with sand. In addition, the effect of organic chemicals on the hardening of concrete was evaluated by preparing ethyl-benzene-mixed mortar specimens. The long-term strength improvement resulting from the addition of fly ash was also examined by performing unconfined compression tests on specimens with fly-ash content. There was no significant reduction in the compressive strength of the mortars containing small oyster shell particles instead of sand. From these test data, the possible application of oyster shells in construction materials could be verified, and the change in the strength parameters according to the presence of organic compounds was also evaluated.     

Lightweight aggregate made from sewage sludge and incinerated ash

In this study, sewage sludge ash (SSA), with similar characteristics to expansive clay, was used as the principal material and sewage sludge (SS) as the admixture to sinter lightweight aggregate and to study the influences of raw material composition on pelletising, sintering effect and aggregate properties. Results showed that both SS and SSA could be sintered to produce synthetic aggregates individually or mixed. Increasing the amount of SS would decrease the pelletising ratio. Under the consideration of energy saving, the mixture of SSA was better for sintering normal weight aggregate. On the contrary, the mixture that added 20-30% of SS was more adequate to make lightweight aggregates. Adding SS would enhance the oxidation-reduction reaction and lower the bulk density and sintering temperature of aggregates to save energy. Sintering temperature affected the properties of sewage sludge ash lightweight aggregate (SSALA) more than retention period did. Prolonging the retention period could improve bloating effect.     

Assessment of the leaching of metallic elements in the technology of solidification in aqueous solution

Results are presented of experiments performed to optimize the solidification/stabilization system for metallic elements in aqueous solution. This system involves mixing cement and a solution of metallic elements in a conventional mixer: the paste thus obtained is transferred drop by drop into a recipient filled with an aqueous solution of NaOH at 20% by weight, in which it solidifies immediately. The separate use of chloride solutions of Li+, Cr3+, Pb2+ and Zn2+ makes it possible to obtain granules displaying various levels of compressive strength. Three different inertization matrices were used in the experiments, the first consisting solely of Portland cement, the second of Portland cement and a superplasticizer additive, and the third of Portland cement partially replaced with silica-fume and superplasticizer. The results of the tests performed showed a very low level of leaching into the alkaline solidification solution for Cr3+, the quantity leached being under 2% as against higher levels for the other metallic elements. For all the considered elements, the best results were obtained by using silica-fume in the inertization matrix.     

Mechanical properties of concrete containing a high volume of tire-rubber particles

Due to the increasingly serious environmental problems presented by waste tires, the feasibility of using elastic and flexible tire-rubber particles as aggregate in concrete is investigated in this study. Tire-rubber particles composed of tire chips, crumb rubber, and a combination of tire chips and crumb rubber, were used to replace mineral aggregates in concrete. These particles were used to replace 12.5%, 25%, 37.5%, and 50% of the total mineral aggregate's volume in concrete. Cylindrical shape concrete specimens 15 cm in diameter and 30 cm in height were fabricated and cured. The fresh rubberized concrete exhibited lower unit weight and acceptable workability compared to plain concrete. The results of a uniaxial compressive strain control test conducted on hardened concrete specimens indicate large reductions in the strength and tangential modulus of elasticity. A significant decrease in the brittle behavior of concrete with increasing rubber content is also demonstrated using nonlinearity indices. The maximum toughness index, indicating the post failure strength of concrete, occurs in concretes with 25% rubber content. Unlike plain concrete, the failure state in rubberized concrete occurs gently and uniformly, and does not cause any separation in the specimen. Crack width and its propagation velocity in rubberized concrete are lower than those of plain concrete. Ultrasonic analysis reveals large reductions in the ultrasonic modulus and high sound absorption for tire-rubber concrete.     

Alkali-silica reactions of mortars produced by using waste glass as fine aggregate and admixtures such as fly ash and Li2CO3

Use of waste glass or glass cullet (GC) as concrete aggregate is becoming more widespread each day because of the increase in resource efficiency. Recycling of wastes is very important for sustainable development. When glass is used as aggregate in concrete or mortar, expansions and internal stresses occur due to an alkali-silica reaction (ASR). Furthermore, rapid loss in durability is generally observed due to extreme crack formation and an increase in permeability. It is necessary to use some kind of chemical or mineral admixture to reduce crack formation. In this study, mortar bars are produced by using three different colors of glass in four different quantities as fine aggregate by weight, and the effects of these glass aggregates on ASR are investigated, corresponding to ASTM C 1260. Additionally, in order to reduce the expansions of mortars, 10% and 20% fly ash (FA) as mineral admixture and 1% and 2% Li(2)CO(3) as chemical admixture are incorporated by weight in the cement and their effects on expansion are examined. It is observed that among white (WG), green (GG) and brown glass (BG) aggregates, WG aggregate causes the greatest expansion. In addition, expansion increases with an increase in amount of glass. According to the test results, it is seen that over 20% FA and 2% Li(2)CO(3) replacements are required to produce mortars which have expansion values below the 0.2% critical value when exposed to ASR. However, usages of these admixtures reduce expansions occurring because of ASR.     

Use of rubble from building demolition in mortars

Because of increasing waste production and public concerns about the environment, it is desirable to recycle materials from building demolition. If suitably selected, ground, cleaned and sieved in appropriate industrial crushing plants, these materials can be profitably used in concrete. Nevertheless, the presence of masonry instead of concrete rubble is particularly detrimental to the mechanical performance and durability of recycled-aggregate concrete and the same negative effect is detectable when natural sand is replaced by fine recycled aggregate fraction. An alternative use of both masonry rubble and fine recycled material fraction could be in mortars. These could contain either recycled instead of natural sand or powder obtained by bricks crushing as partial cement substitution. In particular, attention is focused on the modification that takes place when either polypropylene or stainless steel fibers are added to these mortars. Polypropylene fibers are added in order to reduce shrinkage of mortars, stainless steel fibers for improving their flexural strength. The combined use of polypropylene fibers and fine recycled material from building demolition could allow the preparation of mortars showing good performance, in particular when coupled with bricks. Furthermore, the combined use of stainless steel fibers and mortars containing brick powder seems to be an effective way to guarantee a high flexural strength.     

Utilization of blended fluidized bed combustion (FBC) ash and pulverized coal combustion (PCC) fly ash in geopolymer

In this paper, synthesis of geopolymer from fluidized bed combustion (FBC) ash and pulverized coal combustion (PCC) fly ash was studied in order to effectively utilize both ashes. FBC-fly ash and bottom ash were inter-ground to three different finenesses. The ashes were mixed with as-received PCC-fly ash in various proportions and used as source material for synthesis of geopolymer. Sodium silicate (Na₂SiO₃) and 10 M sodium hydroxide (NaOH) solutions at mass ratio of Na₂SiO₃/NaOH of 1.5 and curing temperature of 65 °C for 48 h were used for making geopolymer. X-ray diffraction (XRD), scanning electron microscopy (SEM), degree of reaction, and thermal gravimetric analysis (TGA) were performed on the geopolymer pastes. Compressive strength was also tested on geopolymer mortars. The results show that high strength geopolymer mortars of 35.0–44.0 MPa can be produced using mixture of ground FBC ash and as-received PCC-fly ash. Fine FBC ash is more reactive and results in higher degree of reaction and higher strength geopolymer as compared to the use of coarser FBC ash. Grinding increases reactivity of ash by means of increasing surface area and the amount of reactive phase of the ash. In addition, the packing effect due to fine particles also contributed to increase in strength of geopolymers.