HIGH PERFORMANCE CONCRETE BASED ON COMPOSITE PORTLAND CEMENTS WITH FLY ASH, METAKAOLIN, GROUND GRANULATED BLAST FURNACE SLAG AND SILICA FUME ADDITIONS

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1 4TO.CONGRESO NACIONAL DE CAMBIO CLIMÁTICO SEDE REGIONAL NORESTE HIGH PERFORMANCE CONCRETE BASED ON COMPOSITE PORTLAND CEMENTS WITH FLY ASH, METAKAOLIN, GROUND GRANULATED BLAST FURNACE SLAG AND SILICA FUME ADDITIONS M.C. Aldo Rubén Campos Silva Dra. Lauren Y. Gómez Zamorano 1

2 CONTENT i. INTRODUCTION ii. iii. iv. BACKGROUND HIPOTESIS OBJECTIVES v. METODOLOGY vi. vii. PRELIMINARY RESULTS PELIMINARY CONCLUSIONS CONTENT 2

3 High Performance Concrete Concrete with enhanced properties. Characteristics Rel. W/C 0.20 to 0.45 Compressive strenght > 70 Mpa Cement content per m³ > 400 Kg/m³ INTRODUCTION 3

4 High Performance Concrete Applications INTRODUCTION 4

5 Ways to obtain High Performance Concrete A. Reduce the floculation of cement grains B. Widen the range of grain size Superplasticizers Cement Additives o Sulphonates melanine formaldehyde condensates o o Silica Fume Blast Slag Furnace Pozzolanic Materials o Sulphonated naphtalene formaldehyde condemsates o o Metakaolin Fly Ash o Lignosulphonates o Calcareous fillers o Polycarboxilates INTRODUCTION 5

6 Chemical composition of alternative materials SiO 2 SiO₂ Microsilica POZZOLANIC MATERIALS Volcanic Ash Blast furnace slag Portland Cement Reaction of Cement Hydration 3CaO SiO 2 + H 2 O --> C-S-H +Ca(OH) 2 Fly ash Pozzolanic Materials SiO 2 + Ca(OH) 2 + H 2 O --> C-S-H CaO CaO Blast furnance slag CaO + SiO 2 + Ca(OH) 2 + H 2 O --> C-S-H INTRODUCTION Al₂O₃ 6

7 Pozzolanic materials Obtained by this process Microstructure Characteristics Fly Ash They are small particles obtained from coal burning plants. Amorphous material is required. Blast Slag Furnace It is derived from the manufacture of cast iron in a blast furnace ~90% amorphous Irregular angular morphology. acceptable size μm INTRODUCTION 7

8 Pozzolanic materials Obtained by this process Microstructure Characteristics Metakaolin Produced by the calcination of kaolinite. Particle size of around 1 micron. Silica Fume It is derived from the manufacture of silicon metal, ferro-alloys and other silicon alloys. Features that make SF a reactive material High content of SiO₂ Highly Amorphous Particle size of about 0.1 micron. INTRODUCTION 8

9 Durability in High Performance concrete Carbonation In urban environments the carbonation of concrete is the main deterioration process in most of the structures. Chlorides In Marine environments it is the main mechanism of deterioration. INTRODUCTION 9

10 Concentration of CO₂ Concentración atmosférica de CO 2. Fuente: Siegenthaler et al., INTRODUCTION

11 Background Authors Description Binder Proportions Compressive strenght(mpa) R. P. Khatri and V. Sirivivatnanon 2004 Mehmet Gesoglu et al Ternary cementitious concrete with water/binder ratio 0.35, cement 430 kg/m³. cured for 28 days. Quaternary cementitious concrete with water/binder ratio 0.32, cement of 550 kg/m³, cured for 28 days. 15%FA + 10%SF + 75%C 25%FA + 10%SF + 65%C 7.5%FA + 7.5%GBSF + 5%SF + 80%C 15%FA + 15%GBSF + 10%SF + 60%C 22.5%FA %GBSF + 15%SF + 40% C Mehmet Gesoglu et al Self-compacting quaternary cementitious concrete with water/binder ratio 0.44, cement 450kg/m³, cured for 90 days. 7.5%FA + 7.5%GBSF + 5%SF + 80%C 15%FA + 15%GBSF + 10%SF + 60%C 22.5%FA %GBSF + 15%SF + 40%C Tahir Kemal Erden et al. High strength ternary cementitious concrete with water/binder ratio 0.26, cement of 500 kg/m³, cured for 28 days. BACKGROUND 5%FA + 5%SF + 90%C 10%FA + 10%SF + 80%C

12 Hypothesis Is possible to produce high performance concrete based in a quaternary system of a supplementary cementitious materials with enhanced properties and durability. HIPOTESIS 12

13 General Objective Evaluate the properties of composite concretes, analyzing the compressive strength, microstructure, and durability, including corrosion and carbonation rates. Based on the results obtained from the caracterization obtain a composition for a high performance concrete with enchanced properties. OBJECTIVES 13

14 Specific Objectives 1. Characterization of the pozzolanic materials (fly ash, metakaolin, granulated blast furnace slag and silica fume). 2. Determination of the properties of concrete in fresh state (volumetric mass, temperature and slump). 3. Determination of the properties of the concrete in long term curing. 4. Analyze the durability of the concretes produced. 5. Evaluate the differences in properties between normal concrete and high performance concrete. OBJECTIVES 14

15 HIGH PERFORMANCE CONCRETE Conditions: Quaternary cements, Rel. W/b 0.35, Sustitutions of 35 y 50% in weight of cement. Characterization Physical Properties of materials Microstructure Properties of concrete Durability Density Granulometry % absorption Fineness Blaine % Superplasticizers Petrograhy SEM Mineralogical phases DRX METODOLOGY Slump Compressive strenght Porosity Air content Carbonation Accelerated test Natural test Chlorides Corrosion potential Polarization Resistance Permeability to chloride ions 15

16 % Pass % Pass Chracteristics of Aggregates Coarse- aggregate Fine-Aggregate 100 Granulometry Coarse 100 Granulometry Fine Limit ASTM Limit ASTM % Pass Limit ASTM Limit ASTM % Pass Grading 1 3/4 ½ 3/ Grading PRELIMINARY RESULTS 16

17 Marsh Cone Time of flux Compatibility of cement/superplasticizers 120 A/C min min 60 min min 120 min Superplasticizers dosage in percentage PRELIMINARY RESULTS 17

18 Characteristics of the cementitious materials Density Material Density in gr/cm 3 Cement CPC30R 3.0 Cement CPO Fly Ash 2.5 Blast slag furnance 2.8 Silica Fume 2.21 Metakaolin 2.5 PRELIMINARY RESULTS 18

19 Casting of the Mortars 19

20 Relativite intensity X-ray diffraction, Fly ash C C M K C: Quartz M: Mullite K: Calcite Angular Position 2θ 20

21 Relative intensity X-ray diffraction, Metakaolin C C: Quartz C Angular Position 2θ 21

22 Relative intensity X-ray diffraction, Blast slag furnance C: Calcite C Angular position2θ 22

23 Intensidad Relativa X-ray diffraction, Silica Fume 500 Cr Cr: Cristobalite Cr Posición angular 2θ 23

24 Compressive strength, MPa Preliminary Tests (Mortars ASTM C 109) Rel a/c 0.43 A. Silica CPC 30R Rel. a/c A. Silica CPC 30R Rel. a/c 0.43 A. Silica CPO 40 Rel. a/c A. Silica CPO 40 Rel. a/c 0.43 A. Silica C. Puz. 40 Rel. a/c A. Silica C. Puz. 40 Rel. a/c 0.43 A. Caliza CPO 40 Rel. a/c A. Caliza CPO Days of Curing Preliminary Tests 24

25 Petrografias (200X) Concrete with Metakaolin Mortars Concrete with Silica Fume Preliminary Tests 25

26 Preliminary conclusions The compression results show that the mortars used cements are not suitable for the development of highperformance concrete. Compatibility testing cement-additive showed the best performance superplasticizer dosage occurs in 2% by weight of cement. The characterization of the physical properties of pozzolans and aggregates show that are suitable for high performance concrete. Preliminary Conclusions 26

27 Future Work Finish the characterization of the raw materials (Granulated Blast Furnace Slag, Silica Fume, Fly Ash and metakaolin). Determination of surface area of pozzolanic materials Compressive strength tests in concrete and mortars. Characterization of the concretes and mortars: SEM-EDS, XRD, TGA. Durability Accelerated and natural carbonation tests in concrete Future Work 27

28 References 1. Aitcin P.C. Concretos de Alto Desempeño, Holcim, PCA, Diseño de Mezclas de Concreto, Concretos de Alto Desempeño, L. Y. Gómez Z., P. E. Fraire L., J. I. Escalante G., CEMENTOS PORTLAND COMPÓSITOS: EFECTO DE TRES MATERIALES DE REEMPLAZO COMÚNMENTE USADOS, CINVESTAV Saltillo, METHA, P. K., Tecnología del concreto para un desarrollo sustentable, Instituto Mexicano del Cemento y el Concreto, 5. Neville Adam M., Tecnología del concreto, Cemento Portland, 4a edición, México D.F., IMCYC, R. P. Khatri and V. Sirivivatnanon, Effect of Different Supplementary Cementitious Material on mechanical properties of high performance concrete, Mehmet Gesoglu et al. Effects of mineral admixtures on fresh and hardened properties of selfcompacting concretes: binary, ternary and quaternary systems, Mehmet Gesoglu et al. Properties of self-compacting concretes made with binary, ternary, and quaternary cementitious blends of fly ash, blast furnace slag, and silica fume, INTRODUCTION 28