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Adding ceramic polishing waste as paste substitute to improve sulphate and shrinkage resistances of mortar
Journal Pre-proof Adding ceramic polishing waste as paste substitute to improve sulphate and shrinkage resistances of mortar
L.G. Li, Z.Y. Zhuo, J. Zhu, A.K.H. Kwan PII:
S0032-5910(19)31078-2
DOI:
https://doi.org/10.1016/j.powtec.2019.11.117
Reference:
PTEC 14999
To appear in:
Powder Technology
Received date:
15 July 2019
Revised date:
30 October 2019
Accepted date:
26 November 2019
Please cite this article as: L.G. Li, Z.Y. Zhuo, J. Zhu, et al., Adding ceramic polishing waste as paste substitute to improve sulphate and shrinkage resistances of mortar, Powder Technology(2019), https://doi.org/10.1016/j.powtec.2019.11.117
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© 2019 Published by Elsevier.
Journal Pre-proof 2019/10/30
Adding ceramic polishing waste as paste substitute to improve sulphate and shrinkage resistances of mortar L.G. Li1 *, Z.Y. Zhuo2 , J. Zhu1 , A.K.H. Kwan3 1
Guangdong University of Technology, Guangzhou, China
University of Hong Kong, Hong Kong, China
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3
Agile Property Holdings Ltd., China
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2
Abstract: Ceramic polishing waste (CPW) is a solid waste generated during the
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polishing process of ceramic tiles. Its disposal as waste has been causing lots of
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environmental problems. In this study, the authors made an attempt to reutilize the CPW in mortar as paste substitute (substituting part of the paste without changing the paste compositions) and a series of mortar mixes containing various CPW, cement
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and water contents were made for conducting the sulphate attack test and drying
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shrinkage test. The test results showed that as paste substitute, the CPW added can significantly enhance the compressive strength, sulphate resistance and shrinkage
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resistance of mortar, and at same time substantially cut down the cement demand to lower the carbon footprint. Regression analysis also revealed that for strength enhancement, the cementing efficiency factor of the CPW was as high as 1.10, whereas for sulphate resistance enhancement, the cementing efficiency factor was about 0.69.
Keywords: carbon footprint; ceramic polishing waste; dimensional stability; drying shrinkage; sulphate resistance
__________________________________________________________________________________
* Corresponding author: Dr. L.G. Li (Email: [email protected])
1
Journal Pre-proof 1. Introduction In building construction, ceramic tiles/panels are indispensable construction materials [1,2]. However, the production of ceramic tiles/panels is generally associated with large amounts of ceramic wastes [3-5]. For instance, China is the largest producer of ceramic tiles in the world and generates 10 million tons of ceramic polishing waste a year [6] whereas Brazil is the second largest producer of ceramic tiles in the word and generates 60 thousand tons of ceramic polishing waste a year [7]. In addition, building demolition also generates a huge quantity of ceramic wastes
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[8-10]. How to deal with these wastes, which are mostly just dumped to landfills, has become a key environmental issue. Currently, some of the ceramic wastes are being
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reutilized in concrete production by adopting the cement substitution method or
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aggregate substitution method.
For the cement substitution method, a portion of the cementing materials is
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substituted by ceramic waste [7,11,12]. This has certain effects on the strength, durability and shrinkage of the concrete produced. Pacheco-Torgal and Jalali [13]
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used four types of ceramic fines to substitute 20% of cement and found that such addition of ceramic fines would reduce the compressive strength, but improve the
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water and chloride resistances of the concrete. Vejmelková et al. [14] revealed that
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adding fine- ground ceramics as cement substitute by not more than 40% has no negative effects on the chemical resistances of concrete in Na2 SO 4 and MgCl2 solutions. Steiner et al. [15] reported that the autogenous shrinkage of cement paste would be substantially decreased when ceramic polishing residues were applied to partially replace cement. However, Cheng et al. [16] demostrated that concrete with ceramic polishing powder added as cement substitute has lower carbonation resistance compared to normal concrete. Moreover, Penteado et al. [17] noted that the usage of porcelain tile waste as cement substitute would impair the compressive strength and water resistance of paving blocks.
For the aggregate substitution method, a portion of the aggregate is substituted by ceramic waste [18-21]. This has somewhat different effects on the properties of the concrete produced. Pacheco-Torgal and Jalali [13] found that concretes with ceramic
2
Journal Pre-proof waste added to replace part of the natural fine or coarse aggregate have better compressive strength, water resistance and chloride resistance than normal concrete. Siddique et al. [22] demostrated that the addition of fine bone china ceramic aggregate as sand substitute can substantially improve the freezing-thawing and drying- wetting resistances of concrete. However, Gonzalez-Corominas and Etxeberria [23] showed that the capillary absorption coefficient and ultrasonic pulse velocity of concrete containing 30% fine ceramic aggregate as substitute of natural sand were worse than those of normal concrete. Likewise, Medina et al. [24] reported that the chloride penetration was slightly higher in concretes containing 20% or 25% ceramic
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sanitary ware coarse aggregate.
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Apart from the above cement substitution and aggregate substitution methods, the authors’ team has established a new method, called the “paste substitution
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method”, for adding fine fillers or solid wastes. The strategy of this method is to substitute a portion of the cement paste (cement + water) by fillers or solid wastes
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without changing the water/cement (W/C) ratio of the cement paste. In recent years, this method has been successfully applied to limestone fines [25,26], marble dust
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[27,28], granite dust [29,30]. The results obtained so far revealed that this method has the benefits of higher strength, durability and dimensional stability, larger recycle of
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waste, and lower cement consumption and carbon emission. For further exploration,
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another comprehensive research programme on the possible use of ceramic polishing waste (CPW) as paste substitute was launched, as presented herein. The aims were to appraise the roles of CPW as paste substitute in the strength, sulphate resistance and shrinkage resistance of the mortar produced.
2. Material and methods
2.1 Raw materials
The cement used was a P·O 42.5 grade ordinary Portland cement (OPC) meeting with the Chinese Standard GB 175-2007 specification [31]. A local river sand with water absorption of 1.10%, moisture content of 0.10% and maximum 3
Journal Pre-proof particle size of 1.18 mm was employed as the fine aggregate. The specific gravities of the cement and fine aggregate were 3.10 and 2.58, respectively. No other cementing materials and larger size aggregates were added.
The ceramic polishing waste (CPW) was provided by a ceramics factory in Foshan, a well-known powerhouse of ceramics production. It was produced during polishing of ceramic tiles. The raw CPW contained some moisture and a small amount of debris. In order to reduce the fluctuation of quality, the CPW was treated by heating at 105ºC for 8 hours to remove the moisture and sieving through a 1.18
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mm sieve to remove the debris. After such treatment, the CPW was turned to a light
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grey colour dry powder with specific gravity of 2.43.
The grading curves of the OPC, CPW and fine aggregate are presented in
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Figure 1. It is observed that both the OPC and CPW have continuous grading, but on
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average, the CPW has a slightly bigger particle size than the OPC.
During trial mixing, it was found that using CPW as paste substitute would
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remarkably impair the workability of fresh mortar. To attain the required workability, a polycarboxylate-based superplasticizer (SP) with solid content by mass of 20% and
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specific gravity of 1.03 was dosed to each mortar mixture.
2.2 Mix proportion
Totally 20 mortar mixtures were produced for performance evaluation. For all the mortar mixtures, the paste volume (cement volume + water volume, expressed as a percentage of mortar volume) plus CPW volume (expressed as a percentage of mortar volume) was set constant as 60%. Since the remaining volume was to be filled with aggregate, the aggregate volume was fixed at 100% - 60% = 40%. When the CPW was added, it was added to substitute a portion of paste volume by the CPW volume. The CPW volume was set as 0%, 5%, 10%, 15% and 20%, whereas the paste volume was adjusted accordingly as 60%, 55%, 50%, 45% and 40%, such that the paste volume plus CPW volume remained the same. Hence, the CPW was added to substitute an equal volume of paste. Regarding the water/cement (W/C) ratio, it was 4
Journal Pre-proof set equal to 0.40, 0.45, 0.50 or 0.55. It is important to note that as the CPW was added to substitute an equal volume of paste, the W/C ratio of the paste was not changed. The mix compositions and proportions of the mortar mixtures are shown in Table 1. Besides, each mortar mixture was given an identification number of A-B, in which A represents the water/cement ratio and B represents the CPW volume (%), as presented in the first column of Tables 1, 2 and 3.
Since the SP was dosed to attain the required workability (target range of flow spread within 200 to 300 mm), the SP dosage (mass of liquid SP as a percentage of
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combined mass of cement + CPW) had to be determined by trial mixing. During the trial mixing, the SP was dosed into the mortar mixture bit by bit until the flow spread
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was within the target range, and then the SP dosage so determined was applied to the
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respective mortar mixtures during the formal mortar production for testing.
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2.3 Testing methods
Similar to the conical slump flow test for concrete [32-34], a small scale
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conical test for mortar, called the mini-conical slump flow test [35-37], was applied in this study to measure the workability of fresh mortar. The mini cone has a base
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diameter of 100 mm, a top diameter of 70 mm and a height of 60 mm. During the test,
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the mini cone was filled up with the mortar and lifted vertically, and then the mean diameter, i.e. the mean of two diameters in perpendicular directions, of the patty formed was taken as the flow spread. Other details of the testing procedures can be found in a previous paper [38].
The sulphate attack test for mortar/concrete in accordance with the Chinese Standard GB/T 50082-2009 [39] was carried out to assess the sulphate resistance of the mortar mixtures. To perform this test, six 100 mm mortar cubes were cast from each batch of mortar mixture. Three cubes were moist cured for 26 days, air dried at 80°C for 2 days, and then subjected to sulphate attack in 5% Na2 SO4 solution for 90 days in a sulphate attack machine. Meanwhile, the other three cubes were moist cured for 28 days and air dried for 90 days. After then, the averaged cube strength of the specimens subjected to sulphate attack was taken as the cube strength after sulphate 5
Journal Pre-proof attack (f1 ) and the averaged cube strength of the specimens not subjected to sulphate attack was taken as the cube strength without sulphate attack (f2 ). Lastly, the strength loss due to sulphate attack was determined by the following equation: Strength loss due to sulphate attack = (f2 – f1 )/f2
(1)
The larger is the strength loss, the lower would be the sulphate resistance, and vice versa. Details of the testing procedures have been presented in a previous paper [40].
The drying shrinkage test established by the authors’ team [41-43] was used to
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evaluate the shrinkage characteristics of the mortar mixtures. To conduct the test,
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three prismatic specimens (160 mm 40 mm 40 mm) were made from each batch of mortar mixture to measure the change in length up to 180 days of drying. The
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specimens were first cured in water for 7 days and then dried in an environmental
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chamber controlled at a temperature of 27ºC and a relative humidity of 75%. The shrinkage strain was calculated by the following equation:
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Shrinkage strain = (L0 – Lt )/L0
(2)
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in which, L0 is initial length; Lt is the length after t days of drying.
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3. Results
3.1 Cement content
The cement content of each mortar mixture is given in the third column of Table 1. It is observed that the cement content would slightly decrease with the increase of W/C ratio. More significantly, the cement content substantially decreased with the increase of CPW volume. To depict the effectiveness of adding CPW as cement paste substitute in reducing the cement content, the percentage reduction in cement content attributed to the substitution of cement paste by CPW has been calculated and presented in the last column of Table 1. The table shows that increasing the CPW volume always increased the percentage reduction in cement content. At CPW volumes of 5%, 10%, 15% and 20%, the cement content was decreased by 8.3%, 16.7%, 25.0% and 33.3%, respectively. 6
Journal Pre-proof 3.2 SP dosage and flow spread
The SP dosage needed for each mortar mixture to achieve the required workability is given in the second column of Table 2. From these results, it is obvious that at a lower W/C ratio and/or a higher CPW volume, the SP dosage was generally higher. These phenomena are reasonable [44-47] and might be caused by the following reasons. First, a lower W/C ratio would lead to a lower water content, causing the demand of more SP to attain the target workability. On the other hand, a higher CPW volume would result in a higher powder (cement + CPW) content and
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also a lower water content, again causing the demand of more SP for the target
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workability.
The measured flow spread results in the formal mortar production are
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summarized in the last column of Table 2. On the whole, the flow spread results
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ranged from 226 to 288 mm, all within the target range of 200 to 300 mm.
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3.3 Cube strength without sulphate attack
The average cube strengths without sulphate attack are given in the second
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column of Table 3. It is clear that at a given CPW volume, the cube strength gradually
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increased with decreasing W/C ratio. Such observed phenomenon is very common and just as expected. More importantly, regardless of the W/C ratio, the cube strength gradually increased with increasing CPW volume, albeit there was actually no change in W/C ratio. For example, at W/C ratio = 0.40, the cube strength with no CPW added was 74.1 MPa, while the addition of 5%, 10%, 15% and 20% of CPW as paste substitute increased the cube strength to 91.5, 96.5, 111.4 and 120.5 MPa, respectively. Hence, adding CPW as paste substitute offers beneficial effect on the strength of mortar.
3.4 Cracking and cube strength after sulphate attack
After the sulphate attack test, each cube specimen was photographed. But due to space limitation of this paper, only representative photographs of the specimens of 7
Journal Pre-proof concrete mixes 0.55-0, 0.55-5, 0.55-10 and 0.55-20 are selected and presented in Figures 2(a), 2(b), 2(c) and 2(d), respectively. Figure 2(a) shows that with no CPW added, serious spalling had occurred and many minor cracks were formed on the mortar surfaces. Figures 2(b) and 2(c) show that with 5% or 10% CPW added, less spalling had occurred and less minor cracks were formed on the surfaces. Lastly, Figure 2(d) shows that with 20% CPW used, no spalling had occurred and no cracks were formed. Hence, it is obvious that adding CPW as paste substitute offers positive effect on mitigating cracking due to sulphate attack.
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The average cube strengths after sulphate attack are summarized in the third column of Table 3. Similar to the phenomenon shown by the cube strengths without
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sulphate attack, the cube strengths after sulphate attack decreased with increasing W/C ratio regardless of the CPW volume, and increased with increasing CPW volume
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at all W/C ratios. For easier interpretation, the cube strengths without sulphate attack and the cube strengths after sulphate attack are both graphically presented in Figure 3.
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Evidently, at each W/C ratio, the cube strength after sulphate attack was substantially lower than the cube strength without sulphate attack, indicating that the sulphate
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attack had seriously impaired the strength of mortar.
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To quantify the sulphate resistance, the strength loss due to sulphate attack of
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each mortar mix was calculated as a percentage, as tabulated in the fourth column of Table 3, and its variations with the CPW volume and W/C ratio are plotted in Figure 4. It is noted that at a given CPW volume, the strength loss decreased with decreasing W/C ratio, showing that the sulphate resistance was better at a lower W/C ratio. This is in agreement with the observations from previous studies that lowering the W/C ratio generally leads to higher sulphate resistance, and vice versa [40,48]. More importantly, at a given W/C ratio, the strength loss decreased with increasing CPW volume, proving that the sulphate resistance was better at a higher CPW volume. Hence, it is evident that adding CPW as paste substitute offers improving effect on the sulphate resistance.
3.5 Shrinkage strain
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Journal Pre-proof For the purpose of illustrating how the shrinkage strains varied with time, the average shrinkage strains (calculated from the shrinkage strains of three specimens) of the mortar mixtures 0.45-0, 0.45-5, 0.45-10, 0.45-15 and 0.45-20 are plotted against time in Figure 5. It can be observed that at the beginning, the shrinkage strain rose up with time rapidly, but after about 45 days, the increase of shrinkage strain became marginal. And, more remarkably, by comparing the curves, the shrinkage strain-time curve shifts downwards as the CPW volume increases, showing that adding CPW as paste substitute provides beneficial effect on the shrinkage resistance.
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Since the measurement of shrinkage strain was stopped at 180 days and the shrinkage strain at this time was almost constant, the 180-day shrinkage strain was
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taken as the ultimate shrinkage strain. Then, the ultimate shrinkage strain are summarised in the last column of Table 3 and plotted against CPW volume for
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different W/C ratios in Figure 6. The figure shows that regardless of the CPW volume, a higher W/C ratio always led to larger ultimate shrinkage strain. Such phenomenon is
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acceptable, since a higher W/C ratio generally renders more water loss during drying and thus larger shrinkage [49,50]. More importantly, regardless of the W/C ratio of
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the mortar, a higher CPW volume resulted in smaller ultimate shrinkage strain due to reduction in paste volume as part of the cement paste was substituted by the CPW
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added. Hence, it is evident that adding CPW as paste substitute is a promising method
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to enhance the shrinkage resistance of mortar.
4. Discussions
4.1 Improved performance at reduced cement content
The above enhancements in sulphate resistance and shrinkage resistance were obtained simultaneously with reduction of cement content. To exhibit the concurrent variations in sulphate resistance or shrinkage resistance and cement consumption, the strength loss due to sulphate attack and the ultimate shrinkage due to long term drying are plotted against the cement content for different W/C ratios and CPW volumes in Figures 7 and 8, respectively. The figures depict that the decrease of W/C ratio would 9
Journal Pre-proof enhance the sulphate resistance and shrinkage resistance, but at the same time increase the cement content and carbon footprint. On the contrary, the increase of CPW volume would not only improve the sulphate resistance and shrinkage resistance, but simultaneously decrease the cement content and carbon footprint. Moreover, the method of adding CPW as paste substitute would allow up to 20% CPW volume to be added to maximize waste reutilization.
4.2 Roles of CPW
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The roles of CPW as paste substitute in the sulphate resistance and shrinkage resistance of mortar are summarized and explained below.
In the paste substitution method, the W/C ratio would not be changed when
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(1)
part of the paste is substituted by an equal volume of CPW, and thus there
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should be no adverse influence on the sulphate and shrinkage resistances due to any increase in effective W/C ratio [27,29]. Since the CPW is derived from ceramic material, which is a kind of calcined
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(2)
clay, the CPW should have certain pozzolanic reactivity. Such pozzolanic
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reactivity of the CPW would densify the microstructure of mortar to improve its general performance [12,51].
Being relatively fine and comparable in size with the cement grains, the CPW
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(3)
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particles would intermix with the cement grains and pack into the voids between the fine aggregate particles to enhance the packing of the solid skeleton [52-55]. Such filling effect should reduce the porosity to improve the sulphate resistance, and provide more restraints against deformation to control the drying shrinkage of cement paste [56]. (4)
The drying shrinkage is generally larger when the W/C ratio is higher and/or the paste volume is larger [50]. In the paste substitution method, the addition of CPW would not change the effective W/C ratio but would substantially reduce the paste volume to reduce the drying shrinkage.
(5)
However, adding CPW as paste substitute would decrease the water content and thus impair the workability. As demonstrated in this study, such drawback could be compensated by adding more SP, so as to more effectively disperse
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Journal Pre-proof the solid particles to avoid agglomeration and restore the workability to the original level [40,57-62].
4.3 Cementing efficiency of the CPW
As explained above, the CPW appeared to have certain pozzolanic reactivity. Its cementing efficiency factor may be evaluated as the ratio of the equivalent mass of cement to the mass of CPW added [63-65]. Let the cementing efficiency factor of the CPW be α. The effective water to cementitious materials ratio (W/CM)eff may be
W C α CPW
(3)
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(W/CM)eff
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obtained as:
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where W, C and CPW are respectively the water content, cement content and CPW
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content by mass.
The theory of cementing efficiency postulates that the various performance
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attributes of the mortar/concrete produced can each be correlated to the effective water to cementitious materials ratio. Herein, the cube strength without sulphate
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attack, the cube strength after sulphate attack and the strength loss after sulphate
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attack are each correlated to the effective water to cementitious materials (W/CM) ratio by regression analysis, as depicted in Figures 9, 10 and 11, respectively. During the regression analysis, different α-values are tried until the best correlation is obtained (i.e. until the maximum R2 value is achieved). As printed in the figures, the R2 values achieved of the correlations are all higher than 0.96. For the cube strength without sulphate attack, the best-fit α-value was found to be 1.10, revealing that from the strength point of view, the CPW has a cementing efficiency even higher than the cement. For the cube strength after sulphate attack, the best-fit α-value was found to be 0.84, indicating that from the residual strength after sulphate attack point of view, the CPW is as good as an equivalent mass of cement equal to 0.84 times the mass of CPW added. For the strength loss after sulphate attack, the best- fit α-value was found to be 0.69. This means that from the strength loss after 11
Journal Pre-proof sulphate attack point of view, the CPW is as good as an equivalent mass of cement equal to 0.69 times the mass of CPW added.
5. Conclusions
For studying the possible reutilization of ceramic polishing waste (CPW) in mortar production so as to minimize the waste disposal and decrease the cement consumption, and hopefully also to improve the performance in terms of strength,
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durability and dimensional stability, a comprehensive research programme had been launched. Unlike the conventional methods of reutilizing the solid waste as cement
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or aggregate substitute, the CPW was herein added as paste substitute. The performance attributes evaluated were the compressive strength, sulphate resistance
(1)
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and shrinkage resistance At the end, the following conclusions are drawn: Regardless of the CPW volume added, lowering the W/C ratio would
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increase the compressive strength, sulphate resistance and shrinkage resistance, but would also increase the cement consumption and carbon
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footprint of the mortar production. Hence, lowering the W/C ratio is an effective way of improving the performance of mortar but may not be the
Regardless of the W/C ratio, adding CPW as paste substitute would
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(2)
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best way when environmental friendliness is also considered.
remarkably improve the compressive strength, sulphate resistance and shrinkage resistance, and at the same time substantially decrease the cement consumption and carbon emission of the mortar production. Moreover, it allows the addition of up to 20% CPW volume to minimize waste disposal. Hence, adding CPW as paste substitute is a much better way of reutilizing the solid waste, improving the performance of mortar and lowering the cement consumption and carbon emission. (3)
However, adding CPW as paste substitute would impair the workability of the mortar, but the reduction in workability could be compensated by simply adding more SP.
(4)
The CPW has certain pozzolanic reactivity. From the strength point of view, its cementing efficiency factor is 1.10, which is even higher than that of the 12
Journal Pre-proof cement. From the sulphate resistance point of view, for enhancing the residual strength after sulphate attack, its cementing efficiency factor is 0.84, whereas for reducing the percentage strength loss after sulphate attack, its cementing efficiency factor is 0.69.
Acknowledgements
This work was supported by National Natural Science Foundation of China
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(Project Nos. 51608131 and 51808134), Featured and Innovative Project for Colleges and Universities of Guangdong Province (Project No. 2017KTSCX061) and Pearl
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River S&T Nova Program of Guangzhou City (Project No. 201906010064).
[1]
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17
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polishing waste as powder filler in mortar to reduce cement content by 33% and
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increase strength by 85%, Powder Technol. (2019) 355 119–126. [62] L.G. Li, Z.P. Chen, Y. Ouyang, J. Zhu, S.H. Chu, A.K.H. Kwan, Synergistic effects of steel fibres and expansive agent on steel bar-concrete bond, Cem. Concr. Compos. (2019) 104 103380. [63] D.W. Hobbs, Portland-pulverized fuel ash concretes: water demand, 28 day strength, mix design and strength development, Proc. Inst. Civil Eng. (1988) 85(2) 317–331. [64] H.S. Wong, H. Abdul Razak, Efficiency of calcined kaolin and silica fume as cement replacement material for strength performance, Cem. Concr. Compos. (2005) 35(4) 696–702. [65] L.G. Li, J.Y. Zheng, P.L. Ng, J. Zhu, A.K.H. Kwan, Cementing efficiencies and synergistic roles of silica fume and nano-silica in sulphate and chloride resistance of concrete, Constr. Build. Mater. (2019) 223 965–975. 18
Journal Pre-proof 2019/10/30
Figures Figure 1 Grading curves of OPC, CPW and fine aggregate Figure 2 Photographs of specimens after sulphate attack Figure 3 Cube strengths without and after sulphate attack versus CPW volume
oo
f
Figure 4 Strength loss after sulphate attack versus CPW volume
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Figure 5 Shrinkage strain-time curves of mortar mixes with different CPW volumes
e-
Figure 6 Ultimate shrinkage strain versus CPW volume
Pr
Figure 7 Strength loss after sulphate attack versus cement content Figure 8 Ultimate shrinkage strain versus cement content
al
Figure 9 Cube strength without sulphate attack versus effective W/CM ratio
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Figure 10 Cube strength after sulphate attack versus effective W/CM ratio
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Figure 11 Strength loss after sulphate attack versus effective W/CM ratio
19
Journal Pre-proof
oo
80
CPW
pr
OPC
Fine aggregate
e-
60
Pr
40
0 0.1
rn
al
20
Jo u
Cumulative passing (%) .
f
100
10
1000
Particle size (μm)
Figure 1 Grading curves of OPC, CPW and fine aggregate
20
(b) Mix no. 0.55-5
Jo u
rn
al
Pr
(a) Mix no. 0.55-0
e-
pr
oo
f
Journal Pre-proof
(c) Mix no. 0.55-10
(d) Mix no. 0.55-20
Figure 2 Photographs of specimens after sulphate attack
21
Cube strength without sulphate attack: W/C = 0.40 W/C = 0.50
pr
W/C = 0.45 W/C = 0.55
e-
100
Pr
80 60
al
40
Cube strength after sulphate attack:
rn
20 0 0
Jo u
Cube strength (MPa)-
120
oo
140
f
Journal Pre-proof
W/C = 0.40 W/C = 0.50
5
10
W/C = 0.45 W/C = 0.55
15
CPW volume (%)
Figure 3 Cube strengths without and after sulphate attack versus CPW volume
22
20
Journal Pre-proof
oo
f
60
pr e-
40
Pr
30 20
al
W/C = 0.40 W/C = 0.45
rn
10
W/C = 0.50 W/C = 0.55
0 0
Jo u
Strength loss (%)-_
50
5
10
15
CPW volume (%)
Figure 4 Strength loss after sulphate attack versus CPW volume
23
20
Journal Pre-proof
oo
f
2500
pr e-
1500
0.45-10
Pr
1000
0.45-15 0.45-20
Jo u
rn
500
0
0.45-5
al
Shrinkage strain ( ε)
2000
0.45-0
0
45
90
135
Time (days)
Figure 5 Shrinkage strain-time curves of mortar mixes with different CPW volumes
24
180
Journal Pre-proof
oo
f
2500
pr
1000
al
W/C = 0.40
Pr
e-
1500
500
W/C = 0.45
rn
W/C = 0.50 W/C = 0.55
0
Jo u
Shrinkage strain ( e)-
2000
0
5
10
15
CPW volume (%)
Figure 6 Ultimate shrinkage strain versus CPW volume
25
20
Journal Pre-proof
60
f oo pr
50
e-
40
W/C = 0.40 W/C = 0.45 W/C = 0.50 W/C = 0.55 CPW= 0% CPW= 5% CPW=10% CPW=15% CPW=20%
Pr
30
al
20
0 400
rn
10
Jo u
Strength loss (%)_ _
Decreasing W/C ratio
Increasing CPW volume
500
600
700
800
900
Cement content (kg/m3)
Figure 7 Strength loss after sulphate attack versus cement content
26
1000
Journal Pre-proof
Increasing CPW volume
Decreasing W/C ratio
pr
2000
e-
1500
Pr
W/C = 0.40 W/C = 0.45 W/C = 0.50 W/C = 0.55 CPW= 0% CPW= 5% CPW=10% CPW=15% CPW=20%
al
1000
0 400
rn
500
Jo u
Shrinkage strain ( e)
oo
f
2500
500
600
700
800
900
Cement content (kg/m3)
Figure 8 Ultimate shrinkage strain versus cement content
27
1000
Journal Pre-proof
oo
f
140 x = W/(C + α×CPW) α = 1.10 y = 164.7 – 219.6x0.90 R2 = 0.972
pr
100
e-
80
Pr
60 CPW = 0%
40
CPW = 5%
al
Cube strength (MPa)-
120
CPW = 10%
20
rn
CPW = 15% CPW = 20%
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0 0.2
0.3
0.4
0.5
Effective W/CM ratio
Figure 9 Cube strength without sulphate attack versus effective W/CM ratio
28
0.6
Journal Pre-proof
140
oo
f
x = W/(C + α×CPW) α = 0.84 y = 159.1 – 242.2x0.84 R2 = 0.961
pr
100
e-
80
Pr
60 CPW = 0%
40
al
CPW = 5% CPW = 10%
20
rn
CPW = 15% CPW = 20%
0 0.2
Jo u
Cube strength (MPa)-
120
0.3
0.4
0.5
Effective W/CM ratio
Figure 10 Cube strength after sulphate attack versus effective W/CM ratio
29
0.6
Journal Pre-proof
oo
f
60
pr e-
40
0 0.2
x = W/(C + α×CPW) α = 0.69 y = –14.6 + 116x0.85 R2 = 0.977
CPW = 5% CPW = 10%
al
10
CPW = 0%
CPW = 15% CPW = 20%
rn
20
Pr
30
Jo u
Strength loss (%)-
50
0.3
0.4
0.5
Effective W/CM ratio
Figure 11 Strength loss after sulphate attack versus effective W/CM ratio
30
0.6
Journal Pre-proof 2019/10/30 Tables
Table 1 Mix proportions of mortar mixtures Water (kg/m3 )
Cement (kg/m3 )
CPW (kg/m3 )
Fine aggregate (kg/m3 )
Reduction in cement content (%)
0.40-0
331
828
0
1032
-
0.40-5
304
759
121
1032
8.3
0.40-10
276
690
243
0.40-15
248
621
0.40-20
221
552
0.45-0
349
775
0.45-5
319
710
0.45-10
290
645
0.45-15
261
0.45-20
16.7
364
1032
25.0
485
1032
33.3
0
1032
-
121
1032
8.3
243
1032
16.7
581
364
1032
25.0
232
516
485
1032
33.3
0.50-0
364
728
0
1032
-
0.50-5
333
667
121
1032
8.3
0.50-10
303
606
243
1032
16.7
0.50-15
273
546
364
1032
25.0
243
485
485
1032
33.3
377
686
0
1032
-
0.55-5
Jo u
rn
al
Pr
pr
oo
1032
e-
f
Mix no.
346
629
121
1032
8.3
0.55-10
314
572
243
1032
16.7
0.55-15
283
514
364
1032
25.0
0.55-20
252
457
485
1032
33.3
0.50-20 0.55-0
Note: The water absorption of the aggregate and the water in the SP are taken into account in the calculation of the water content.
31
Journal Pre-proof
Table 2 Test results of mortar mixtures – Part 1 SP dosage (%)
Flow spread (mm)
0.40-0
0.40
228
0.40-5
1.10
288
0.40-10
1.65
0.40-15
2.45
0.40-20
3.35
0.45-0
0.37
0.45-5
0.90
0.45-10
1.40
228
271 282 230 227 279
2.24
231
2.80
260
0.23
240
0.65
252
1.20
278
1.90
256
0.50-20
2.50
229
0.55-0
0.14
226
0.55-5
0.58
248
0.55-10
1.05
287
0.55-15
1.53
241
0.55-20
2.30
236
Pr
e-
pr
oo
f
Mix no.
0.45-15
0.50-5 0.50-10
Jo u
0.50-15
rn
0.50-0
al
0.45-20
32
Journal Pre-proof
Cube strength after sulphate attack (MPa)
Strength loss after sulphate attack (%)
Ultimate shrinkage strain (ε)
0.40-0
74.1
43.6
41.2
1592
0.40-5
91.5
60.0
34.4
1405
0.40-10
96.5
67.3
30.3
1349
0.40-15
111.4
85.8
23.0
1193
0.40-20
120.5
95.4
20.8
938
0.45-0
62.7
34.0
45.8
1759
0.45-5
79.7
50.3
36.9
1626
0.45-10
92.0
62.2
32.4
1448
0.45-15
110.6
80.8
26.9
1287
0.45-20
116.4
89.1
23.5
1183
0.50-0
49.9
25.4
49.1
1848
0.50-5
71.0
41.2
42.0
1711
0.50-10
85.9
53.4
37.8
1583
0.50-15
92.7
61.6
33.5
1470
103.3
78.3
24.2
1317
47.3
21.7
54.1
2074
64.5
32.2
50.1
1831
0.55-10
73.7
38.4
47.9
1718
0.55-15
90.4
49.7
45.0
1518
0.55-20
94.8
69.8
26.4
1422
0.55-0 0.55-5
oo pr
e-
al
rn
Jo u
0.50-20
f
Mix no.
Cube strength without sulphate attack (MPa)
Pr
Table 3 Test results of mortar mixtures – Part 2
33
Journal Pre-proof 2019/10/30 Graphical abstract:
2500
60 Increasing CPW volume
40
f
30
oo pr
20
600
700
Pr
500
e-
10
800
Cement content (kg/m3)
900
1000
Increasing CPW volume
1500
1000
500
0 400
500
C
al
Adding CPW as paste substitute would not only improve sulphate and shrinkage resistances, b
rn
0 400
W/C = 0.40 W/C = 0.45 W/C = 0.50 W/C = 0.55 CPW= 0% CPW= 5% CPW=10% CPW=15% CPW=20%
Shrinkage strain ( e)
2000
Jo u
Strength loss (%)_ _
50
Decreasing W/C ratio
34
Journal Pre-proof 2019/10/30 Highlights:
Re-use of ceramic polishing waste as paste substitute in mortar is proposed.
Such usage decreases not only waste disposal but also cement consumption.
Such usage also improves strength, sulphate resistance and shrinkage resistance.
Jo u
rn
al
Pr
e-
pr
oo
f
35
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
L.G. Li, Z.Y. Zhuo, J. Zhu, A.K.H. Kwan PII:
S0032-5910(19)31078-2
DOI:
https://doi.org/10.1016/j.powtec.2019.11.117
Reference:
PTEC 14999
To appear in:
Powder Technology
Received date:
15 July 2019
Revised date:
30 October 2019
Accepted date:
26 November 2019
Please cite this article as: L.G. Li, Z.Y. Zhuo, J. Zhu, et al., Adding ceramic polishing waste as paste substitute to improve sulphate and shrinkage resistances of mortar, Powder Technology(2019), https://doi.org/10.1016/j.powtec.2019.11.117
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© 2019 Published by Elsevier.
Journal Pre-proof 2019/10/30
Adding ceramic polishing waste as paste substitute to improve sulphate and shrinkage resistances of mortar L.G. Li1 *, Z.Y. Zhuo2 , J. Zhu1 , A.K.H. Kwan3 1
Guangdong University of Technology, Guangzhou, China
University of Hong Kong, Hong Kong, China
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3
Agile Property Holdings Ltd., China
f
2
Abstract: Ceramic polishing waste (CPW) is a solid waste generated during the
e-
polishing process of ceramic tiles. Its disposal as waste has been causing lots of
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environmental problems. In this study, the authors made an attempt to reutilize the CPW in mortar as paste substitute (substituting part of the paste without changing the paste compositions) and a series of mortar mixes containing various CPW, cement
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and water contents were made for conducting the sulphate attack test and drying
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shrinkage test. The test results showed that as paste substitute, the CPW added can significantly enhance the compressive strength, sulphate resistance and shrinkage
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resistance of mortar, and at same time substantially cut down the cement demand to lower the carbon footprint. Regression analysis also revealed that for strength enhancement, the cementing efficiency factor of the CPW was as high as 1.10, whereas for sulphate resistance enhancement, the cementing efficiency factor was about 0.69.
Keywords: carbon footprint; ceramic polishing waste; dimensional stability; drying shrinkage; sulphate resistance
__________________________________________________________________________________
* Corresponding author: Dr. L.G. Li (Email: [email protected])
1
Journal Pre-proof 1. Introduction In building construction, ceramic tiles/panels are indispensable construction materials [1,2]. However, the production of ceramic tiles/panels is generally associated with large amounts of ceramic wastes [3-5]. For instance, China is the largest producer of ceramic tiles in the world and generates 10 million tons of ceramic polishing waste a year [6] whereas Brazil is the second largest producer of ceramic tiles in the word and generates 60 thousand tons of ceramic polishing waste a year [7]. In addition, building demolition also generates a huge quantity of ceramic wastes
oo
f
[8-10]. How to deal with these wastes, which are mostly just dumped to landfills, has become a key environmental issue. Currently, some of the ceramic wastes are being
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reutilized in concrete production by adopting the cement substitution method or
e-
aggregate substitution method.
For the cement substitution method, a portion of the cementing materials is
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substituted by ceramic waste [7,11,12]. This has certain effects on the strength, durability and shrinkage of the concrete produced. Pacheco-Torgal and Jalali [13]
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used four types of ceramic fines to substitute 20% of cement and found that such addition of ceramic fines would reduce the compressive strength, but improve the
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water and chloride resistances of the concrete. Vejmelková et al. [14] revealed that
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adding fine- ground ceramics as cement substitute by not more than 40% has no negative effects on the chemical resistances of concrete in Na2 SO 4 and MgCl2 solutions. Steiner et al. [15] reported that the autogenous shrinkage of cement paste would be substantially decreased when ceramic polishing residues were applied to partially replace cement. However, Cheng et al. [16] demostrated that concrete with ceramic polishing powder added as cement substitute has lower carbonation resistance compared to normal concrete. Moreover, Penteado et al. [17] noted that the usage of porcelain tile waste as cement substitute would impair the compressive strength and water resistance of paving blocks.
For the aggregate substitution method, a portion of the aggregate is substituted by ceramic waste [18-21]. This has somewhat different effects on the properties of the concrete produced. Pacheco-Torgal and Jalali [13] found that concretes with ceramic
2
Journal Pre-proof waste added to replace part of the natural fine or coarse aggregate have better compressive strength, water resistance and chloride resistance than normal concrete. Siddique et al. [22] demostrated that the addition of fine bone china ceramic aggregate as sand substitute can substantially improve the freezing-thawing and drying- wetting resistances of concrete. However, Gonzalez-Corominas and Etxeberria [23] showed that the capillary absorption coefficient and ultrasonic pulse velocity of concrete containing 30% fine ceramic aggregate as substitute of natural sand were worse than those of normal concrete. Likewise, Medina et al. [24] reported that the chloride penetration was slightly higher in concretes containing 20% or 25% ceramic
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sanitary ware coarse aggregate.
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Apart from the above cement substitution and aggregate substitution methods, the authors’ team has established a new method, called the “paste substitution
e-
method”, for adding fine fillers or solid wastes. The strategy of this method is to substitute a portion of the cement paste (cement + water) by fillers or solid wastes
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without changing the water/cement (W/C) ratio of the cement paste. In recent years, this method has been successfully applied to limestone fines [25,26], marble dust
al
[27,28], granite dust [29,30]. The results obtained so far revealed that this method has the benefits of higher strength, durability and dimensional stability, larger recycle of
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waste, and lower cement consumption and carbon emission. For further exploration,
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another comprehensive research programme on the possible use of ceramic polishing waste (CPW) as paste substitute was launched, as presented herein. The aims were to appraise the roles of CPW as paste substitute in the strength, sulphate resistance and shrinkage resistance of the mortar produced.
2. Material and methods
2.1 Raw materials
The cement used was a P·O 42.5 grade ordinary Portland cement (OPC) meeting with the Chinese Standard GB 175-2007 specification [31]. A local river sand with water absorption of 1.10%, moisture content of 0.10% and maximum 3
Journal Pre-proof particle size of 1.18 mm was employed as the fine aggregate. The specific gravities of the cement and fine aggregate were 3.10 and 2.58, respectively. No other cementing materials and larger size aggregates were added.
The ceramic polishing waste (CPW) was provided by a ceramics factory in Foshan, a well-known powerhouse of ceramics production. It was produced during polishing of ceramic tiles. The raw CPW contained some moisture and a small amount of debris. In order to reduce the fluctuation of quality, the CPW was treated by heating at 105ºC for 8 hours to remove the moisture and sieving through a 1.18
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f
mm sieve to remove the debris. After such treatment, the CPW was turned to a light
pr
grey colour dry powder with specific gravity of 2.43.
The grading curves of the OPC, CPW and fine aggregate are presented in
e-
Figure 1. It is observed that both the OPC and CPW have continuous grading, but on
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average, the CPW has a slightly bigger particle size than the OPC.
During trial mixing, it was found that using CPW as paste substitute would
al
remarkably impair the workability of fresh mortar. To attain the required workability, a polycarboxylate-based superplasticizer (SP) with solid content by mass of 20% and
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rn
specific gravity of 1.03 was dosed to each mortar mixture.
2.2 Mix proportion
Totally 20 mortar mixtures were produced for performance evaluation. For all the mortar mixtures, the paste volume (cement volume + water volume, expressed as a percentage of mortar volume) plus CPW volume (expressed as a percentage of mortar volume) was set constant as 60%. Since the remaining volume was to be filled with aggregate, the aggregate volume was fixed at 100% - 60% = 40%. When the CPW was added, it was added to substitute a portion of paste volume by the CPW volume. The CPW volume was set as 0%, 5%, 10%, 15% and 20%, whereas the paste volume was adjusted accordingly as 60%, 55%, 50%, 45% and 40%, such that the paste volume plus CPW volume remained the same. Hence, the CPW was added to substitute an equal volume of paste. Regarding the water/cement (W/C) ratio, it was 4
Journal Pre-proof set equal to 0.40, 0.45, 0.50 or 0.55. It is important to note that as the CPW was added to substitute an equal volume of paste, the W/C ratio of the paste was not changed. The mix compositions and proportions of the mortar mixtures are shown in Table 1. Besides, each mortar mixture was given an identification number of A-B, in which A represents the water/cement ratio and B represents the CPW volume (%), as presented in the first column of Tables 1, 2 and 3.
Since the SP was dosed to attain the required workability (target range of flow spread within 200 to 300 mm), the SP dosage (mass of liquid SP as a percentage of
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f
combined mass of cement + CPW) had to be determined by trial mixing. During the trial mixing, the SP was dosed into the mortar mixture bit by bit until the flow spread
pr
was within the target range, and then the SP dosage so determined was applied to the
e-
respective mortar mixtures during the formal mortar production for testing.
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2.3 Testing methods
Similar to the conical slump flow test for concrete [32-34], a small scale
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conical test for mortar, called the mini-conical slump flow test [35-37], was applied in this study to measure the workability of fresh mortar. The mini cone has a base
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diameter of 100 mm, a top diameter of 70 mm and a height of 60 mm. During the test,
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the mini cone was filled up with the mortar and lifted vertically, and then the mean diameter, i.e. the mean of two diameters in perpendicular directions, of the patty formed was taken as the flow spread. Other details of the testing procedures can be found in a previous paper [38].
The sulphate attack test for mortar/concrete in accordance with the Chinese Standard GB/T 50082-2009 [39] was carried out to assess the sulphate resistance of the mortar mixtures. To perform this test, six 100 mm mortar cubes were cast from each batch of mortar mixture. Three cubes were moist cured for 26 days, air dried at 80°C for 2 days, and then subjected to sulphate attack in 5% Na2 SO4 solution for 90 days in a sulphate attack machine. Meanwhile, the other three cubes were moist cured for 28 days and air dried for 90 days. After then, the averaged cube strength of the specimens subjected to sulphate attack was taken as the cube strength after sulphate 5
Journal Pre-proof attack (f1 ) and the averaged cube strength of the specimens not subjected to sulphate attack was taken as the cube strength without sulphate attack (f2 ). Lastly, the strength loss due to sulphate attack was determined by the following equation: Strength loss due to sulphate attack = (f2 – f1 )/f2
(1)
The larger is the strength loss, the lower would be the sulphate resistance, and vice versa. Details of the testing procedures have been presented in a previous paper [40].
The drying shrinkage test established by the authors’ team [41-43] was used to
f
evaluate the shrinkage characteristics of the mortar mixtures. To conduct the test,
oo
three prismatic specimens (160 mm 40 mm 40 mm) were made from each batch of mortar mixture to measure the change in length up to 180 days of drying. The
pr
specimens were first cured in water for 7 days and then dried in an environmental
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chamber controlled at a temperature of 27ºC and a relative humidity of 75%. The shrinkage strain was calculated by the following equation:
Pr
Shrinkage strain = (L0 – Lt )/L0
(2)
rn
al
in which, L0 is initial length; Lt is the length after t days of drying.
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3. Results
3.1 Cement content
The cement content of each mortar mixture is given in the third column of Table 1. It is observed that the cement content would slightly decrease with the increase of W/C ratio. More significantly, the cement content substantially decreased with the increase of CPW volume. To depict the effectiveness of adding CPW as cement paste substitute in reducing the cement content, the percentage reduction in cement content attributed to the substitution of cement paste by CPW has been calculated and presented in the last column of Table 1. The table shows that increasing the CPW volume always increased the percentage reduction in cement content. At CPW volumes of 5%, 10%, 15% and 20%, the cement content was decreased by 8.3%, 16.7%, 25.0% and 33.3%, respectively. 6
Journal Pre-proof 3.2 SP dosage and flow spread
The SP dosage needed for each mortar mixture to achieve the required workability is given in the second column of Table 2. From these results, it is obvious that at a lower W/C ratio and/or a higher CPW volume, the SP dosage was generally higher. These phenomena are reasonable [44-47] and might be caused by the following reasons. First, a lower W/C ratio would lead to a lower water content, causing the demand of more SP to attain the target workability. On the other hand, a higher CPW volume would result in a higher powder (cement + CPW) content and
oo
f
also a lower water content, again causing the demand of more SP for the target
pr
workability.
The measured flow spread results in the formal mortar production are
e-
summarized in the last column of Table 2. On the whole, the flow spread results
Pr
ranged from 226 to 288 mm, all within the target range of 200 to 300 mm.
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3.3 Cube strength without sulphate attack
The average cube strengths without sulphate attack are given in the second
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column of Table 3. It is clear that at a given CPW volume, the cube strength gradually
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increased with decreasing W/C ratio. Such observed phenomenon is very common and just as expected. More importantly, regardless of the W/C ratio, the cube strength gradually increased with increasing CPW volume, albeit there was actually no change in W/C ratio. For example, at W/C ratio = 0.40, the cube strength with no CPW added was 74.1 MPa, while the addition of 5%, 10%, 15% and 20% of CPW as paste substitute increased the cube strength to 91.5, 96.5, 111.4 and 120.5 MPa, respectively. Hence, adding CPW as paste substitute offers beneficial effect on the strength of mortar.
3.4 Cracking and cube strength after sulphate attack
After the sulphate attack test, each cube specimen was photographed. But due to space limitation of this paper, only representative photographs of the specimens of 7
Journal Pre-proof concrete mixes 0.55-0, 0.55-5, 0.55-10 and 0.55-20 are selected and presented in Figures 2(a), 2(b), 2(c) and 2(d), respectively. Figure 2(a) shows that with no CPW added, serious spalling had occurred and many minor cracks were formed on the mortar surfaces. Figures 2(b) and 2(c) show that with 5% or 10% CPW added, less spalling had occurred and less minor cracks were formed on the surfaces. Lastly, Figure 2(d) shows that with 20% CPW used, no spalling had occurred and no cracks were formed. Hence, it is obvious that adding CPW as paste substitute offers positive effect on mitigating cracking due to sulphate attack.
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f
The average cube strengths after sulphate attack are summarized in the third column of Table 3. Similar to the phenomenon shown by the cube strengths without
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sulphate attack, the cube strengths after sulphate attack decreased with increasing W/C ratio regardless of the CPW volume, and increased with increasing CPW volume
e-
at all W/C ratios. For easier interpretation, the cube strengths without sulphate attack and the cube strengths after sulphate attack are both graphically presented in Figure 3.
Pr
Evidently, at each W/C ratio, the cube strength after sulphate attack was substantially lower than the cube strength without sulphate attack, indicating that the sulphate
al
attack had seriously impaired the strength of mortar.
rn
To quantify the sulphate resistance, the strength loss due to sulphate attack of
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each mortar mix was calculated as a percentage, as tabulated in the fourth column of Table 3, and its variations with the CPW volume and W/C ratio are plotted in Figure 4. It is noted that at a given CPW volume, the strength loss decreased with decreasing W/C ratio, showing that the sulphate resistance was better at a lower W/C ratio. This is in agreement with the observations from previous studies that lowering the W/C ratio generally leads to higher sulphate resistance, and vice versa [40,48]. More importantly, at a given W/C ratio, the strength loss decreased with increasing CPW volume, proving that the sulphate resistance was better at a higher CPW volume. Hence, it is evident that adding CPW as paste substitute offers improving effect on the sulphate resistance.
3.5 Shrinkage strain
8
Journal Pre-proof For the purpose of illustrating how the shrinkage strains varied with time, the average shrinkage strains (calculated from the shrinkage strains of three specimens) of the mortar mixtures 0.45-0, 0.45-5, 0.45-10, 0.45-15 and 0.45-20 are plotted against time in Figure 5. It can be observed that at the beginning, the shrinkage strain rose up with time rapidly, but after about 45 days, the increase of shrinkage strain became marginal. And, more remarkably, by comparing the curves, the shrinkage strain-time curve shifts downwards as the CPW volume increases, showing that adding CPW as paste substitute provides beneficial effect on the shrinkage resistance.
oo
f
Since the measurement of shrinkage strain was stopped at 180 days and the shrinkage strain at this time was almost constant, the 180-day shrinkage strain was
pr
taken as the ultimate shrinkage strain. Then, the ultimate shrinkage strain are summarised in the last column of Table 3 and plotted against CPW volume for
e-
different W/C ratios in Figure 6. The figure shows that regardless of the CPW volume, a higher W/C ratio always led to larger ultimate shrinkage strain. Such phenomenon is
Pr
acceptable, since a higher W/C ratio generally renders more water loss during drying and thus larger shrinkage [49,50]. More importantly, regardless of the W/C ratio of
al
the mortar, a higher CPW volume resulted in smaller ultimate shrinkage strain due to reduction in paste volume as part of the cement paste was substituted by the CPW
rn
added. Hence, it is evident that adding CPW as paste substitute is a promising method
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to enhance the shrinkage resistance of mortar.
4. Discussions
4.1 Improved performance at reduced cement content
The above enhancements in sulphate resistance and shrinkage resistance were obtained simultaneously with reduction of cement content. To exhibit the concurrent variations in sulphate resistance or shrinkage resistance and cement consumption, the strength loss due to sulphate attack and the ultimate shrinkage due to long term drying are plotted against the cement content for different W/C ratios and CPW volumes in Figures 7 and 8, respectively. The figures depict that the decrease of W/C ratio would 9
Journal Pre-proof enhance the sulphate resistance and shrinkage resistance, but at the same time increase the cement content and carbon footprint. On the contrary, the increase of CPW volume would not only improve the sulphate resistance and shrinkage resistance, but simultaneously decrease the cement content and carbon footprint. Moreover, the method of adding CPW as paste substitute would allow up to 20% CPW volume to be added to maximize waste reutilization.
4.2 Roles of CPW
oo
f
The roles of CPW as paste substitute in the sulphate resistance and shrinkage resistance of mortar are summarized and explained below.
In the paste substitution method, the W/C ratio would not be changed when
pr
(1)
part of the paste is substituted by an equal volume of CPW, and thus there
e-
should be no adverse influence on the sulphate and shrinkage resistances due to any increase in effective W/C ratio [27,29]. Since the CPW is derived from ceramic material, which is a kind of calcined
Pr
(2)
clay, the CPW should have certain pozzolanic reactivity. Such pozzolanic
al
reactivity of the CPW would densify the microstructure of mortar to improve its general performance [12,51].
Being relatively fine and comparable in size with the cement grains, the CPW
rn
(3)
Jo u
particles would intermix with the cement grains and pack into the voids between the fine aggregate particles to enhance the packing of the solid skeleton [52-55]. Such filling effect should reduce the porosity to improve the sulphate resistance, and provide more restraints against deformation to control the drying shrinkage of cement paste [56]. (4)
The drying shrinkage is generally larger when the W/C ratio is higher and/or the paste volume is larger [50]. In the paste substitution method, the addition of CPW would not change the effective W/C ratio but would substantially reduce the paste volume to reduce the drying shrinkage.
(5)
However, adding CPW as paste substitute would decrease the water content and thus impair the workability. As demonstrated in this study, such drawback could be compensated by adding more SP, so as to more effectively disperse
10
Journal Pre-proof the solid particles to avoid agglomeration and restore the workability to the original level [40,57-62].
4.3 Cementing efficiency of the CPW
As explained above, the CPW appeared to have certain pozzolanic reactivity. Its cementing efficiency factor may be evaluated as the ratio of the equivalent mass of cement to the mass of CPW added [63-65]. Let the cementing efficiency factor of the CPW be α. The effective water to cementitious materials ratio (W/CM)eff may be
W C α CPW
(3)
pr
(W/CM)eff
oo
f
obtained as:
e-
where W, C and CPW are respectively the water content, cement content and CPW
Pr
content by mass.
The theory of cementing efficiency postulates that the various performance
al
attributes of the mortar/concrete produced can each be correlated to the effective water to cementitious materials ratio. Herein, the cube strength without sulphate
rn
attack, the cube strength after sulphate attack and the strength loss after sulphate
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attack are each correlated to the effective water to cementitious materials (W/CM) ratio by regression analysis, as depicted in Figures 9, 10 and 11, respectively. During the regression analysis, different α-values are tried until the best correlation is obtained (i.e. until the maximum R2 value is achieved). As printed in the figures, the R2 values achieved of the correlations are all higher than 0.96. For the cube strength without sulphate attack, the best-fit α-value was found to be 1.10, revealing that from the strength point of view, the CPW has a cementing efficiency even higher than the cement. For the cube strength after sulphate attack, the best-fit α-value was found to be 0.84, indicating that from the residual strength after sulphate attack point of view, the CPW is as good as an equivalent mass of cement equal to 0.84 times the mass of CPW added. For the strength loss after sulphate attack, the best- fit α-value was found to be 0.69. This means that from the strength loss after 11
Journal Pre-proof sulphate attack point of view, the CPW is as good as an equivalent mass of cement equal to 0.69 times the mass of CPW added.
5. Conclusions
For studying the possible reutilization of ceramic polishing waste (CPW) in mortar production so as to minimize the waste disposal and decrease the cement consumption, and hopefully also to improve the performance in terms of strength,
oo
f
durability and dimensional stability, a comprehensive research programme had been launched. Unlike the conventional methods of reutilizing the solid waste as cement
pr
or aggregate substitute, the CPW was herein added as paste substitute. The performance attributes evaluated were the compressive strength, sulphate resistance
(1)
e-
and shrinkage resistance At the end, the following conclusions are drawn: Regardless of the CPW volume added, lowering the W/C ratio would
Pr
increase the compressive strength, sulphate resistance and shrinkage resistance, but would also increase the cement consumption and carbon
al
footprint of the mortar production. Hence, lowering the W/C ratio is an effective way of improving the performance of mortar but may not be the
Regardless of the W/C ratio, adding CPW as paste substitute would
Jo u
(2)
rn
best way when environmental friendliness is also considered.
remarkably improve the compressive strength, sulphate resistance and shrinkage resistance, and at the same time substantially decrease the cement consumption and carbon emission of the mortar production. Moreover, it allows the addition of up to 20% CPW volume to minimize waste disposal. Hence, adding CPW as paste substitute is a much better way of reutilizing the solid waste, improving the performance of mortar and lowering the cement consumption and carbon emission. (3)
However, adding CPW as paste substitute would impair the workability of the mortar, but the reduction in workability could be compensated by simply adding more SP.
(4)
The CPW has certain pozzolanic reactivity. From the strength point of view, its cementing efficiency factor is 1.10, which is even higher than that of the 12
Journal Pre-proof cement. From the sulphate resistance point of view, for enhancing the residual strength after sulphate attack, its cementing efficiency factor is 0.84, whereas for reducing the percentage strength loss after sulphate attack, its cementing efficiency factor is 0.69.
Acknowledgements
This work was supported by National Natural Science Foundation of China
oo
f
(Project Nos. 51608131 and 51808134), Featured and Innovative Project for Colleges and Universities of Guangdong Province (Project No. 2017KTSCX061) and Pearl
e-
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River S&T Nova Program of Guangzhou City (Project No. 201906010064).
[1]
Pr
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[49] J.A. Almudaiheem, W. Hansen, Effect of specimen size and shape on drying shrinkage of concrete, Mater. J. (1987) 84(2) 130–135. [50] A.M. Neville, Properties of Concrete. 4th edn. Longman, UK (1995). [51] A. Tironi, A.N. Scian, E.F. Irassar, Blended cements with limestone filler and kaolinitic calcined clay: Filler and pozzolanic effects, J. Mater. Civil Eng. (2017) 29(9) 04017116. [52] A.B., Yu, J., Bridgwater, A., Burbidge, On the modelling of the packing of fine particles, Powder Technol. (1997) 92(3) 185–194. [53] T. Zhang, Q. Yu, J. Wei, P. Zhang, P. Chen, A gap–graded particle size distribution for blended cements: analytical approach and experimental validation, Powder Technol. (2011) 214(2) 259–268. [54] L.G. Li, H.X. Zhuo, J. Zhu, A.K.H. Kwan, Packing density of mortar containing polypropylene, carbon or basalt fibres under dry and wet conditions, Powder
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Journal Pre-proof Technol. (2019) 342 433–440. [55] L.G. Li, C.J. Lin, G.M. Chen, A.K.H. Kwan, T. Jiang, Effects of packing on compressive behaviour of recycled aggregate concrete, Constr. Build. Mater. (2017) 157 757–777. [56] J. Zhang, C. Gong, Z. Guo, M. Zhang, Engineered cementitious composite with characteristic of low drying shrinkage, Cem. Concr. Res. (2009) 39(4) 303–312. [57] L.G. Li, Z.H. Huang, J. Zhu, A.K.H. Kwan, H.Y. Chen, Synergistic effects of micro-silica and nano-silica on strength and microstructure of mortar, Constr. Build. Mater. (2017) 140 229–238.
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[58] L.G. Li, J.Y. Zheng, J. Zhu, A.K.H. Kwan, Combined usage of micro-silica and nano-silica in concrete: SP demand, cementing efficiencies and synergistic
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effect, Constr. Build. Mater. (2018) 168 622–632.
[59] L.G. Li, Z.H. Lin, G.M. Chen, A.K.H. Kwan, Z.H. Li, Reutilization of clay
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brick waste in mortar: Paste replacement versus cement replacement, J. Mater. Civil Eng. (2019) 31(7) 04019129.
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[60] H.Y. Chen, L.G. Li, Z.M. Lai, A.K.H. Kwan, P.M. Chen, P.L. Ng, Effects of crushed oyster shell on strength and durability of marine concrete containing fly
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ash and blastfurnace slag, Mater. Sci.-Medzg. (2019) 25(1) 97-107. [61] L.G. Li, Z.Y. Zhuo, J. Zhu, J.J. Chen, A.K.H. Kwan, Reutilizing ceramic
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polishing waste as powder filler in mortar to reduce cement content by 33% and
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increase strength by 85%, Powder Technol. (2019) 355 119–126. [62] L.G. Li, Z.P. Chen, Y. Ouyang, J. Zhu, S.H. Chu, A.K.H. Kwan, Synergistic effects of steel fibres and expansive agent on steel bar-concrete bond, Cem. Concr. Compos. (2019) 104 103380. [63] D.W. Hobbs, Portland-pulverized fuel ash concretes: water demand, 28 day strength, mix design and strength development, Proc. Inst. Civil Eng. (1988) 85(2) 317–331. [64] H.S. Wong, H. Abdul Razak, Efficiency of calcined kaolin and silica fume as cement replacement material for strength performance, Cem. Concr. Compos. (2005) 35(4) 696–702. [65] L.G. Li, J.Y. Zheng, P.L. Ng, J. Zhu, A.K.H. Kwan, Cementing efficiencies and synergistic roles of silica fume and nano-silica in sulphate and chloride resistance of concrete, Constr. Build. Mater. (2019) 223 965–975. 18
Journal Pre-proof 2019/10/30
Figures Figure 1 Grading curves of OPC, CPW and fine aggregate Figure 2 Photographs of specimens after sulphate attack Figure 3 Cube strengths without and after sulphate attack versus CPW volume
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f
Figure 4 Strength loss after sulphate attack versus CPW volume
pr
Figure 5 Shrinkage strain-time curves of mortar mixes with different CPW volumes
e-
Figure 6 Ultimate shrinkage strain versus CPW volume
Pr
Figure 7 Strength loss after sulphate attack versus cement content Figure 8 Ultimate shrinkage strain versus cement content
al
Figure 9 Cube strength without sulphate attack versus effective W/CM ratio
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Figure 10 Cube strength after sulphate attack versus effective W/CM ratio
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Figure 11 Strength loss after sulphate attack versus effective W/CM ratio
19
Journal Pre-proof
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80
CPW
pr
OPC
Fine aggregate
e-
60
Pr
40
0 0.1
rn
al
20
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Cumulative passing (%) .
f
100
10
1000
Particle size (μm)
Figure 1 Grading curves of OPC, CPW and fine aggregate
20
(b) Mix no. 0.55-5
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rn
al
Pr
(a) Mix no. 0.55-0
e-
pr
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(c) Mix no. 0.55-10
(d) Mix no. 0.55-20
Figure 2 Photographs of specimens after sulphate attack
21
Cube strength without sulphate attack: W/C = 0.40 W/C = 0.50
pr
W/C = 0.45 W/C = 0.55
e-
100
Pr
80 60
al
40
Cube strength after sulphate attack:
rn
20 0 0
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Cube strength (MPa)-
120
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140
f
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W/C = 0.40 W/C = 0.50
5
10
W/C = 0.45 W/C = 0.55
15
CPW volume (%)
Figure 3 Cube strengths without and after sulphate attack versus CPW volume
22
20
Journal Pre-proof
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f
60
pr e-
40
Pr
30 20
al
W/C = 0.40 W/C = 0.45
rn
10
W/C = 0.50 W/C = 0.55
0 0
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Strength loss (%)-_
50
5
10
15
CPW volume (%)
Figure 4 Strength loss after sulphate attack versus CPW volume
23
20
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f
2500
pr e-
1500
0.45-10
Pr
1000
0.45-15 0.45-20
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rn
500
0
0.45-5
al
Shrinkage strain ( ε)
2000
0.45-0
0
45
90
135
Time (days)
Figure 5 Shrinkage strain-time curves of mortar mixes with different CPW volumes
24
180
Journal Pre-proof
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f
2500
pr
1000
al
W/C = 0.40
Pr
e-
1500
500
W/C = 0.45
rn
W/C = 0.50 W/C = 0.55
0
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Shrinkage strain ( e)-
2000
0
5
10
15
CPW volume (%)
Figure 6 Ultimate shrinkage strain versus CPW volume
25
20
Journal Pre-proof
60
f oo pr
50
e-
40
W/C = 0.40 W/C = 0.45 W/C = 0.50 W/C = 0.55 CPW= 0% CPW= 5% CPW=10% CPW=15% CPW=20%
Pr
30
al
20
0 400
rn
10
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Strength loss (%)_ _
Decreasing W/C ratio
Increasing CPW volume
500
600
700
800
900
Cement content (kg/m3)
Figure 7 Strength loss after sulphate attack versus cement content
26
1000
Journal Pre-proof
Increasing CPW volume
Decreasing W/C ratio
pr
2000
e-
1500
Pr
W/C = 0.40 W/C = 0.45 W/C = 0.50 W/C = 0.55 CPW= 0% CPW= 5% CPW=10% CPW=15% CPW=20%
al
1000
0 400
rn
500
Jo u
Shrinkage strain ( e)
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f
2500
500
600
700
800
900
Cement content (kg/m3)
Figure 8 Ultimate shrinkage strain versus cement content
27
1000
Journal Pre-proof
oo
f
140 x = W/(C + α×CPW) α = 1.10 y = 164.7 – 219.6x0.90 R2 = 0.972
pr
100
e-
80
Pr
60 CPW = 0%
40
CPW = 5%
al
Cube strength (MPa)-
120
CPW = 10%
20
rn
CPW = 15% CPW = 20%
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0 0.2
0.3
0.4
0.5
Effective W/CM ratio
Figure 9 Cube strength without sulphate attack versus effective W/CM ratio
28
0.6
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140
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x = W/(C + α×CPW) α = 0.84 y = 159.1 – 242.2x0.84 R2 = 0.961
pr
100
e-
80
Pr
60 CPW = 0%
40
al
CPW = 5% CPW = 10%
20
rn
CPW = 15% CPW = 20%
0 0.2
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Cube strength (MPa)-
120
0.3
0.4
0.5
Effective W/CM ratio
Figure 10 Cube strength after sulphate attack versus effective W/CM ratio
29
0.6
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oo
f
60
pr e-
40
0 0.2
x = W/(C + α×CPW) α = 0.69 y = –14.6 + 116x0.85 R2 = 0.977
CPW = 5% CPW = 10%
al
10
CPW = 0%
CPW = 15% CPW = 20%
rn
20
Pr
30
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Strength loss (%)-
50
0.3
0.4
0.5
Effective W/CM ratio
Figure 11 Strength loss after sulphate attack versus effective W/CM ratio
30
0.6
Journal Pre-proof 2019/10/30 Tables
Table 1 Mix proportions of mortar mixtures Water (kg/m3 )
Cement (kg/m3 )
CPW (kg/m3 )
Fine aggregate (kg/m3 )
Reduction in cement content (%)
0.40-0
331
828
0
1032
-
0.40-5
304
759
121
1032
8.3
0.40-10
276
690
243
0.40-15
248
621
0.40-20
221
552
0.45-0
349
775
0.45-5
319
710
0.45-10
290
645
0.45-15
261
0.45-20
16.7
364
1032
25.0
485
1032
33.3
0
1032
-
121
1032
8.3
243
1032
16.7
581
364
1032
25.0
232
516
485
1032
33.3
0.50-0
364
728
0
1032
-
0.50-5
333
667
121
1032
8.3
0.50-10
303
606
243
1032
16.7
0.50-15
273
546
364
1032
25.0
243
485
485
1032
33.3
377
686
0
1032
-
0.55-5
Jo u
rn
al
Pr
pr
oo
1032
e-
f
Mix no.
346
629
121
1032
8.3
0.55-10
314
572
243
1032
16.7
0.55-15
283
514
364
1032
25.0
0.55-20
252
457
485
1032
33.3
0.50-20 0.55-0
Note: The water absorption of the aggregate and the water in the SP are taken into account in the calculation of the water content.
31
Journal Pre-proof
Table 2 Test results of mortar mixtures – Part 1 SP dosage (%)
Flow spread (mm)
0.40-0
0.40
228
0.40-5
1.10
288
0.40-10
1.65
0.40-15
2.45
0.40-20
3.35
0.45-0
0.37
0.45-5
0.90
0.45-10
1.40
228
271 282 230 227 279
2.24
231
2.80
260
0.23
240
0.65
252
1.20
278
1.90
256
0.50-20
2.50
229
0.55-0
0.14
226
0.55-5
0.58
248
0.55-10
1.05
287
0.55-15
1.53
241
0.55-20
2.30
236
Pr
e-
pr
oo
f
Mix no.
0.45-15
0.50-5 0.50-10
Jo u
0.50-15
rn
0.50-0
al
0.45-20
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Journal Pre-proof
Cube strength after sulphate attack (MPa)
Strength loss after sulphate attack (%)
Ultimate shrinkage strain (ε)
0.40-0
74.1
43.6
41.2
1592
0.40-5
91.5
60.0
34.4
1405
0.40-10
96.5
67.3
30.3
1349
0.40-15
111.4
85.8
23.0
1193
0.40-20
120.5
95.4
20.8
938
0.45-0
62.7
34.0
45.8
1759
0.45-5
79.7
50.3
36.9
1626
0.45-10
92.0
62.2
32.4
1448
0.45-15
110.6
80.8
26.9
1287
0.45-20
116.4
89.1
23.5
1183
0.50-0
49.9
25.4
49.1
1848
0.50-5
71.0
41.2
42.0
1711
0.50-10
85.9
53.4
37.8
1583
0.50-15
92.7
61.6
33.5
1470
103.3
78.3
24.2
1317
47.3
21.7
54.1
2074
64.5
32.2
50.1
1831
0.55-10
73.7
38.4
47.9
1718
0.55-15
90.4
49.7
45.0
1518
0.55-20
94.8
69.8
26.4
1422
0.55-0 0.55-5
oo pr
e-
al
rn
Jo u
0.50-20
f
Mix no.
Cube strength without sulphate attack (MPa)
Pr
Table 3 Test results of mortar mixtures – Part 2
33
Journal Pre-proof 2019/10/30 Graphical abstract:
2500
60 Increasing CPW volume
40
f
30
oo pr
20
600
700
Pr
500
e-
10
800
Cement content (kg/m3)
900
1000
Increasing CPW volume
1500
1000
500
0 400
500
C
al
Adding CPW as paste substitute would not only improve sulphate and shrinkage resistances, b
rn
0 400
W/C = 0.40 W/C = 0.45 W/C = 0.50 W/C = 0.55 CPW= 0% CPW= 5% CPW=10% CPW=15% CPW=20%
Shrinkage strain ( e)
2000
Jo u
Strength loss (%)_ _
50
Decreasing W/C ratio
34
Journal Pre-proof 2019/10/30 Highlights:
Re-use of ceramic polishing waste as paste substitute in mortar is proposed.
Such usage decreases not only waste disposal but also cement consumption.
Such usage also improves strength, sulphate resistance and shrinkage resistance.
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Pr
e-
pr
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f
35
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11