Production of sustainable mortar comprising waste ceramic nanoparticles

Production of sustainable mortar comprising waste ceramic nanoparticles

25

Hossein Mohammadhosseini a , Mahmood Md Tahir a , Nor Hasanah Abdul Shukor Lim a , Rayed Alyousef b , Mostafa Samadi a a Institute for Smart Infrastructure and Innovative Construction (ISIIC), School of Civil Engineering, Faculty of Engineering, Universiti Teknologi Malaysia (UTM) Skudai, Johor, Malaysia; bDepartment of Civil Engineering, Prince Sattam Bin Abdulaziz University, Al-Kharj, Saudi Arabia

Chapter outline 1. Introduction 560 2. Waste ceramic 561 2.1 2.2 2.3

Types and sources of waste ceramic 561 Handling and preparation of waste ceramic 562 Properties of nano ceramic powder 563 2.3.1 Physical properties 563 2.3.2 Chemical compositions 564 2.3.3 Morphology 564

3. Properties of mortar comprising ceramic nanoparticles 3.1

3.2

3.3

566

Fresh properties 566 3.1.1 Flow test 566 3.1.2 Setting time test 567 Hardened properties 568 3.2.1 Compressive strength 568 3.2.2 Splitting tensile strength 569 3.2.3 Flexural strength 570 3.2.4 Modulus of elasticity 571 3.2.5 Drying shrinkage 571 3.2.6 Water absorption 572 Microstructural analysis 573 3.3.1 SEM analysis 573 3.3.2 XRD analysis 575 3.3.3 Thermal gravimetric analysis 575

4. Applications 578 5. Conclusions 578 References 579

Smart Nanoconcretes and Cement-Based Materials. https://doi.org/10.1016/B978-0-12-817854-6.00025-8 Copyright © 2020 Elsevier Inc. All rights reserved.

560

1.

Smart Nanoconcretes and Cement-Based Materials

Introduction

Nanotechnology is a developing field of science associated with the understanding and control of material at the nanoscale, mainly at dimensions ranged between 1 and 100 nm (Birgisson et al., 2012). Nanotechnology comprises nanoscale science, engineering, and technology that encompass imaging, measuring, modeling, and manipulating matter at this length scale. Nanotechnology is not just working at ever-smaller sizes; instead, the working at the nanoscale allows scientists to use the exclusive chemical, physical, optical, and mechanical properties of materials that inherently occur at that scale. Of particular significance for mortar and concrete is the considerably raised the surface area of cementing constituent at the nanoscale. Therefore, as the surface area per mass of a cementing materials rises, a more extensive amount of these materials can come into interaction with contiguous materials, consequently modifying the reactions and enhanced the hydration products (Bj€ ornstr€ om et al., 2004; Birgisson and Dham, 2011). Concrete and mortar, the most ubiquitous construction materials in the world, are composites, nanostructured, and multiphase materials that ages over time (Sanchez and Sobolev, 2010). They are mostly composed of an amorphous phase, nanometerto micrometer-size crystals, as well as bound water. The properties of mortar and concrete exist in, and the degradation mechanisms occur through, multiple length scales of nano to micro and then to macro, where the properties of each scale originate from those of the next smaller scale. Nanoengineering of mortar and concrete can occur in one or more of the three following phases (i) the solid phases, (ii) the liquid phases, and (iii) at the boundaries amongst liquidesolid and solidesolid (Garboczi, 2009). The addition of fine nano particles can significantly enhance the properties of mortar and concrete owing to the effective increase in the surface area of binders and also effects on hydration process as well as through filling the nanopores in the matrix (Constantinides et al., 2003; Constantinides and Ulm, 2004). Nano ceramic powder is probably one of the most potential additives that can be used in nanomodified mortar and concrete. Nanomaterials such as ceramic nanoparticles can significantly develop the mechanical properties of mortar and concrete. Besides, the durability of mortar and concretes can also be enhanced through a reduction in permeability and provide a dense matrix by filling the nano and micropores (Lim et al., 2018; Sobolev et al., 2009). The enhancement in the mechanical and durability of mortar and concrete can be achieved through nanomodified types of cement, or the use of nano developed supplementary cementing materials to the paste. Sustainable achievement and reduction in CO2 emission into the atmosphere are essential factors that need to be considered toward a clean environment (Mohammadhosseini and Tahir, 2018a). One of the major producers and emission of CO2 is related to cement manufacturing industries which used in the construction (Phoo-ngernkham et al., 2016; Mohammadhosseini et al., 2018a). The production of cement approximately takes into account 5% of the total CO2 emission in the world (Mohammadhosseini et al., 2018b; Kadapure et al., 2017; Mohammadhosseini and Tahir, 2018b). Consequently, in this regard, Canakci et al. (2017) proposed partial

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561

substituting the cement with pozzolanicmaterials produced by waste products as one of the efficient methods to diminish the environmental impact due to the CO2 emission from the cement production industries. In the last decades, various types of natural pozzolanicmaterials were used as a cement replacement in construction owing to their positive influences on the mechanical and durability performance of concrete and mortar (Mohammadhosseini et al., 2018c). Nevertheless, owed to the environmental regulations, researchers leaned to effort on the utilization of solid wastes in the construction. The total manufacture of ceramic in the form of tiles in the world was reported as about 11.9 billion m2 in the year 2012. Also, the ceramic production in the same year was about 92 million m2 in Malaysia (Stock, 2011), and the production is growing by 2.2% by year. It was expected that during the manufacturing process about 10%e30% of the produced ceramics goes to waste. It has also been reported that the majority of generated wastes by ceramic industries cannot be reused, and therefore, send for landfill and become an environmental hazard at longer ages. Consequently, Huang et al. (Huang et al., 2009) stated that the utilization of ceramic waste in the production of concrete provides to cost and energy savings, environmental balance, and preservation of raw materials. Moreover, the massive amount of ceramic waste generated and lack of methods to recycle these wastes, have been encouraged the researchers such as Xiao et al. (2011) and Vieira et al. (2016), to utilize the ceramic wastes as aggregates and partial cement replacement in mortar and concrete. In the recent years, numerous studies by researchers, such as Sanchez de Rojas et al. (2006), Frías et al. (2008), and Lavat et al. (2009), were carried out on the utilization of ceramic waste in concrete. Their results showed that in concrete comprising a low volume of waste ceramic, the compressive strength was reduced as associated with that of conventional concrete. Nevertheless, Pacheco-Torgal and Jalali (2010) stated that with the increase in the fineness of ceramic powder, the pozzolanic reactivity enhanced, and consequently, caused in higher strength values. Furthermore, Fulvio et al. (2011) and Lim et al. (2015) stated that nano-materials have significant effects on the enhancement in the mechanical properties of cement-based composites due to their higher finesses. Consequently, this research focused on the feasibility of Al2O3 eSiO2 nanoparticles from ceramic waste to developing the mechanical and durability performance of mortar. In addition, the chemical compositions, physical properties, and microstructural analysis of Al2O3eSiO2 nanoparticles and mortar were investigated and described in this chapter.

2. Waste ceramic 2.1

Types and sources of waste ceramic

Ceramic is a common word used to refer the ceramic products. Generally, ceramics products include wall tiles, floor tiles, sanitary ware, household ceramics, and technical ceramics. Ceramic tiles are manufactured by firing clay, feldspar, and quartz at high

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temperatures. Generally, in the waste stream, ceramic wastes can be divided into two different groups depending on the raw materials used for production as well as the manufacturing process. In the first category, all wastes are generated from the structural ceramic industries that only use the red paste as raw material for the manufacturing of the products, for example, bricks, blocks, and roof tiles. In the second category, the wastes generated from stone wares ceramic, for instance, wall ceramic, floor tiles, and sanitary wares. In this group, the use of white paste is more common and therefore, the massive amount of waste ceramics are from these products. Fig. 25.1 shows the common classification of ceramicsand also the sources of ceramic waste by type and production process from the manufacturing factories.

2.2

Handling and preparation of waste ceramic

The ceramic nanoparticle, as mentioned earlier, is a supplementary cementing material that obtained from industrial waste ceramic particles. The waste ceramic particles were collected from the packing section of ceramic tile industries in the form of broken tile specimens which are free of cost. The waste ceramic particles were then dried in an electronic oven at a temperature of 110
C for 24 h.Following, the bigger size particles were broken in smaller pieces by crushing machine and then were sieved in order to collect a specific size of the particles as well as to remove the impurities. Subsequently, the small size ceramic particles were ground in the modified Los Angeles abrasion test machine (Fig. 25.2) having 10 stainless steel bars of 12 mm diameter and 800 mm long to convert the particles in a powder form (Mohammadhosseini et al., 2018d). The grinding process was continued until 90% of the ceramic powder passed through a sieve of size 45 mm in accordance withASTM C618-15 specifications. Afterward, the micro size ceramic powder was exposed to further grinding using a ball mill to ensure that 80% of the ceramic powder is finer than 1 mm. To confirm the consistency Ceramic wastes

Red Paste

White paste

Once Fired -Sanitary ware -Porous Stoneware Tile -Stoneware Tile -China Stoneware Tile

Twice Fired

-Porous Stoneware Tile

Once Fired -Bricks -Blocks

Twice Fired

-Porous Stoneware Tile

-Roof Tiles -Porous Stoneware Tile

Fig. 25.1 Classification of ceramicsand source of ceramic waste by type and production process.

Production of sustainable mortar comprising waste ceramic nanoparticles

(A)

(B)

Ceram ic waste in the factor y

(C)

563

Ceramic fine particles

(D)

Modified L Los Angeles abrasion t est machine

Ceramic powder

Fig. 25.2 The preparation process of the ceramic powder.

and adequate fineness of ceramic powder, the process of grinding was controlled based on the standard specifications. The process and preparation of the ceramic powder are shown in Fig. 25.2.

2.3 2.3.1

Properties of nano ceramic powder Physical properties

Nano-ceramic particles are extremely small, with more than 80% of the particles finer than 1 mm. The typical physical properties of ceramic powder are given in Table 25.1 Table 25.1 Physical properties of OPC and ceramic powder.

a

Properties

OPC

a

Color

Dark Gray

Light Gray

Specific gravity

3.15

2.35

% Passing through a 45 mm wet sieve

90.0

99.9

Strength activity index 7 days (%) 28 days (%)

e e

81 95

N: Al2O3eSiO2 Nanoparticles.

N

564

Smart Nanoconcretes and Cement-Based Materials 100 90 80 70 60 50 40 30 20 10 0

Percent finer

Ceramic powder OPC

10

100

1000

10000

100000

Particle size (nm)

Fig. 25.3 Distribution of the OPC and ceramic nanoparticles.

and compared with those of OPC. The color of ceramic nanoparticles is either premium gray. Also, the particle distribution of OPC and ceramic nanoparticles are illustrated in Fig. 25.3. It can be observed that the ceramic nanoparticles are comparatively finer than that of Portland cement particles.

2.3.2

Chemical compositions

Ceramic nanoparticles are composed primarily of pure silica in a non-crystalline form(Al2O3eSiO2). The chemical compositions of the Portland cement and ceramic nanoparticles are revealed in Table 25.2. In line with ASTM C618-15 specifications and the obtained chemical compositions, Al2O3eSiO2 nanoparticles can be categorized as class F pozzolans due to the higher proportion of SiO2þ Al2O3þ Fe2O3 which is about 75% (Awal and Mohammadhosseini, 2016). The silica content of OPC and ceramic powder are 16.4 and 74.1, respectively, which shows that the main component of ceramic powder is silica (SiO2). The existence of SiO2 at the high proportion in ceramic powder can significantly affect the pozzolanic reactivity of powder and increase in the hydration products which results in providing durable and denser.

2.3.3

Morphology

The morphological structure of Al2O3eSiO2 nanoparticles was examined using a Scanning Electron Microscope (SEM). Fig. 25.4A displays the SEM of the Al2O3eSiO2 Table 25.2 Chemical compositions of OPC and Al2O3eSiO2 nanoparticles. Chemical composition (%) SiO2

Al2O3

Fe2O3

CaO

K2O

TiO2

LOI

OPC

16.40

4.24

3.53

68.30

0.22

0.09

2.40

a

74.10

17.80

3.57

1.11

2.69

0.46

0.10

N a

N: Al2O3eSiO2 Nanoparticles.

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565

Fig. 25.4 (A) SEM and (B)TEM of Al2O3eSiO2 nanoparticles.

nanoparticles. Besides, the transmission electron microscopy (TEM) analysis of the Al2O3eSiO2 nanoparticles is illustrated in Fig. 25.4B. The fineness of pozzolanic material is known to have played an essential role in the activity index. By increasing the fineness, the activity index of pozzolans increases. The size of ceramic nanoparticles found to be in the range of 150e250 nm.Due to the extreme fineness and very high amorphous SiO2 of ceramic nanoparticles, it is considered a very reactive pozzolanic material. This extreme fineness of ceramic particles can significantly fill up the nano and micropores in the matrix and therefore, enhanced the performance of mortar and concrete in terms of strength and durability. Ceramic nanoparticles also act as filler owing to the higher fineness and therefore, fits into the gaps amongst bigger size grains in the same manner that sand fills the gaps between the coarse aggregates and cement particles fill the cavities among the fine aggregates (Lavat et al., 2009). The particle size of the Al2O3eSiO2 nanoparticles was significantly finer than the OPC. Consequently, the surface area of the Al2O3eSiO2 nanoparticles is comparatively larger than that of OPC. The greater surface area of ceramic nanoparticles could leads to faster reaction with water and enhanced hydration process and therefore, strong bond amongst the binders and aggregates. Fig. 25.5 and Fig. 25.6 demonstrate the

Fig. 25.5 XRD of Al2O3eSiO2 nanoparticles.

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Smart Nanoconcretes and Cement-Based Materials

Fig. 25.6 Xrd of OPC.

XRD patterns of the Al2O3eSiO2 nanoparticles and OPC,correspondingly. For the Al2O3eSiO2 nanoparticles, the amorphous pick was observed in the range of 15
e30
2q degrees, whereas the OPC particle did not obtain any amorphous pick. The results show that in the Al2O3eSiO2 nanoparticles the major phase was silicon oxide (SiO2), although tricalcium silicate (C3S) and dicalcium silicate (C2S) were the main phases in the OPC. It is interesting to note that the silicate minerals in the glassy or amorphous state are extremely reactive during the hydration process, and therefore, react with the released Ca(OH)2 from the hydration process of OPC and resulted in the formation of additional calcium silicate hydrate (CeSeH) crystals. These extra C eSeH gels contributed to the decrease in the amount of Ca(OH)2, and consequently, caused in the growth in strength and dense microstructure of mortar (Frías et al., 2008). Based on the obtained XRD results, it can be concluded that the Al2O3eSiO2 nanoparticles are categorized as a semi-crystalline material.

3.

Properties of mortar comprising ceramic nanoparticles

3.1

Fresh properties

3.1.1

Flow test

The results of the slump flow test of both OPC and ceramic mortars are presented in Fig. 25.7. The measured flow diameter for OPC and ceramic mortars were 145 mm and 140 mm, respectively. The mortar containing ceramic particles shows slightly lower workability as associated to the OPC mortar. The addition of finer particles such as ceramic powder into a mortar and concrete mixtures generally provides a solid microstructure of the matrix by filling up the cavities and reduce the porosity. Consequently, it made the matrix stiffer and resulted in lower flowability of the

Production of sustainable mortar comprising waste ceramic nanoparticles

567

Fl di Flow diameter ((mm))

150 140 130 120 110 100 OPC

Type of mo ortar

Ceramic

Fig. 25.7 Comparison flow diameter between OPC and ceramic mortars.

ceramic mortar. Such an influence can consequence in the higher demand for water to keep the matrix flowable. Therefore super plasticizers or water-reducing admixtures can be used in a certain percentage based on the weight of binders to retain the water demand similar to the control mix. It has been found that the higher the replacement level of ceramic powder, the larger the water required to maintain the standard consistency of mortar and therefore, reduction in the workability. Moreover, Pacheco-Torgal and Jalali (Pacheco-Torgal and Jalali, 2010) also reported on the reduction of workability of mortar with the addition of ceramic powder. Due to the high finesses and higher water demand of the ceramic powder, it is known as a factor that can decrease the workability of mortar and concrete (Lim et al., 2015).

3.1.2

Setting time test

Fig. 25.8 shows the effect of ceramic powder replacement at different percentages on the setting time of mortars. It can be seen that the initial and final setting times of the OPC paste were 130 and 235 min, correspondingly. It indicates that the OPC paste required 105 min to reach the final setting time after the initial setting time. Both initial

Setting time (minutes)

6600 5500

Initial setting

Final setting

4400 3300 2200 1100 0 OPC

20% Ceramic 40% Ceramic Type of mortar m

60% Ceramic

Fig. 25.8 Effects of ceramic powder replacement level on setting time.

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Smart Nanoconcretes and Cement-Based Materials

and final setting times of the mortar comprising ceramic nanoparticles increase with the increase in the percentage of ceramic powder replacement. This was because of the reduction of C3S in the mix as ceramic powder replacement increases, thus, reducing the cement hydration process of mortar. The initial and final setting time of the 20% ceramic paste was 160 and 355 min, respectively. In contrast to the 20% ceramic paste, the initial and final setting times of 60% ceramic paste were 230 and 500 min, correspondingly. The 20% ceramic paste required 195 min to reach the final setting time after the initial setting time while the 60% ceramic paste required longer setting time which was 270 min to reach the final setting time. However, the setting time of ceramic paste is longer than the OPC paste. This is due to the pozzolanic reaction between SiO2 from ceramic and Ca(OH)2 evolved from cement hydration which is only can occur after the cement started to react with water, therefore, as this reaction is comparatively slower, it lengthened the setting time of pastes (Frías et al., 2008).

3.2 3.2.1

Hardened properties Compressive strength

Fig. 25.9 illustrates the obtained results of the compressive strength test of the OPC mortar and mortar containing Al2O3eSiO2 nanoparticles at a different level of replacement. The compressive strength values of 41.86, 38.79, 40.58, and 29.35 MPa were recorded for OPC mortar and mortar mixes containing 20%, 40%, and 60% ceramic nanoparticles, respectively, at the age of 7-day. It can be seen that the obtained strength values for mortar mixes containing ceramic powder were relatively lesser than that of OPC mortar. Nevertheless, with the increase in the curing time, the mortar containing 20% and 40% ceramic nanoparticles obtained higher compressive strength values as compared to that of OPC mortar. It can be attributed to the pozzolanic nature of the ceramic nanoparticles, and the reactions happened amongst the silicon dioxide (SiO2) exist in ceramic powder, and calcium hydroxide (Ca(OH)2) released from the

Compressive strength (MPa)

70 60

0%

20%

40%

60%

50 40 30 20 10 0 7

Time (days)

28

90

Fig. 25.9 Effects of Al2O3eSiO2 nanoparticles on the compressive strength of mortar.

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569

OPC hydration. Similar results were described by Frías et al. (2008) and Samadi et al. (2015), who used different sorts of waste ceramic at 10% and 20% cement substitution level. However, the rise in the compressive strength was marginal as associated to that of OPC mix, which could be owing to the amount of active silicate in the ceramic nanoparticles. The microstructure analysis of the Al2O3eSiO2 nanoparticles revealed that the amount of amorphous silicate content was minor and a majority of the silicate was in crystal form and non-active. Besides, the proportion of aluminum oxide (Al2O3) content was high in the Al2O3eSiO2 nanoparticles. The higher Al2O3 content can consequence in the strength particularly at the early ages. During the hydration process, Al2O3 reacts with liberated (Ca(OH)2) and water and results in the formation of calcium aluminate hydrates (C-A-H). Moreover, C-A-H will react with amorphous silicate and leads to the creation of calcium aluminate silicate hydrate (C-A-SeH) crystals. Also, with the increase in the amount of Al2O3eSiO2 nanoparticles in the matrix, the CeSeH crystals significantly growth. It,therefore, leads to the reduction of porosity, which provides a sense of microstructure and caused in higher compressive strength values. The results also show that further increase in the ceramic powder content, for example, the mortar containing 60% of Al2O3eSiO2 compressive strength was lower as associated to that of 20% and 40% mixes. The reduction in compressive strength of mortar containing 60% of ceramic powder might be attributed to the lower amount of OPC that required for the hydration process as well as the lower workability, which resulted in lower compatibility of matrix and existence of voids. In contrast, the lower OPC content results in the reduction of C3S andC2S content in the mixture. It, therefore, leads to delaying the hydration process and decrease the strength of the mortar (Subas¸ı et al., 2017; Mohammadhosseini et al., 2016). Moreover, the results show that in the mortar mix containing 40% of Al2O3eSiO2 nanoparticles the compressive strength increased by 7% as compared to that of control mix at the age of 90-day.

3.2.2

Splitting tensile strength

The results of the splitting tensile strength for OPC and ceramic mortars are shown in Fig. 25.10. A similar trend like that of compressive strength was detected in tensile strength of mortar mixes containing ceramic powder. The splitting tensile strength of ceramic mortar was found to be increased with the increasing ages of curing. It can be attributed to the pozzolanic reaction arisen amongst the reactive SiO2 and Ca(OH)2, which was formed from the hydration process of the OPC. Besides, due to the pozzolanic nature of ceramic powder, the splitting tensile strength values for the ceramic mortar at the age of 7 days was slightly lesser than that of OPC mortar (Senthamarai and Manoharan, 2005). At the curing period of 7-day, the tensile strength value of mortar mix containing 40% ceramic powder was recorded as 2.85 MPa, which is about 4% lower than that of 2.95 MPa recorded for OPC mortar. However, at the longer curing periods, the splitting tensile strength of ceramic mortar increased as compared with the OPC mortar. For example, at the age of 90 days, the tensile strength of mortar containing 40% ceramic powder was found as 4.45 MPa which is about 15%

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Smart Nanoconcretes and Cement-Based Materials 5

0%

Tensile strength (MPa)

4.5

20%

40%

60%

4 3.5 3 2.5 2 1.5 1 0.5 0 7

28 Time (days)

90

Fig. 25.10 Effect of Al2O3eSiO2 nanoparticles on the tensile strength of mortar.

higher than that of OPC mortar at the same curing time. It indicates that the ceramic powder up to a certain percentage is sufficient to enhance the splitting tensile strength of mortar.

3.2.3

Flexural strength

The experimental results of the flexural strength for mortar mixes containing a different volume of ceramic powder are illustrated in Fig. 25.11. Similar to the tensile strength, the flexural strength of mortar mixes containing ceramic powder was increased. It can be observed that the flexural strength of ceramic mortars was found to be increased with the increasing the curing period. The results show that at the age of 7 days, the flexural strength values of mortar mixes containing ceramic powder was comparatively lower than that of OPC mortar. For example, for the mortar containing 40% ceramic powder, the flexural strength was recorded as 4.6 MPa which is about 3% lower than that of OPC mortar. It mightbe attributed to the pozzolanic action of ceramic powder at which the hydration process is slow at the early ages and resulted in lower strength values (Mohammadhosseini et al., 2017). 8

0%

20%

40%

60%

Flexural strength (MPa)

7 6 5 4 3 2 1 0 7

28 Time (days)

90

Fig. 25.11 Effect of Al2O3eSiO2 nanoparticles on the flexural strength of mortar.

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571

However, at the longer curing periods, the flexural strength values of ceramic mortar increased as compared with the OPC mortar. For instance, at the curing period of 90 days, the flexural strength of mortar containing 40% ceramic powder was recorded as 6.85 MPa which is about 12% higher than that of OPC mortar at the same curing period. The increase in the flexural strength of ceramic mortars is attributed to the hydration process of ceramic nanoparticles by the development of extra CeSeH gels at longer curing periods and therefore, increase in the strength values of mortar (Senthamarai and Manoharan, 2005).

3.2.4

Modulus of elasticity

Modulus of elasticity (MOE) of mortar is an essential mechanical parameter reflecting the ability of the mortar to deform under the loads. The modulus of elasticity values of the OPC mortar and mortar containing 40% ceramic powder is presented in Fig. 25.12. It can be seen that the ceramic mortar exhibited a higher value of modulus of elasticity at all ages and tended to be stiffer than OPC mortar. It can be observed that the MOE of the ceramic mortar was comparatively higher than that of OPC mortar at one month and continued to increase at later ages. For example, at one month curing period, the elastic modulus of the OPC mortar was recorded as 29.74 GPa, while 34.73 GPa was obtained for ceramic mortar. The enhancement in the modulus of elasticity of ceramic mortar could be attributed to the delayed formation of the micro-cracks at increasing loading rate (Sanchez de Rojas et al., 2006). Furthermore, the dense microstructure of ceramic mortar due to the nanoceramic particles which resulted in higher strength of mortar also leads to higher MOE of ceramic mortar. Also, the MOE of OPC and ceramic mortars were increased by 13% and 14%, respectively, after 1-year curing.

3.2.5

Drying shrinkage

The results of the drying shrinkage for OPC mortar and mortar containing 40% ceramic nanoparticles are illustrated in Fig. 25.13. The results show that OPC mortar

M d l off elasticity l ti it (GP Modulus (GPa))

45 40

1 month

1 year

35 30 25 20 15 10 5 0 OPC

Ceramic Type of morrtar

Fig. 25.12 Modulus of elasticity of OPC and 40% ceramic powder mortars.

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Smart Nanoconcretes and Cement-Based Materials

Shrinkage strain (10-6)

1200 1000 800 600 400 OPC mortar Ceramic morttar

200 0 0

20

400 60 Age (days)

80

100

Fig. 25.13 Drying shrinkage of OPC and ceramic mortars.

obtained higher drying shrinkage than that of ceramic mortar. It can be observed that the rate of rising in drying shrinkage for both mixes is very rapidly at the early ages of the test. The recorded drying shrinkage of OPC and ceramic mortars at the age of 90-day are 993  106microstrain and 837  106 microstrain, respectively. The use of ceramic powder significantly reduces the drying shrinkage of the mortar which was mainly related to the reduced free water content in the capillary pore. The less free water content in the matrix will cause in lower water lost during drying that leads to a reduction in shrinkage (Lavat et al., 2009). Mohammadhosseini et al. (Mohammadhosseini and Tahir, 2018a) also reported that the drying shrinkage of concrete and mortar is mostly associated to the size and amount of pores in addition to the continuity of the capillary system in the hydrated cement paste. Furthermore, ceramic nanoparticles exhibited a good pozzolanic reaction by providing a dense microstructure and resulted in lower drying shrinkage as compared to OPC mortar and assisting in converting large voids into fine pores. The refinement of pores then reduces the loss of free and bound water in the matrix, and consequently prevent the shrinkage of mortar specimens.

3.2.6

Water absorption

The volume of pore space in a mortar, as distinct from the ease with which a fluid can penetrate it, is measured by absorption. According to Mohammadhosseini et al. (2018a), absorption cannot be used as a measure of the quality of concrete or mortar, but in general, the best quality concrete or mortar has an absorption lower than10%. The water absorption of the OPC mortar and mortar containing 40% ceramic powder at different ages is shown in Fig. 25.14. The water absorption for OPC and ceramic mortars at 90 days were 2.11% and 1.32%, respectively. At 90 days, ceramic mortar obtained lower water absorption compared to OPC mortar by about 37%. It can be due to the reduction in the average pore radius of mortar with the formations of CeS eH gel by the pozzolanic reaction that gradually fills the original water-filled space. Another possible reason is that higher fineness of unreacted ceramic powder that would act as filler between cement particles (Lavat et al., 2009). In addition, it is

Production of sustainable mortar comprising waste ceramic nanoparticles 4.0

OPC mortar

3.5 Water absorption (%)

573

Ceramic mortar

3.0 2.5 2.0 1.5 1.0 0.5 0.0 7

14

28 Age (Day ys)

56

90

Fig. 25.14 Water absorption of OPC and ceramic mortars.

evident that more CeSeH gel was produced at an early age resulting in higher compressive strength of the mortar. At the age of 7-day, the water absorption for ceramic mortar was higher than that of OPC mortar possibly due to the small particles size of ceramic powder that has larger surface area thus, tends to absorb more water. However, as the age of water curing rises, the water absorption was reduced. The application of continuous water curing for 28 days has enabled ceramic particles in the mix to be actively involved in the pozzolanic reaction. Therefore, it is positively modifying the internal microstructure of mortar to be denser. Therefore, the use of ceramic waste can significantly reduce the water absorption of mortar with prolonging curing age.

3.3 3.3.1

Microstructural analysis SEM analysis

Microstructural analysis was used to reach a deep understanding of the influences of ceramic nanoparticles on the hydration process and performance of the mortar. Fig. 25.15, Figs. 25.16 and 25.17 demonstrate the SEM images of the mortar specimens comprising of Al2O3eSiO2 nanoparticles at various level of replacement. It can be seen that in the mortar mix containing 20% ceramic nanoparticles, the amount of Ca(OH)2 crystals are considerably high as compared to those mixes with 40% and 60%, which are mostly hexagonal plate shape. This high quantity of Ca(OH)2 is due to the hydration of OPC and existence of CaO which is higher in the mortar with 20% ceramic powder as compared to 40% and 60% mortar mixes. Nevertheless, a lesser amount of Ca(OH)2 crystals were formed in the mortar containing 40% and 60% ceramic powder owing to the lower amount of OPC in mixes. This is attributed to the decrease in the C3S and C2S content which exists in OPC. However, a further increase in the ceramic powder content at replacement level of 60%, results in the lower strength. The reduction in strength at higher replacement level could be attributed to the lack of Ca(OH)2crystals which are the primary parameter in the

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Smart Nanoconcretes and Cement-Based Materials

Fig. 25.15 SEM image of a mortarcomprising 20% Al2O3eSiO2 nanoparticles.

Fig. 25.16 SEM image of a mortar comprising 40% Al2O3eSiO2 nanoparticles.

Fig. 25.17 SEM image of a mortar comprising 60% Al2O3eSiO2 nanoparticles.

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formation of CeSeH gels and increase in strength of matrix through reaction with the reactive silica (Sanchez de Rojas et al., 2006). Furthermore, a higher amount of CeSeH crystals were detected in the mortar containing 40% ceramic nanoparticles. The formation of higherC-SeH crystals is owing to the proper reaction amongst the reactive silica present in ceramic powder and Ca(OH)2 available from OPC hydration. During the hydration process various forms of CeSeH gel with different shape of crystals, such as rosette, fibrous, plumose, massive, and finely granular were formed and these are displayed in Fig. 25.18. In addition, the EDX analysis evidenced the existence of CeSeH crystals in the matrix with the very high proportion of calcium and silica content. The existence of these crystals then influenced to the enhancement in the strength of the mortar.

3.3.2

XRD analysis

Fig. 25.19 illustrates the results of the XRD analysis for the OPC mortar and mortar mixes comprising 20%, 40%, and 60% of Al2O3eSiO2 nanoparticles.The results indicate the peaks of Ca(OH)2 crystals that obtained at 18.05
, 34.11
, and 47.13
. The peaks of Ca(OH)2 crystals reduced with an increase in the amount of Al2O3eSiO2 nanoparticles, while the peaks Quartz (SiO2) minerals increased particularly at the higher level of replacement. The higher peaks of Quartz is owing to the pozzolanic action that takes place amongst the reactive SiO2 in the ceramic powder and Ca(OH)2 from OPC hydration. Though, few peaks of Ca(OH)2 crystals at lower intensity were found in the mortar containing 60% ceramic powder as less amount of Ca(OH)2 existed to react with the SiO2. Moreover, due to the lack of sufficient Ca(OH)2 in the hydration, the dilution effect occurred and then led to the decrease in the strength (Sanchez de Rojas et al., 2006). The C3S/C2S peaks intensity also reduced with a rise in the Al2O3eSiO2 nanoparticles content, as a consequence of lower OPC content. In addition, a peak of gypsum was observed at the angles of 21.50
in the mortar containing ceramic powder, but with lower intensity in the OPC mortar. It indicates the decomposition of the CeSeH phase in the mortar containing ceramic powder with the existence of required calcium for the formation of gypsum (Pacheco-Torgal and Jalali, 2010).

3.3.3

Thermal gravimetric analysis

The results of the thermal gravimetric analysis (TGA) for OPC mortar and mortar comprising Al2O3eSiO2 nanoparticles in the range of 30e1000
C are shown in Fig. 25.20. According to the obtained results, the mass loss of specimens can be divided into four major phases, where the water vaporization occurred at the temperature of 100  5
C, dehydration of CeSeH crystals took place in the temperatures ranged amongst 100e200
C, dehydration of Ca(OH)2 emerged in the range of 440e550
C, and decarbonisation arisen at the temperatures of 600e850
C. It can be seen from Fig. 25.20 that there is a sharp mass loss of all specimens at the temperature of 100  5
C owing to the vaporization of water in the matrix. In this phase, the free water which was not used in the cement hydration process and just used for workability purpose throughout the mixing process. The existence of bound water is another

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Smart Nanoconcretes and Cement-Based Materials

Fig. 25.18 SEM and EDX of the formation of different types of CeSeH crystals in mortarcomprising Al2O3eSiO2 nanoparticles.

cause of mass loss in the matrix.This water exists in the micro and nano-size voids (Mohammadhosseini et al., 2018b). It can be observed that the mass loss at the temperature of 100  5
C raised with an increase in the Al2O3eSiO2 nanoparticles content. Moreover, the dehydration of Ca(OH)2 reached at the temperatures between 400 and 550
C, and the moisture content evaporated following Eq. (25.1): CaðOHÞ2 ðsÞ / CaOðsÞ þ H2 OðgÞ

(25.1)

Production of sustainable mortar comprising waste ceramic nanoparticles

577

Fig. 25.19 XRD patterns of OPC mortar and mortar comprising Al2O3eSiO2 nanoparticles.

Fig. 25.20 TGA and DTA of different mixes.

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Smart Nanoconcretes and Cement-Based Materials

The mass losses in the mortar specimens at the temperatures of 600e850
C mightbe attributed to the decarbonization of calcium carbonate (CaCO3), as the melting point of CaCO3is about 825
C (Mohammadhosseini and Yatim, 2017; Halicka et al., 2013), and in this range of temperature, the decomposition takes place following Eq. (25.2): CaCO3 ðsÞ / CaOðsÞ þ CO2 ðgÞ

(25.2)

After the mortar specimens exposed to the temperature of 850
C, the average percentages of the residual masses for 60%, 40%, 20% ceramic mortars, and OPC mortar were recorded as 84%, 82%, 81%, correspondingly. The results of DT analysis showed a similar tendency like that of TGAresults, whereas the mass loss can be alienated into four different phases, as revealed in Fig. 25.20. Phase I, which fell in the temperature range of 100e200
C and linked to the dehydration of CeSeH crystals. Phase II, which is in the temperature range of 200e350
C, indicates the dehydration of calcium aluminate silicate hydrate and calcium aluminate hydrate. Phase III arosein the temperatures amongst 450e550
C, which illustrated the dehydration of Ca(OH)2 crystals. Phase IV which corresponded to the decarbonization of CaCO3 took place in the temperatures of 650e800
C.

4.

Applications

Mortar is more and more used on account of the benefits of increased bonding between building materials as well as the repair works. The dense microstructure of mortar incorporating ceramic nanoparticles offers advanced performance in terms of strength and durability. Since sustainability is a crucial concern in construction, the utilization of waste materials such as waste ceramic can help to achieve eco-friendly and low-cost construction materials. The followings are the most common applications that mortar comprising ceramic nanoparticles can be used. • • • •

5.

Mortar comprising ceramic nanoparticles can be effectively used in the repair and overlay of damaged cement concrete surfaces in various applications such as pavements, bridges, floors, and dams. It can be used in brick masonry works when high quality of mortar is required. It is potential to be used in plastering works to reduce the permeability and prevent the entrance of water or any other disturbance liquids. It can also be used as flooring materials in industries as this mortar is highly resistance to the chemical attacks.

Conclusions

The current chapter investigated the potential use of ceramic nanoparticle as cement replacement to enhance the mechanical and microstructural properties of mortar.

Production of sustainable mortar comprising waste ceramic nanoparticles

579

The following are the conclusions drawn based on the experimental results and observations: • • • • • •

•

The ceramic nanoparticles from industrial ceramic wastes are potential to be used as a cement replacement in a mortar to improve the compressive, tensile and flexural strengths. The fineness of Al2O3eSiO2 nanoparticles found to be higher than that of OPC particles. Therefore, finer particles caused in superior performance in the mortar both as binder and filler. The inclusion of ceramic nanoparticles demonstrated a significant reduction in the drying shrinkage of mortar. Ceramic nanoparticles significantly reduce the permeability of mortar. The water absorption of ceramic mortar was found lower than that of OPC mortar. Based on the microstructural analysis, the SEM images demonstrate the development of additional CeSeH crystals in the matrix comprising Al2O3eSiO2 nanoparticles as associated to that of OPC mortar. The results of the TG, DT and XRD analyses indicated that using Al2O3eSiO2 nanoparticles as supplementary cementing materials significantly enhanced the performance of the mortar. It is owing to the pozzolanic action of ceramic nanoparticles which leads to the creation of extra CeSeH gels and consequently, increase the strength by providing a dense microstructure. The outcomes of the study demonstrated that the production of a sustainable mortar comprising waste ceramic nanoparticles is feasible with adequate strength and microstructural properties. As such, waste conservation and the reduction in destructive impacts on the environment could also be achieved. Therefore, this would eventually lead to sustainable and eco-friendly construction.

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