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Construction and Building Materials: David O. Koteng, Chun-Tao Chen
Construction and Building Materials: David O. Koteng, Chun-Tao Chen
h i g h l i g h t s
a r t i c l e i n f o a b s t r a c t
Article history: This study explores the lime–pozzolana pastes made from high calcium hydrated lime blended with type
Received 5 November 2014 F fly ash and silica fume, with the total pozzolana content up to 40%. Research focuses on the develop-
Received in revised form 28 February 2015 ment of the compressive strength by varying the water–binder ratio, powder proportioning, fineness
Accepted 8 March 2015
of lime, and curing conditions. The lime–pozzolana cement shows good promise as a binder which can
Available online 25 March 2015
be used alongside the Portland cement. With lower unit weight and higher compressive strength per unit
weight than the Portland cement paste, the lime–pozzolana pastes can reduce the weight of structural
Keywords:
elements and the overall cost of structures.
Lime
Pozzolana
Ó 2015 Elsevier Ltd. All rights reserved.
Compressive strength
Silica fume
Fly ash
http://dx.doi.org/10.1016/j.conbuildmat.2015.03.052
0950-0618/Ó 2015 Elsevier Ltd. All rights reserved.
D.O. Koteng, C.-T. Chen / Construction and Building Materials 84 (2015) 294–300 295
Table 1 Table 3
Typical chemical compositions and burning temperatures of lime and cement. Mixing proportions and curing conditions of specimens used to explore variations in
pozzolana content and w/b.
Material Chemical compositions (%) Burning temperature
Pozzolana Paste Curing conditions
CaO MgO SiO2 Al2O3 Fe2O3 (°C)
composition by
NHL 96.0 1.0 1.5 0–1.5 0–1.5 900–950 weight (%)
HL 54.3 7.7 12.6 5.4 1.2 1000–1250
Content (%) SF FA NHL 0–7 days 7–14 days 14–28 days
PC 60–67 0.5–4 17–25 3–8 0.5–6 1250–1450
10 10 00 90 Mold Air Water, RT
20 10 10 80 Mold Air Water, RT
28 days and 29.8 MPa at 90 days. The authors also made mortar 30 10 20 70 Mold Air Water, RT
specimens with lime blended with 30% SF and obtained 28-day 40 10 30 60 Mold Air Water, RT
and 90-day strengths of 28.7 MPa and 37.6 MPa, respectively. Note: RT = room temperature.
Day and Shi [6] tested paste specimens made by hydrated lime
with natural pozzolana of 554 m2/kg Blaine fineness in a mass ratio CaðOHÞ2 þ SiO2 þ H2 O ! C S H ð1Þ
of 1:4 and incorporated calcium chloride as reaction activator.
Specimens were cured in water at 50 °C for up to 90 days. The CaðOHÞ2 þ Al2 O3 þ H2 O ! C A H ð2Þ
authors obtained 28-day and 90-day cylindrical crushing strengths
LPP also hardens in moist air by the reaction of calcium hydrox-
of 17 MPa and 19 MPa, respectively. Strength rose continuously
ide with atmospheric CO2 to form calcite as shown in Eq. (3) and
until 14 days, remained constant until 28 days, and then rose
(4).
slightly until 90 days. Lanas, et al. [7] tested mortar specimens
made with natural hydraulic lime and sand in a ratio of 1:1 by vol- H2 O þ CO2 ! H2 CO3 ð3Þ
ume and cured in water at ambient laboratory conditions until
365 days. The 28-day and 365-day cubic crushing strengths were H2 CO3 þ CaðOHÞ2 ! CaCO3 þ 2H2 O ð4Þ
9 MPa and 16 MPa, respectively. Between the hydration times of
The aim of this study is to explore the effects of powder propor-
28 and 180 days, the strength increased only slightly to 9.5 MPa
tioning, water–binder ratio (w/b), fineness of lime, and curing con-
but rose steadily after 180 days. In summary, specimens in most
ditions on the early strength of LPP. The total amount of pozzolana
of the studies were cured in water until the time of testing and
in the paste is limited to 40% in order to observe the effects of
had high strengths. However, onsite structures are often cured in
carbonation of free lime on strength development.
water for only limited periods. In view of this issue, this study
investigates the strength development of the paste when exposed
2. Experimental work
to air after an initial water curing regime.
Calcitic or high calcium hydrated lime is obtained by burning 2.1. Materials
calcite (CaCO3) bearing rocks, such as limestone and chalk, at
900–1250 °C to release CO2 and produce quick lime (CaO). Water NHL in accordance with ASTM C821 was used. FA produced in accordance with
is added to the lime to produce hydrated lime (Ca(OH)2). The cal- ASTM C618 was supplied by Formosa Petrochemical Corporation, Taiwan. Type I PC
in accordance with ASTM C150 was used to prepare control specimens. SF was sup-
cite bearing sands and shells of eggs, snails, oysters and sea organ- plied by Elkem Materials, China. The properties of the powders are given in Table 2.
isms can also be used in lime production. Hydraulic lime (HL) A polycarboxylated superplasticizer (SP) in accordance with ASTM C 494 type G
contains significant natural quantities of silica and alumina and admixture was used.
sets in both air and water. Non-hydraulic lime (NHL) sets only in
moist air but also sets in water when mixed with pozzolana. 2.2. Sample preparation
Table 1 shows the typical chemical compositions and burning tem-
Densities of the raw materials used in this study were determined in accor-
peratures of NHL [8], HL [7], and PC [2,8]. The choice of NHL over dance with ASTM C 188. Weights of the desired NHL, FA, SF, and water were calcu-
HL is preferred due to the lower calcination temperature range of lated by predetermined proportions of the total mass of powder. The mixing
NHL and the reduced production energy. In addition, NHL has proportions of the powders are given in Tables 3 and 4.
40% more CaO than HL. Therefore, when NHL blends with more SF, FA and PC were used as supplied, but NHL was sieved by ASTM #50 sieve to
remove hard lumps and sintered particles. Some NHL was sieved through ASTM
pozzolana, the production energy, raw materials and CO2 emission
#30, #50, #100 and #200 sieves in order to obtain different particle size fractions.
is further reduced. Pozzolanas contain reactive silica and alumina. The materials required to make each mix were weighed to the nearest gram. A pad-
Among the pozzolans, FA is a by-product of burning coal and rich dle mixer shown in Fig. 1(a) was used for mixing. The water was added to the pan
in reactive silica and alumina. Type F FA has a low amount of followed by SF and FA. The pozzolanas were mixed to produce a uniform paste as
CaO compared to type C FA. SF is a powder with particles finer than shown in Fig. 1(b). NHL was then added to the pozzolana paste in three equal por-
tions, and each addition was followed by mixing at low speed of 140 rpm to pro-
cement, consisting almost entirely of very reactive silica. It is a by- duce a uniform paste. A stiff paste as shown in Fig. 1(c) was formed and drops of
product during the manufacture of silicon and ferro-silicon alloys. SP were added while mixing at low speed to bring the paste to imminent flow, as
Lime–pozzolana paste (LPP) hardens partly by the chemical shown in Fig. 1(d). The paste was then mixed at high speed of 245 rpm for one min-
reaction of calcium hydroxide in hydrated lime with silica and ute. SP dosages were varied with the paste proportions and w/b but less than 0.5%
of the total weight of powder. In general, an increase in w/b or FA reduced the
alumina in pozzolana in the presence of water to form cementing
amount of SP required to provide the target workability. The paste was used to cast
C–S–H and C–A–H phases as shown in Eq. (1) and (2). test cylinders with 50-mm in diameter and 100-mm in height.
Table 2
Chemical and physical properties of raw materials.
Table 4 average of three tests. Representative samples for microstructure examination were
Mixing proportions and curing conditions of specimens used to explore variations in taken and preserved in 95% alcohol. Specimens cured in air were broken across and
fineness of lime, silica fume, fly ash, and curing conditions at w/b of 0.35. the exposed cross-section was sprayed with 1% phenolphthalein in 70% ethyl alco-
hol. The un-carbonated inner core rich in calcium hydroxide turned pink while the
Pozzolana Paste composition by Curing conditions carbonated outer shell remained neutral. The depth of the carbonated outer shell
content weight (%) was measured to the nearest 0.1 mm using Vernier calipers.
(%) SF FA NHL 0– 7–28 days 28–
7 days 180 days
2.5. Microstructure examination
25 10 15 75 Mold Water, RT Water, RT
30 10 20 70 Mold Water, RT Water, RT Tests were carried out to determine the compositions of the outer shell and
35 10 25 65 Mold Water, RT Water, RT inner core at 90 days for specimens with 10% SF, 30% FA, and 60% NHL, which were
40 10 30 60 Mold Water, RT Water, RT cured in water at room temperature up to 28 days and then cured in air. Test sam-
40 00 40 60 Mold Water, RT Water, RT ples were cleaned with alcohol, dried by compressed air, crushed and sieved
40 10 30 60 Mold Water, RT Air, RT through ASTM #200 sieve. The powder was placed in a plastic sample holder and
40 10 30 60 Mold Air, RT Air, RT the surface levelled smooth with a glass pane. The sample was then examined by
40 10 30 60 Mold Water, Air, RT an X-ray diffractometer (D2 Phaser, Bruker Corp.) using X-ray radiation with a
60 °C dwell time of 0.3 s and step size of 0.02° in 2h.
(a) (b)
(c) (d)
Fig. 1. Preparation for the pastes: (a) paddle mixer, (b) silica fume and fly ash paste, (c) stiff paste before adding superplasticizer, (d) final paste used to cast test specimens.
D.O. Koteng, C.-T. Chen / Construction and Building Materials 84 (2015) 294–300 297
in the paste by 28% and increased the porosity. The two factors is due to the aging of free lime in the paste and was observed
caused a great reduction in 28-day strength from 21.1 MPa to in all specimens cured continuously in water. Several authors
7.4 MPa. However, too little water in the paste can lead to incom- [9–13] have suggested that when calcium hydroxide is continu-
plete reaction of the powders and strength reduction. It is thus ously wetted, morphological changes take place in the crystal
important to determine the minimum w/b that gives the best structure so that its physical properties are changed. For instance,
results. Cazzalla et al. [9], Mascolo et al. [10], Margalha et al. [11], and
Rodriguez-Navarro et al. [12] have suggested that single prismatic
calcium hydroxide crystals break down into many small platelike
3.2. Effect of fineness of lime crystals under continuous wetting. Ruiz-Agudo and Rodrigues-
Navarro [13] found that the viscosity and plasticity of the paste
Specimens containing 10% SF, 30% FA, and 60% NHL were pre- increases initially due to the random alignment of the platelike
pared with NHL with particle range of ASTM sieves #30-50, #50- crystals, but the viscosity and yield stress reduces with time as
100, #100-200 and passing ASTM #200 sieve. A w/b of 0.35 was the plates realign themselves face to face. The increase in
used and all specimens were cured in water at room temperature strength after 90 days is attributed to the increased pozzolanic
until test. Test results are shown in Fig. 3. Results for LPP with reactions.
the same mix proportions but made with NHL passing ASTM #50
sieve is included for comparison. Specimens with NHL passing
ASTM #200 sieve show slightly higher strength than the other 3.3. Effect of silica fume content
mixes after 24 days. NHL passing ASTM #50 sieve gives better
results than NHL in all the remaining particle ranges. Some drop Specimens for this test were prepared with paste containing
in strength occurs between the ages of 28 and 90 days in all 10% SF and FA amounts of 15%, 20%, 25%, or 30%. Another set of
specimens. specimens was made with 40% FA and no SF. Specimens had a w/
The specimens with NHL passing ASTM #200 sieve had b of 0.35 and were cured in water at room temperature until test.
increases in 28-day and 180-day strengths by 11.8% and 11.5% Results are given in Fig. 4. It is shown that the 28-day strengths of
respectively, which may not justify the extra effort in sieving or the pastes with FA contents between 20% and 30% were very close,
grinding necessary to produce the finer powder. The increase in indicating that SF content contributes more to early strength than
strength is attributed to the improved reactivity of the powder. the total pozzolana content. Without SF, the strength development
The decrease in strength of specimens between 28 and 90 days is very slow, as shown in the paste with 40% FA but no SF.
Fig. 2. Strength development of pastes with 10% silica fume and varying fly ash at (a) w/b = 0.3, (b) w/b = 0.4, (c) w/b = 0.5, or (d) w/b = 0.6, cured in air for 7–14 days and then
in water for 14–28 days.
298 D.O. Koteng, C.-T. Chen / Construction and Building Materials 84 (2015) 294–300
Fig. 5. Effect of curing condition on the compressive strength of paste with 10%
Fig. 3. Effect of fineness of lime on compressive strength of paste with 10% silica silica fume, 30% fly ash, and 60% lime at w/b = 0.35.
fume, 30% fly ash, and 60% lime made with w/b = 0.35 and cured in water at room
temperature.
Fig. 6. Carbonation of pastes with 10% silica fume, 30% fly ash, and 60% lime at w/
b = 0.35 at 90 days by (a) air curing or (b) water curing at room temperature for
28 days and then air curing.
Fig. 9. Strength-weight ratios of Portland cement paste cured in water and lime–
Fig. 7. Variation of carbonation depths of pastes with 10% silica fume, 30% fly ash,
pozzolana pastes with 10% silica fume, 30% fly ash, and 60% lime and different
and 60% lime at w/b = 0.35 and different curing conditions between 7 and 28 days.
curing conditions at w/b = 0.35.
Fig. 8. Failure of pastes with 10% silica fume, 30% fly ash and 60% lime at w/b = 0.35 and curing in (a) water until 180 days, (b) water for 28 days then in air until 56 days, or (c)
water until 28 days then in air until 180 days.
300 D.O. Koteng, C.-T. Chen / Construction and Building Materials 84 (2015) 294–300
2
60 °C. The LPP can thus be used alongside the PCP or replace the
1. PCP paste in some instances with economic and environmental
2. advantages. On the other hand, this study shows that the LPP
3.
strength continues to rise when exposed to air after an initial per-
4.
5. - calcite.
iod of water curing. This observation is important since concrete
6. - aragonite. specimens in practice are cured in water for limited periods only.
7. Specimens kept in water for long periods lose some strength
5
4
between the ages of 28 and 90 days and it is important to use
the lowest strength in this zone for design purposes. The LPP has
1 2 4 1 3 the advantage over the PCP for its appreciable strength gain
1 73 5 6 16 5 57 5 56
Outer shell
beyond 28 days.
Acknowledgement
References