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Construction and Building Materials 254 (2020) 119042

Contents lists available at ScienceDirect

Construction and Building Materials


journal homepage: www.elsevier.com/locate/conbuildmat

Assessment of packing, flowability, hydration kinetics, and strength of


blended cements with illitic calcined shale
Guillermina Marchetti a,⇑, Viviana Rahhal a, Zbyšek Pavlík b, Milena Pavlíková b, Edgardo F. Irassar a
a
Departamento de Ingeniería Civil, Facultad de Ingeniería, Universidad Nacional del Centro de la Provincia de Buenos Aires, Av. del Valle 5737, B7400JWI Olavarría, Argentina
b
Department of Materials Engineering and Chemistry, Faculty of Civil Engineering, Czech Technical University in Prague, Thákurova 7, 166 29 Prague 6, Czech Republic

h i g h l i g h t s

 Illitic calcined shale have great potential as low-energy and low-carbon SCM.
 The packing density of blended cement paste decreases, but it increases for mortar.
 The flowability depends on the particle size distribution and the specific surface area.
 Blended cements with illitic calcined shale show the CH-reduction and the pore size refinement.
 The compressive strength of blended cements is higher than the OPC mortar 90 days.

a r t i c l e i n f o a b s t r a c t

Article history: The effects of two illitic calcined shales as supplementary cementitious materials (SCMs) on the perfor-
Received 12 December 2019 mance of ordinary Portland cement (OPC)-based pastes and mortars were investigated. The packing den-
Received in revised form 19 March 2020 sity of blended cement pastes and mortars were predicted with compressible packing model (CPM). The
Accepted 5 April 2020
water film thickness (WFT) and flowability were calculated and measured. Early hydration was described
by calorimetric curves and the hydration microstructure was identified by X-ray diffraction (XRD), differ-
ential thermal analysis (DSC/TG), and pore size distribution (MIP). The compressive strength was tested
Keywords:
at 2, 7, 28, and 90 days. The results showed that the partial replacement of OPC by illitic calcined shale
Blended cement
Calcined clay
decreased the packing density and the flowability of cement pastes but this does not occur for standard
Illite mortars. For blended cements, the hydration products were similar to that corresponding to OPC, the
Packing pozzolanic reaction contributed from 28 days to the densifying of solid structure and it was also noticed
Flowability the pore size refinement that improved the compressive strength at later age.
Hydration Ó 2020 Elsevier Ltd. All rights reserved.
Strength

1. Introduction the calcinations temperature, it is also possible to improve the


strength, due to a combination of the filler effect and the stimula-
Concrete is the building material with the greatest potential to tion of cement hydration. Several studies have demonstrated the
meet the growing housing demand in developing countries, and effectiveness of calcined clays, particularly for kaolinitic clay to
Portland cement is its high embodied energy and CO2-emmision produce metakaolin with increased pozzolanity [1–3]. However,
component. However, locally available materials should be consid- there are other calcined clays barely used as supplementary
ered as a possible replacement, to reduce the costs and environ- cementitious materials (SCMs) due to the complexity of clay min-
mental impact associated with cement production. The erals and lack of knowledge of the reaction mechanisms. Illitic
utilization of calcined clay or calcined shale as a pozzolanic addi- clays or shale have a high activation temperature and their poz-
tion for mortar and concrete is widely recommended to reduce zolanic activity is slow compared with kaolinitic clays, but it is
CO2 emission due to their great availability and enhancement of the most abundant type of clay in several regions of the world
durability. Additionally, depending on clay mineral present and and therefore their potential as SCM in cement based materials
contributing to reduce the environmental impact is high. Previous
studies [4,5] have shown that the addition of illitic calcined clays
⇑ Corresponding author.
as cement replacement has little effect on the water demand and
E-mail addresses: gmarchetti@fio.unicen.edu.ar (G. Marchetti), vrahhal@fio.
unicen.edu.ar (V. Rahhal), pavlikz@fsv.cvut.cz (Z. Pavlík), milena.pavlikova@fsv.
28-days strength, but could slow down the rate of strength devel-
cvut.cz (M. Pavlíková), firassar@fio.unicen.edu.ar (E.F. Irassar). opment at earlier age. For high replacement levels, this type of cal-

https://doi.org/10.1016/j.conbuildmat.2020.119042
0950-0618/Ó 2020 Elsevier Ltd. All rights reserved.
2 G. Marchetti et al. / Construction and Building Materials 254 (2020) 119042

cined clays reduces the early compressive strength due to the dilu- cement. Common clays, including illitic shales, are in the same
tion effect. He et al. [3] have studied illitic clays thermally activated market niche and they have a great potential to become eco-
at three different temperatures (650, 750 and 930 °C) and have efficient, cheap, and sustainable alternative SCM [46].
demonstrated that the highest pozzolanic activity is produced with
the calcination at 930 °C, reaching to 79% of the compressive
strength of reference OPC after 28 days. Lemma et al. [4] have indi- 2. Experimental
cated that illitic clays are appropriate as raw material to prepare
calcined pozzolan when fired at 950 °C. Garg et al. [6] have demon- 2.1. Materials
strated that illite-smectite clay exhibits the optimum reactivity
when fired at 900 °C, and the white Portland cement-calcined clay An Ordinary Portland Cement (OPC) supplied by Loma Negra
blend (mass ratio 70/30) revealed a small degree of calcined clay CIASA (Olavarría, Argentina) and two natural illitic shales (I1 and
reaction at early age, but an important degree of reaction after pro- I2) from L’amalí (Olavarría) and La Cabañita (San Jacinto) quarries
longed hydration. were used. They were calcined at 950 °C (MI1 and MI2) and ground
An important property of cementitious materials, that affects until the retained on 45 mm sieve was lower than 12%.The calcina-
the rheological and strength performance, is the packing density, tion temperature was chosen according to the original work pub-
which determines the amount of voids between particles to be lished by Lemma et al. [4]. The specific densities of these
filled with water. Essentially, when the packing density is high, less powders measured according to ASTM C 188 [27] were 3.13 g/cm3
water would be needed to fill the voids, and at the same water/ (OPC), 2.63 g/cm3 (MI1) and 2.72 g/cm3 (MI2). The corresponding
cementitious materials ratio (w/cm) more water in excess is surface areas measured by Blaine test method (ASTM C 204 [28])
released to increase the flowability. In addition, at the same flowa- were 354, 622, and 507 m2/kg, respectively.
bility requirement, it would allow to reduce the w/cm and thereby The chemical and mineralogical composition of cement and
increase the strength [7]. both illitic calcined shale is reported in Table 1. The chemical com-
From several studies [8–11], it can be inferred that the most position was determined using an Axios sequential WD-XRF spec-
important factors affecting the rheology of cement pastes/mortars trometer (PANalytical, Almelo). The resulting data were collected
are the packing density, the water content, and the surface area of by SuperQ software, and further evaluated by Omnian software.
the particles in the mixture. Kaufmann et al. [12] studied cement The mineralogical composition of both SCM was determined using
pastes containing different SCMs (metakaolin, silica fume, ultrafine Rietveld method with external standard on X-ray diffraction (XRD)
cement or limestone filler) and found that blending the ordinary patterns collected on Philips PW 3710 diffractometer (PANalytical,
cement with finer SCM can improve the rheological properties of Almelo) operating with CuKa radiation at 40 kV and 20 mA, using a
cement paste. Some researchers [13–15] developed a method for carbon monochromator.
measuring the packing density of granular materials. This method, For the fine aggregate (FA), CEN-standard sand (Normensand
called wet packing method, is capable of simulating the wet condi- GmbH, Germany) according to the EN 196-1 [29] was used. Its den-
tion in fresh cement paste/mortar and allowing the presence of any sity was 2.65 g/cm3, and the calculated specific surface area was
type of superplasticizer (SP) which may have significant effect on 8.1 m2/kg. The particle size distribution of OPC, MI1, MI2 and FA
the packing density. The results obtained indicated that the com- was determined using a laser diffraction particle size analyzer
bined effects of packing density, water content and surface area (Malvern Mastersize 2000) and the accumulated volume curve is
can be evaluated in terms of the water film thickness (WFT) of
the mixture and that the WFT is an important factor governing
the rheology of pastes and mortars [11,16–18,19]. Furthermore, Table 1
to predict the packing density of blended cement, the compressible Chemical and mineralogical composition of cementitious materials.

packing model (CPM) has good correlation with the experimental OPC MI1 MI2
values obtained with the wet packing method [15,20]. Chemical composition [wt.%]
The performance of blended cements containing calcined natu- SiO2 20.14 66.30 62.61
ral pozzolans depends on the evolution of hydration of the fraction Al2O3 4.20 16.28 18.28
of clinker and the pozzolan. The replacement of Portland cement Fe2O3 4.46 9.23 7.79
CaO 60.48 0.33 0.77
by SCM causes the dilution effect that can be computed as the
MgO 0.56 1.46 2.73
increases of effective w/c reducing the early strength, and it can SO3 1.90 <0.01 0.07
partly be compensated by the stimulation effect of clinker phases. K2O 1.07 5.60 4.25
The pozzolanic reaction of kaolinite calcined clay contributes after Na2O 0.05 0.08 1.61
few days [21,22] while its occurs after two weeks for calcined shale TiO2 – 0.76 0.89
P2O5 – 0.09 0.13
reducing the large capillary pores and improving the mechanical BaO – 0.09 0.06
strength and durability of blended cements [23–25]. Cr2O3 – 0.05 0.02
In this study, the performance of blended cements formulated MnO – 0.01 0.08
using two new calcined natural pozzolans obtained by calcination SrO – 0.01 0.01
LOI 1.90 0.58 0.81
of illitic shale locally available was analyzed. These cements are
developed for general use (GU) and delivery in bags for a low tech- Mineralogical composition [%]
C3S 59.1 – –
nological concrete use in developing countries. These blended
C2S 14.0 – –
cements require low water demand, adequate development of C3A 2.6 – –
strength and stability of hydrated products. For this purpose, the C4AF 14.0 – –
packing density, water film thickness, flowability, hydration kinet- Gypsum 4.8 – –
ics and strength development were conducted to understanding Calcite 3.2 –
Amorphous alumina-silica % – 56 49
the behavior of these calcined pozzolans and their application in Quartz – 35 31
the development of low-energy and low-carbon binders. According Illite dehydrated – 4 –
to the USGS Mineral commodity summaries 2020 [26], the world Feldspars – – 18
resources of all clays are extremely large, and the principal uses Hematite – 5 2
Hercynite – – 1
of common clays are to produce brick, lightweight aggregate, and
G. Marchetti et al. / Construction and Building Materials 254 (2020) 119042 3

pressive strength. A total of six blended cement were obtained


by replacement 15, 25, and 35% of OPC by MI1 or MI2 by mass of
the total cementitious materials. The mix proportions of pastes
and mortars are reported in Table 2.

2.3. Packing density and WFT

The packing density (u) of OPC, MI1, MI2, and FA was measured
with a SP dosage of 1.5% (by mass of cementitious materials) using
the wet packing method [13]. The packing density of blended
cement pastes and mortars was predicted by the CPM [30] and
the WFT was calculated at w/cm varied from 0.4 to 0.8 by mass.
Basically, u was determined as the maximum solid concentra-
tion obtained varying the amount of water in the mixture from
insufficient to more than sufficient to fill the voids between the
particles. The WFT represents the average thickness of water film
around the particles [31,19], and was obtained dividing the excess
water ratio (ew) by surface area (SA) of particles in the mixture. In
previous work [20], complete details of the method and the predic-
tion model are given.
The minimum voids ratio umin can be evaluated as:
1u
umin ¼ ð1Þ
Fig. 1. Particle size distributions of OPC, MI, MI2, and FA. u
From the voids ratio, the excess water ratio ew can be obtained
shown in Fig. 1. The median particle size (d50) was 19.65, 8.76,
ew ¼ uw  umin ð2Þ
12.74 and 450 lm for OPC, MI1, MI2 and FA, respectively.
To disperse the particles in paste and mortar mixtures, a where uw is the w/s (defined as the ratio of the volume of water to
polycarboxylate-based superplasticizer (SP) with a solid mass con- the volume of the particles). On the other hand, the surface area of
tent of 35% and a relative density of 1.03 g/cm3 was used. particles SA can be calculated as
SA ¼ SAOPC  ROPC þ SAMI1  RMI1 þ SAMI2  RMI2 þ SAFA  RFA ð3Þ
2.2. Test program and mixture proportions in which SAOPC, SAMI1, SAMI2, and SAFA are the surface areas of
cement, calcined shale and fine aggregate, and ROPC, RMI1, RMI2,
The first part of the test program was to measure the packing and RFA are the volumetric ratios of cement, calcined shale, and fine
density of materials (OPC, MI1, MI2 and FA), to predict the packing aggregate to the total solid volume. With ew and SA so determined,
density of blended cement pastes and mortars with MI1or MI2 and the WFT may be obtained as
to calculate the WFTs at different w/cm. The second part was to
ew
analyze the flowability, the heat of hydration, the progress of WFT ¼ ð4Þ
hydration, and the pore size distribution of blended cement pastes. SA
The third part of experimental tests was aimed to measure the
flowability and the compressive strength of mortars. Based on 2.4. Flowability
the calculated WFT sand the results obtained in the second and
third parts of the experimental program, the effects of packing The flowability of cement pastes and mortars was measured
density and WFT on the flowability are discussed. The dilution, with SP dosage of 1.5% by mass of cementitious materials. For
stimulation, and pozzolanic effects in hydration of blended cement cement paste, the mini slump test using the Kantro‘s cone (top
caused by illitic calcined shale are discussed to validate the com- Ø = 19 mm; bottom Ø = 38 mm and height = 57 mm) [32] having

Table 2
Mix proportion of blended cement pastes and mortars.

Samples Dosage of each ingredient (kg/m3)


OPC MI1 MI2 Fine aggregate Water SP
OPC 1243.0 – – – 602.9 18.65
0.15MI1 1044.7 184.4 – – 596.1 18.44
0.25MI1 915.0 305.0 – – 591.7 18.30
0.35MI1 787.2 423.9 – – 587.4 18.17
0.15MI2 1047.2 – 184.8 – 597.5 18.48
0.25MI2 918.5 – 306.2 – 594.0 18.37
0.35MI2 791.4 – 426.1 – 590.5 18.26
M-OPC* 520.4 – – 1561.2 250.4 7.75
M-0.15MI1 436.9 77.1 – 1541.9 249.3 7.71
M-0.25MI1 384.3 128.1 – 1537.1 248.5 7.69
M-0.35MI1 332.0 178.8 – 1532.3 247.7 7.66
M-0.15MI2 437.3 – 77.2 1543.4 249.5 7.72
M-0.25MI2 384.9 – 128.3 1539.6 248.9 7.70
M-0.35MI2 332.8 – 179.2 1535.8 248.3 7.68

* M stands for mortar with cm/FA = 1/3.


4 G. Marchetti et al. / Construction and Building Materials 254 (2020) 119042

the same proportions as the slump cone of ASTM C 143 [33] was ratio which increases with the OPC replacement and is also greater
carry out. After mixing, the paste was poured into the cone cen- for pastes with MI1.
tered on polished steel plate until it was full, the cone was gradu- For blended cement mortars (Fig. 2b), the incorporation of MI1
ally lifted and after few seconds, two orthogonal diameters of the and MI2 increased the packing density of M-OPC (0.743) for all the
paste-patty formed was measured and the flow spread was deter- replacements, reaching values of 0.749 and 0.747 for 15%, 0.753
mined as the average diameter minus the bottom-Ø cone. For mor- and 0.749 for 25% and 0.756 and 0.751 for 35% OPC replacement
tars, the flow table test specified in ASTM C 230 [34] standard was with MI1 and MI2, respectively. These increases were due to the
followed. combination of the cementitious materials used (OPC and MI1/
MI2) filling the voids between the FA particles achieving a denser
2.5. Heat of hydration, hydration compounds and pore size arrangement. The fact that the packing density of blended mortars
distribution was improved, which was not the case of packing density of
blended cement pastes, could be due that the calcined clay was
The rate of heat released during hydration of the examined added as a cement replacement by mass. As the calcined clay has
pastes (w/cm = 0.50) was measured in a conduction calorimeter a lower density, when added to replace an equal mass of cement,
under isothermal conditions at 20 °C during 48 h. To study the pro- the total volume of powder (cement plus calcined clay) was
gress of hydration and the development of pastes structure, the increased. It means it was the increased powder volume that
paste (w/cm = 0.50) of OPC, 0.25MI1 and 0.25MI2 were prepared increased the packing density of mortars.
and cured in sealed plastic bags at 20 °C for 2, 7, 28 and 90 days. The incorporation of MI1 enabled reaching higher values of
At this time, the fragments of paste samples were immersed in iso- packing density than when MI2 was incorporated; this may be
propyl alcohol, dried and ground to particle size lower than 45 mm. due to the fact that the particle size distribution of MI2 was closer
The crystalline compounds were identified by XRD on X́Pert Philips to that of the OPC, and therefore its filling effect was not as effec-
PW 3710 diffractometer (CuKa radiation at 40 kV and 20 mA). The tive as that of MI1. There was also a greater decrease in the mini-
combined TG-DSC analysis was performed on a Labsys Evo mum voids ratio for mortars with MI1.
(Setaram) apparatus from 25 °C to 1000 °C. The ground sample
was placed into an alumina crucible with a volume of 100 mm3,
the applied heating rate was 5 °C/min and the measurement was
conducted in an inert atmosphere. Pore size distribution was mea-
sured on a mercury porosimetry principle using devices Pascal 140
and Pascal 440 (Thermo Scientific) measuring the 4–100 lm and
the 3–4000 nm pore radium. Before the measurement, the samples
were dried at vacuum drier. The sample mass was ~2 g, whereas
the ungrounded specimens maintaining their unique structure
and morphology were tested.

2.6. Compressive strength

To measure the compressive strength, the standard mortars


specimens (w/cm = 0.5 by mass; cm/FA = 1/3) were cast, com-
pacted and kept in the laboratory during the first 24 h, demolded
at one day after casting, and cured in water at 20 ± 2 °C until the
age of testing. The mortar prisms (40 mm  40 mm  160 mm)
were tested at 2, 7, 28, and 90 days of maturing in accordance with
the standard EN 196-1 [29].

3. Results and discussion

3.1. Packing density and WFT

The packing density and the minimum voids ratio of the


blended cement pastes and mortars calculated by CPM are pre-
sented in Fig. 2. For blended cement pastes (Fig. 2a), it was
observed that the incorporation of MI1 or MI2 decreases the pack-
ing density of OPC paste (0.636) for all the replacements analyzed.
This may be due to the fact that these ground calcined shales had a
particle size distribution similar to OPC, so the filling effect was
slight, added to the fact that their packing densities were lower
than that of OPC (0.586 and 0.592 for MI1 and MI2, respectively).
As occur in aggregates [35], the particle shape is other parameter
that affects the packing density. Fig. 3 shows SEM micrographs
for OPC, MI and MI2 particles. OPC particles are irregularly shaped
with high angularity and chamfered edges, while MI1 and MI2 con-
tains some thin plates particles with frayed edges. The angularity
of particles may affect the frictional forces between the particles
and the aspect ratio (flakiness) of particles can reduce the packing
density. These effects can also be observed in the minimum voids Fig. 2. Packing density of blended cement: (a) pastes and (b) mortars.
G. Marchetti et al. / Construction and Building Materials 254 (2020) 119042 5

Fig. 3. SEM micrographs of OPC, MI1, and MI2 particles.

When a SCM is incorporated, it can increase not only the pack-


ing density but also increase the surface area of the solid particles,
and for the same amount of excess water, decrease the average
thickness of water that coating the particles. To take into account
these two opposite effects, the WFT of blended cement pastes
and mortars was calculated and it is presented in Fig. 4. Although
the WFT was calculated from the w/cm by volume, in Fig. 4 it is
plotted against w/cm by mass that is more commonly used.
The WFT against w/cm curves are all straight lines because the
WFT is a linear function of the w/cm. Comparing the OPC paste
with those containing illitic calcined shale (Fig. 4a), it can be seen
that the WFT decreased with the incorporation of MI1 and MI2 for
all replacements. It was because the addition of MI1 and MI2
decreased the packing density of OPC and at the same time
increased the specific surface area (622 and 507 m2/kg for MI1
and MI2, respectively). Therefore, their incorporation to fill the
gaps between the OPC cement particles was not effective.
For the cement mortars, the WFT was calculated from the w/s
by volume (w/s includes cementitious materials and fine aggre-
gate) but was also plotted against the w/cm by mass (Fig. 4b). It
is observed that the WFT ranged from 0.268 mm to 0.787 mm.
All the WFT values were negative for the w/cm of 0.4, because
the amount of water was not enough to fill the gaps between the
solid particles. For w/cm of 0.5, the M-OPC had a negative WFT,
while mortars with MI1 and MI2 had positive values for all replace-
ments. The increase in the WFT was generally larger for a low w/
cm and became smaller as the w/cm increased. This was because
the WFT was governed by both the excess water ratio and the total
surface area. The proportional increase in excess water ratio due to
the addition of illitic calcined shale was larger at a lower w/cm, but
smaller at a higher w/cm, whereas the proportional increase in
total surface area was independent on the w/cm. As can be seen,
for w/cm lower than 0.6, the addition of up to 35% of MI1 or MI2
increased the WFT with respect to the M-OPC; while for higher
w/cm, the WFT begun to decrease due to the increase in the surface
area that predominated over the increase in excess water. In gen-
eral, it was observed that the incorporation of MI1/MI2 signifi-
cantly affected the packing density, the surface area and the
WFT. Although the incorporation of MI1 or MI2 did not improve
the packing density of cement paste for any replacement, it was
improved when they are added into mortars.

3.2. Flowability

Fig. 5 shows the flowability of pastes (Fig. 5a) and mortars


(Fig. 5b) plotted against the replacement percentage of MI1/MI2.
In Fig. 5a, the flowability decreased with the increasing replace-
ment of MI1/MI2 in paste. This was in agreement with the packing
results that showed that the incorporation of MI1 and MI2 not Fig. 4. WFT plotted against w/cm by mass for: (a) pastes and (b) mortars.
6 G. Marchetti et al. / Construction and Building Materials 254 (2020) 119042

3.3. Heat of hydration, hydration compounds and pore size


distribution

Fig. 6 shows the heat release rate curve for OPC paste and
cement pastes with 15%, 25% and 35% replacement by MI1
(Fig. 6a) and MI2 (Fig. 6b).
In Fig. 6a a first stage can be observed with a high rate of heat
released due to the initial hydrolysis and the reaction of the alu-
minum phase (formation of the AFt phase). This rate decreased
with the first minimum at approximately 200 min with intensity
of 0.11, 0.28, 0.25 and 0.19 mW/g for OPC, 0.15MI1, 0.25MI1, and
0.35MI1 pastes, respectively. After the first minimum, the particu-
lar slopes were similar and the second maximum occurred at the
same time (800 min) for all pastes with intensity of 1.01, 1.21,
1.11, and 1.01 mW/g for OPC, 0.15MI1, 0.25MI1, and 0.35MI1
pastes, respectively. The third peak occurred at 1000 min for OPC

Fig. 5. Flowability of blended cements: (a) pastes and (b) mortars.

effectively filled the gaps between the OPC particles, and thus,
there was no increase in the WFT to lubricate the particles
(Fig. 4a). The flowability values were slightly lower in pastes con-
taining MI1, because it had a surface area greater than MI2. There-
fore, the WFT values of pastes with MI1 were lower than those
containing MI2. Hence, flowability decreased with the incorpora-
tion of MI1/MI2, due to the decrease in WFT values.
The flowability of mortars (Fig. 5b) containing MI1/MI2 was for
all replacements higher than the flowability of M-OPC. The incor-
poration of both illitic calcined shales improved the flowability of
M-OPC as expected, due to the increase in WFT as it can be seen
in Fig. 4b for a w/cm of 0.50. However, the increase in flowability
was reduced with the increase in the replacement percentage.
From the above, it can be concluded that the flowability in both,
pastes and mortars, is highly dependent on WFT. In other words,
the WFT is the key factor that governs the flowability. Fig. 6. Rate of heat of hydration of blended cement pastes with (a) MI1 and (b) MI2.
G. Marchetti et al. / Construction and Building Materials 254 (2020) 119042 7

paste (1.00 mW/g) and at 1000, 1025, and 1050 min for 0.15MI1
(1.24 mW/g), 0.25MI1 (1.20 mW/g), and 0.35MI1 (1.12 mW/g)
pastes, respectively. Finally, the period of deceleration of the reac-
tions took place until 48 h, at which time the test was finished.
It can be seen that due to a stimulation effect the heat release of
cement pastes with MI1 was greater than that of the OPC paste.
The highest value was recorded when the OPC replacement was
15%, and the heat release was lower as the replacement level
increased. It was also observed that the third peak was more
increased than the second peak. This increase was greater with
the increase of the replacement percentage (0.01 mW/g for
OPC, 0.03 mW/g for 0.15MI1, 0.09 mW/g for 0.25MI1, and
0.11 mW/g for 0.35MI1). This evidence could indicate a selective
stimulation of the aluminum phase.
In Fig. 6b, the first minimum had a similar occurrence time for
all pastes (200 min.) with the decreasing intensities for the
higher replacement percentages (0.22, 0.12, and 0.026 mW/g for
0.15MI2, 0.25MI2, and 0.35MI2 cement pastes, respectively). It
can be seen that the 0.15MI2 cement paste reached a higher inten-
sity than that corresponding to the OPC paste. It was due to the
stimulation effect, while for 0.25MI2 and 0.35MI2 pastes the dilu-
tion effect predominated.
The second peak occurred in all pastes with MI2 around
Fig. 7. Relative total heat released per Portland cement gram of blended cement 800 min, and its intensity decreased as the MI2 replacement
pastes at 48 h.
increased. Only the peak recorded for paste 0.15MI2 (1.17 mW/g)
exceeded the intensity of the OPC paste (1.01 mW/g). For the third
peak, the occurrence times were slightly in advance with respect to

Fig. 8. XRD patterns of cement pastes at 2, 7, 28, and 90 days.


8 G. Marchetti et al. / Construction and Building Materials 254 (2020) 119042

the OPC (1000 min), and its intensity decreased with the increasing consumed and judging by its peak intensity, the pozzolanic reac-
of cement replacement ratio; being 1.16 (1000 min), 0.87 tion of MI2 is lower than the corresponding to MI1.
(980 min), and 0.65 mW/g (965 min) for 0.15MI2, 0.25MI2, and Fig. 9 shows the differential scanning calorimetry (DSC) curve
0.35MI2 pastes, respectively. The stimulation effect was observed for hydrated cement pastes in mV at 2 (Fig. 8a), 7 (Fig. 8b), 28
for the 0.15MI2 pastes, and the dilution effect predominated in (Fig. 8c), and 90 days (Fig. 8d). These curves show three main
high replacement levels. endothermic heat flow peaks: a) from 100 °C to 250 °C the
The relative total heat released per gram of OPC at 48 h is pre- recorded peak corresponded to the free and physically bound
sented in Fig. 7. The heat released by cement pastes containing MI1 water loss and the dehydration of ettringite, C-S-H, and AFm
was always higher than that of OPC pastes and increased with the phases [36,37]; b) from 410 °C to 520 °C the decomposition of cal-
replacement percentage. The total heat released by 0.15MI2 and cium hydroxide took place and c) from 650 °C to 800 °C the decom-
0.25MI2 cement pastes exceed heat released by OPC paste, while position of calcite (CaCO3) [36,38] and carbonated C-S-H [39] was
the relative total heat released for 0.35MI2 was lower. observed. Table 3 reports the relative mass changes obtained by
Fig. 8 shows the XRD patterns for OPC and blended cement thermogravimetric analysis for the analyzed temperature range.
pastes with 25% replacement from 2 to 90 days. The OPC paste The mass loss at the temperature range 100–250 °C increased
showed ettringite (E) and calcium hydroxide (CH) as hydration with the age for all samples. For OPC, it was always greater than
compounds at 2 days, accompanied with calcite (CC) and un- that corresponding to blended cements, but the relative proportion
hydrated phases (C4AF and C2S) from cement. For blended of mass loss decreased with the progress of hydration which indi-
cements, the hydrated products (E and CH) and unhydrated com- cated the contribution of cement compounds derivate from the
pounds were the same as OPC; with additional quartz (Q) from cal- pozzolanic reaction.
cined shale. The AFm (hemicarboaluminate - Hc) was detected for The mass loss attributed to CH decomposition (410–520 °C)
all cements at 7 days. For blended cements with MI1, the intensity increased for all samples up to 28 days, and decreased at 90 days
of CH peaks decreased at 28 days; but it had high intensity for for MI1 and MI2 samples. This revealed that the pozzolanic reac-
blended cement with MI2. The AFm transformation begun and tion of illitic calcined clays consumed some part of CH at later ages.
the monocarboaluminate (Mc) coexisted with Hc. Later, the Mc The CH-reduction was more significant for MI1 blended cements
was the predominant AFm phase. At 90 days, the CH was partly than for those with the same replacement of MI2. However, the

Fig. 9. Differential scanning calorimetry (DSC) of cement pastes at 2, 7, 28, and 90 days.
G. Marchetti et al. / Construction and Building Materials 254 (2020) 119042 9

Table 3
Mass loss (%) at selected temperature range observed for OPC, MI1, and MI2 pastes.

Sample Temperature range Age (days)


2 7 28 90
OPC 100–250 °C 2.40 2.72 3.52 6.64
410–520 °C 4.21 4.27 5.17 6.17
650–800 °C 1.92 1.87 1.27 2.22
0.25MI1 100–250 °C 2.29 2.66 3.37 5.69
410–520 °C 2.22 3.07 3.99 3.22
650–800 °C 1.64 1.82 2.22 2.31
0.25MI2 100–250 °C 2.26 2.29 3.18 5.23
410–520 °C 3.26 3.54 4.22 3.97
650–800 °C 1.52 1.86 1.95 2.29

CH-content was always lower than that obtained from OPC which was approximately 1.6% at 2 days. Then it has increased with the
was due to the dilution effect. hydration time and reached approximately 2.0% at 28 days
The carbonation of C-S-H led to the formation of vaterite, which (Table 3).
seems to be an unstable type of calcium carbonate which decom- Fig. 10 shows the cumulative and volumetric pore size distribu-
poses typically between 500 °C and 700 °C, at a lower temperature tion measured for pastes at 2, 7, 28, and 90 days. The relative vol-
than calcite [40]. The temperature range of the corresponding ume of pores for selected ranges of pore diameter is also shown in
decompositions was difficult to determine because the peaks were this figure. At all investigated ages, the 0.25MI1 and 0.25MI2
overlapping. The peak temperature of the vaterite decomposition pastes had a higher value of the total cumulative pore volume than
was visible for samples analyzed at 7 and 28 days of ageing and those of OPC. Moreover, the threshold pore diameter was reduced
it was located approximately at 700 °C and 690 °C, respectively. for all samples with the increase of age, as expected.
The peak temperature of the calcite decomposition was between At 2 days (Fig. 10a), the critical pore diameter (the pore size
780 °C (for 2-days samples) and 730 °C (for 28-days samples). with the highest frequency in the incremental volume curve) was
These reactions were accompanied by a significant mass loss which approximately 0.5 lm. At 7 days (Fig. 10b), the critical pore size

Fig. 10. Relative volume of pores by d.


10 G. Marchetti et al. / Construction and Building Materials 254 (2020) 119042

for 0.25MI1 and 0.25MI2 (~0.2 lm) was higher than that corre-
sponding to OPC (~0.06 lm); it was assigned to the prevailing dilu-
tion effect. At 28 and 90 days (Fig. 10c and d), the similar critical
pore size was monitored for all pastes (~0.06 lm) and it was also
observed an increase in the pore volume of small size (~0.01 lm)
for 0.25MI1 and 0.25MI2 paste indicating the pozzolanic effect of
illitic calcined shale.
In details of Fig. 10, the relative volume of pores size range is
reported. For macropores (100–1 lm), its volume was approxi-
mately constant at all ages. The volume of capillary pores ranged
from 1 to 0.1 lm was considerably reduced with the age of the
paste. Comparing the OPC and blended cements pastes, the dilu-
tion effect of calcined shale replacement caused a large volume
of capillary pores at early ages. The progress of pozzolanic reaction
led to the increased volume of finer pores (0.1–0.01 lm) attaining
to the volume larger than the corresponding to OPC at 7 days. From
28 to 90 days, the volume of very fine pores (0.001–0.01 lm) was
also increased for both blended cements.

3.4. Compressive strength

Fig. 11 shows the mortar compressive strength for MI1


(Fig. 11a) and MI2 (Fig. 11b) blended cements. In Fig. 11a, the com-
pressive strength of mortars containing MI1 at 2 days was 13.8,
11.2, and 9.1 MPa for 15, 25, and 35% replacements, and the OPC
mortar reached the compressive strength value of 17.7 MPa. At
7 days, the compressive strength of mortars with MI1 was lower
than that of M-OPC (35.8 MPa), and at 28 days, mortar M-
0.15MI1 (49.2 MPa) exceeded the strength of control mortar M-
OPC (46.6 MPa); while M-0.25MI1 and M-0.35MI1 reached the
compressive strength values of 44.9 and 40.9 MPa, respectively.
At 90 days, all mortars with MI1 exceed the strength of M-OPC
(53.7 MPa), reaching the highest value of 58.5 MPa for M-
0.15MI1 mortar.
This finding is highly promising for the use of this type of cal-
cined shale as SCM because most of the calcined clay such as cera-
mic dust are applicable in the lower amounts, typically in the range
10–20% of OPC mass taking into consideration particle size and
character of minerals forming the clay silicates [41].
At early ages (2 and 7 days), the compressive strength of mor-
tars with MI1 was lower than that of corresponding to control
mix M-OPC. It was owing to the dilution effect that was predomi-
nant due to the increase in the effective w/c, while from 28 days
samples the pozzolanic activity of the illitic calcined shale begun
to reveal resulting in the compressive strength of M-0.15MI1 mor-
tar higher than that of M-OPC. In this way, the reactivity of studied
shales in the presence of Portland cement hydrates was clearly
proven.
Fig. 11. Compressive strength of mortars with calcined shale: a) MI1 and b) MI2.
Mortars with MI2 (Fig. 11b) had lower compressive strength for
all replacements than those of M-OPC up to 28 days. At 90 days,
only mortar M-0.15MI2 exceeded the compressive strength of M-
OPC with a value of 55.6 MPa, and M-0.25MI2 reached a value sim- is ~1450 °C, which is much higher than that of calcined clays.
ilar to that corresponding to M-OPC. Therefore, a decrease in both CO2 production and energy consump-
In summary, due to the dilution effect the strength was lower as tion with the increasing dosage of calcined clays in cement blends
the replacement percentage increased. The lowest compressive can be anticipated. Based on the calcination technology, there are
strength was obtained for M-0.35MI2 which reached the lowest differences in CO2 emissions basically linked with the energy effi-
values at all studied ages, without exceeding the compressive ciency of the used kiln. Díaz et al. [42] reported on energy con-
strength of control mortar M-OPC. sumption and CO2 emissions of various calcination technologies.
The energy consumed for the production calcined clay varied from
3.5. Eco-efficiency of illitic blended cement 4223 MJ/t to 2734 MJ/t with the CO2 emissions in the range of 393–
196 kg/t. For these studied shales, the data of industrial pilot trials
The use of illitic clays calcined at 950 °C as partial Portland indicated an energy consumption of 2900–2750 MJ/t during calci-
cement substitute represents eco-efficient ‘‘green solution” for nation and the CO2 emission of 240–260 kg/t. On the other hand,
production of cement-based composites with reduced energy and the energy composition and CO2 emissions coming from OPC man-
carbon footprint. The clinkering temperature of Portland cement ufacturing are much higher (3230 MJ and 980 kg CO2eq/t) [43].
G. Marchetti et al. / Construction and Building Materials 254 (2020) 119042 11

Specific thermal energy demand for production of Portland clinker Declaration of Competing Interest
is also dependent on the applied production technology, i.e., dry
process, multi-stage cyclone preheater and pre-calcining kilns, The authors declare that they have no known competing finan-
semi-dry/semi-wet processes, dry process with long kilns, dry pro- cial interests or personal relationships that could have appeared
cess rotary kilns equipped with cyclone preheaters, etc. For exam- to influence the work reported in this paper.
ple specific thermal energy demand for production of 1 t of
Portland clinker in dry process rotary kilns varies from 3100 MJ
to 4200 MJ [44]. Energy demand for clinkering using semi-dry Acknowledgments
techniques varies from 3300 MJ to 5400 MJ [45]. So, the energy
savings by any partial cement replacement are quite apparent The authors gratefully acknowledge the financial support
and help ensure the sustainability of the concrete production with received from CICPBA-CONICET under project PIO 004 and from
equivalent engineering properties at later ages [47]. the Czech Science Foundation, under project No 18-18-07332S –
Properties, durability, and performance of lightweight mortars
with mineral admixtures.
4. Conclusions
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