Alkaline Activation of Binders: A Comparative Study.

Binders formulated with activated alkali materials to replace Portland cement, which has high polluting potential due to CO2 emissions in its manufacture, have increasingly been developed. The objective of this study is to evaluate the main properties of activated alkali materials (AAM) produced by blast furnace slag, fly ash, and metakaolin. Initially, binders were characterized by their chemical, mineralogical and granulometric composition. Later, specimens were produced, with molarity variation between 4.00 and 5.50, using the binders involved in the research. In preparing the activating solution, sodium hydroxide and silicate were used. The evaluated properties of AAM were consistency, viscosity, water absorption, density, compressive strength (7 days of cure), calorimetry, mineralogical analysis by X-ray diffraction, and morphological analysis by scanning electron microscopy. The results of evaluation in the fresh state demonstrate that metakaolin has the lowest workability indices of the studied AAM. The results observed in the hardened state indicate that the metakaolin activation process is optimized with normal cure and molarity of 4.0 and 4.5 mol/L, obtaining compressive strength results after 7 days of curing of approximately 30 MPa. The fly ash activation process is the least intense among the evaluated binders. This can be seen from the absence of phases formed in the XRD in the compositions containing fly ash as binder. Unlike blast furnace slag and metakaolin, the formation of sodalite, faujasite or tobermorite is not observed. Finally, the blast furnace slag displays more intense reactivity during thermal curing, obtaining compressive strength results after 7 days of curing of around 25 MPa. This is because the material's reaction kinetics are low but can be increased in an alkaline environment, and by the effect of temperature. From these results, it is concluded that each precursor has its own activation mechanism, observed by the techniques used in this research. From the results obtained in this study, it is expected that the alkaline activation process of the types of binders evaluated herein will become a viable alternative for replacing Portland cement, thus contributing to cement technology and other cementitious materials.

Characterization and photocatalytic performance of cement mortars with incorporation of TiO2 and mineral admixtures.

As the main components of the building envelope, construction materials have a straight relation with air contaminants from anthropogenic origins. Titanium dioxide has been recently applied in construction industry products since its photocatalytic properties can be used for pollutant degradation purposes. This study evaluated the performance of cement-based mortars with the incorporation of TiO2 nanoparticles and mineral admixtures. Six mortar compositions were defined by considering two reference mixes (with and without TiO2 incorporation), two mineral admixtures (bentonite and metakaolin) as partial cement replacement and one waste from ornamental stone processing in two levels of partial substitution of natural sand. Consistency index, density, and entrained air content of mixtures were investigated at fresh state. Compressive strength, water absorption, sorptivity, and micrographs from scanning electron microscopy were used to characterize mortars at hardened state. It was observed that incorporation of TiO2 does not considerably change mortar's properties at fresh and hardened state, despite a denser microstructure and improved interfacial transition zone. In general, the relation between the water-to-cement ratio and porosity on the performances of TiO2-added mortars was shown, which is strongly related to their photocatalytic efficiency. Metakaolin mixtures were more efficient to NO conversion, and high selectivity was observed for the bentonite mortars.

Methods for Evaluating Pozzolanic Reactivity in Calcined Clays: A Review.

The search for alternative materials to replace ordinary Portland cement has been the object of work that enhances the investigation of the use of pozzolanic materials and the reduction of the carbon footprint with supplementary cementitious materials. However, not all materials are available to meet the large-scale demand for cement replacement. A relevant exception is the calcined clay, a material found worldwide that, when subjected to appropriate heat treatment, presents pozzolanic reactivity and can be used as a supplementary material to cement. This review presents, through a systematic search, methods for measuring the pozzolanic reactivity of calcined clays, namely, direct, indirect, qualitative, quantitative, chemical and physical methods such as electrical conductivity (Lùxan), the force activity index, the modified Chapelle, R3, Frattini test, thermal analysis, X-ray diffraction and X-ray fluorescence spectrometry. The most usual methods to assess the pozzolanic reactivity of calcined clays were exposed and analyzed. It should be pointed out that there is greater use of the Frattini and modified Chapelle methods as well as the analysis of the mechanical strength behavior of the material in cementitious matrices. X-ray diffraction and thermal analysis were exposed as the most used correlation methods but it was also concluded that different tests are needed to generate accurate results.

Comparison of the Permeability of Potential Ballast Rocks from Northern Rio de Janeiro State under Different Fouling Rates after Sodium Sulfate Attack.

This paper aimed to analyze the reduction in the ballast layer permeability simulated in a laboratory in saturated conditions by the presence of rock dust as a contaminant of three types of rocks explored in different deposits in the northern region of the state of Rio de Janeiro, Brazil, through laboratory testing relating the physical properties of rock particles before and after sodium sulfate attack. Sodium sulfate attack is justified by the proximity of some sections of the planned EF-118 Vitória-Rio railway line to the coast and of the sulfated water table to the ballast bed, which could degrade the material used and compromise the railway track. Granulometry and permeability tests were performed to compare ballast samples with fouling rates of 0, 10, 20, and 40% rock dust by volume. A constant head permeameter was used to analyze hydraulic conductivity and establish correlations between the petrography and mercury intrusion porosimetry of the rocks, namely two types of metagranite (Mg1 and Mg3) and a gneisse (Gn2). Rocks, such as Mg1 and Mg3, with a larger composition of minerals susceptible to weathering according to petrography analyses, tend to be more sensitive to weathering tests. This, in conjunction with the climate in the region studied, with average annual temperature and rainfall of 27 °C and 1200 mm, could compromise track safety and user comfort. Additionally, the Mg1 and Mg3 samples showed greater percentage variation in wear after the Micro-Deval test, which could damage the ballast due to the considerable changeability of the material. The mass loss caused by abrasion due to the passage of rail vehicles was assessed by the Micro-Deval test, with Mg3 (intact rock) declining from 8.50 ± 1.5 to 11.04 ± 0.5% after chemical attack. However, Gn2, which exhibited the greatest mass loss among the samples, showed no significant variation in average wear, and its mineralogical characteristics remained almost unchanged after 60 sodium sulfate cycles. These aspects, combined with its satisfactory hydraulic conductivity rate, indicate that Gn2 is suitable for use as railway ballast in the EF-118 railway line.

Mechanical Feasibility Study of Pressed and Burned Red Ceramic Blocks as Structural and Sealing Masonry.

In the search for better constructive efficiency and a reduction of the waste of construction materials, several researches have been performed in the last years around the world. Red ceramic blocks are artifacts widely used in civil construction around the world, and they result in a great consumption of raw materials and energy. The great innovation of this research was the development of ceramic blocks through an innovative method of pressing and dosing materials, replacing the traditional stage of extrusion in the manufacture of ceramics. In such a sense, a new manufacturing technology for ceramic blocks was proposed through the pressing process, adapting the soil-cement brick press machine, thus attaining more even pieces with greater compliance to the dimensions and preset geometry. In this work, the physical and mechanical features of the pressed and burned blocks (PBB) are produced in a partnership with Arte Cerâmica Sardinha, a traditional ceramic industry in the region of Campos dos Goytacazes, RJ, Brazil. It was sought to set the quality parameters for the blocks, to set their mechanical compressive strength, deformation modules and the Poisson coefficient. The blocks were tested in use by means of three layers of prism and small wall samples, and it was checked the fragile-type failure of the PBB. Results indicate that the blocks can be employed in small-sized construction works, as the characteristic compressive strength to block measured was 3.62 N/mm2 for average water absorption of 20.84%.

Eco-friendly ceramic bricks: a comparative study of life cycle impact methods.

The growing need for natural resources for the production of inputs for construction, such as ceramic bricks, as well as the high rates of solid waste generation in the sector, makes construction an industrial segment with unfavorable environmental effects. The Life Cycle Assessment (LCA) emerges as a tool capable of assisting in the quantification and analysis of the impacts associated with construction materials, whether traditional or alternative. Thus, the goal of this paper is to assess the environmental impacts associated with the development of alternative building materials. To compare the conventional and the alternative bricks, both were evaluated according to the LCIA methods Ecoindicator 99, IMPACT 2002+, and ReCiPe 2016, in the midpoint and endpoint levels. The sensitivity analysis was carried out considering as an alternative input for the firing process, a mixture composed of wood and biomass originating from the Pennisetum purpureum. According to Ecoindicator 99 method, the categories respiratory organics, fossil fuels, and radiation stand out, which showed greater sensitivity in altering the input used in the firing process, reducing their impacts by 38.38%, 34.68%, and 31.81%, respectively, when comparing product III (ceramic brick incorporated with OSPW and submitted to the firing process with the mix of wood and Pennisetum purpureum) and product I (ceramic brick incorporated with OSPW and submitted to the traditional firing process). In addition, in the respiratory organics category, the IMPACT 2002+ method showed a reduction of approximately 43% of the impacts associated with product III, when compared to the product with the greatest impact in this category. In a global analysis of the results presented by the ReCiPe 2016 method, the product III had the lowest associated environmental impact when compared to the other evaluated systems.

Technological Characterization of PET-Polyethylene Terephthalate-Added Soil-Cement Bricks.

The ever-growing consumption and improper disposal of non-biodegradable plastic wastes is bringing worrisome perspectives on the lack of suitable environmentally correct solutions. Consequently, an increasing interest in the circular economy and sustainable techniques is being raised regarding the management of these wastes. The present work proposes an eco-friendly solution for the huge amount of discarded polyethylene terephthalate (PET) wastes by addition into soil-cement bricks. Room temperature molded 300 × 150 × 70 mm bricks were fabricated with mixtures of clay soil and ordinary Portland cement added with up to 30 wt.% of PET waste particles. Granulometric analysis of soil indicated it as sandy and adequate for brick fabrication. As for the PET particles, they can be considered non-plastic and sandy. The Atterberg consistency limits indicated that addition of 20 wt.% PET waste gives the highest plasticity limit of 17.3%; moreover, with PET waste addition there was an increase in the optimum moisture content for the compaction and decrease in specific weight. Standard tests showed an increase in compressive strength from 0.83 MPa for the plain soil-cement to 1.80 MPa for the 20 wt.% PET-added bricks. As for water absorption, all bricks displayed values between 15% and 16% that attended the standards and might be considered an alternative for non-structural applications, such as wall closures in building construction.

Characterizing the paper industry sludge for environmentally-safe disposal.

The world paper industry produces a great amount of industrial solid waste that undergoes a treatment process that can be either primary, secondary, or tertiary, in order to adapt the waste for correct disposal. The paper manufacturing industries search for the best way to dispose of their wastes, generally in landfills, but there are few studies proving the effectiveness of such measure from the environmental, technological and economic points of view. Knowing the characteristics of this waste and understanding the treatment process it is submitted to are fundamental issues to manage it and comply with environmental demands. The purpose of this paper is to perform a chemical, mineralogical, thermal, morphological, physical and environmental characterization of the paper and pulp industry wastes, in order to assess alternatives for their adequate disposal, such as controlled landfills, sanitation, incineration, and sea dumping. It was observed that the material presents physical, chemical, and morphological features that indicate the possibility of reusing it in other production chains, such as the ceramic industry, besides being classified as non-hazardous wastes. Furthermore, disposal in sanitary landfills presents advantages in environmental and technological terms.

Effect of Granite Residue Incorporation on the Behavior of Mortars.

Civil construction is one of the most resource-consuming sectors in the world. For this reason, the last years have witnessed the study of reusing industrial residues in building materials. The ornamental stone processing industry has a considerable environmental liability related to residue generation during the cutting stages of granite blocks. The objective of this work is to analyze the viability of incorporating granite residues, up to 100%, to substitute sand in coating mortars for building construction. Mortars without residue, as control, and incorporated with 20, 40, 60, 80, and 100% of granite residue were subjected to consistency tests, incorporated air and water retention together with the rheological characterization using the squeeze-flow and the dropping-ball methods. The results show that mortars with 40% granite residues presented greater plastic deformation, helping their applicability by also presenting improved technological properties in the fresh state.