The pore structure and water absorption in Portland/slag blended hardened cement paste determined by synchrotron X-ray microtomography and neutron radiography.

The pore structures of hardened Portland/slag cement pastes (>75 wt% slag content), and the initial capillary absorption of moisture through these pores, were monitored using ex situ synchrotron X-ray computerised microtomography and in situ quantitative neutron radiography. The pore structure becomes more constricted as the cement hydrates and its microstructure develops. This mechanism was effective even at a slag content as high as 90 wt% in the cementitious blend, where the lowest total porosity and a significant pore refinement were identified at extended curing ages (360 d). By combining this information with neutron radiographic imaging, and directly quantifying both depth and mass of water uptake, it was observed that 90 wt% slag cement outperformed the 75 wt% slag blend at 90 days in terms of resistance to capillary water uptake, although the higher-slag blend had not yet developed such a refined microstructure at 28 days of curing. The assumptions associated with the "sharp front model" for water ingress do not hold true for highly substituted slag cement pastes. Testing transport properties at 28 days may not give a true indication of the performance of these materials in service in the long term.

Thermodynamic modelling of cements clinkering process as a tool for optimising the proportioning of raw meals containing alternative materials.

The valorisation of waste or by-products in Portland clinker production is a promising alternative for developing sustainable cements. The complexity of the chemical reactions during clinkering demands an adequate dosing method that considers the effect of feedstock impurities to maximise the potential substitution of natural resources by waste or by-products, while guaranteeing the clinker reactivity requirements. This study proposes a raw meal proportioning methodology for optimising co-processing of natural feedstocks with alternative raw materials in clinker production, intending to reduce the content of natural raw materials needed, while promoting an optimal clinker reactivity. A thermodynamic modelling sequence was developed considering the variability of raw materials composition and heating temperatures. The model was then validated by comparing simulation outcomes with results reported in previous studies. An experimental case study was conducted for validation of the proposed method using a spent fluid catalytic cracking catalyst (SFCC), a by-product from the oil industry as an alternative alumina source during clinkering. The modelling simulations indicated that substitution of natural feedstocks by 15 wt% SFCC promotes the formation of reactive clinkers with more than 54% tricalcium silicate (C3S). Mixes with the potential to form the highest C3S were then produced, and heating microscopy fusibility testing was applied for evaluating the clinkers' stability. The main factors governing the reactivity and stability of the clinker phases were the melt phase content, alumina modulus, and formation of C3S and dicalcium silicate (C2S). The self-pulverisation of clinker during cooling was observed in selected mixes, and it is potentially associated with high viscosity and low Fe content in the melt phase. The proposed framework enables optimisation of the dosing of raw meals containing alternative alumina-rich feedstocks for clinker production and allows a deeper interpretation of limited sets of empirical data.

Characterization of and Structural Insight into Struvite-K, MgKPO4·6H2O, an Analogue of Struvite.

Struvite-K (MgKPO4·6H2O) is a magnesium potassium phosphate mineral with naturally cementitious properties, which is finding increasing usage as an inorganic cement for niche applications including nuclear waste management and rapid road repair. Struvite-K is also of interest in sustainable phosphate recovery from wastewater and, as such, a detailed knowledge of the crystal chemistry and high-temperature behavior is required to support further laboratory investigations and industrial applications. In this study, the local chemical environments of synthetic struvite-K were investigated using high-field solid-state 25Mg and 39K MAS NMR techniques, alongside 31P MAS NMR and thermal analysis. A single resonance was present in each of the 25Mg and 39K MAS NMR spectra, reported here for the first time alongside the experimental and calculated isotropic chemical shifts, which were comparable to the available data for isostructural struvite (MgNH4PO4·6H2O). An in situ high-temperature XRD analysis of struvite-K revealed the presence of a crystalline-amorphous-crystalline transition that occurred between 30 and 350 °C, following the single dehydration step of struvite-K. Between 50 and 300 °C, struvite-K dehydration yielded a transient disordered (amorphous) phase identified here for the first time, denoted δ-MgKPO4. At 350 °C, recrystallization was observed, yielding ß-MgKPO4, commensurate with an endothermic DTA event. A subsequent phase transition to γ-MgKPO4 was observed on further heating, which reversed on cooling, resulting in the α-MgKPO4 structure stabilized at room temperature. This behavior was dissimilar from that of struvite exposed to high temperature, where NH4 liberation occurs at temperatures >50 °C, indicating that struvite-K could potentially withstand high temperatures via a transition to MgKPO4.

Incorporation of strontium and calcium in geopolymer gels.

Radioactive waste streams containing 90Sr, from nuclear power generation and environmental cleanup operations, are often immobilised in cements to limit radionuclide leaching. Due to poor compatibility of certain wastes with Portland cement, alternatives such as alkali aluminosilicate 'geopolymers' are being investigated. Here, we show that the disordered geopolymers ((N,K)-A-S-H gels) formed by alkali-activation of metakaolin can readily accommodate the alkaline earth cations Sr2+ and Ca2+ into their aluminosilicate framework structure. The main reaction product identified in gels cured at both 20 °C and 80 °C is a fully polymerised Al-rich (N,K)-A-S-H gel comprising Al and Si in tetrahedral coordination, with Si in Q4(4Al) and Q4(3Al) sites, and Na+ and K+ balancing the negative charge resulting from Al3+ in tetrahedral coordination. Faujasite-Na and partially Sr-substituted zeolite Na-A form within the gels cured at 80 °C. Incorporation of Sr2+ or Ca2+ displaces some Na+ and K+ from the charge-balancing sites, with a slight decrease in the Si/Al ratio of the (N,K)-A-S-H gel. Ca2+ and Sr2+ induce essentially the same structural changes in the gels. This is important for understanding the mechanism of incorporation of Sr2+ and Ca2+ in geopolymer cements, and suggests that geopolymer gels are excellent candidates for immobilisation of radioactive waste containing 90Sr.

Alkali aluminosilicate geopolymers as binders to encapsulate strontium-selective titanate ion-exchangers.

Alkali-activated metakaolin geopolymers are attracting interest in the conditioning of nuclear wastes, especially for their ability to immobilise cationic species. However, there is limited understanding of the chemical interactions between the encapsulated spent ion-exchangers, used for decontaminating waste water, and the host aluminosilicate matrix. The lack of such understanding makes it difficult to predict the long-term stability of the waste form. In this study, the suitability of using metakaolin based geopolymer as a matrix for encapsulation of titanate-type ion-exchangers loaded with non-radioactive Sr was investigated for the first time, via spectroscopic and microstructural inspection of the encapsulated ion-exchangers and the aluminosilicate gel matrix. The microstructural and chemical properties of metakaolin geopolymers remained stable after encapsulating titanate type spent ion-exchangers, performed desirably as host materials for conditioning of Sr-loaded titanate ion-exchangers.

Exploiting in-situ solid-state NMR spectroscopy to probe the early stages of hydration of calcium aluminate cement.

We report a high-field in-situ solid-state NMR study of the hydration of CaAl2O4 (the most important hydraulic phase in calcium aluminate cement), based on time-resolved measurements of solid-state 27Al NMR spectra during the early stages of the reaction. A variant of the CLASSIC NMR methodology, involving alternate recording of direct-excitation and MQMAS 27Al NMR spectra, was used to monitor the 27Al species present in both the solid and liquid phases as a function of time. Our results provide quantitative information on the changes in the relative amounts of 27Al sites with tetrahedral coordination (the anhydrous reactant phase) and octahedral coordination (the hydrated product phases) as a function of time, and reveal significantly different kinetic and mechanistic behaviour of the hydration reaction at the different temperatures (20 °C and 60 °C) studied.

Influence of slag composition on the stability of steel in alkali-activated cementitious materials.

Among the minor elements found in metallurgical slags, sulfur and manganese can potentially influence the corrosion process of steel embedded in alkali-activated slag cements, as both are redox-sensitive. Particularly, it is possible that these could significantly influence the corrosion process of the steel. Two types of alkali-activated slag mortars were prepared in this study: 100% blast furnace slag and a modified slag blend (90% blast furnace slag + 10% silicomanganese slag), both activated with sodium silicate. These mortars were designed with the aim of determining the influence of varying the redox potential on the stability of steel passivation under exposure to alkaline and alkaline chloride-rich solutions. Both types of mortars presented highly negative corrosion potentials and high current density values in the presence of chloride. The steel bars extracted from mortar samples after exposure do not show evident pits or corrosion product layers, indicating that the presence of sulfides reduces the redox potential of the pore solution of slag mortars, but enables the steel to remain in an apparently passive state. The presence of a high amount of MnO in the slag does not significantly affect the corrosion process of steel under the conditions tested. Mass transport through the mortar to the metal is impeded with increasing exposure time; this is associated with refinement of the pore network as the slag continued to react while the samples were immersed.

Blast furnace slag-Mg(OH)2 cements activated by sodium carbonate.

The structural evolution of a sodium carbonate activated slag cement blended with varying quantities of Mg(OH)2 was assessed. The main reaction products of these blended cements were a calcium-sodium aluminosilicate hydrate type gel, an Mg-Al layered double hydroxide with a hydrotalcite type structure, calcite, and a hydrous calcium aluminate phase (tentatively identified as a carbonate-containing AFm structure), in proportions which varied with Na2O/slag ratios. Particles of Mg(OH)2 do not chemically react within these cements. Instead, Mg(OH)2 acts as a filler accelerating the hardening of sodium carbonate activated slags. Although increased Mg(OH)2 replacement reduced the compressive strength of these cements, pastes with 50 wt% Mg(OH)2 still reached strengths of ∼21 MPa. The chemical and mechanical characteristics of sodium carbonate activated slag/Mg(OH)2 cements makes them a potentially suitable matrix for encapsulation of high loadings of Mg(OH)2-bearing wastes such as Magnox sludge.

Reproducible mini-slump test procedure for measuring the yield stress of cementitious pastes.

The mini-slump test is a fast, inexpensive and widely adopted method for evaluating the workability of fresh cementitious pastes. However, this method lacks a standardised procedure for its experimental implementation, which is crucial to guarantee reproducibility and reliability of the test results. This study investigates and proposes a guideline procedure for mini-slump testing, focusing on the influence of key experimental (mixing and testing) parameters on the statistical performance of the results. The importance of preparation of always testing at the same time after mixing, testing each batch once rather than conducting multiple tests on a single batch of material, is highlighted. A set of alkali-activated fly ash-slag pastes, spanning from 1 to 75 Pa yield stresses, were used to validate the test method, by comparison of calculated yield stresses with the results obtained using a conventional vane viscometer. The proposed experimental procedure for mini-slump testing produces highly reproducible results, and the yield stress calculated from mini-slump values correlate very well with those measured by viscometer, in the case of fresh paste of pure shear flow. Mini-slump testing is a reliable method that can be utilised for the assessment of workability of cements.

Chloride binding and mobility in sodium carbonate-activated slag pastes and mortars.

This study evaluates the chloride binding capacity and the migration of chloride in sodium carbonate-activated slag cements and mortars. The effect on chloride mobility and binding of adding a calcined layered double hydroxide (CLDH) to the binder mix was also assessed. Significantly improved durability characteristics can be achieved for sodium carbonate-activated slag mortars by the addition of small fractions of CLDH, as a consequence of a higher degree of reaction, higher chloride binding capacity, and the refined pore structures present in these modified materials, in comparison with alkali-activated cements produced without CLDH. The addition of CLDH enables the production of sodium carbonate-activated slag cements with notably reduced chloride ingress compared to silicate activated slag cements.

Structure and properties of binder gels formed in the system Mg(OH)2-SiO2-H2O for immobilisation of Magnox sludge.

A cementitious system for the immobilisation of magnesium rich Magnox sludge was produced by blending an Mg(OH)2 slurry with silica fume and an inorganic phosphate dispersant. The Mg(OH)2 was fully consumed after 28 days of curing, producing a disordered magnesium silicate hydrate (M-S-H) with cementitious properties. The structural characterisation of this M-S-H phase by (29)Si and (25)Mg MAS NMR showed clearly that it has strong nanostructural similarities to a disordered form of lizardite, and does not take on the talc-like structure as has been proposed in the past for M-S-H gels. The addition of sodium hexametaphosphate (NaPO3)6 as a dispersant enabled the material to be produced at a much lower water/solids ratio, while still maintaining the fluidity which is essential in practical applications, and producing a solid monolith. Significant retardation of M-S-H formation was observed with larger additions of phosphate, however the use of 1 wt% (NaPO3)6 was beneficial in increasing fluidity without a deleterious effect on M-S-H formation. This work has demonstrated the feasibility of using M-S-H as binder to structurally immobilise Magnox sludge, enabling the conversion of a waste into a cementitious binder with potentially very high waste loadings, and providing the first detailed nanostructural description of the material thus formed.

Generalized structural description of calcium-sodium aluminosilicate hydrate gels: the cross-linked substituted tobermorite model.

Structural models for the primary strength and durability-giving reaction product in modern cements, a calcium (alumino)silicate hydrate gel, have previously been based solely on non-cross-linked tobermorite structures. However, recent experimental studies of laboratory-synthesized and alkali-activated slag (AAS) binders have indicated that the calcium-sodium aluminosilicate hydrate [C-(N)-A-S-H] gel formed in these systems can be significantly cross-linked. Here, we propose a model that describes the C-(N)-A-S-H gel as a mixture of cross-linked and non-cross-linked tobermorite-based structures (the cross-linked substituted tobermorite model, CSTM), which can more appropriately describe the spectroscopic and density information available for this material. Analysis of the phase assemblage and Al coordination environments of AAS binders shows that it is not possible to fully account for the chemistry of AAS by use of the assumption that all of the tetrahedral Al is present in a tobermorite-type C-(N)-A-S-H gel, due to the structural constraints of the gel. Application of the CSTM can for the first time reconcile this information, indicating the presence of an additional activation product that contains highly connected four-coordinated silicate and aluminate species. The CSTM therefore provides a more advanced description of the chemistry and structure of calcium-sodium aluminosilicate gel structures than that previously established in the literature.

High-resolution nanoprobe X-ray fluorescence characterization of heterogeneous calcium and heavy metal distributions in alkali-activated fly ash.

The nanoscale distribution of elements within fly ash and the aluminosilicate gel products of its alkaline activation ("fly ash geopolymers") are analyzed by means of synchrotron X-ray fluorescence using a hard X-ray Nanoprobe instrument. The distribution of calcium within a hydroxide-activated (fly ash/KOH solution) geopolymer gel is seen to be highly heterogeneous, with these data providing for the first time direct evidence of the formation of discrete high-calcium particles within the binder structure of a geopolymer synthesized from a low-calcium (<2 wt % as oxides) fly ash. The silicate-activated (fly ash/potassium silicate solution) sample, by contrast, shows a much more homogeneous geopolymer gel binder structure surrounding the unreacted fly ash particles. This has important implications for the understanding of calcium chemistry within aluminosilicate geopolymer gel phases. Additionally, chromium and iron are seen to be very closely correlated within the structures of both fly ash and the geopolymer product and remain within the regions of the geopolymer which can be identified as unreacted fly ash particles. Given that the potential for chromium release has been one of the queries surrounding the widespread utilization of construction materials derived from fly ash, the observation that this element appears to be localized within the fly ash rather than dispersed throughout the gel binder indicates that it is unlikely to be released problematically into the environment.