Utilizing of waste ceramic powders as filler material in self-consolidating concrete
Introduction
Some of the concrete types need high amounts of cement and consequently several disadvantages can be encountered such as potential of high hydration heat, risk of quick setting, shrinkage and high cost etc. In addition to that one of the big problems of cement production is high carbon emission during raw material procurement and production of cement [1], [2]. Recently, various studies have been performed in different laboratories in an attempt to find alternative raw materials can be used instead of cement. Use of some natural and/or artificial pozzolans and minerals such as fly ash [3], [4], [5], [6], [7], ground granulated blast furnace slag [8], [9], [10], [11], [12], [13], [14], silica fume [15], [16], [17], [18], [19], [20], [21], [22], [23], calcite [8], [24], [25], metakaolin [26], [27], [28], [29], [30], diatomite [31], [32], [33], [34], zeolite [35], brick powder [36], [37], [38], and waste marble dust [39], [40], [41], [42] are widely evaluated for use them in the production of different types of concretes.
Self-consolidating concretes (SCCs), one of the most popular concrete types, have high durability performance and fresh state characteristics of SCCs are not available in traditional concretes. In addition to their systematic mix proportion, filler materials are essential for production of SCC. In the text drafted by EFNARC describes the function of inert or semi inert, pozzolanic and hydraulic additives/fillers materials of particle sizes smaller than 0.125 mm as to improve and maintain the cohesion and segregation resistance of SCC [43], [44]. In earlier studies, fly ash, silica fume, ground granulated blast furnace slag, limestone powder and blended cements are commonly preferred to manufacture of SCC [7], [15], [17], [45], [46], [47], [48], [49]. As a matter of fact that the effects of these fillers on strength and durability performance of SCC are non-negligible. However, usability of different kind of filler materials has been investigated and some of the alternatives have been asserted recently. Some of the materials such as calcite, brick powder, waste marble powder, metakaolin etc. are highly interest by the researchers [8], [26], [37], [42].
Ceramic is a product made of clay, feldspar and quartz as basic raw materials which are processed through mixing, molding, drying and burning. When it is applied to building projects, it is called building ceramic which is a popular materials preferred in walls and floors in construction industry [50]. Senthamarai and Manoharan (2005) have indicated that 30 percent of daily production of ceramic industry goes to waste. This waste is not recycled in a sufficient way at present [51]. A huge amount of ceramic wastes arose from both manufacturing and application and also maintenance stages. Although there are no realistic solutions of the management of these wastes, some of the researchers have been used ceramic waste as aggregate or filler in traditional concrete mixes [51], [52], [53], [54], [55]. As the ceramic waste is piling up every day, there is pressure on the ceramic industries to find a solution for its disposal [51]. There are some of the studies focused the reuse of ceramic wastes in construction industry. Ceramic wastes have been used as road fill, as a partial substitute instead of fine or coarse natural aggregate, and cement replacement in the mortar and pavement in the previous studies [56], [57], [58], [59], [60], [61]. Torkittikul, and Chaipanich (2010) investigated the feasibility of using ceramic waste and fly ash to produce mortar and concrete, and they indicated that the compressive strength of ceramic waste concrete was found to increase with ceramic waste content and was optimum at 50% for the control concrete [62]. Medina Martinez et al. (2009) reported that, ceramics industry wastes (recycled ceramic aggregates) are suitable for the manufacture of concrete [56]. Alves et. al. (2014) pointed out that, regarding the mechanical performance, in terms of compressive and tensile strength, the use of ceramic recycled aggregates for concrete is suitable [63], [64].
Ceramics are construction materials, made of mixing and heating of feldspar and quartz. In this study, fine grounded WCPs were used to product self-consolidating concrete with the idea of having a high potential of filler effect. Fresh and hardened state properties of self-consolidating concretes including 5 different ratios of ceramic powders (0%, 5%, 10%, 15% and 20% by weight of cement) substituted with cement have been investigated.
Section snippets
Materials
CEM I 42.5 R type cement obtained from Oyak Bolu Cement Inc., limestone aggregate with 0–5, 5–12 and 12–20 mm grain sizes, Sika Viscocrete BT8 trade mark superplasticizer was obtained from Sika Construction Chemical Company in Turkey and ground granulated waste ceramic wastes were used to produce self-consolidating concrete mixtures. Chemical compositions and particle size distributions of cement and ceramic powders used in this study are summarized in Table 1 and Fig. 1 respectively. Waste
Fresh concrete properties
Fresh concrete properties of self-consolidating concretes (SCC) including waste ceramic powders were given in Table 3.
Analyzing the Table 3, up to 15% waste ceramic substitutions an improvement was observed on the flowability properties of self-consolidating concretes. Although, a decrease was observed on the flowability of the self-consolidating concretes with the 20% waste ceramic replacement, it has similar flowability compared to reference specimen (without WCP substitution). Based on the T
Conclusions
Based on the results of self-compacting concrete mixes prepared with the WCPs are substituted into the cement in amount of 0%, 5%, 10%, 15% and 20% ratios by cement weight. Some of the key parameters of fresh mixes and density, compressive strength, split tensile strength, ultrasonic pulse velocity and bond performance of the SCC mixes were evaluated experimentally. Flowability of the fresh concrete was improved with the increase of WCP ratio. Besides, passing ability of the fresh concrete mix
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