1 s2.0 S0950061821014136 Main
1 s2.0 S0950061821014136 Main
1 s2.0 S0950061821014136 Main
h i g h l i g h t s
RCW composed of calcined low-grade kaolinitic clay showed potential to be used as SCM.
The RCW increased the amount of ettringite and stimulated the formation of monocarboaluminate in blended mortars.
The 30% Portland cement replacement by RCW slightly decreased the compressive strength of blended mortars.
The w/b ratio influences the compressive strength and apparent porosity of blended mortars.
The use of RCW can reduce CO2 emissions by reducing the cement demand per unit of compressive strength.
a r t i c l e i n f o a b s t r a c t
Article history: The red ceramic waste (RCW) powder has the potential to be used as supplementary cementitious mate-
Received 7 December 2020 rial (SCM) since ceramic bricks, essentially composed of calcined low-grade kaolinitic clay, presents
Received in revised form 5 April 2021 amorphous phases resulted from the sintering process. This paper investigates the effects of 30%
Accepted 12 May 2021
Portland cement replacement by RCW in the microstructure of cementitious pastes and mortars’ physi-
Available online 29 May 2021
cal–mechanical properties. The use of RCW changed the hydrated pastes’ microstructure by increasing
the amount of ettringite (AFt) and stimulating the formation of monocarboaluminate (AFm). The com-
Keywords:
pressive strength of the blended mortars reduced by 7 to 16% at 182 days. The apparent porosity for mor-
Red ceramic waste powder
Limestone calcined clay reaction
tars with w/b ratio of 0.35 was equivalent to that of reference over the 182 days. The gradual increase in
Pozzolanic activity the w/b ratio of blended mortars tends to maximize the decrease in compressive strength and increase
the apparent porosity. The use of RCW can reduce CO2 emissions by reducing the cement demand per
unit of compressive strength.
Published by Elsevier Ltd.
https://doi.org/10.1016/j.conbuildmat.2021.123653
0950-0618/Published by Elsevier Ltd.
J. Hoppe Filho, C.A.O. Pires, O.D. Leite et al. Construction and Building Materials 296 (2021) 123653
affect the strength and pore characteristics in cementitious sys- RCW was also addressed. The results of this investigation con-
tems [16]. tribute to generating knowledge that leads to an alternative route
The red ceramic industry uses low-grade kaolin clay as a raw for RCW disposal and the use of SCM in the Brazilian Portland
material in conforming and sintering brick production processes, cement industry.
resulting in 0.20 to 0.24 ton CO2/ton brick [18–20]. Ceramic bricks
often break during handling and transportation or are discarded
during quality control, resulting in up to 30% of red ceramic waste 2. Experimental program
(RCW) [15]. The RCW contains quartz, calcined clay, and other
minor phases [14,21]. In the São Paulo State (Southeast Brazil), 2.1. Materials
the clays used as a raw material in the red ceramic industry con-
tain 21 to 36% of kaolinite [14]. The RCW from damaged bricks pro- The RCW was produced from damaged bricks collected in a
duced in this region, with particles smaller than 75 lm, has been ceramic industry located in a small municipality (23,264 inhabi-
proved to fix between 434 and 599 mg Ca(OH)2/g RCW when sub- tants and 5,673.02 km2) of Northeast Brazil, whose sintering tem-
mitted to the modified Chapelle test, which denotes reasonable perature reached 950 °C. The collected damaged bricks were
pozzolanic reactivity [14]. Thus, the fragmentation and milling fragmented with a sledgehammer until reaching approximately
can attribute pozzolanic activity to the waste, adding value to 25 mm. Each 5 kg of fragmented material was then comminuted
the RCW and making it suitable for application as SCM [22,23]. in a Los Angeles abrasion apparatus using 12 iron spheres (Ø
As a result, it reduces environmental impacts caused by clay 47 mm, 445 g each) and cycles of 3.5 h at 33 rpm. After comminu-
extraction and calcining, mitigates environmental liabilities tion, each 400 g of material was sieved for 15 min in an electro-
related to the massive amount of waste generated by the local magnetic stirrer with 150 lm (100 mesh), 75 lm (200 mesh),
ceramic industry, and stimulates reverse logistics in the construc- and 45 lm (325 mesh) sieves. Three Ø 20 mm metal disks were
tion and building sector. added to each sieve to improve particle dispersion. The material
The RCW reactivity is a result of the amorphous and disordered retained in the 150 lm and 75 lm meshes was collected and re-
aluminosilicate structure formed during the sintering process. The comminuted until passing the 45 lm sieve.
calcination temperature allows the micro-structural decomposi- The raw clay material was collected in the brick manufacturing
tion of kaolinite, resulting in metakaolin, primarily responsible plant before the extrusion process, dried for 24 h at 105 °C, and
for the RCW reactivity [24]. The amorphous phase of the RCW sol- ground to produce particles below 150 lm.
ubilizes partially in a high alkaline system, enriching the solution The Portland cement used in the paste and mortar production is
in silica and alumina. These ions react with portlandite to form a Brazilian high-early-strength with sulfate resistance [31].
hydrated cementitious compounds by pozzolanic activity, usually The fine aggregate used in the mortars is natural river sand
C-(A)-S-H (calcium aluminate silicate hydrate), ettringite, and (bulk specific gravity 2.65 g/cm3, loose bulk density 1.57 g/cm3,
AFm phases [25]. Another specific interaction in the presence of fineness modulus 1.95, and maximum size 1.20 mm).
limestone filler is the reaction of alumina from the RCW with car-
bonate, consuming calcium to precipitate hemi and/or monocar-
2.1.1. Mineralogical characterization of RCW and raw clay material
boaluminate (AFm) [16,26]. The RCW reactivity is profoundly
Fig. 1 presents diffraction patterns and mineralogical composi-
affected by the variability in the mineralogical composition and
tion obtained through Rietveld refinement for RCW and raw clay,
physical–chemical properties of the raw material [11,27], which
considering a 5°–75° 2h range, steps of 0.02° for 1 s, Cu Ka Radia-
are related to the material composition and therefore cannot be
tion, 40 kV / 30 mA, and 1° divergence slit. The crystalline phases
generalized [7]. The unfamiliarity regarding mineral composition
were identified by the ICSD (Inorganic Crystal Structure Database).
and sintering temperature requires a comprehensive characteriza-
Lithium fluoride p.a. (10% in mass) was added to the RCW sample
tion to confirm the pozzolanic activity [28], which demands the
as an internal standard. The RCW is composed basically of quartz
availability being assessed locally [25].
and illite phases. The amorphous structure characteristic halo
In the Brazilian cement industry, the use of high amounts of
observed between 17° e 33° 2h represents 61.1% of the sample.
SCM is one of the main strategies to reduce CO2 emissions [29].
The clay material is mainly composed of quartz, illite, kaolinite,
Increasing the volume of SCM in the cement composition, the
and feldspar, with anatase, mica, and magnetite as minority crys-
Brazilian cement industry reduced the clinker/cement ratio from
talline phases. The kaolinite content (21.9%) quantified in the clay
80% to 67% from 1990 to 2014 and aims at reaching 59% by 2030
raw material before sintering at 950 °C was not identified in the
and 52% by 2050 [30]. Depending on the local availability, fly
RCW diffraction pattern.
ash, blast furnace slag, and calcined clay are used, in proportions
Fig. 2 presents the thermogravimetric analysis of the raw clay
up to 50% for pozzolanic additions or up to 75% for slag [31]. In
material (temperature range 30–1000 °C, heating rate 10 °C/min,
Northeast Brazil, calcined clay is the primary SCM used in Portland
nitrogen atmosphere (50 mL/min), sample mass 10 mg in a plat-
cement production, which justifies investigations on the potential
inum crucible). The mass loss between 300 e 600 °C corresponds
use of RCW produced in the region, especially for being a clean and
to the decomposition of kaolinite. The kaolinite content estimated
ready to use waste material that can be used straight from the pro-
by stoichiometry (21.9%) is identical to that quantified by Rietveld
duction line [24] with no need for any calcining.
refinement. The mass loss related to dehydroxylation was 3.05%.
In this context, this paper investigates the use of a low-grade
kaolinite calcined clay waste obtained from broken ceramic bricks
(RCW) as a potential source of SCM. The pozzolanic reactivity of 2.1.2. Physical and chemical characterization of cement and RCW
the RCW has been investigated through chemical, mineralogical, The particle size distribution was performed in isopropyl alco-
and physical characterization. The analysis has been comple- hol (cement) or water (RCW) after ultrasound exposure (60 s) for
mented by a microstructural characterization performed in cemen- particle dispersion. Fig. 3 shows that the RCW is composed pre-
titious paste produced with 30% of RCW. Additionally, the dominantly of particles smaller than those of Portland cement.
evolution of compressive strength and apparent porosity of mor- However, the particle size of both is similar up to 0.8 lm.
tars produced with 30% of RCW in mass and different water/binder Table 1 shows bulk specific gravity [32], BET specific surface
ratios has been evaluated. The eco-efficiency in terms of global area (by hydrogen adsorption), and particle size distribution
warming potential for a Portland cement produced with 30% of parameters.
2
J. Hoppe Filho, C.A.O. Pires, O.D. Leite et al. Construction and Building Materials 296 (2021) 123653
Fig. 1. Diffraction pattern and Rietveld refinement of RCW and raw clay material.
2.2. Methods
Table 1
Physical properties of RCW and Portland cement.
Table 2 duced for each age of test [40]. The mortars’ production started
Chemical composition of RCW and Portland cement. by cement and RCW homogenization, through continuous stirring
Chemical composition (%) RCW Portland for 5 min, followed by mixing (binder and water for 1 min and the
cement paste with sand for 4 min). After mixing, the samples were kept in
CaO 0.22 50.17 the molds for 24 h, demolded, and then submerged in saturate lime
SiO2 72.20 20.14 water. The samples were removed from the curing tanks at the
Al2O3 16.20 5.82 ages of 7, 28, 56, 91, and 182 days and submitted to the axial com-
Fe2O3 6.29 3.10
SO3 — 7.57
pressive strength test in an EMIC DL 30,000 universal testing
MgO 0.82 7.40 machine at 0.25 ± 0.05 MPa/s.
K2O 2.12 1.47 In Table 3, the mix proportion 1.00 cement: 2.06 sand (w/b
Na2O < 0.10 3.20 0.55) corresponds to a common cement/sand proportion used in
TiO2 0.96 0.44
concrete. The mix proportions for w/b ratios of 0.35 and 0.45 con-
MnO < 0.10 0.06
SrO — 0.24 sidered the same water/(cement + sand) ratio to keep similar con-
P2O5 < 0.10 0.22 sistency and avoid superplasticizers.
V2O5 — 0.06 The apparent porosity (P) of the mortars was determined
L.O.I. 1.17 3.29 according to Eq. (1) using fragments with an approximate dimen-
Insoluble Residue (IR) (average ± standard — 7.7 ± 0.6
sion of 8 mm, extracted from the central part of the cylinders sub-
deviation)
Gypsum — 3.11 mitted to the axial compressive strength test.
Limestone filler — 5.18 Statistical analysis of axial compressive strength and apparent
Clinker content (Portland cement – IR – gypsum — 84.00 porosity test results was performed by variance analysis and
– limestone filler)
Tukey’s test with a confidence level of 95%.
Modified Chapelle (mg Ca(OH)2/g) 684.7 ± 12.7 —
Table 3
Mix proportion of mortars.
Mixtures Binders (kg) Portland cement Fine aggregate (kg) Water/binder ratio
consumption (kg/m3) (Cement + RCW)
Cement RCW
Reference 0.35 1.00 — 968 0.94 0.35
30% RCW 0.35 0.70 0.30 668
Reference 0.45 1.00 — 744 1.50 0.45
30% RCW 0.45 0.70 0.30 515
Reference 0.55 1.00 — 604 2.06 0.55
30% RCW 0.55 0.70 0.30 419
Table 4
CO2 emission related to cement and RCW.
Mixtures Binders (kg) Binder consumption (kg/m3) Carbon dioxide emission (kg/m3)
Cement RCW Cement RCW Total Clinker1 RCW2 Total
Reference 0.35 1.00 — 968 — 968 695 — 695
30% RCW 0.35 0.70 0.30 668 286 955 486 94 580
Reference 0.45 1.00 — 744 — 744 534 — 534
30% RCW 0.45 0.70 0.30 515 221 736 374 72 446
Reference 0.55 1.00 — 604 — 604 433 — 433
30% RCW 0.55 0.70 0.30 419 180 599 303 59 362
1
Clinker: clinker content in Portland cement was 84%. Carbon dioxide emission from clinker = clinker content in Portland cement 0.855 kg/kg clinker [42]. Ex. Reference
0.35 ? Carbon dioxide emission from clinker = 968 0.84 0.855 = 695 kg/m3.
2
RCW: Carbon dioxide emission from RCW = RCW consumption 0.327 kg/kg RCW. Ex. 30% RCW 0.35 ? Carbon dioxide emission from RCW = 286 0.327 = 94 kg/m3.
vent, CML method) over 200 km would increase the CO2 release by Portland cement paste), occurs due to the increase in the reaction
about 0.034 tCO2/t of RCW. Thus, the CO2 emission related to the kinetics of Portland cement in the presence of fine particles (filler
RCW considering brick production, processing, and transport is effect), and the RCW pozzolanic activity [16].
about 0.287 to 0.327 tCO2/t of RCW. The CO2 emissions for mix- The CBW and portlandite content of the reference paste
tures with 30% of RCW, presented in Table 4, reduce by 12% with increases over time. In the paste produced with RCW, the port-
the brick production emission allocated to the origin (ceramic landite content is similar to that theoretically predicted up to
industry). 7 days. In subsequent ages, the portlandite content reduced grad-
ually as a result of RCW pozzolanic activity. The portlandite con-
sumption at 182 days was 6.4%, which results in a lime content
3. Results and discussion
fixed by the pozzolanic activity of 214 mg Ca(OH)2/g RCW. The
portlandite consumption corresponds to about 31% of the ability
3.1. Microstructural characterization in cementitious paste
to fix lime determined through the Modified Chapelle test
(684 mg Ca(OH)2/g RCW). It means that the lime content fixed
Fig. 4 shows the chemically bound water (CBW) and portlandite
by pozzolanic activity is lower than that determined in conditions
contents of the cementitious pastes obtained through thermal
to maximize the reaction. Thus, it is evident that, after 182 days,
analysis. Masses losses between 35 °C and 385 °C were consid-
the RCW can still develop pozzolanic activity, even with reactions
ered as CBW in the form of C-S-H, AFt, and AFm phases, masses
occurring slowly over time.
losses between 385 °C and 490 °C as portlandite constitution
Fig. 5 presents TG/DTG curves for the paste produced with RCW,
water, and mass loss between 490 °C and 1000 °C as carbon diox-
and the theoretical curves determined considering 70% of Portland
ide bound in calcite [44–46]. The use of RCW as SCM increased the
cement.
CBW content if compared to the Portland content paste (Fig. 4A).
The higher CBW content at 7 days, compared to the propor-
The CBW content was similar to the reference at 7 days, but a grad-
tional Portland cement content, occurs due to the higher content
ual distancing was observed in subsequent ages. The higher CBW
of C-S-H and the formation of AFm phases. The higher C-S-H con-
content in the paste produced with RCW, compared to the propor-
tent is related to the heterogeneous nucleation effect provided by
tional Portland cement content (theoretical corresponds to 70% of
Fig. 4. Chemically bound water as C-S-H and AFt/AFm phases (A). Portlandite content in pastes (B). All results in a non-volatile basis.
5
J. Hoppe Filho, C.A.O. Pires, O.D. Leite et al. Construction and Building Materials 296 (2021) 123653
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J. Hoppe Filho, C.A.O. Pires, O.D. Leite et al. Construction and Building Materials 296 (2021) 123653
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J. Hoppe Filho, C.A.O. Pires, O.D. Leite et al. Construction and Building Materials 296 (2021) 123653
Fig. 10. Relative variation of compressive strength and apparent porosity of mortars with RCW compared to reference mortars.
Fig. 11. Correlation of apparent porosity of paste and mortar with water/binder of 0.45.
presented in this paper corroborates the findings of Avet et al. [12]. Fig. 11 presents the correlation of apparent porosity of pastes
Despite the apparent porosity higher than the reference, the com- and mortars with water/binder of 0.45. The initial theoretical
pressive strength of RCW mortar (water/binder ratio of 0.55) apparent porosity was determined through the relationship
reached 88% of the reference between 28 and 182 days, which between the volume of mixing water and the total volume of mate-
can be considered a satisfactory mechanical performance. rials. The high coefficients of determination (R2) observed in Fig. 11
8
J. Hoppe Filho, C.A.O. Pires, O.D. Leite et al. Construction and Building Materials 296 (2021) 123653
confirm the test consistency for evaluating pastes and mortars Fig. 13 presents the carbon dioxide intensity of mortars. The
apparent porosity at different ages. partial replacement of Portland cement by RCW resulted in a
reduction in the carbon dioxide emitted per unit of compressive
3.3. Eco-efficiency strength. Thus, the incorporation of RCW in mortars can reduce
environmental impacts originated by inappropriate disposal,
Fig. 12 shows the Portland cement intensity of mortars. The besides mitigating greenhouse gases emission from the construc-
Portland cement intensity of reference mortars is higher than those tion industry. Data presented in Figs. 12 and 13 show that the
of mortars produced with RCW, regardless of the water/binder modified binder with 30% Portland cement replacement by RCW
ratio. The use of RCW reduces the Portland cement consumption is environmentally more efficient considering the cement con-
and the compressive strength of mortars. On the other hand, the sumption and carbon dioxide emission per unit of compressive.
compressive strength of mortars can be partially re-established
due to the pozzolanic activity of the RCW, which results in a posi-
tive impact regarding Portland cement intensity. Therefore, the use 4. Conclusions
of RCW tends to reduce the Portland cement consumption per unit
of compressive strength. This trend enhances the environmental The potential application of RCW as SCM presented in this
performance of mortars produced with RCW. paper allows the following conclusions:
9
J. Hoppe Filho, C.A.O. Pires, O.D. Leite et al. Construction and Building Materials 296 (2021) 123653
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material in Brazil, Cem. Concr. Res. 37 (9) (2007) 1357–1365, https://doi.org/
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The authors declare that they have no known competing finan-
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