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Abstract
The hydration products of three high replacement, composite cement pastes, i.e. Portland cement mixed with 75% and 90%
ground, granulated blast furnace slag (BFS) and 75% pulverised fuel ash (PFA), are reported and compared with those from a 100%
ordinary Portland cement (OPC) paste. The samples were cured in air under the same temperature and humidity conditions and
tested at various times for up to six months. The hydration products were identified by means of X-ray diffraction (XRD) and their
microstructure by scanning electron microscopy (SEM). Although the observed hydration products were mostly as expected, due to
the high replacement levels, the degree to which these phases was present was unusual. In particular the calcium hydroxide initially
formed in the BFS-cement systems was totally consumed within six months, indicating the important pozzolanic behaviour of BFS
at such high replacement levels. Ó 2002 Elsevier Science Ltd. All rights reserved.
Keywords: Blast furnace slag; Composite cements; Portland cement; Pulverised fuel ash; Scanning electron microscopy; X-ray diffraction
0958-9465/02/$ - see front matter Ó 2002 Elsevier Science Ltd. All rights reserved.
PII: S 0 9 5 8 - 9 4 6 5 ( 0 1 ) 0 0 0 4 1 - 5
192 J. Hill, J.H. Sharp / Cement & Concrete Composites 24 (2002) 191–199
Four cement systems were used for this work. These 2.2. Casting and curing
were 100% ordinary Portland cement (OPC) (included
as a reference material), 3:1 BFS:OPC, 9:1 BFS:OPC Cements were prepared in 500 g batches with a w:s
and 3:1 PFA:OPC. The OPC and BFS were supplied by ratio of 0.35. However, this does not equate to a con-
Castle Cement and the PFA by Pozzolanic Lytag. All stant water:cement (w:c) ratio of 0.35 for the composite
the powders were prepared to comply with the specifi- cement systems because of the different amount of OPC
cation of British Nuclear Fuels plc, essentially to the present in each. Table 3 shows the w:c and w:s ratios for
appropriate British Standard but with modified physical all four cement systems.
and chemical limitations. The chemical analyses for the Powders ð500 0:1 gÞ were weighed and, where
OPC and BFS are shown in Table 1. A Bogue analysis necessary, thoroughly mixed. Distilled water
indicates a potential phase composition of C3 S, 53.2%; ð175 0:1 gÞ was weighed and the cement powder
C2 S, 20.1%; C3 A, 8.3%; C4 AF, 9.4%; suggesting a nor- gradually added to the water. Once all the powder had
mal Portland cement. There was no chemical analysis been added the cement was mixed manually for ap-
supplied for the PFA, therefore, it is only possible to proximately 3 min. The paste was then poured into
quote the calcium oxide content which was 1.9%. PTFE moulds creating 100 mm 10 mm 10 mm
However, an analysis [4] of a typical UK fly ash is shown prisms.
in Table 2. The samples were cured at 23 2°C and 86 2%
An XRD trace of the PFA indicated the presence relative humidity. This was achieved by placing the
of small amounts of crystalline quartz and mullite, sample in an environmental cabinet in the laboratory
while that of the BFS indicated the presence of gehl- and using a saturated solution of potassium sulfate,
K2 SO4 , to control the humidity. The freshly cast sam-
ples were placed in the cabinet for 24 h and were then
Table 1 demoulded. The samples were returned to the cabinet
Chemical analyses for OPC and BFS and left until they were required for analysis. When re-
moved from the cabinet the samples were quenched in
OPC BFS
acetone and then stored in acetone to prevent further
CaO 64.1 41.4 hydration.
SiO2 21.0 32.9
Al2 O3 5.1 13.5
Fe2 O3 3.1 0.8
MgO 2.5 8.3 Table 3
SO3 2.2 – w:c ratios for the composite cements studied
K2 O 0.7 0.4
Na2 O 0.3 0.2 Cement system w:s w:c
Chloride 0.03 0.03
Insolubles 0.3 – 100% OPC 0.35 0.35
Loss on ignition 0.6 0.5 3:1 BFS:OPC 0.35 1.4
Free Lime 0.8 – 9:1 BFS:OPC 0.35 3.5
Sulphide – 0.9 3:1 PFA:OPC 0.35 1.4
J. Hill, J.H. Sharp / Cement & Concrete Composites 24 (2002) 191–199 193
3. Characterisation
Fig. 8. Backscattered electron image of the of the 3:1 PFA:OPC cement hydrated for 90 days.
out in stark contrast to the spherical grains of PFA 3:1 system seem to have been more extensively broken
shown in Fig. 8. In the 3:1 composite cement, it can be down. The cement hydration products seemed to be
seen from Fig. 10 that a thin rim had formed around quite localised in the 9:1 system, leading to the very
some of the slag grains, while the cement fraction had porous microstructure observed in Fig. 11. The slag
hydrated (e.g. region A). As in the PFA-containing grains did not show any rims, but instead many of them
system, the hydrated cement gel was building up a ma- were surrounded by a gap. In some respects, this mi-
trix between the slag particles, hence reducing the po- crostructure is reminiscent of that reported recently by
rosity. The micrograph of the 9:1 BFS:OPC composite Escalante-Garcia and Sharp [9] in a BFS–OPC com-
cement is shown in Fig. 11 at the same magnification as posite cement paste with 60% replacement cured at
in Fig. 10 to allow direct comparison. Although at first 10°C. This microstructure was notably different from
glance the microstructures may appear similar because that developed in the same cement paste hydrated at
they are dominated by the angular slag grains, there are 30°C and 60°C, when extensive rims of hydration
notable differences. The 9:1 system (Fig. 11) contains products were observed around the anhydrous slag
more slag grains of larger size, whereas the grains in the grains.
J. Hill, J.H. Sharp / Cement & Concrete Composites 24 (2002) 191–199 197
Fig. 10. Backscattered electron image of the 3:1 BFS:OPC cement hydrated for 90 days.
Fig. 11. Backscattered electron image of the 9:1 BFS:OPC cement hydrated for 90 days.
it was below the level observable by XRD after 180 Although the compressive strength is much reduced, in
days. applications where this is unimportant, other properties
Blast furnace slag is generally regarded as a very dif- may be advantageous, e.g. low heat evolution and low
ferent replacement material from PFA, because it is a level of CH. The 9:1 BFS:OPC cement paste was the
latent hydraulic material whereas PFA is pozzolanic. weakest of those investigated, and took longer to set
This means that in the presence of an alkali activator, than the other pastes. It had a high level of porosity, as
such as calcium hydroxide formed during the hydration was evident from the scanning electron micrographs
of alite in OPC, the slag grains themselves hydrate to (e.g. Fig. 11).
form additional C–S–H gel. The calcium content of BFS The hydration products formed in the four systems
is, however, less than that in the C–S–H gel commonly studied were as expected, although they differed in
formed in hydrated Portland cement pastes, so that at magnitude. Calcium hydroxide was formed initially in
the high replacement levels used in the present study, it all systems, but in the presence of large amounts of PFA
too acts as a pozzolanic material. This is clearly evident and BFS, it did not become such a major reaction
from the XRD traces shown in Figs. 3 and 4 for the 3:1 product as in the OPC system (Fig. 5), and had disap-
and 9:1 BFS:OPC composite cement pastes, respectively. peared from all three composite cement systems after
In the 3:1 paste, the calcium hydroxide formed after 3 hydration for 180 days (Fig. 6). Hence, at such high
days was gradually consumed, until no trace of it re- replacement levels, BFS acts as a pozzolanic material as
mained after 180 days. Qualitatively its behaviour was, well as PFA. The disappearance of calcium hydroxide
therefore, very similar to that of the 3:1 PFA:OPC paste, from the three composite cements was in the sequence:
but quantitatively more calcium hydroxide was formed 3:1 PFA:OPC sooner than 9:1 BFS:OPC, sooner than
in the BFS system, indicating that the PFA was a 3:1 BFS:OPC, which correlates with the lime content of
stronger pozzolanic material. In both these 3:1 systems, these systems.
the increasing extent of the pozzolanic reaction with in-
creasing time resulted in a denser microstructure, al-
though not as dense as that observed in the control Acknowledgements
system. The occurrence of a pozzolanic reaction with slag
replacement has been documented previously [10–13]. We are grateful to British Nuclear Fuels Limited for
The amount of calcium hydroxide formed initially the financial support to allow J. Hill to study for a Ph.D.
in the 9:1 BFS:OPC composite cement paste was less and for the supply of the blended cements. We wish to
than that formed in the 3:1 cement paste, because it thank Mr. E. Miller and Dr. M. Hayes for many helpful
contained appreciably less OPC (10% compared with discussions.
25%). After 28 days, however, the magnitude of the
strongest calcium hydroxide XRD peak at 18:1°2h in
the 9:1 cement paste was comparable with that in the References
3:1 cement paste, although the second peak at 34:1°2h,
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