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Strength and durability of concrete

incorporating crushed limestone sand

Article in Construction and Building Materials · February 2009

DOI: 10.1016/j.conbuildmat.2008.02.005 · Source: OAI

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Construction
and Building
MATERIALS
Construction and Building Materials 23 (2009) 625–633
www.elsevier.com/locate/conbuildmat

Strength and durability of concrete incorporating crushed

limestone sand
B. Menadi a, S. Kenai a,*, J. Khatib b, A. A¨ıt-Mokhtar c
a
Geomaterials Laboratory, Civil Engineering Department, University of Blida, P.O. Box 270, Blida, Algeria
b
School of Engineering and the Built Environment, University of Wolverhampton, England, United Kingdom
c
LEPTAB, University of la Rochelle, France
Received 27 July 2007; received in revised form 8 February 2008; accepted 8 February 2008
Available online 21 March 2008

Abstract

In recent years, there is a growing interest in the use of crushed sand obtained from limestone quarries in some countries where river
sand is not widely available. The fines content is usually high in crushed sand which can adversely affect concrete properties. The influ-
ence of fines in crushed sand on physical and mechanical properties of concrete has been widely investigated. The results proved that up
to 15% of fines content in crushed sand could be used without adversely affecting concrete strength. However, little work has been done
so far on the effect of fines in crushed sand on the durability of concrete. This paper examines the influence of limestone fines in crushed
sand on concrete properties. Properties include strength, water, gas and chloride-ion permeability and capillary water absorption. Four
different cement types were used while maintaining a constant water/cement ratio. The results show that concrete containing 15% of lime-
stone fines as replacement of crushed sand reduces the water permeability and increases the gas and chloride-ion permeability.
© 2008 Elsevier Ltd. All rights reserved.

Keywords: Limestone fines; Crushed sand; Durability; Permeability; Strength

1. Introduction Some countries such as Spain, France, Algeria and Argen-

Recently, there has been an increasing interest in using
crushed sand from limestone quarries in concrete construc-
tion to overcome inherent deficiencies in river sand in some
countries all over the world [1]. Crushed limestone fine
sand is a by-product of the quarry process and typically
does not have a significant demand due to its high fines
content that exceeds the standard allowable limit of 5%.
The fines are particles whose diameters are less than 80
lm. For this reason, most of the fines at present are des-
tined to landfill.
Crushed sand is very abundant in limestone quarries
and its use could significantly decrease the materials cost
of concrete, eliminate the dust disposal cost, reduces envi-
ronmental pollutions and dilapidation of natural resources.
*
Corresponding author. Tel.: +213 25433939; fax: +213 25431164.
E-mail address: sdkenai@yahoo.com (S. Kenai).
tina experienced a big shortage in natural sand but crushed
sand is abundant. Its use is limited to either road basements
or in landfill applications. However, because of the need to
utilise rock fines and the research results which showed that
higher fines content could be used in concrete without dam-
aging its main properties, standards have increased the
fines allowable limit in crushed sand to allow its use in rein-
forced concrete applications (see the European norm EN-
206 for instance). British standards (BS 882) allow up to
15% of fines in sand whereas ASTM C33 sets the limit to
less than 7%. In addition, up to 35% of limestone fines
are allowed in European cements according to EN197-1
(1996) [2].
The effect of inclusion of limestone fines in crushed sand
on fresh and hardened mortar and concrete has been a
major research topic for many years. It was found that
up to 15% of limestone fines do not affect strength perfor-
mance of limestone concrete manufacture [3,4]. It has been

0950-0618/$ - see front matter © 2008 Elsevier Ltd. All rights reserved.
doi:10.1016/j.conbuildmat.2008.02.005
626 B. Menadi et al. / Construction and Building Materials 23 (2009) 625–633

established that 12–18% of fines could be allowed in sand
without harmful effects on the physical and mechanical
properties of mortar and concrete [5–13]. However, little
work has been done so far on the effect of fines in crushed
sand on the durability of concrete. Therefore, this paper
reports the results of an experimental investigation on the
influence of limestone fines as replacement of crushed sand
on concrete properties. Properties include strength, water,
gas and chloride-ion permeability, as well as total porosity
and water absorption by capillarity. The level of limestone
fines in crushed sand for the investigation of durability was
fixed at 15% by weight based on the results of a previous
investigation [1].
2. Experimental program
2.1. Materials
The chemical and physical properties of the four differ-
ent cements used in this investigation are shown in Table 1.
Cement A is an ordinary Portland cement produced in the
laboratory and Cement B is an ordinary Portland cement
fabricated by a local cement factory, Cements C and D
are commercial Portland limestone cements containing
15% by weight of limestone. Blaine specific area of cements
A, B, C and D are 268, 297, 308 and 330 m2/kg respec-
tively. The limestone fines used as partial replacement of
sand are those obtained by sieving the crushed sand below
80 lm. Chemical composition of the limestone fines are
given in Table 2. The fine aggregates used were crushed
quarry sand with particles ranging from 80 lm to 4 mm
in size. Its bulk density, fineness modulus and sand equiv-
alent were 2.54 kg/m3, 2.78% and 70% respectively. The
coarse aggregates were natural crushed limestone, with
maximum size of 8 mm and 16 mm with a specific gravity
of 2.57 kg/m3. The grading curves of the aggregates are
presented in Fig. 1.
2.2. Mix proportions
For all concrete mixtures, cement content and water/
cement (W/C) ratio were kept constant at 350 kg/m3 and
0.65, respectively. The mixtures had proportions of 1
(cement): 1.71 (sand): 0.75 (coarse aggregate 8 mm): 2.53
(coarse aggregate 16 mm). A total of 8 mixtures were cast
in order to investigate the effect of limestone fines on the
properties of concrete. The mixture code consists of a letter
which indicated the type of cement and a number indicat-
ing the percentage of limestone fine in the crushed sand.
For example B15 represents the concrete mixtures contain-
ing cement B where 15% of crushed sand is replaced with
limestone fines. The slump of mixtures ranged from 40
mm to 70 mm without the use of chemical admixtures. Fur-
ther details about the mixtures are given in Table 3.
2.3. Samples preparation, curing and testing
Concrete specimens were cast in steel moulds and com-
pacted in two layers using vibrating table. After casting,
concrete specimens were left covered in the casting room
for approximately 24 h, after which time they were demoul-
ded and stored in a water tank, saturated with lime at
20 ± 2° C until the test age.

Table 1 100

Compositions of the different cements Crushed sand

Composition Cement type 80

A B C D
Gravel 3/8
% passing the sieve

Chemical Gravel 8/16

SiO2 21.33 21.50 20.32 20.92 60
CaO 64.65 65.52 64.34 61.74
MgO 1.21 1.05 0.56 1.58
Fe2O3 3.07 2.84 3.20 3.43 40
Al2O3 5.74 5.13 4.71 5.33
Loss on ignition 0.21 2.02 4.26 1.65
SO3 2.30 1.53 1.26 1.83 20
Insoluble residue 0.06 1.60 1.14 1.35
Free CaO 0.30 0.39 0.21 2.17
Mineralogical 0
C2S 19.88 15.45 20.30 16 0,1 1 10
C3S 53.44 56.58 50.59 56 Sieve diameter (mm)
C3A 9.96 8.79 7.7 5.65
C4AF 9.31 8.63 9.55 12.0 Fig. 1. Aggregates grading curves.

Table 2
Chemical properties of limestone fines
Oxide SiO2 CaO MgO Fe2O3 Al2O3 H2O Loss on ignition
% 1.78 54.3 0.20 0.34 0.79 2.8 42.5
 B. Menadi et al. / Construction and Building Materials 23 (2009) 625–633 627

Table 3
Details on concrete mixtures
Cement type Mixture code Content (kg/m3) Slump (mm)
Cement Water Crushed sand Limestone fines CA 8 mm CA 16 mm
A A0 350 227.5 601 0 263 887 70
A A15 350 227.5 510 90 263 887 50
B B0 350 227.5 601 0 263 887 60
B B15 350 227.5 510 90 263 887 45
C C0 350 227.5 601 0 263 887 70
C C15 350 227.5 510 90 263 887 55
D D0 350 227.5 601 0 263 887 60
D D15 350 227.5 510 90 263 887 40

For the compressive strength determination cubes of
100 mm in size were used and testing was conducted
according to NF P 18-406 [14].
For the determination of total porosity, water absorp-
tion by capillary, water, gas and chloride-ion permeability
discs were cut from a cylindrical specimen of either 100 mm
or 150 mm in diameter as shown in Fig. 2.
The total porosity test was performed on 100 mm
(diam.) × 50 mm cylindrical specimens using water vacuum
saturation according to the procedure given in [15]. Water
absorption by capillarity was measured on concrete cylin-
drical specimens 150 mm (diam.) × 50 mm oven-dried at
80 °C until the mass became constant [15]. Specimens were
left to cool in an air-tight container. In order to ensure that
water flows in a single direction, specimens were sealed on
the side. Specimens were then subject to contact with water
as shown in Fig. 3. Further details on the testing procedure
are given elsewhere [15].
Water penetration depth under pressure for concretes
mixtures was determined in accordance to DIN 1048 [16].
100mm or 150mm
200 mm 50 mm
In this investigation, a 3 bars water pressure was applied
at the bottom of the cube specimen of 150 mm in size
for 24 h. At the end of the test, the specimen was
removed from the permeability cell and then split into
two halves in order to measure the penetration depth.
The results are the average of two samples at curing age
of 90 days.
Rapid chloride-ion penetration test used in this investi-
gation was performed at 90 days as per recommended by
ASTM C 1202 [17]. In this test, a 50 mm thick specimen
is cut from 100 mm (diam.) × 200 mm cylindrical concrete
sample as shown in Fig. 2. Specimen side is then coated
with epoxy. When the epoxy is dried, it is introduced in a
vacuum chamber for 3 h. The specimen was vacuum
water-saturated for 1 h and then immersed in water for
18 h. After that the specimen is placed in the test device
and subjected to a 60 V applied DC voltage for 6 h. The
total charge passed is determined for each concrete mix-
ture. The results are the average of two samples.
Gas permeability of the different concrete mixes was
measured on preconditioned specimen 150 mm (diam.) ×
50 mm by using the Cembereau apparatus (Fig. 4). Test
and preconditionnement procedures are detailed elsewhere
[18]. Hagen–Poiseuille relationship for laminar flow of a
compressible fluid through a porous media with small cap-
illaries under steady-state condition was used to determine
the specific permeability coefficient K, which can be calcu-
lated using the modified Darcy’s equation:
Kðm2Þ ¼ ð2gP outQLÞ=AðP 2 — P 2 Þ ð1Þ
m out

Disc where Q is the volume flow rate (m3 s—1), L is the sample
thickness (m), Pm is the inlet pressure (Nm—2), Pout is the
outlet pressure assumed in this test to be equal to atmo-
Fig. 2. Disc used for durability tests. spheric pressure (Nm—2), A is the sample cross-sectional

Sealed on side
Specimen
Water container

Water level

5 mm

Fig. 3. Capillary water absorption test.

628 B. Menadi et al. / Construction and Building Materials 23 (2009) 625–633

At the age of 90 days, there is a continuing improvement in

the strength performance of all the mixtures. Concrete with
15% of fines showed a decrease in strength between 6% and
15% compared to those without fines. This decrease in
strength is comparable to the decrease observed with mor-
tars specimens and could be considered as acceptable for
all types of cements used in this investigation [1].

3.2. Total porosity

Total water porosity results for the different concrete

Fig. 4. Cembureau gas permeability test set-up.
area (m2), and g is the dynamic viscosity of the fluid at test
temperature (Ns m—2). For nitrogen, at temperature of
20 °C, the dynamic viscosity is 1.76 × 10—5 Ns m—2.
3. Results and discussion
3.1. Compressive strength
Compressive strength results of all concrete mixtures at
the age of 28 and 90 days of water curing age are illustrated
in Fig. 5. The strength values are the average of three test
samples. Compressive strength of all concrete mixtures var-
ied between 25 MPa and 34 MPa. At 28 days, concrete
mixtures containing cements A and B showed comparable
strength but lower than those containing cements C and D.
mixtures at 90 days are shown in Fig. 6. Limestone fines
increases the total porosity of concrete containing cements
B and D compared to that without fines. However, a slight
decrease is noticed for mixtures with cements A and C. The
total porosity of concrete mixtures with 15% of limestone
fines varies from 15% to 17.5%. The total porosities are
slightly higher to those obtained by Tsivillis et al. [23] for
limestone fines as replacement of cement. This could be
attributed to the testing procedure used in this investiga-
tion, where specimens were vacuum saturated. Fig. 7 plots
the relationship between compressive strength and
total porosity of all mixtures at the age of 90 days. An
increase in total porosity is associated with an increase in
compressive strength. A good correlation (R2 = 0.85) is
observed between the total porosity (P) and the compres-
sive strength (fc) results is represented by the following
equation:
fc ¼ 96e—0:065P ð2Þ
3.3. Capillary water absorption
Fig. 8 shows the amount of water absorbed per unit area
as a function of square root of time for all concrete mix-
tures (with and without fines). The results show clearly that
15% of limestone fines addition as replacement of crushed

40
Compressive strength (MPa)

30
A0
A1 5
B0
20 B1 5
C0
C1 5
D0
D1 5
10

0
28 Day 90 Day
Age, days

Fig. 5. Effect of limestone fines on compressive strength.


Total porosity (%)
40
Compressive strength (MPa)
35
30
25
15 16
Total porosity (%)
Fig. 7. Compressive strength and porosity correlation at 90 days.
sand has a negligible effect on capillary water absorption.
Tsivillis et al. [19] have reported that substitution of 15%
of fines by weight of cement slightly reduces the concrete
sorptivity. A reduction of 5% in sorptivity was found for
concrete with 15% of fines compared to concrete without
fines with a water to cement ratio of 0.70. This is consistent
with the findings of Khatib and Mangat [20], who reported
that incorporation of 22% of fly ash as cement replacement
does not significantly affect the water absorption coeffi-
cient. However, Yuksel et al. [21] using bottom ash, blast
furnace slag and a combination of both of these materials
as fine aggregates in concrete, reported that capillarity
coefficients were higher for all replacement levels except
10%. The effect of cement type on water absorption by cap-
illary action for concrete with and without limestone fines
is shown in Fig. 9. Concrete containing cement A with
and without fines has a higher water absorption values
than that of all other mixtures. Lower values were obtained
for concretes containing cements C and D. This may be
B. Menadi et al. / Construction and Building Materials 23 (2009) 625–633 629
25
20
15
10
0
A0 A15 B0 B15 C0 C15 D0 D15
Concrete mixtures
Fig. 6. Total porosity of concrete mixtures at 90 days.
attributed to the fact that these mixtures contained fewer
Experimental data interconnected pores compared to concrete mixture A.
Regression (R²= 0.85) Results plotted in Fig. 10 present the measured
absorbed water values versus compressive strength for con-
crete mixtures with and without limestone fines. A linear
curve is intended to fit experimental data, gives an R2 of
about 0.26, showing no dependence between water absorp-
tion and strength.
3.4. Water permeability
Fig. 11 shows the water penetration depth for all con-
crete mixtures with and without limestone fines at 90 days.
17 18 19 20
There is reduction in the water penetration depth for all
concretes with limestone fines. The higher penetration
depth was observed in concrete mixtures containing cement
A with and without fines (A0, A15) while the lowest water
penetration depth is observed in concrete mixture contain-
ing cements C and D. Using either cement C or D did not
affect the water penetration depth. Also the presence of
15% fines in these cement exhibits similar penetration
depth. The incorporation of limestone fines up to 15% as
replacement of crushed sand may improve pore structure
in transition zone, and thereby reduces water permeability.
The results of this research are in agreement with those
obtained by Kenai et al. [22] who reported a reduction in
the water depth penetration when 15% of limestone fines
as cement replacement were used.
The relationship between compressive strength and
water depth penetration at 90 days curing is plotted in
Fig. 12. Although there is tendency for the water penetra-
tion depth to decrease with the increase in strength, how-
ever, this correlation is poor (R2 = 0.26 for a linear
relationship). This could be explained by the fact that water
permeability does not only depend on compressive strength
but also on tortuosity, specific surface, pore size distribu-
tion and connectivity of pores.
630 B. Menadi et al. / Construction and Building Materials 23 (2009) 625–633

8 8

A0 B0
Absorbed Water x 10 (g/mm )

Absorbed Water x 10 (g/mm )

2

2
A15 B15
6 6
-3

-3
4 4

2 2

0 0
0 2 4 6 8 0 2 4 6 8
1/2 1/2
Time, (min ) Time, (min )

8 8

C0 D0
Absorbed Water x 10 -3 (g/mm 2)

Absorbed Water x 10 (g/mm )

D15

2
C15
6 6
-3

4 4

2 2

0 0
0 2 4 6 8 0 2 4 6 8
1/2 1/2
Time, (min ) Time, (min )

Fig. 8. Water absorbed per unit area of concrete mixtures with and without fines.

8 8
A0 A15
B0 B15
C0 C15
Absorbed Water x 10 (g/mm )

Absorbed Water x 10 (g/mm )

2
2

D0 D15
6 6
-3

-3

4 4

2 2

0 0
0 2 4 6 8 0 2 4 6 8
1/2 1/2
Time, (min ) Time, (min )

Fig. 9. Water absorbed per unit area of crushed sand concrete at 90 days.

3.5. Chloride-ion penetration illustrated in Fig. 13. All the results of concrete mixtures
for different types of cement with and without fines as
Results of concrete chloride-ion penetration resistance replacement of crushed sand, showed higher values of the
at 90 days measured in terms of electric charge passed charge passed indicating lower resistance to chloride-ion
through the specimens in coulombs (ASTM C1202) are penetration. Coulomb values above 4000 indicate high-per-
 B. Menadi et al. / Construction and Building Materials 23 (2009) 625–633 631

38 40
Experimental data Experimental data
38
36

Compressive strength (MPa)

Compressive strength (MPa)

36
34

34
32
32

30
30

28 28

26 26
4 5 6 7 40 60 80 100
-3 Water penetration depth (mm)
Absorbed water x 10 (g/mm²)
Fig. 12. Relationship between compressive strength and water penetration
Fig. 10. Relationship between compressive strength and water absorbed
depth for concrete mixtures.
per unit area.

meability concrete according to ASTM C 1202 [17]. This and 30% limestone fines, as cement replacement. The
could be attributed to the higher water to cement ratio of higher permeability of concrete with limestone fines could
0.65 used in this investigation. limit its use in structures exposed to marine environment.
At 90 days, chloride-ion penetration of concretes incor-
porating 15% of limestone fines was found to be higher 3.6. Gas permeability
than that of concrete without fines. Concrete mixture
A15 presented higher charge value compared to all others Fig. 14 illustrates gas permeability results of all concrete
mixtures. The results showed that 15% of fines in crushed mixtures with and without limestone fines. The presence of
sand did not have a significant effect on the chloride-ion limestone fines increases the gas permeability of concrete
penetration of concrete containing cements C or D. regardless of the cement type. The permeability values
Charges of concretes incorporating cement C are similar range from 5.08 × 10—17 m2 to 9.06 × 10—17 m2 for con-
to those of type D cement. These results are in agreement crete mixtures without fines. For mixtures incorporating
with those obtained by Bonavetti et al. [23], who reported fines, permeability varies between 6.03 × 10—17 m2 and
an increase of chloride-ion penetration for water cured 9.72 × 10—17 m2 which is somewhat similar to concretes
concretes containing 10% and 20% limestone filler as without fines. In general, using cements A or B in concrete
replacement of cement. Also, Tsivillis et al. [24] reported causes high gas permeability compared with those contain-
an increase of charge for concrete mixtures with 0%, 20% ing cements C and D with and without the inclusion of

120

100
Water penetration depth (mm)

80

60

40

20

0
A0 A15 B0 B15 C0 C15 D0 D15
Concrete mixtures

Fig. 11. Water penetration depth of various concrete mixtures at 90 days.

632 B. Menadi et al. / Construction and Building Materials 23 (2009) 625–633

14000
a 36
12000 Experimental data
Total charge (Coulombs)

10000 34

Compressive strength (MPa)

8000
32
6000

4000 30

2000
28
0
A0 A15 B0 B15 C0 C15 D0 D15
Concrete mixtures
26
Fig. 13. Total charge passed for concrete mixtures at 90 days. 4 6 8 10 12
-17 2
Coefficient of permeability x 10 (m )
b 36
12
Experimental data
Coefficient of permeability x 10 (m )
2

10
-17

Compressive strength (MPa) 34

32
6

4 30

2
28

0
A0 A15
Fig. 14. Permeability coefficient values for various concrete mixtures at 90
days.
fines. This is could be due to the lower fineness of cements
A and B compared to cement C and D. Gas permeability
increase due to the incorporation of 15% of limestone fines
in all concrete mixtures could be attributed to the dilution
effect of the filler. This is similar to the chloride-ion pene-
tration results for all concrete mixtures at the age of 90
days (Fig. 13).
The compressive strength versus gas permeability and
the total charge passed of concrete mixtures are shown in
Fig. 15a and b, respectively. There is a tendency for the
gas permeability to increase as strength decreases. How-
ever, the total charge passes does not exhibit a correlation
with compressive strength.
4. Conclusions
Based on the results of this experimental investigation,
the following conclusions could be drawn:
● The incorporation of 15% limestone fines in concrete
caused a reduction in compressive strength regardless
of the cement type.
B0 B15 C0 C15 D0 D15
26
Concrete mixtures 6 7 8 9 10 11 12
3
Total charge x 10 (Coulombs)
Fig. 15. Relationship between compressive strength and (a) permeability
coefficient and (b) total charge for concrete mixtures at 90 days.
● Similar capillary water absorptions were obtained for all
concrete mixtures and higher values were observed in
concretes with lower cement fineness irrespective of the
limestone fines content.
● The resistance to chloride-ion penetration and gas per-
meability decreased for all concrete mixtures with the
inclusion of 15% limestone fines as sand replacement.
The presence of 15% limestone fines as partial replace-
ment of fine aggregates causes an increase in chloride-
ion penetration and gas permeability whereas reduces
water permeability.
● The higher chloride-ion penetration and gas permeabil-
ity of crushed sand concrete with 15% of limestone fines
means that its use in structures exposed to marine envi-
ronment should be limited.
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