Development of Flash-Calcined Sediment and Blast Furnace Slag Ternary Binders

Abstract

Partial cement replacement by low-carbon-impact additions has the potential to reduce CO2 emissions. The aim of this study is the development of a ternary binder that includes ordinary Portland cement (OPC), ground granulated blast furnace slag (GGBS), and flash-calcined sediment (FCS). To upgrade dredged mineral material into FCS, a new heat treatment, i.e., flash calcination, was used. The used materials were physically, chemically, and mineralogically characterized. The mixture design method was used to optimize the design of the ternary blended binders. A model was developed and validated for the prediction of the 90-day compressive strength for mortars composed of OPC (C), GGBS (S), and FCS (F). Five mixes, reference RM (100% OPC), binary mix (50% OPC and 50% GGBS), and three ternary mixes with FCS rates of 10%, 15%, and 20% were characterized in fresh and hardened states. The results show that the incorporation of FCS reduced the workability of the mixes and increased their densities. Moreover, the initial setting time of the mix was delayed, and the heat of the hydration peak was decreased. The 90-day compressive strengths of the mix containing 10% FCS were higher than those of RM. In conclusion, the use of 10% FCS and 40% GGBS was an efficient substitute for 50% OPC.

Study of Microstructure, Crystallographic Phases and Setting Time Evolution over Time of Portland Cement, Coarse Silica Fume, and Limestone (PC-SF-LS) Ternary Portland Cements

“…Analyzing their physical and mechanical characteristics, they concluded that these new mixes comply with the specifications of the current Portland cement standards [5]. Zeraoui et al [6] prepared some ternary binders by mixing common Portland cement, ground granulated blast-furnace slag, and flash-calcined sediment. They found that the mix with 10% flash-calcined sediment and 40% ground granulated blast-furnace slag could replace 50% common Portland cement.…”

Efficient Multi-Composite Cement Made of Granulated Blast Furnace Slag (GBFS) and Flash-calcined Sediment

“…The BET-specific surface area of CEM III SF is much higher than that of CEM III Ref. An increase in BET surface area could lead to an increase in water demand and the initial setting time of CEM III SF cement compared with the reference as indicated in previous studies [39,32,45] . The curve of particle size distribution of both cements is shown in Figure 4.…”

“…Although the use of flash-calcined sediment as a replacement for GBFS and metakaolin (MK) in cementitious materials was investigated in previous studies [39,40], the impacts of flash-calcined sediment substitution on the hydration kinetics, the formation of hydration products, and the potential change in the composition of hydrates were not studied. In addition, in these studies, the supplementary cementitious materials were directly mixed with the cement; this could lead to a potential change in the particle size distribution of blended cement, affecting the hydration and the development of mechanical-microstructural properties of mixtures.…”

Carbonation Resistance of Ternary Portland Cements Made with Silica Fume and Limestone

“…In an attempt to produce low-carbon and cost-effective blended cements, new formulations are currently being investigated [ 34 ]. Zeraoui et al [ 35 ] studied ternary binders (Portland cement-ground granulated blast-furnace slag-flash-calcined sediment) and reported that 10% flash-calcined sediment plus 40% ground granulated blast-furnace slag can replace 50% of Portland cement. However, the water demand increases with the use of flash-calcined sediment, but it enhances the compactness and density of the mortar.…”