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a
School of Technology, University of Glamorgan, Treforest Cardi, Wales CF37 1DL, UK
b
School of Applied Sciences, University of Glamorgan, Treforest Cardi, Wales CF37 1DL, UK
Abstract
The thaumasite form of sulfate attack (TSA), is a deleterious physico-chemical attack of the calcium silicate hydrate (CSH),
binding phase of concrete. Water:binder ratios (w:b), are known to control ingress of potentially deleterious ions by pore structure
renement at low (0.40) values. Equally, a physicalchemical barrier exists at about w:b ratio of 0.45 regardless of the binder type.
The inclusion of ultra-ne pozzalans (e.g. metakaolin) in the binder has been shown to impart such properties through densication
of the matrix and removal of calcium hydroxide.
A small-scale experimental design programme to establish the potential resistance of metakaolinPortland cement (MKPC),
blended concrete to the thaumasite-type of attack is ongoing. Results are presented for concrete incorporating dolomitic limestone
aggregate and with 0% and 7% metakaolin replacement of a high-C3 A PC binder at w:b ratios to 0.40 and 0.46. Exposure to three
environments containing a sulfatic clay, sulfate solution and water has produced evidence of deleterious reactions within these
samples. Visual data are quantied by a wear rating and supported by compressive strength and expansion values for up to 280 days
of exposure. These results conrm the importance of low water binder ratios in the resistance of ion ingress and give an early
indication of the desirable durability-enhancing properties of MK replacement of PC. Finally, the results also show that the two
sulfatic environments of exposure produce marked dierences in the degradation modes, which may be important in the meth-
odologies used to determine TSA in the laboratory with reference to eld observations.
2003 Elsevier Ltd. All rights reserved.
0958-9465/$ - see front matter 2003 Elsevier Ltd. All rights reserved.
doi:10.1016/S0958-9465(03)00150-1
932 I. Smallwood et al. / Cement & Concrete Composites 25 (2003) 931938
investigations [9] and eld trials [10] of the pozzalan reaction products including viscous gels. Classically, for
Metakaolin (MK) as a PC replacement, have established argillaceous dolomitic limestones dedolomitisation oc-
both enhanced physical and chemical properties asso- curs in which brucite, calcite and alkali carbonates are
ciated with improved durability. the products. Subsequent reaction of the carbonates
Physically, densication of the hydration products with calcium hydroxide regenerates the alkali hydrox-
within the matrix occurs as a function of MKs ner ides to further the reaction as described below:
particle size relative to that of PC, resulting in pore
CaMgCO3 2 2Na; KOH
structure renement. Though apparently contradictory,
an increasing inclusion of a pozzalan increases the total ) MgOH2 CaCO3 Na; K2 CO3
pore volume with no apparent detriment to imperme- Na; K2 CO3 CaOH2 ) CaCO3 2Na; KOH
ability [5]. Resistance to the ingress of sulfate ions is
reported, as is a decrease in ion diusivity. Both reect AAR is inuenced by the alkali content of the pore
an associated suppression of the water absorption ca- solution primarily as a function of binder composition.
pacity of metakaolin blended materials demonstrated by Also the pore structure and volume control the water
their reduced sorptivity [11]. ingress and subsequent hydraulic regime, in which the
Pozzalanic hydration reactions are described in the ions and water interact. In addition external environ-
literature [12,13] in which calcium hydroxide (CH), from mental factors including temperature and humidity also
PC hydration is consumed in the formation of CSH play an important role in AAR [18].
gel. The signicance of CH removal and the potential The objectives of the current research programme
chemical durability of MKPC blended materials where are:
TSA may occur is highlighted by the recent work of
Hartshorn et al. [14]. Bensted [15] describes the typical To establish the resistance of MKPC blended con-
route of thaumasite formation by Si substitution of Al in crete to TSA.
ettringite by interaction with CSH gel in the presence To discern the physical and chemical resistance of
of CO23 within a cold, wet environment:
cementitious materials at w:b above and below the
theoretical threshold of 0.45.
C3 A 3CS H32 C3 S2 H3 2CC 4H To contribute to the understanding and knowledge of
) 2CS CC CS H15 CSH2 AH3 4CH the modes and mechanisms of TSA.
Table 1
Physical and chemical properties of the component materials
Material % Analysis
SiO2 Al2 O3 Fe2 O3 Mn2 O3 TiO2 CaO MgO SO3 CO2 K2 O Na2 O LOI IR s.s.
total (m2 /kg)e
Dolomite 2.0 0.7 1.4 29.9 20.4
l/sta
PCb 20.9 5.5 2.1 0.04 0.26 64.9 0.9 3.0 0.9 0.54 0.19 1.3 0. 45 350
MKc 52.1 41.0 4.32 0.81 0.07 0.19 0.63 0.26 0.6 12 000
ggbsd 35.5 12.0 0.4 8.0 42.0 8.0 1.2 0.2 0.3 450
a
Provided by Hanson Aggregate, Aberdare.
b
Provided by Blue Circle Technical Centre.
c
Provided by Imerys Ltd., St. Austell.
d
Provided by Civil and Marine Slag cement UK.
e
Specic surface.
Table 2
Mineralogy of Lower Oxford clay
Mineral Quartz Illite Kaolinite Calcite Feldspar Chlorite Organic Pyrite Gypsum
a
% Content 29 23 10 10 8 7 7 4 2
a
Provided by Hanson Brick Co., Stewartby.
analytical tests have been carried out on concrete sam- clay were kept in a saturated environment by inclusion
ples with w:b ratios of 0.40 and 0.46 and exposed to of a small reservoir of deionised water at the base of and
water, sulfate solution and the sulfatic LOC at 5 C, and in contact with the clay mass, whilst the control samples
these tests are ongoing. Sample sizes and the associated in water were left undisturbed.
data determinations are given in Table 3. All the samples were placed in appropriate sealable
Trial mixes with a minimum binder content of 450 kg/ containers at 5 5 C which enabled a unit volume of
m3 as recommended by the Thaumasite Expert Group exposure equivalent to 0.005 ml of solution to 1 mm3 of
[17] were conducted and the nal mix composition se- concrete for those placed in water and sulfate solution.
lected (based upon satisfactory workability to give full Similarly, in the clay a cell volume of exposure of be-
compaction on a vibrating table using no superplasti- tween 35 mm3 per mm3 of the concrete sample was
ciser) was 1 binder:1 coarse aggregate (6.3 mm):0.5 achieved. At 28, 56, 112, 196 and 280 days of exposure
medium aggregate (5.0 mm):1 ne aggregate (<2.36 samples were assessed P as described in Table 3. The
mm). Mixing and casting of the samples was carried out wearing value, W loss of diagonals mm=8 is de-
to BS 1881 part 125 [20]. After 24 h they were de- termined after Harrison who used the value of W to
moulded, wrapped in clinglm and moist cured for 14 assess the degree of sulfate resistance [22]. The criteria
days prior to placing in the three dierent environments are; W P 5 poor sulfate resistance, W P 2 but <5 satis-
of exposure. The European prestandard for sulfate ex- factory resistance and W < 2 good sulfate resistance for
posure, pr ENV 196-X [21], was modied to include re- one year of exposure. Compressive strength values for
seeding of the sulfate ions to the original concentration 25 mm cubes were determined on a Instron 8502 with a
at 100 day intervals, which reduces the disturbance of loading rate of 11.2 kN/min, equivalent to the BS 1881
the chemical system thus allowing potential secondary part 116 loading rate of 0.3 N/(mm2 sec), and expansion
reactions to proceed unhindered. Samples exposed to of the 20 20 160 bars was determined to 0.002 mm
Table 3
Sample sizes with appropriate visual and/or analytical determinations
Sample size (mm) Visual assessments and analytical determinations
20 20 160 bar Expansion, mass and qualitative visual assessment
50 50 50 cube Qualitative visual assessment, wearing value, mass, density and surface voids
25 25 25 cube Qualitative visual assessment, compressive strength, mass and density
20 20 18 tablet Qualitative visual assessment and dried at 40 C over silica gel to constant
mass wrapped in cling lm and stored in airtight containers
as reserve samples. Samples for TG, SEM, XRD and petrographic analysis are
taken from all samples as appropriate
934 I. Smallwood et al. / Cement & Concrete Composites 25 (2003) 931938
Table 4
Wearing values (W ) for 50 cm3 exposed for 280 days
Sample descriptiona Wearing value (W ) 0280 days Observations
0.40-00W 00 good No visible erosion, evidence of gel coating
0.46-00W <1<1 good No visible erosion, evidence of gel coating
0.40-07W <1<1 good No visible erosion, evidence of gel coating
0.46-07W <1<1 good No visible erosion, evidence of gel coating
0.40-00S 04 satisfactory Loss of exterior material by physical removal,
<0.46-00S
0.46-00S 14 satisfactory Loss of surface integrity, exposure of aggregate
and matrix
0.40-07S <1<1 good Below surface reactions producing exfoliation
0.46-07S 01 good Loss of edges and corners with blistering
0.40-00C 00 good No loss of material, evidence of surface reaction
zones
0.46-00C <1<3 satisfactory Reaction zones notable at corners with loss of
material
0.40-07C <11 good Reaction zones notable at corners with some
loss of material
0.46-07C <1<3 satisfactory Reaction zones notable at corners with loss of
material
a
0.40-00W where 0.40 and 0.46 denotes the w:b ratios, -00 0% and 07 7% replacement of PC by MK and W water, S sulfate and C clay
environments of exposure.
I. Smallwood et al. / Cement & Concrete Composites 25 (2003) 931938 935
Fig. 2. 196 day 20 20 160 mm bar 100% PC at w:b 0.46 exposed to sulfate solution.
Fig. 3. 196 day 20 20 160 mm bar 7% MK replacement at w:b 0.46 exposed to sulfate solution.
Fig. 5 shows the strength development (up to 280 there is then a general decline in strength up to at least
days) of the concretes with w/b ratios of 0.40 and 0.46, 280 days. In Lower Oxford clay, for three of the samples
and with the PC partially replaced with 0% and 7% MK, near maximum strength is achieved at 28 days, then
in the three exposure environments of water, sulfate after about 150 days strength begins to show a signi-
solution and Lower Oxford clay. For specimens without cant decline. For the sample with w/b 0.46 and no MK
MK the strength, as might be expected is higher at the strength is not maintained after 28 days and shows
lower w:b ratio. The eect of partial replacement of PC continual decline.
with 7% MK is to generally enhance the strengths al- Fig. 6 shows the expansion of these concretes in the
though this eect is more consistent for the concretes of three dierent exposure conditions, and it is clear that
w:b ratio 0.46 and is less consistent for concretes of w:b their behaviour in clay is qualitatively dierent from
0.40, particularly at extended ages. that in either water or sulfate solution. In water ex-
Strength development clearly shows consistently dif- pansion is very small (<0.2%) and occurs within the rst
ferent behaviours in the three exposure environments. In 28 days of soaking. The specimens without MK show
water, near maximum strength is achieved by about 28 the greatest expansion, which increases with increase in
days and subsequently there are relatively small changes w:b ratio. In sulfate solution expansion also occurs within
in strength up to at least 280 days. In sulfate solution the rst 28 days of soaking but then continues to increase
maximum strength is attained at about 28 days and systematically with exposure time. As in water, expansion
936 I. Smallwood et al. / Cement & Concrete Composites 25 (2003) 931938
Fig. 4. 196 day 20 20 160 mm bar 100% PC at w:b 0.46 exposed to sulfatic clay.
120 1
Compressive strength
0
60 -0.2
-0.4
40 -0.6
40-00W 46-00W 0 50 100 150 200 250 300
20 (a) Time (days)
40-07W 46-07W
0
0 50 100 150 200 250 300 1
40-00S 46-00S
(a) Time (days) 0.8
% Expansion
40-07S 46-07S
0.6
120 0.4
0.2
Compressive strength
100 0
80 -0.2
-0.4
(N/mm )
2
60 -0.6
0 50 100 150 200 250 300
40
(b) Time (days)
20 40-00S 46-00S
40-07S 46-07S 1
0 40-00C 46-00C
0.8
% Expansion
-0.4
100
-0.6
80 0 50 100 150 200 250 300
(c) Time (days)
(N/mm )
2
60
40 Fig. 6. Expansion values for samples exposed to water, sulfate solu-
20 40-00C 46-00C tion and sulfatic clay: (a) exposure to water, (b) exposure to sulfate
40-07C 46-07C solution and (c) exposure to sulfatic clay.
0
0 50 100 150 200 250 300
(c) Time (days) is greatest for specimens without MK and is higher at
Fig. 5. Compressive strength values for samples exposed to water, higher w:b ratio. By 280 days, although the samples show
sulfate solution and sulfatic clay: (a) exposure to water, (b) exposure to spalling of surface reaction products, they remain intact.
sulfate solution and (c) exposure to sulfatic clay. For concrete exposed to saturated clay, specimens with
I. Smallwood et al. / Cement & Concrete Composites 25 (2003) 931938 937
w:b 0.40 show a dierent pattern of length change from resulting from chemical reaction continually spalls
that with w:b 0.46. After small initial expansion both away from the outer surfaces leaving them continu-
concretes (with and without MK) show signicant con- ously exposed to the aggressive solution. In the latter
traction followed by sharp expansion, the expansion of case the vulnerable surface regions transform into
the bar with MK occurring at a later time than that a white pulpy mush. Clearly diusion rates and con-
without MK. Also the concrete prisms are still intact at centration gradients of aggressive species at the con-
280 days. The contraction at low w:b ratio is attributed to creteexposure-medium interface are going to be very
autogenous shrinkage, where (unlike concrete fully im- dierent in the two dierent exposure environments
mersed in water/sulfate solution) the movement of water and the former may not be appropriate for investigat-
into the concrete is inhibited by the restricted availability ing reaction mechanisms under eld conditions.
of water at the clayconcrete interface. A similar pattern
of initial expansion followed by shrinkage has previously Although monitoring is continuing, the preliminary
been reported by Wild et al. [23] for PCMK pastes. evidence (not all reported here in detail) does conrm
Surprisingly, although the concretes with w:b 0.40 sub- that both MK and ggbs inhibit TSA in the short term
sequently show marked expansion, they are still intact at and may therefore have potential application for pre-
280 days, whereas the concretes with w:b ratio 0.46 venting TSA in concrete. In addition the observation of
fractured in a number of places at periods between 112 extrusion of gel, particularly extreme for the concrete
and 196 days for the concrete without MK and between with w:b ratio 0.40 and with 7% MK, suggests that al-
196 and 280 days for the concrete with MK. kali carbonate reaction may be associated with the TSA
Currently there is no visual evidence of sulfate attack in the particular system under investigation. It is antic-
in the 14% MK, 21% MK and 80% ggbs concretes and ipated that planned detailed analytical work will answer
the expansion of these concretes is negligible. It may be some of these questions.
signicant that these concretes do not show the exten-
sive development of surface gel coatings when exposed
to water as do the PC control and 7% MK concretes,
Acknowledgements
suggesting that the formation of this gel may be indi-
rectly associated with TSA.
The authors are grateful to Imerys for providing
funding support for an EPSRC CASE Studentship,
analytical facilities and raw materials, and would also
5. Conclusions
wish to thank EPSRC for providing the CASE stu-
dentship. The authors are also grateful to Professor
The investigation is ongoing and therefore the results
M.H. Lewis for providing TEM analysis of the gel.
reported here are of a preliminary nature. The visual
evidence accumulated of concrete degradation is typical
of TSA although this has yet to be conrmed by the
planned analytical programme. From the observations References
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