Utilization of By-Products and Wastes As Supplementary Cementitious Materials in Structural Mortar For Sustainable Construction
Utilization of By-Products and Wastes As Supplementary Cementitious Materials in Structural Mortar For Sustainable Construction
Utilization of By-Products and Wastes As Supplementary Cementitious Materials in Structural Mortar For Sustainable Construction
Review
Utilization of By-Products and Wastes as
Supplementary Cementitious Materials in
Structural Mortar for Sustainable Construction
Shamir Sakir 1 , Sudharshan N. Raman 1,2 , Md. Safiuddin 3,4,5, *, A. B. M. Amrul Kaish 1
and Azrul A. Mutalib 1
1 Department of Civil Engineering, Faculty of Engineering and Built Environment,
Universiti Kebangsaan Malaysia, 43600 UKM Bangi, Selangor, Malaysia; [email protected] (S.S.);
[email protected] (S.N.R.); [email protected] (A.B.M.A.K.); [email protected] (A.A.M.)
2 Department of Architecture and Built Environment, Faculty of Engineering and Built Environment,
Universiti Kebangsaan Malaysia, 43600 UKM Bangi, Selangor, Malaysia
3 Angelo DelZotto School of Construction Management, George Brown College, 146 Kendal Avenue,
Toronto, ON M5T 2T9, Canada
4 Department of Civil Engineering, Faculty of Engineering and Architectural Science, Ryerson University,
350 Victoria Street, Toronto, ON M5B 2K3, Canada
5 Department of Civil and Environmental Engineering, Faculty of Engineering, University of Windsor,
401 Sunset Avenue, Windsor, ON N9B 3P4, Canada
* Correspondence: [email protected]; Tel.: +1-416-415-5000 x6692
Received: 4 February 2020; Accepted: 20 April 2020; Published: 9 May 2020
Abstract: Rapid growth in industrial development has raised the concern of proper disposal of the
by-products generated in industries. Many of them may cause serious pollution to the air, land, and
water if dumped in open landfills. Agricultural and municipal wastes also cause environmental
issues if not managed properly. Besides, minimizing the carbon footprint has become a priority in
every industry to slow down global warming and climate change effects. The use of supplementary
cementitious materials (SCMs) obtained from agricultural, industrial, municipal, and natural sources
can decrease a significant amount of fossil fuel burning by reducing cement production and contribute
to proper waste management. Also, SCMs can enhance desirable material properties like flowability,
strength, and durability. Such materials may play a big role to meet the need of modern time for
resilient construction. The effective application of SCMs in cement-based materials requires a clear
understanding of their physical and chemical characteristics. Researchers studied how the flowability,
strength, and durability properties of structural mortar change with the replacement of cement
with different SCMs. Various experiments were conducted to examine the behavior of structural
mortar in extreme conditions (e.g., high temperature). Many scholars have attempted to improve
its performance with various treatment techniques. This article is an attempt to bring all the major
findings of the recent relevant studies together, identify research gaps in the current state of knowledge
on the utilization of SCMs in structural mortar, and give several recommendations for further study.
The available results from recent studies have been reviewed, analyzed, and summarized in this
article. A collection of the updated experimental findings will encourage and ease the use of various
by-products and wastes as SCMs in structural mortar for sustainable construction.
1. Introduction
Every second, a rain forest with the size of 19 tennis courts vanishes, 1600 tons of ice melt in
Greenland, a desert area of 78 m2 expands in China, and 720 tons of CO2 are emitted by fossil fuel
combustion [1]. This is how industrial development affects Mother Nature. The cement production
industry is one of the prominent industries of the world. The history of cement-based materials is as
old as human civilization. The development of modern hydraulic cement began at the beginning of the
industrial revolution to meet the requirements of stronger and more durable cementitious products,
which can survive in wet and salty conditions. The cement production has hiked up at an increasing
rate in the last century. In 2015, the global production of cement was 3 billion tons, which had a 6.3%
annual growth rate [2,3]. The production of each metric ton of Portland cement requires about 4–5 GJ
of energy [4,5]. Around 60–130 kg of fuel oil or its equivalent and about 110 KW-h of electricity are
required to produce one metric ton of cement, depending on the cement type and the processes used [6].
Approximately, 800–1000 kg of CO2 emissions occur during the production of each ton of cement [3,7,8].
About 5%–8% of the global man-made emissions of CO2 is caused by cement production [3,5,8–10]. To
reduce the risk and impact of global warming and climate change, the “Paris Agreement” was signed
in 2016. In this agreement, 152 parties (collectively responsible for 84.64% of the global emissions
of greenhouse gases) have agreed to pursue limiting the temperature increase to 1.5 ◦ C above the
preindustrial levels [11,12]. The utilization of cementitious and/or pozzolanic by-products and wastes
as partial cement replacement materials can be helpful in this perspective. Within the context of this
paper, if a secondary outcome of a process has some market value, it is referred to as “by-product”.
If it does not have any market value and is usually disposed of, it is considered as “waste”.
Many industrial processes generate a huge quantity of by-products. Agricultural and municipal
operations also generate a vast quantity of wastes. The proper disposal of these materials is a big
concern. As these materials possess cementitious and/or pozzolanic properties, they can be used as a
partial replacement of cement in cementitious composites, thus decreasing the high production cost
and environmental pollution associated with cement factories. Such supplementary cementitious
materials (SCMs) can save a significant amount of cement and give specific properties to cementitious
products that help to meet the requirements of modern construction.
Different SCMs have various chemical and physical properties; thus, they produce different impacts
on cement-based materials. Moreover, the generation of a specific SCM depends on a specific industrial,
agricultural, or municipal process. Therefore, various SCMs are available in different parts of the
world. Besides, the desired properties of cement-based materials mostly depend on the socio-economic
and environmental conditions. Some societies are focused on new buildings, while some others are
focused on retrofitting. In some cases, the performance is the highest priority while controlling cost is
the highest priority in some other cases. Coastal, polar, and desert areas need cementitious products of
special properties for their structures. For these limiting conditions, it is difficult to find an appropriate
SCM for a specific purpose and optimize its quantity for cement-based materials.
In the present study, the research question was, “how can we utilize SCMs obtained from
industrial, agricultural, municipal, and natural sources to reduce the carbon footprint of the
construction industry?” To find the answer, scholarly articles were searched through Web of Science,
Google Scholar, and Science Direct databases. During the search, the following keywords were
used: “SCM”, “supplementary cementitious materials”, “cement replacement”, “mortar”, “fly ash”,
“silica fume”, “ground granulated blast-furnace slag”, “palm oil fuel ash”, “rice husk ash”, “bottom ash”,
“volcanic ash”, “limestone powder”, “metakaolin”, “glass powder”, and their different combinations.
From the search outcomes, only the recent experimental results on cement mortar were emphasized.
The fiber-reinforced mortar was excluded from this study because of its different working mechanism
and characteristics.
The use of more SCMs as a partial replacement of cement will decrease the cost of cementitious
products, reduce the environmental pollution, and consume the agricultural and industrial by-products
or wastes; thus, it will contribute to significant progress towards sustainable construction. The objective
Sustainability 2020, 12, 3888 3 of 35
of the present study is to summarize the effects of the major SCMs on the key properties of structural
mortar so that the experts can easily decide a suitable amount for their purpose.
2. Structural Mortar
Mortar is defined as “a mixture of finely divided hydraulic cementitious material, fine aggregate,
and water” [13]. Papayianni et al. [14] have classified mortar in three basic types:
In the case of floor covering and rendering mortars, strength is not a major concern. In certain
applications, mortar has a load-bearing role. When a mortar is expected to resist some external forces
and provide strength, it is referred to as “structural mortar”.
The strength-oriented application of mortar is rising day by day. The structural mortar is being
used as:
Versatile applications of structural mortar require different fresh and hardened properties.
In masonry work, the mortar should be adequately workable to allow proper placement of masonry
units above it. Usually, a mortar strength lower than the masonry unit is recommended so that cracks
would occur at the joints [15]. Unlike masonry work, concrete repair and thin reinforced cementitious
products need higher flowability to ensure proper placement in narrow and/or congested spaces. The
mortar strength directly influences the performance of the whole structure in such cases. Usually,
a higher strength is desirable.
The strength requirements of structural mortar for different applications are given in Table 1. To
achieve the desirable properties and find a suitable mixture design for structural mortar, SCMs can be
very effective tools. The use of appropriate SCMs at a proper ratio can enhance both the fresh and
hardened properties of structural mortar, resulting in cost-effective construction and better performance.
3. Major SCMs
The major SCMs obtained from different sources are briefly described in the following subsections.
The chemical compositions and key physical properties of ordinary Portland cement (OPC) and
different SCMs are given in Table 2.
Sustainability 2020, 12, 3888 4 of 35
Chemical
Composition FA 1 BA 1 SF 1 GGBS 1 LP 1 MK 1 VA 1 POFA 1 RHA 1 WGP 1 OPC 2
(wt.%)
SiO2 36–65 44–59 85–99 28–41 0–8 49–69 45–65 47–69 17–94 56–81 16–23
CaO 1–19 1–17 0–4 37–50 45–55 0–2 3–11 4–12 0–2 5–11 49–69
Al2 O3 17–29 5–32 0–6 5–14 0–3 25–44 11–18 1–9 0–3 0–6 4–7
Fe2 O3 4–31 2–9 0–3 0–1 0–2 0–3 1–13 1–10 0–2 0–1 2–7
MgO 0–7 1–3 0–5 4–10 0–7 0–3 1–9 2–6 0–1 0–4 0–5
SO3 0–3 0–2 0–2 0–3 0–1 0–1 0–1 0–3 0–1 0–1 0–1
Na2 O 0–2 0–1 0–2 0–3 0–1 0–1 3–4 0–1 0–1 7–16 0–1
K2 O 0–3 1–8 0–2 0–2 0–1 0–2 1–6 5–11 0–5 0–1 0–1
P2 O 5 0–2 0–1 0–1 – – 0–1 0–1 3–5 – – –
TiO2 0–2 0–3 – 0–1 – 0–1 0–3 – – – –
LOI 0–5 1–13 0–6 1–2 36–45 0–4 1–6 1–21 0–6 0–12 –
Sp. gravity 2.26 2.64 2.24 2.88 2.72 2.51 2.66 2.42 2.16 2.50 3.15
Ref. [19–30] [31–38] [20,23,39–47] [7,48–54] [41,46,55–62] [43,58,63–67] [60,62,68–71] [38,72–77] [78–83] [84–88] [20,40,50,51,55,72,89,90]
1 FA = Fly Ash; SF = Silica Fume; GGBS = Ground Granulated Blast-Furnace Slag; WGP = Waste Glass Powder; LP = Limestone Powder; MK = Metakaolin; POFA = Palm Oil Fuel Ash;
RHA = Rice Husk Ash; BA = Bottom Ash; VA = Volcanic Ash. 2 Ordinary Portland cement complying with EN 197-1 (Cement Type I-42.5 R).
Sustainability 2020, 12, 3888 5 of 35
about 300–360 million tons per year [105]. The most dominant minerals in GGBS are CaO and SiO2 ,
followed by MgO and Al2 O3 (Table 2). GGBS allows a relatively high replacement level of cement
without compromising the strength of mortar due to its self-cementing properties [53].
3.2.1. Metakaolin
The raw material for porcelain manufacture is known as china clay or kaolin. It is a type of stone
which is rich in kaolinite. Metakaolin (MK) is a dehydroxylated form of the clay mineral kaolinite.
Purified kaolin clay is calcined at a temperature of 650–900 ◦ C to break down crystalline structure and
drive off water from it [66]. The production of 1 ton of MK requires 2.95 GJ of energy and releases 175 kg
of CO2 [65]. These values are 74% and 27% of those of the cement production process, respectively.
Having a high specific surface area or surface fineness and irregular structure, MK raises the water
demand of cementitious material for a given flowability. The calcination method determines the shape
of MK particles. Smooth surface particles are produced through flash calcination [65]. MK mainly
contains SiO2 and Al2 O3 (Table 2). Owing to these minerals, MK shows an excellent pozzolanic effect
on cement hydration in cementitious composites. Almost every study reported a positive impact of
MK on the strength of mortar.
POFA without prior treatment may cause some undesirable effects on the properties of cement-based
materials [76,111]. Treated POFA can save as much as 80% of OPC without compromising the key
properties of mortar [74].
Practically cement paste is a yield stress fluid [120]. The viscosity of binder paste generates viscous
stress, resisting the mortar flow. Different sizes of particles move at different rates, causing shear
stresses by collision, friction, and interlocking. The interaction between binder paste and aggregate
particles also generates stress. Lu et al. [121] have identified the following sources of resistance against
the mortar flow:
Figure 1. Forces
Figure 1. Forces against
against the
the mortar
mortar flow
flow as
as portrayed
portrayed by
by Lu
Lu et
et al.
al. [121].
[121].
Roussel
Roussel etet al.
al. [120]
[120] have
have identified
identified four
four main
main forces
forces that
that determine
determine the the rheological
rheological nature
nature of
of the
the
binder paste:
binder paste:
• surface •forcessurface forces (or
(or colloidal colloidal interactions),
interactions),
• Brownian • forces,
Brownian forces,
• hydrodynamic forces, and
• hydrodynamic forces, and
• various contact forces between particles.
• various contact forces between particles.
The fresh properties of mortar are basically affected by the size, shape, and surface area of its
solidThe
ingredients. Smoothof
fresh properties and spherical
mortar particlesaffected
are basically usually by improve theshape,
the size, flow properties
and surface of area
mortar by
of its
ball-bearing
solid effect Smooth
ingredients. [29]. In contrast, the smaller
and spherical sizeusually
particles and higher surface
improve thearea
flowof properties
particles usually reduce
of mortar by
the flowability
ball-bearing of mortar
effect [29]. In mixture
contrast,due to the increased
the smaller water demand
size and higher for wetness;
surface area also,
of particles angular
usually and
reduce
porous
the particlesofabsorb
flowability mortarsome mixing
mixture duewater
to theand thus decrease
increased the flowability
water demand of mortar
for wetness; also,mixture
angular[122].
and
The static
porous stability
particles of a some
absorb freshly mixed
mixing cement-based
water materialthe
and thus decrease depends on the
flowability of yield
mortarstress (fluidity)
mixture [122].
and static
The the difference
stability between the densities
of a freshly of binder paste
mixed cement-based and aggregates
material depends [123].
on theOn the stress
yield other hand, the
(fluidity)
dynamic
and stability of
the difference a cementitious
between mixture
the densities mostly
of binder depends
paste on its viscosity
and aggregates [123]. [124].
On theInother
closehand,
distance,
the
van der Waals
dynamic force
stability of is
a the most dominant
cementitious mixture force among
mostly the particles
depends on its in binder paste
viscosity [124].[125]. Electrostatic
In close distance,
repulsion
van alsoforce
der Waals originates from dominant
is the most the adsorbedforceions at the
among theparticle
particlessurface [126].
in binder A [125].
paste smaller portion of
Electrostatic
cement particles
repulsion may have
also originates fromBrownian motion
the adsorbed and
ions at diffuse through
the particle the [126].
surface liquid.AUsually,
smaller most SCM
portion of
cement particles may have Brownian motion and diffuse through the liquid. Usually, most SCM
particles are far smaller than cement particles. The substitution of a portion of cement by such particles
may significantly increase the Brownian motion, resulting in higher diffusion, reduced bleeding,
and more stable suspension [120].
Brownian motion causes the diffusion of cement particles through the liquid. In the course,
the particles may come close enough to develop the van der Waals force of attraction. Usually, Brownian
motion and electrostatic repulsion are not enough alone or even together to overcome van der Waals
force. The addition of water-reducing admixture may increase the distance among particles by getting
adsorbed on the surface of cement particles and causing electrostatic repulsion and steric hindrance,
thus reducing the magnitude of van der Waals force [120]. These interparticle forces are influenced by
the hydration process of cementitious ingredients, material properties, mixture proportions, mixing
and placement procedures, elapsed time, ambient temperature, relative humidity, etc. [52].
SCM particles decrease the porosity and increase the strength by filling up the gaps between
cement particles. This effect is termed as “filler effect” [127]. The surface of SCM particles affects
the hydration in two ways. Providing additional nucleation sites, SCM particles help the hydration
products to precipitate [128]. In addition, calcium ions get adsorbed on the SCM surface, resulting in a
lower Ca/Si ratio, which leads to the stability of the initial C–S–H (calcium-silicate-hydrate) layer in
cement-based materials [129].
Sustainability 2020, 12, 3888 9 of 35
Effective water-to-cement (w/c) ratio directly affects the porosity and strength of mortar. The
lower ratio gives more strength and less porosity. Partial cement replacement by any SCM will raise the
effective w/c ratio at a constant water-to-binder (w/b) ratio. This phenomenon is called “dilution effect”.
The dilution effect helps the long-term hydration reaction of cement although the degree of hydration
of binder may be relatively low. That is why the substitution of cement by SCM above a certain
level may harm the mechanical properties of mortar [56,130]. At a constant w/c ratio, the fineness of
binder materials controls the porosity and pore size distribution in cement-based materials such as
mortar [131].
The “pozzolanic effect” of SCM is to react with the secondary product, Ca(OH)2 (calcium hydroxide,
also known as portlandite), of cement hydration to form additional C–S–H gel (secondary C–S–H).
During the pozzolanic reaction, the longer silicate chains are formed as the Ca:Si molar ratio of C–S–H
drops [132]. This secondary C–S–H reduces the porosity in bulk cement paste and improves the
interfacial bond between aggregate particles, and thus increases the strength, density, and ion diffusion
resistance of mortar; pozzolanic activity results in a lower Ca(OH)2 concentration, causing a higher
Ca 2+ dissolution
Sustainability 2020, 12,rate
x FOR PEER
from REVIEW
the 9 of 36
cement particles [41,129]. It is possible that the smallest basic particles
of C–S–H gel (≤ size 4.2 nm) deposit on the walls of large gel pores, which have a diameter of 3–12 nm.
drop of pH to a level at which the embedded steel may start acting as an electrode and become
Such deposition causes a partial or complete blockage of diffusion path, reducing the porosity in
corroded [131].
hardened cement compound [129]. Figure 2 shows an illustration of this phenomenon.
Figure 2.
Figure 2. Deposition
Deposition mechanism
mechanism of
of C–S–H
C–S–H particles
particles [129].
[129].
5. Effects of SCMs
Excessive on the Properties
secondary of Structural
hydration may Mortar
have a detrimental effect on the corrosion resistance of
cement-based
The effects of various SCMs on2 the flowability, strength, andsolution,
materials [41]. Ca(OH) provides a buffer for the pore maintaining
durability a minimum
are discussed in the
pH level of 12.6. Extreme pozzolanic activity may damage the pH buffer, resulting in a drop
following subsections. The influences of SCMs on these mortar properties are summarized in Tables of pH to a
level at which the embedded steel may start acting as an electrode and
3 and 4. The best results provided by prominent SCMs are given in Table 5. become corroded [131].
Table 3. Effects of major SCMs on the flow and strength properties of mortar.
Flowability Strength
Replacement
Replacement Ratio
SCM Effect Ref. Effect Ratio Ref.
[% w/w]
[% w/w]
N 5–30 [20,24,25,29,56,89] N 0–40 [22,24,25,43,133,134]
FA
H 25–30 [26] H 10–70 [22,24,26,28–30,43,89]
N 7.3 [135] N 5–25 [26,39,46,135–137]
SF
H 5–20 [26,46,101] H 5–20 [39]
N 20–60 [49,50]
GGBS N 10–30 [49]
H 10–70 [49,53]
N 5–25 [20,87]
WGP H 5–25 [20]
H 5–40 [84,85,87,88]
N 5–70 [25,46,56,138,139] N 2.4–15 [55,138–140]
LP
H 20–30 [138] H 5–50 [41,46,59,62]
N 5–20 [43,64,67,141–144]
MK H 12.5–25 [64,65]
H 5–15 [145]
N 5–50 [72] N 10–80 [74,77]
POFA
H 10–30 [76,111] H 10–30 [38,76,111]
N 5–25 [78,83]
RHA H 5–20 [113]
H 5–30 [79,80,83,113]
N 5–33 [32,34,35,146]
BA N 9–41 [32,37]
H 6–41 [32–35,37,38,97,146]
– – – N 20–30 [60]
VA
H 20–50 [60,62,68–71]
Note: “N” indicates an increase and “H” indicates a decrease in the behavior.
Figure 3.
Figure 3. Effects
Effects of
of FA
FA microsphere
microsphere (FAM) and condensed
(FAM) and condensed SF
SF (CSF)
(CSF) on
on the
the mortar
mortar strength
strength at
at different
different
w/cm or
w/cm or w/b
w/b ratios
ratios [135].
[135]. [W/CM
[W/CM ratio
ratio =
= water-to-cementitious material ratio].
water-to-cementitious material ratio].
resistance. Same as the transport properties, the freezing and thawing resistance of mortar improves
with the inclusion of FA. After 300 freeze-thaw cycles, 18% of the compressive strength of 10% FA
Sustainability 2020, 12, x FOR PEER REVIEW 13 of 36
mortar was lost while 26% was lost for the mortar with no FA [43].
Effect
Figure 4. Figure of ofFA
4. Effect andMKMK
FA and on theon thestrength
mortar mortar strength
at different at different
temperatures [67]. [PCtemperatures
= Portland [67].
[PC = Portland
cement].
cement].
FA poses Densifying the matrix, FA improves the transport properties of mortar. FA decreased the
a higher risk of heavy metal leaching, compared to BA and GGBS. Some metals like Ti,
chloride permeability of mortar at all ages for 10% cement replacement and after 90 days for 20%
Mo, B, andcement
Cu had a higher degree
replacement [29,43]. of release
Similarly, from
almost the stabilized
two-fold and more thancement-FA mixture.
three-fold electrical The presence of
resistivity
chloride and sulphate in FA may have caused this phenomenon [95]. In addition, metallic
values were recorded at 180 days for 10% and 20% FA, respectively [29]. Freezing and thawing Al and Zn of
behavior is highly influenced by the degree of saturation. That is why certain transport
FA may produce H2 during cement hydration. A significant amount of H2 might result in expansion properties
and voids (e.g., water absorption, water permeability) can be considered as an indirect measure of freezing and
in cement-based materials [161].
thawing resistance. Same as the transport properties, the freezing and thawing resistance of mortar
improves with the inclusion of FA. After 300 freeze-thaw cycles, 18% of the compressive strength of
5.2. Bottom10%
AshFA(BA)
mortar was lost while 26% was lost for the mortar with no FA [43].
FA poses a higher risk of heavy metal leaching, compared to BA and GGBS. Some metals like Ti,
5.2.1. Effects
Mo,onB, Flowability
and Cu had a higher degree of release from the stabilized cement-FA mixture. The presence
of chloride and sulphate in FA may have caused this phenomenon [95]. In addition, metallic Al and
The effect of BA on the mortar flowability depends on its particle size and treatment process.
Zn of FA may produce H2 during cement hydration. A significant amount of H2 might result in
Ground orexpansion
sieved BA andof 425inµm
voids size enhanced
cement-based the[161].
materials flowability of mortar mixture; 21% of both ground
and sieved BA provided a flow spread in the range of 225–232 mm, while the OPC mortar had a
5.2. Bottom Ash (BA)
flow spread of 158 mm; the advantage of using sieved BA lies in retaining the flowability of mortar
mixture for5.2.1.
a longer
Effectstime. The mortar with sieved BA lost a little amount of flow after 1 h following the
on Flowability
completion of mixing compared to the mortar containing ground BA as well as the control mortar with
The effect of BA on the mortar flowability depends on its particle size and treatment process.
100% OPC;Ground
after 1orh,sieved
the flow
BA ofspread
425 µm sizeof the mortar
enhanced theincluding
flowability sieved
of mortarBA was above
mixture; 220 ground
21% of both mm; the mortar
with ground andBA andBA
sieved the controla flow
provided mortar had
spread in 199 and of
the range 130 mm flow
225–232 spread,
mm, while respectively;
the OPC mortar had the presence of
a flow
spread of 158 mm; the advantage of using sieved BA lies in retaining the
a higher level of washable carbon in ground BA may have caused this phenomenon [37]. Besides, theflowability of mortar mixture
for a longer time. The mortar with sieved BA lost a little amount of flow after 1 hour following the
mortar with 41% pulverized BA of mean particle size 4.5 µm yielded 14% higher flowability than the
completion of mixing compared to the mortar containing ground BA as well as the control mortar
OPC mortar; withthe
100%same
OPC;amount
after 1 h, of
theBAflowof size of
spread 6.3theµm provided
mortar including a sieved
flow spread of 112
BA was above mm,
220 mm; which
the was a
little higher than that given by 4.5 µm BA [32]. Smaller BA particles are subjected to higher Brownian
mortar with ground BA and the control mortar had 199 and 130 mm flow spread, respectively; the
motion butpresence
requireofmorea higher levelto
water of cover
washable carbon
their in ground
surface withBA themay
samehavefilm
caused this phenomenon
thickness. [37]. opposing
These two
Besides, the mortar with 41% pulverized BA of mean particle size 4.5 µm yielded 14% higher
conditions significantly influence the overall effect of BA on the flowability of mortar mixture.
of the control mortar; for any further addition, the compressive strength decreased; high porosity, high
organic matter content (5.26%), and high abrasion susceptibility (29%) were responsible for this drop in
strength [97]. Crushing to a particle size finer than 125 µm, combusting at 800 ◦ C for 18 h and removing
lightweight particles by flotation were applied to improve the quality of biomass BA; among these
techniques, crushing was the most effective; for a 13% crushed biomass BA, the compressive strength
was increased from 25 MPa to 36 MPa; the application of all three processes on the same sample
provided 52 MPa strength for the mortar with the same BA content, while the OPC mortar strength
was 58 MPa [33]. The positive impact of BA was observed when it was ground to a size finer than OPC;
the mortar with 10% such BA provided the 28 days compressive strength of 54 MPa, which was a little
higher than that of the corresponding control mortar; in the case of 25% such BA, the mortar samples
still passed the minimum strength requirement of 42.5 MPa [34]. The pulverized sub-bituminous BA
was milled for 0.5 and 3 h to make it two and three times finer than OPC (mean particle size of 6.3 µm
and 4.5 µm; Blaine fineness of 800 m2 /kg and 1000 m2 /kg), respectively; for 9% cement replacement, the
mortar with such BA gained 4.3% and 10.7% higher strength than the control mortar [32]. After ball
milling for 2 h and sieving by 300 µm sieve, 5% BA mortar provided 82 MPa compressive strength at
28 days, compared to the 78 MPa compressive strength of the control mortar; 20% BA mortar provided
85% strength of the control mortar at 28 days [35]. The compressive strength dropped for 10%–20%
coal BA with the particle size finer than 425 µm (ground or sieved); 67–72 MPa strength was reported
at 28 days for the mortars with this replacement range, while the control mortar had a compressive
strength of 79 MPa [37]. Surprisingly, the mortar containing BA of particles finer than 300 µm lost
about 32%–42% of its 28-day strength at 180 days; 454,000 parts per billion (ppb) of potassium (K+ ) ions
were detected in the solutions (water plus dissolved salts) processed from the water absorption test of
30% BA mortar samples; this value was only 52,700 ppb for the control mortar samples; ASR may have
occurred at this high concentration of dissolved K+ ions, resulting in degradation of amorphous, as
well as crystalline silica: the progressive dissolution of K+ ions in ASR imparts the loss of mechanical
properties at later ages [35].
and incinerator BA and cement solidification mitigate the risk of leaching, making BA a favorable
material for cement replacement [98].
particle size and surface area but also the size distribution of SF particles affects the strength properties
of mortar. The mortar including SF with an average particle size of 12 µm and a size distribution over
0–150 µm showed lower strength than the control mortar with 100% OPC. On the contrary, the mortar
including 25% SF, with a 45-µm sieve residue of 0.98% and a size distribution over 0–600 µm, provided
3.5% more strength at 28 days; therefore, a 0.98%–4.13% residue on the 45-µm sieve is advisable for the
use of SF in high performance mortar [137]. In the presence of 5%–35% LP, SF replacement causes an
adverse effect on the strength of mortar due to the reduction of hydraulically active clinker fraction of
cement [46].
30% substitution, the flow spread of mortar was raised by 28 mm (from 204 mm to 232 mm) [49]. The
influence of GGBS on the mortar flowability depends largely on the surface morphology of GGBS
particles. GGBS consisting of particles with smoother surface enhances the flowability of mortar
mixture [153].
with the other SCMs (e.g., FA, GGBS, SF, MK), LP improves the pore structure related properties
(e.g., porosity, absorption, permeability) if used with an appropriate amount [107]. The packing density
decreases as the LP content increases at a fixed cement paste volume. The packing density dropped from
0.720 to 0.705 for a rise in LP content from 0% to 34% at 50% cement paste volume [139]. Usually, the
sulphate resistance of mortar is not affected by LP content. However, higher cement replacement levels
with LP may cause earlier failure due to sulphate attack [148,149]. Torres et al. [155] have expressed
their concern for exposure to low-temperature and marine environments. They observed that the
mortar samples with 5%–35% LP underwent higher deterioration than the control mortar samples with
100% OPC when stored in 1.8% MgSO4 solution for 5 years. The extent of deterioration increases with
the content of LP. The mortar samples with 5% LP took 5 years to have higher deterioration than the
samples with 15% LP had after 1 year [155]. Moreover, together with white Portland cement, 31.9% LP
caused a hike in carbonation depth; after 7 days of exposure to 1% (v/v) CO2 at 20 ◦ C and 57% relative
humidity, there was a measurable degree of carbonation; the carbonation rate was 0.85 mm/d1/2 while
it was only 0.17 mm/d1/2 for the samples without LP, up to 280 days of exposure [58].
strength increases with the increasing replacement of cement up to 5%, then it decreases with any
additional amount of nano-MK; 23% higher compressive strength was attained for 5% nano-MK [145].
10% POFA and pulverized burnt clay (5% each) together had the best performance for the w/b ratios of
0.30–0.40; the highest flow spread (310 mm) was achieved for 10% cement replacement at 0.35 w/b
ratio with 2%–2.25% water-reducing admixture [72].
Figure 5.
Figure 5. Effect ofEffect
80%ofPOFA
80% POFA (before
(before andand aftertreatment)
after treatment) onon
thethe
strength development
strength of mortar of
development [74].
mortar [74].
[GPOFA = Ground POFA; UPOFA = Ultrafine POFA].
[GPOFA = Ground POFA; UPOFA = Ultrafine POFA].
5.8.3. Effects on Durability and Other Properties
The incorporation of POFA may lead to a rise in the water absorption and permeable porosity
of mortar at all ages depending on the particle size distribution of binder. Both water absorption and
permeable porosity increased by more than 50% at 90 days for 30% POFA [111]. The use of 10% POFA
gave a similar permeability as compared with the OPC mortar but higher replacements affected
permeability adversely; 30% POFA increased the permeability of mortar by up to 200% at 28 days
[76]. Furthermore, POFA mortar showed a better resistance against sulphate attack; the expansion
values due to external sulphate attack were 0.046%–0.068% for the POFA mortars whereas the control
mortar had an expansion value of 0.075%; the expansion of mortar samples was reduced by 37% for
Sustainability 2020, 12, 3888 23 of 35
700 ◦ C for 3 h. The mortar samples containing this RHA as 10%–30% cement substitutions provided
approximately 20% more compressive strength at 28 days [80]. A theoretical model suggests that the
optimum content of RHA without any non-reactive silica is nearly 14.3% for a cementitious system
(e.g., cement mortar) containing ASTM Type I cement [172].
the formation of expansive compounds (e.g., delayed ettringite), which may decrease the compressive
strength of mortar [85]. Matos and Sousa-Coutinho [84] also reported inferior compressive strength
values for 10% and 20% WGP at 28 days although both contents provided a strength value (54 MPa)
like that of OPC mortar at 90 days. Conversely, a significant improvement in the tensile bond strength
was observed in the presence of WGP; the mortars with 10% and 20% WGP resulted in 280% and 170%
higher tensile bond strength, respectively, than the control mortar [85].
The particle size distribution plays a significant role in the performance of WGP as a partial
replacement of cement. The lower the particle size, the higher is the reaction rate. WGP possessing
particles in the size range of 0–25 µm shows pozzolanic activity just after 7 days, while 25–38 µm and
63–75 µm size ranges show this activity only after 28 days at 50 ◦ C. A reduction in the particle size
of WGP results in more and denser secondary C–S–H, thus higher strength. When the WGP with
0–25 µm size distribution was used, Ca(OH)2 content was depleted 1.5 and 2.3 times more than the
size ranges of 25–38 µm and 63–75 µm, respectively [173]. According to the activation energy values,
WGP could be classified as a moderately temperature-dependent SCM. The growth in reaction rate
and the reduction in portlandite content as much as 100% and 30%, respectively, were reported at
elevated temperatures compared to low temperatures [115]. The mortar samples containing WGP did
not show any significant pozzolanic reaction at 23 ◦ C even at the age of 91 days. Rather it resulted in
lower strength due to higher effective w/b ratio. The WGP with 0–25 µm size distribution showed 21%
higher reactivity at 50 ◦ C than 10 ◦ C and 23 ◦ C. The mortar including WGP in 63–75 µm size range also
had 30% less portlandite content than the control mortar at 28 and 91 days; however, no pozzolanic
reactivity was observed for this WGP mortar at 23 ◦ C even at 91 days [173]. At a pH level higher than
12.5, green-colored glass liberates more silica and alumina ions than clear glass; therefore, the mortar
containing green WGP achieves higher strength than the control mortar and the mortar including clear
WGP just after 7 days at 50 ◦ C; at this temperature, the mortar including green WGP gained more than
40 MPa compressive strength, which was 30% higher than the strength of the other two mortars [86].
less than that of the OPC mortar samples but still failed to reach the recommended safe level [84,152];
however, 20% WGP dropped the expansion to 0.041% [84], which is much lower than the critical level
of 0.1% given in ASTM C1567 [169]. These findings suggest that, to avoid ASR, the quantity of WGP
should be optimized to use up all reactive silica and moisture during the pozzolanic reaction with
Ca(OH)2 . Nevertheless, it should be kept in mind that the increased amount of WGP may increase the
drying shrinkage of mortar; the greater the substitution level of OPC by WGP, the higher is the drying
shrinkage value of mortar; at 63 days, the drying shrinkage value of the mortar including 20% WGP
was 16% higher than that of the control mortar [85].
Table 6. Greenhouse gas generation (as equivalent CO2 ) by the factory-made cement types [174].
• Some treatments (e.g., controlled burning and/or grinding) substantially improve SCM properties.
The effects of such treatment processes on most SCMs were not studied thoroughly. The optimum
treatment process needs to be determined for each SCM, especially for those obtained from
agricultural sources.
• Different researchers experimented in different conditions for very specific purposes. Comparing
SCMs for use in construction is difficult based on these situation-dependent data. The detailed
characterization of each widely available SCM should be accomplished.
Sustainability 2020, 12, 3888 27 of 35
• Studies on how the behavior of SCM changes with its source and application conditions are still
inadequate. The behavior of SCM incorporated mortars in every real-life situation (e.g., frost, high
temperature, impact loading, exposure to seawater, etc.) should be determined.
• The effects of VA on the flowability of mortar mixture and its resistance against carbonation, acid
attack, sulphate attack, and freezing and thawing are unknown. Therefore, broad research should
be carried out to study these properties of VA mortar.
• The durability performance of BA mortar needs to be investigated thoroughly. Especially, the
ASR resistance of BA mortar is very important, as some studies reported the signs of ASR due to
the high concentration of K+ ions released from BA.
• RHA mortar should be investigated for its resistance against carbonation, ASR, sulphate attack,
and freezing and thawing.
• The applications of POFA and GGBS as an SCM in mortar should be explored by examining their
resistance against carbonation, acid attack, ASR, and freezing and thawing. Especially, the high
content of K2 O in POFA raises a concern about ASR.
• The behavior in acidic and freeze-thaw environments are still unexplored for the mortars
containing LP and WGP. In addition, the influence of LP on ASR and chloride penetration needs
broad investigation.
• The resistance of FA mortar against carbonation and acid attack needs to be examined
systematically.
• Studies on the use of SCMs in structural mortar at different multilevel combinations, such as
binary and ternary levels, were not performed meticulously.
• Dependable analytical models for predicting the effects of SCM on the mortar-performance are
absent. Such models should be established considering all influencing parameters to predict the
consequences of SCM inclusion.
• The carbon footprints of the mortars made with blended cement types, including various SCMs
need to be determined.
• To ensure sustainable development, the total impact of the SCM incorporated structural mortar
on the environment and economy should be quantified in a holistic manner, considering the
treatment process, replacement level, and durability.
• To avoid contamination, the leaching of heavy metals from the cementitious products containing
SCM should be quantified before any industrial application.
8. Concluding Remarks
Like all other industries, the construction industry is also looking for eco-friendly strategies.
Cement is one of the main ingredients of construction. The production of cement is an energy- and
carbon-intensive process. Many industrial by-products, several materials obtained from agricultural
and municipal wastes, and some materials found from natural sources have shown promising
performance as SCMs, when used as a partial replacement of cement in structural mortar. In many
cases, the use of such by-products or wastes supersedes the sole performance of cement. Furthermore,
such utilization can reduce the consumption of natural resources and the production cost in cement
factories, as well as ensure the proper management of by-products or wastes. However, effective
utilization of SCMs demands more intensive studies. A holistic study of SCM properties and
their effects on the end products under different conditions is required for efficient environmental
management, as well as to further optimize the desired engineering performance of structural mortar
for sustainable construction.
Author Contributions: S.N.R., A.B.M.A.K. and S.S. designed the research program. The data collection, assessment,
and analysis were performed by S.S. under the guidance and supervision of S.N.R., A.B.M.A.K. and A.A.M. M.S.
significantly assisted in the analysis of research findings to facilitate the present study. The manuscript was written
by S.S. and S.N.R. and was supplemented by the contributions of M.S., A.B.M.A.K. and A.A.M. M.S. critically
Sustainability 2020, 12, 3888 28 of 35
reviewed the paper and provided valuable technical inputs to improve its overall quality. All authors have read
and agreed to the published version of the manuscript.
Funding: This research was funded by the Ministry of Higher Education, Malaysia through the Fundamental
Research Grant Scheme (FRGS/1/2019/TK01/UKM/02/2).
Acknowledgments: Ministry of Higher Education, Malaysia and Universiti Kebangsaan Malaysia (UKM).
Conflicts of Interest: The authors declare no conflict of interest.
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