iii durability of self-compacting concrete with...
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iii
DURABILITY OF SELF-COMPACTING CONCRETE WITH COAL BOTTOM
ASH AS SAND REPLACEMENT MATERIAL UNDER AGGRESSIVE
ENVIRONMENT
AHMAD FARHAN BIN HAMZAH
A thesis submitted in fulfilment of the
requirements for the award of the degree of
Doctor of Philosophy (Civil Engineering)
Faculty of Civil and Environmental Engineering
Universiti Tun Hussein Onn Malaysia
SEPTEMBER 2017
v
Special dedication to the memory of
Allahyarham Muhammad Faiz Hamzah.
May ALLAH bless his soul and forgiveness.
Al-Fatihah
vi
ACKNOWLEDGEMENT
In the name of Allah S.W.T., most gracious and most merciful, with His
permission, Alhamdulillah this dissertation has been completed. Praise to Prophet
Muhammad S.A.W of His companions and to those on the path as what He preached
upon, may Allah the Almighty keep us in His blessing and tenders.
First and foremost, I would like to convey my highest gratitude to my
supervisors, Assoc. Prof. Dr. Mohd Haziman Wan Ibrahim and Dr. Norwati
Jamaluddin who has helped, led and advised me in preparing a good proposal and for
all their contributions. They gave me so many useful advices from the first day until
the day of submitting this thesis. A special appreciation to my beloved co-supervisors,
Dr. Ramadhansyah Putra Jaya from Universiti Teknologi Malaysia (UTM) and Dr.
Mohd Fadzil Arshad from Universiti Teknologi MARA (UiTM) who has helped
tremendously in providing constructive comments and suggestions throughout the
experimental works and thesis writing.
Above and beyond, I would like to thank to my parent, my wife, sibling and
family-in-law for their prayers, understanding, and support during the preparation of
this dissertation.
My appreciation is also dedicated to Norul Ernida Zainal Abidin, Norzubaidah
Fadzil, Mohd Hanif Hasbullah, Mohd Arief Mohamed, Syahredza Salikin and all my
friends for their useful advices and instilled besides giving me their moral support.
Last but not least, there is too numerous persons to be mentioned here that have been
sharing their knowledge on how to complete this work effectively as a teaching and
learning tool. I would like to express my most sincere thoughts for those who helped.
Thank you.
AHMAD FARHAN BIN HAMZAH.
vii
ABSTRACT
Concrete is a major building material use for numerous purposes in construction
including the concrete structures that exposed to aggressive environment or seawater
such as coastal berthing facilities, breakwaters, retaining walls, tidal barriers, dry
docks, container terminals, off-shore floating docks and drilling platforms. As these
concrete structures that usually exposed to an aggressive environment, it is expected
to require a minimum level of repair or maintenance during their service life. The
ingress of aggressive agents, in particular chloride and sulphate ions, can lead to
corrosion of reinforcing steel bars and thus cause a reduction in strength and
subsequent decrease in the service life of concrete structures. In context to resist this
type of premature deterioration, concrete must be proportioned to achieve high
durability in aggressive environments. The incorporation of coal bottom ash as sand
replacement material was possible to help self-compacting concrete in designing mix
proportion which contains extra fine particles content and fewer amounts of coarse
aggregates. On the other hand, self-compacting concrete was developed to respond to
the need for a self-compacting concrete with improved durability. In this study, six
replacement levels were considered for self-compacting concrete: 0%, 10%, 15%,
20%, 25% and 30% by volume. The essential workability properties of the fresh self-
compacting concrete containing coal bottom ash were prepared and evaluated by the
test of slump flow, L-box and sieve segregation resistance. Later, the effect of coal
bottom ash subjected to sodium chloride (NaCl), sodium sulphate (Na2SO4) and
seawater through cyclic wetting and drying was also investigated. The durability
performance of the coal bottom ash self-compacting concrete exposed to aggressive
environment was evaluated through compressive strength, Rapid Chloride
Permeability Test (RCPT), chloride penetration by Rapid Migration Test (RMT) and
carbonation depth test. In addition, microstructural changes that occur in specimens
due to aggressive environmental effects were identified through X-ray diffraction
(XRD) techniques and Scanning Electron Microscopy (SEM). Test results show that
coal bottom ash can be acceptably used as a fine aggregate replacement material in
order to achieve good durability of concrete. The self-compacting concrete containing
10% coal bottom ash replacement showed excellent durability to chloride, sulphate
and seawater attack. The test results also indicate that the amount of calcium hydroxide
(Ca(OH)2) in the 10% coal bottom ash concrete was slightly lower than that of control
sample due to the pozzolanic reaction of coal bottom ash and cement. The
combination of compressive strength, XRD and SEM analysis leads to the
identification of Friedel’s salt, ettringite, gypsum, calcium hydroxide formations in
specimen.
viii
ABSTRAK
Konkrit adalah bahan binaan utama yang digunakan untuk pelbagai tujuan dalam
pembinaan termasuk struktur konkrit yang terdedah kepada persekitaran yang agresif
atau air laut seperti kemudahan pantai (berthing), pemecah ombak, dinding penahan
(retaining wall), benteng pasang surut, dok kering, terminal kontena, dok terapung di
luar pantai dan penggerudian pelantar. Oleh kerana struktur konkrit tersebut terdedah
kepada persekitaran yang agresif, ia memerlukan tahap pembaikan yang minimum
atau penyelenggaraan semasa hayat perkhidmatan. Pendedahan dan kemasukan agen
agresif, terutamanya ion klorida dan sulfat boleh mengakibatkan kakisan bar tetulang
keluli dan menjejaskan kekuatan dan seterusnya menyebabkan penurunan hayat
perkhidmatan struktur konkrit. Justeru, bagi mengelakkan kemerosotan konkrit
pramatang ini, konkrit perlu dinisbahkan mengikut kesesuaian untuk mencapai
ketahanan yang tinggi dalam persekitaran yang agresif. Penggunaan abu enapan arang
batu (coal bottom ash) sebagai bahan pengganti pasir adalah sesuai untuk
menghasilkan konkrit tanpa getar (self-compacting concrete) dalam merancang nisbah
campuran yang mengandungi kandungan zarah halus dan jumlah agregat kasar yang
sedikit. Sehubungan dengan itu, konkrit tanpa getar telah dibangunkan dengan
ketahanan yang lebih baik. Melalui kajian ini, enam tahap penggantian berdasarkan
volumetrik telah dipertimbangkan untuk konkrit tanpa getar iaitu 0%, 10%, 15%, 20%,
25% dan 30%. Sifat penting kebolehkerjaan dalam konkrit tanpa getar yang
mengandungi abu enapan arang batu dinilai oleh ujian aliran turunan (slump flow),
ujian L-box dan ujian rintangan pengasingan. Selain itu, kesan abu enapan arang batu
yang tertakluk kepada natrium klorida (NaCl), natrium sulfat (Na2SO4) dan air laut
melalui kitaran pembasahan dan pengeringan juga dikaji. Prestasi ketahanan konkrit
tanpa getar mengandungi abu enapan arang batu yang terdedah kepada persekitaran
yang agresif telah dinilai melalui ujian kekuatan mampatan, ujian kebolehtelapan ion-
klorida pantas (RCPT), penembusan ion-klorida oleh ujian migrasi pantas (RMT) dan
ujian karbonasi. Di samping itu, perubahan mikrostruktur yang berlaku dalam
spesimen kerana kesan alam sekitar yang agresif telah dikenal pasti melalui teknik X-
ray pembelauan (XRD) dan Scanning Electron Microscopy (SEM). Keputusan ujian
menunjukkan bahawa abu enapan arang batu boleh digunakan sebagai bahan gantian
agregat halus untuk mencapai ketahanan konkrit yang baik. Penggantian sebanyak
10% abu enapan arang batu menunjukkan ketahanan yang sangat baik untuk
persekitaran klorida, sulfat dan air laut. Keputusan ujian juga menunjukkan bahawa
jumlah kalsium hidroksida (Ca(OH)2) dalam spesimen konkrit penggantian 10% abu
enapan arang batu adalah lebih rendah daripada sampel kawalan yang disebabkan oleh
tindakbalas pozzolanik abu enapan arang batu dan simen. Berdasarkan keputusan
RCPT dan RMT, kadar penembusan ion-klorida meningkat dengan peningkatan abu
enapan arang batu di dalam konkrit. Hasil ujian karbonasi bagi spesimen yang
terdedah kepada air laut melalui kitaran pembasahan-pengeringan menunjukkan
ix
bahawa hasil dapatan adalah selari dengan spesimen yang terdedah kepada
persekitaran klorida dan sulfat. Berdasarkan hasil keputusan ujian, dapat diperhatikan
bahawa kedalaman pengkarbonan spesimen terdedah kepada persekitaran yang agresif
pada tahap penggantian sebanyak 10% abu enapan arang batu adalah paling rendah
berbanding spesimen yang lain. Ini menunjukkan bahawa rintangan pengkarbonan
adalah sangat tinggi dengan penggunaan nisbah penggantian sebanyak 10%. Justeru,
gabungan hasil ujian kekuatan mampatan, analisis XRD dan SEM telah membawa
kepada pengenalpastian garam Friedel, ettringite, gypsum, kalsium hidroksida dan
lain-lain sebatian kimia dalam spesimen.
x
TABLE OF CONTENTS
INTRODUCTION 1
1.1 Introduction 1
1.2 Problem Statement 4
1.3 Research Objectives 5
1.4 Research Significant 6
1.5 Scope of Works 7
1.6 Structure of Thesis 9
LITERATURE REVIEW 10
2.1 Introduction 10
2.2 Salt attack in concrete material 10
2.3 Factors affecting salt attack on concrete 10
2.3.1 Cement type and composition 11
2.3.2 Water binder ratio 11
2.3.3 Curing condition 12
2.3.4 Type of sulphate and concentration 12
2.3.5 Presence of chloride 13
2.3.6 Temperature of exposure 14
2.4 Mechanism of salt attack 15
2.4.1 Salt crystallization 15
xi
2.4.2 Chloride attack 17
2.4.3 Sulphate attack 18
2.4.4 Seawater attack 19
2.5 Aggressive exposure condition 21
2.5.1 Wetting and drying 22
2.5.2 Freeze and thaw 23
2.5.3 Laboratory simulation of wetting and drying cycles 24
2.6 Coal bottom ash concrete 24
2.6.1 Durability of coal bottom ash concrete 28
2.6.1.1 Permeability 28
2.6.1.2 Wet and dry resistance 29
2.6.1.3 Salt attack resistance 29
2.7 Summary 30
MATERIALS PROPERTIES, RESEARCH DESIGN AND
EXPERIMENTAL DETAILS 32
3.1 Introduction 32
3.2 Research Design 33
3.3 Materials 37
3.3.1 Cement 37
3.3.2 Coal bottom ash 39
3.3.3 Aggregates 42
3.3.3.1 Coarse aggregates 42
3.3.3.2 Fine aggregates 43
3.3.3.3 Specific gravity and water absorption test 45
3.3.3.4 Flakiness Index and Elongation Index test 47
3.3.3.5 Aggregate Impact Value and Aggregate Crushing Value test 49
3.3.4 Water 50
3.3.5 Superplasticizer 51
3.4 Characterization of raw materials 52
3.4.1 Physical properties 52
3.4.1.1 Particle size distribution 52
xii
3.4.1.2 Specific gravity 53
3.4.2 Chemical compositions 54
3.4.2.1 X-ray Fluorescence (XRF) 54
3.4.2.2 X-ray Diffraction (XRD) 55
3.4.2.3 Scanning Electron Microscopy (SEM) 55
3.5 Mix design mix proportioning 56
3.6 Cyclic wetting and drying 58
3.6.1 Samples preparation and curing condition 58
3.6.2 Sodium Chloride (NaCl) 59
3.6.3 Sodium Sulphate (Na2SO4) 60
3.6.4 Seawater sampling 61
3.6.5 Laboratory simulation-Temperature and Relative humidity data
63
3.7 Concreting procedure 63
3.7.1 Fresh properties of concrete 64
3.7.1.1 Slump flow and Slump spread time test 64
3.7.1.2 L-box test 65
3.7.1.3 Sieve stability test 66
3.7.2 Hardened properties 67
3.7.2.1 Compressive strength 67
3.7.2.2 Split tensile strength 68
3.7.2.3 Flexural strength 69
3.7.2.4 Water absorption test 71
3.8 Durability test 72
3.8.1 Rapid Chloride-ion Permeability Test (RCPT) 72
3.8.2 Rapid Migration Test 74
3.8.3 Carbonation test 75
3.9 Summary 76
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SELF-COMPACTING CONCRETE WITH COAL BOTTOM ASH 78
4.1 Introduction 78
4.2 Properties of fresh self-compacting concrete 78
4.2.1 Flow ability 78
4.2.2 Passing ability 81
4.2.3 Segregation resistance 82
4.2.4 Concluding remarks on fresh properties 84
4.3 Properties of hardened self-compacting concrete 84
4.3.1 Unit weight 85
4.3.2 Compressive strength 87
4.3.3 Split tensile strength 91
4.3.4 Flexural strength 95
4.3.5 Permeable pore space and water absorption 98
4.3.6 Relationship of density and compressive strength 102
4.3.7 Relationship of compressive strength and split tensile strength
103
4.3.8 Relationship of compressive strength and flexural strength 104
4.3.9 Relationship of compressive strength and water absorption 106
4.3.10 Nomograph Development 107
4.4 X-ray diffraction (XRD) 109
.6 Scanning electron microscopy 116
4.7 Summary 119
EFFECT OF CHLORIDE AND SULPHATE EXPOSURE ON SELF-
COMPACTING CONCRETE WITH COAL BOTTOM ASH BY WETTING
AND DRYING CYCLES 120
5.1 Introduction 120
5.2 Compressive strength of self-compacting concrete with coal bottom
ash cured in tap water 120
5.3 Compressive strength of self-compacting concrete with coal bottom
ash subjected to sodium chloride solution 122
xiv
5.2.1 Reduction in compressive strength due to chloride attack 124
5.2.2 Weight loss due to chloride attack 126
5.4 Compressive strength of self-compacting concrete with coal bottom
ash subjected to sodium sulphate solution 127
5.4.1 Reduction in compressive strength due to sulphate attack 129
5.4.2 Weight loss due to sulphate attack 130
5.5 Rapid Chloride-ion Permeability Test (RCPT) 131
5.5.1 Relationship between total charge passed and compressive
strength 135
5.5.2 Relationship between total charged passed, current and time
(chloride exposure) 138
5.5.3 Relationship between total charged passed, current and time
(sulphate exposure) 141
5.6 Chloride penetration by Rapid Migration Test 144
5.6.1 Relationship between total charge passed and depth of chloride
penetration 147
5.7 Carbonation depth test 150
5.7.1 Relationship between carbonation depth and compressive strength
153
5.8 X-ray diffraction (XRD) 150
5.9 Scanning Electron Microscopy (SEM) 163
5.10 Summary 174
EFFECT OF SEAWATER ON SELF-COMPACTING CONCRETE WITH
COAL BOTTOM ASH BY WETTING AND DRYING CYCLES 175
6.1 Introduction 175
6.2 Compressive strength of self-compacting concrete with coal bottom
ash subjected to seawater 176
6.2.1 Reduction in compressive strength due to seawater attack 178
6.2.2 Weight loss due to seawater attack 179
6.3 Rapid Chloride-ion Permeability Test (RCPT) 180
6.3.1 Relationship between RCPT and compressive strength 182
xv
6.3.2 Relationship between total charge passed, current and time 184
6.4 Chloride penetration by Rapid Migration Test 187
6.4.1 Relationship between total charge passed and depth of chloride
penetration 188
6.5 Carbonation depth test 190
6.5.1 Relationship between carbonation depth and compressive strength
191
6.6 X-ray diffraction (XRD) 193
6.7 Scanning Electron Microscopy (SEM) 197
6.8 Summary 201
CONCLUSIONS AND RECOMMENDATIONS 202
7.1 Conclusions 202
7.1.1 Properties of self-compacting concrete and optimum content of
coal bottom ash 202
7.1.2 Microstructure of self-compacting concrete incorporating coal
bottom ash with different percentage of sand replacement 203
7.1.3 Performance of coal bottom ash self-compacting concrete with
different percentages of sand replacement subjected to
aggressive environments by wetting and drying cycles 204
7.2 Recommendations for future research 205
References 207
List of publications 228
A. International Journal Papers 228
B. International / National Conference 229
C. International Competition 230
Appendix A 231
Appendix B 232
Appendix C 233
Appendix D 234
Appendix E 235
xvi
LIST OF TABLES
2.1 Parameters related due to salt attack 11
2.2 Effect of coal bottom ash on properties of concrete 27
3.1 Number of specimens by experiments 36
3.2 Overall number of specimens 36
3.3 Chemical composition of cement 38
3.4 Gradation for coal bottom ash 40
3.5 Compounds composition of coal bottom ash 41
3.6 Gradation of coarse aggregates 43
3.7 Gradation for fine aggregates 44
3.8 Specific gravity and water absorption for coarse and fine aggregates 47
3.9 Specific gravity and water absorption for coal bottom ash aggregate 47
3.10 Chemical analysis of tap water 51
3.11 Technical data of ADVA 181 superplasticizer 52
3.12 Mix proportions (kg/m3) 57
3.13 Mix proportions by weight (kg) 57
3.14 Chemical analysis of sodium chloride 59
3.15 Chemical composition of sodium sulphate 60
3.16 Chemical analysis of seawater 62
3.17 Monthly analysis of seawater 62
3.18 Segregation resistance test (EFNARC, 2002) 67
3.19 Chloride ion penetrability (ASTM C1202, 2010) 74
4.1 Unit weight of specimen (g/cm3) 85
xvii
4.2 Compressive strength result 88
4.3 Split tensile strength 92
4.4 Flexural strength 96
4.5 Coefficients of linear relationship between concrete density and
compressive strength
103
4.6 Coefficients of linear relationship between compressive strength and
split tensile strength
104
4.7 Coefficients of linear relationship between compressive strength and
flexural strength
105
4.8 Coefficients of linear relationship between compressive strength and
water absorption
107
5.1 Chloride ion penetrability of self-compacting concrete subjected to
sodium chloride solution with wetting-drying cycles
133
5.2 Chloride ion penetrability of self-compacting concrete subjected to
sodium sulphate solution with wetting-drying cycles
135
5.3 Coefficients of linear relationship between total charge passed and
compressive strength (exposed to chloride solution)
137
5.4 Coefficients of linear relationship between total charge passed and
compressive strength (exposed to sulphate solution)
138
5.5 Measurement of total charge passed, current and temperature
determined through RCPT (exposed to chloride solution)
139
5.6 Coefficients of linear relationship between total charge passed and time
(exposed to chloride solution)
140
5.7 Coefficients of linear relationship between total charge passed and
current (exposed to chloride solution)
141
5.8 Measurement of total charge passed, current and temperature
determined through RCPT (exposed to sulphate solution)
143
5.9 Coefficients of linear relationship between total charge passed and time
(exposed to sulphate solution)
144
5.10 Coefficients of linear relationship between total charge passed and
current (exposed to sulphate solution)
144
5.11 Coefficients of linear relationship between total charge passed and
chloride penetration (exposed to chloride solution)
148
5.12 Coefficients of linear relationship between total charge passed and
chloride penetration (exposed to sulphate solution)
150
xviii
6.1 Chloride ion penetrability of self-compacting concrete subjected to
seawater with wetting-drying cycles
183
6.2 Coefficients of linear relationship between total charge passed and
compressive strength (exposed to seawater)
184
6.3 Coefficients of linear relationship between total charge passed and time
(exposed to seawater)
185
6.4 Measurement of total charge passed, current and temperature
determined through RCPT (exposed to seawater)
186
6.5 Coefficients of linear relationship between total charge passed and
current (exposed to seawater)
187
6.6 Coefficients of linear relationship between total charge passed and
chloride penetration (seawater)
191
xix
LIST OF FIGURES
2.1 Effect of physical condition of exposure (Hekal et al., 2002) 15
2.2 Chloride attack on reinforced concrete (Kung, 2014) 18
2.3 Schematic diagram for sulphate attack (China Microsilica
Union, 2011)
19
2.4 Concrete exposed to seawater (Malhorta, 2000) 21
3.1 Experimental stages in this research 33
3.2 Flow chart of experimental works 35
3.3 Holcim Top standard cement 38
3.4 Raw coal bottom ash 39
3.5 Sieved coal bottom ash 39
3.6 Grain size analysis for coal bottom ash 40
3.7 Coal bottom ash particle 41
3.8 Crushed blue stone aggregates 42
3.9 Grain size analysis for coarse aggregates 43
3.10 River sand used in this study 44
3.11 Grain size analysis for fine aggregates 45
3.12 Elongation gauge 48
3.13 Flakiness gauge 48
3.14 Flakiness and elongation index of aggregates 49
3.15 AIV and ACV test appratus 50
3.16 AIV and ACV of aggregates 50
xx
3.17 ADVA 181 polymer-based superplasticizer 52
3.18 Particle size analyser 53
3.19 Micromeritics AccuPyc 1330 53
3.20 XRF equipment 54
3.21 XRD instrument used in this study 55
3.22 NOVA NANOSEM 230 equipment 56
3.23 Sodium chloride 59
3.24 Sodium sulphate 60
3.25 Location of seawater sampling 61
3.26 Temperature and relative humidity data (laboratory
simulation)
63
3.27 Slump flow test 64
3.28 Measurement of slump flow 65
3.29 L-box test equipment 66
3.30 Sieve stability test 67
3.31 Compressive strength test 68
3.32 Cylindrical tensile test 69
3.33 Flexural test on concrete beam 70
3.34 Flexural breaking point failure 71
3.35 RCPT apparatus 73
3.36 RCPT sample in testing 73
3.37 Apparatus set up for RMT (NT Build 492, 1999) 75
3.38 Carbonation depth using a solution of phenolphthalein 76
3.39 Measurement of carbonation depth 76
4.1 Slump flow 79
4.2 Slump spread time (T500) 79
4.3 L-box passing ability 81
xxi
4.4 Sieve stability test results 83
4.5 Density of concrete at 28 days 87
4.6 Compressive strength for specimens of 0.35 water cement
ratio
89
4.7 Compressive strength for specimens of 0.40 water cement
ratio
90
4.8 Compressive strength for specimens of 0.45 water cement
ratio
90
4.9 Split tensile strength for specimens of 0.35 water cement
ratio
93
4.10 Split tensile strength for specimens of 0.40 water cement
ratio
94
4.11 Split tensile strength for specimens of 0.45 water cement
ratio
94
4.12 Flexural strength for specimens of 0.35 water cement ratio 97
4.13 Flexural strength for specimens of 0.40 water cement ratio 97
4.14 Flexural strength for specimens of 0.45 water cement ratio 98
4.15 Permeable pore space for specimens of 0.35 water cement
ratio
99
4.16 Water absorption for specimens of 0.35 water cement ratio 100
4.17 Permeable pore space for specimens of 0.40 water cement
ratio
100
4.18 Water absorption for specimens of 0.40 water cement ratio 101
4.19 Permeable pore space for specimens of 0.45 water cement
ratio
101
4.20 Water absorption for specimens of 0.45 water cement ratio 102
4.21 Relationship between concrete density and compressive
strength
103
4.22 Relationship between compressive strength and split
tensile strength
104
4.23 Relationship between compressive strength and flexural
strength
105
4.24 Relationship between compressive strength and water
absorption
106
4.25 Compressive-tensile strength nomograph 108
4.26 Compressive-flexural strength nomograph 108
4.27 Diffractogram of control concrete at 28 days 110
xxii
4.28 Diffractogram of 10% coal bottom ash replacement concrete
at 28 days
110
4.29 Diffractogram of 15% coal bottom ash replacement concrete
at 28 days
111
4.30 Diffractogram of 20% coal bottom ash replacement concrete
at 28 days
111
4.31 Diffractogram of 25% coal bottom ash replacement concrete
at 28 days
112
4.32 Diffractogram of 30% coal bottom ash replacement concrete
at 28 days
112
4.33 Diffractogram of control concrete at 180 days 113
4.34 Diffractogram of 10% coal bottom ash replacement concrete
at 180 days
113
4.35 Diffractogram of 15% coal bottom ash replacement concrete
at 180 days
114
4.36 Diffractogram of 20% coal bottom ash replacement concrete
at 180 days
114
4.37 Diffractogram of 25% coal bottom ash replacement concrete
at 180 days
115
4.38 Diffractogram of 30% coal bottom ash replacement concrete
at 180 days
115
4.39 Scanning electron micrograph of control concrete at 28 days 117
4.40 Scanning electron micrograph of 10% coal bottom
ash replacement concrete at 28 days
117
4.41 Scanning electron micrograph of 15% coal bottom ash
replacement concrete at 28 days
117
4.42 Scanning electron micrograph of 20% coal bottom
ash replacement concrete at 28 days
118
4.43 Scanning electron micrograph of 25% coal bottom
ash replacement concrete at 28 days
118
4.44 Scanning electron micrograph of 30% coal bottom
ash replacement concrete at 28 days
118
5.1 Compressive strength of specimens cured in tap water 121
5.2 Compressive strength of specimens subjected to sodium
chloride solution with wetting-drying cycles
123
5.3 Compressive strength reduction of coal bottom ash self-
compacting concrete due to chloride attack
126
5.4 Weight loss of coal bottom ash self-compacting concrete
due to chloride attack
127
5.5 Compressive strength of specimens subjected to sodium
sulphate solution with wetting-drying cycles
128
xxiii
5.6 Compressive strength reduction of coal bottom ash
self- compacting concrete due to sulphate attack
130
5.7 Weight loss of coal bottom ash self-compacting concrete
due to sulphate attack
131
5.8 Total charge passed of self-compacting concrete
subjected to sodium chloride solution with wetting-drying
cycles
132
5.9 Total charge passed of self-compacting concrete
subjected to sodium sulphate solution with wetting-drying
cycles
134
5.10 Relationship between total charge passed and
compressive strength specimens subjected to chloride
solution
136
5.11 Relationship between total charge passed and
compressive strength specimens subjected to sulphate
solution
136
5.12 Relationship between total charge passed and time (exposed
to chloride solution)
140
5.13 Relationship between total charge passed and current
(exposed to chloride solution)
141
5.14 Relationship between total charge passed and time (exposed
to sulphate solution)
142
5.15 Relationship between total charge passed and current
(exposed to sulphate solution)
142
5.16 Chloride penetration rate of concrete subjected to
chloride solution
145
5.17 Chloride penetration rate of concrete subjected to
sulphate solution
146
5.18 Relationship between total charge passed and chloride
penetration (exposed to chloride solution)
148
5.19 Relationship between total charge passed and chloride
penetration (exposed to sulphate solution)
149
5.20 Carbonation for concrete subjected to chloride solution 151
5.21 Carbonation for concrete subjected to sulphate solution 152
5.22 Relationship between carbonation depth and
compressive strength (exposed to chloride solution)
154
5.23 Relationship between carbonation depth and
compressive strength (exposed to sulphate solution)
155
5.24 Diffractogram of control concrete after 180 days of
cyclic wetting-drying in chloride solution
156
xxiv
5.25 Diffractogram of 10% coal bottom ash replacement
concrete after 180 days of cyclic wetting-drying in chloride
solution
157
5.26 Diffractogram of 15% coal bottom ash replacement
concrete after 180 days of cyclic wetting-drying in chloride
solution
157
5.27 Diffractogram of 20% coal bottom ash replacement
concrete after 180 days of cyclic wetting-drying in chloride
solution
158
5.28 Diffractogram of 25% coal bottom ash replacement
concrete after 180 days of cyclic wetting-drying in chloride
solution
158
5.29 Diffractogram of 30% coal bottom ash replacement
concrete after 180 days of cyclic wetting-drying in chloride
solution
159
5.30 Diffractogram of control concrete after 180 days of
cyclic wetting-drying in sulphate solution
160
5.31 Diffractogram of 10% coal bottom ash replacement
concrete after 180 days of cyclic wetting-drying in sulphate
solution
160
5.32 Diffractogram of 15% coal bottom ash replacement
concrete after 180 days of cyclic wetting-drying in sulphate
solution
161
5.33 Diffractogram of 20% coal bottom ash replacement
concrete after 180 days of cyclic wetting-drying in sulphate
solution
161
5.34 Diffractogram of 25% coal bottom ash replacement
concrete after 180 days of cyclic wetting-drying in sulphate
solution
162
5.35 Diffractogram of 30% coal bottom ash replacement
concrete after 180 days of cyclic wetting-drying in sulphate
solution
162
5.36 Microstructure of control concrete subjected to sodium
chloride solution with cyclic wetting-drying
164
5.37 Microstructure of 10% coal bottom ash replacement
concrete subjected to sodium chloride solution with cyclic
wetting-drying
164
5.38 Microstructure of 15% coal bottom ash replacement
concrete subjected to sodium chloride solution with cyclic
wetting-drying
165
5.39 Microstructure of 20% coal bottom ash replacement
concrete subjected to sodium chloride solution with cyclic
wetting-drying
166
xxv
5.40 Microstructure of 25% coal bottom ash replacement
concrete subjected to sodium chloride solution with cyclic
wetting-drying
166
5.41 Microstructure of 30% coal bottom ash replacement
concrete subjected to sodium chloride solution with cyclic
wetting-drying
167
5.42 Hexagonal-plate particle - Portlandite crystal 168
5.43 Fine layered particle – Calcium Silicate Hydrate (CSH) 168
5.44 Irregular-shaped particle – Friedel’s salt 169
5.45 Microstructure of control concrete subjected to sodium
sulphate solution with cyclic wetting-drying
169
5.46 Microstructure of 10% coal bottom ash replacement
concrete subjected to sodium sulphate solution with cyclic
wetting-drying
170
5.47 Microstructure of 15% coal bottom ash replacement
concrete subjected to sodium sulphate solution with cyclic
wetting-drying
170
5.48 Microstructure of 20% coal bottom ash replacement
concrete subjected to sodium sulphate solution with cyclic
wetting-drying
171
5.49 Microstructure of 25% coal bottom ash replacement
concrete subjected to sodium sulphate solution with cyclic
wetting-drying
171
5.50 Microstructure of 30% coal bottom ash replacement
concrete subjected to sodium sulphate solution with cyclic
wetting-drying
172
5.51 Ettringite and thaumasite 173
5.52 Hexagonal platy Portlandite crystal 173
5.53 Gypsum formation 174
6.1 Compressive strength of specimens subjected to sodium
sulphate solution with wetting-drying cycles
178
6.2 Compressive strength reduction of coal bottom ash
self- compacting concrete due to seawater attack
180
6.3 Weight loss of coal bottom ash self-compacting concrete
due to seawater attack
181
6.4 Total charge passed of self-compacting concrete
subjected to seawater with wetting-drying cycles
182
6.5 Relationship between total charge passed and
compressive strength specimens subjected to seawater
184
xxvi
6.6 Relationship between total charge passed and time (exposed
to seawater)
185
6.7 Relationship between total charge passed and current
(exposed to seawater)
187
6.8 Chloride penetration rate of concrete subjected to seawater 188
6.9 Relationship between total charge passed and chloride
penetration (exposed to seawater)
190
6.10 Carbonation for concrete subjected to seawater 192
6.11 Relationship between carbonation depth and
compressive strength (exposed to seawater)
193
6.12 Diffractogram of control concrete after 180 days of
cyclic wetting-drying in seawater
194
6.13 Diffractogram of 10% coal bottom ash replacement
concrete after 180 days of cyclic wetting-drying in seawater
195
6.14 Diffractogram of 15% coal bottom ash replacement
concrete after 180 days of cyclic wetting-drying in seawater
195
6.15 Diffractogram of 20% coal bottom ash replacement
concrete after 180 days of cyclic wetting-drying in seawater
196
6.16 Diffractogram of 25% coal bottom ash replacement
concrete after 180 days of cyclic wetting-drying in seawater
196
6.17 Diffractogram of 30% coal bottom ash replacement
concrete after 180 days of cyclic wetting-drying in seawater
197
6.18 Microstructure of control concrete subjected to seawater
with cyclic wetting-drying
198
6.19 Ettringite and Portlandite 199
6.20 CSH and Gypsum 199
6.21 Microstructure of 10% coal bottom ash replacement
concrete subjected to seawater with cyclic wetting-drying
200
6.22 Microstructure of 15% coal bottom ash replacement
concrete subjected to seawater with cyclic wetting-drying
200
6.23 Microstructure of 20% coal bottom ash replacement
concrete subjected to seawater with cyclic wetting-drying
201
6.24 Microstructure of 25% coal bottom ash replacement
concrete subjected to seawater with cyclic wetting-drying
201
6.25 Microstructure of 30% coal bottom ash replacement
concrete subjected to seawater with cyclic wetting-drying
202
xxvii
LIST OF ABBREVIATION
ACV Aggregate Crushing Value
AIV Aggregate Impact Value
ASTM American Society for Testing and Materials
BS EN British Standard
CBA Coal Bottom Ash
CSH Calcium silicate hydrate
EFNARC European Federation of National Associations
Representing for Concrete
RCPT Rapid Chloride-ion Permeability Test
RMT Rapid Migration Test
SCC Self-compacting concrete
SEM Scanning Electron Microscopy
XRD X-ray Diffraction
XRF X-ray Fluoresence
xxviii
LIST OF SYMBOL
Ca(OH)2 Calcium hydroxide
CaCO3 Calcium carbonate
CaO Calcium oxide
CO2 Carbon dioxide
CPR Chloride penetration rate (mm/v.hr)
f’ch Average compressive strength subjected to
chloride solution with wetting-drying cycles
f’dw Average compressive strength cured in tap
water
f’sl Average compressive strength subjected to
sulphate solution with wetting-drying cycles
f’sw Average compressive strength subjected to
seawater with wetting-drying cycles
fct Compressive strength (N/mm2 or MPa)
ff Flexural strength (N/mm2 or MPa)
ft Split tensile strength (N/mm2 or MPa)
H2CO3 Carbonic acid
H2O Water
mp Weight of pan
mpl Weight of sample
ms Weight of laitance
Na2SO4 Sodium Sulphate
xxix
NaCl Sodium Chloride
Wd Dry weight of specimen after 24 hours in oven
WLch Average initial weight of specimens subjected
to chloride solution with wetting-drying cycles
WLdw Average initial of weight of the specimens
cured in tap water
WLsl Average initial weight of specimens subjected
to sulphate solution with wetting-drying cycles
WLsw Average initial weight of specimens subjected
to seawater with wetting-drying cycles
Wssd Weight of sample in saturated surface dry
condition in air
Wssw Weight of saturated sample in water
1
INTRODUCTION
1.1 Introduction
Concrete is one of major building materials use for numerous purposes in construction
such as buildings, dams, foundations, highways, and others (Matthias, 2010). Often,
the structures exposed to aggressive environment or seawater such as coastal berthing
facilities, breakwaters, retaining walls, tidal barriers, dry docks, container terminals,
off-shore floating docks and drilling platforms. Therefore, it is expected that the
concrete structures will require a minimum maintenance during their service life. The
ingress of aggressive agents particularly chloride and sulphate ions can led to
corrosion of reinforcing steel bars, therefore will cause a reduction in strength and the
service life of concrete structures. In context to resist this type of premature
deterioration, concrete must be proportioned to achieve high durability in an
aggressive environment.
A common method used to prevent premature deterioration of concrete
structures is the application of concrete mixture in which designed to be relatively
impermeable. However, deterioration on a structure can usually be attributed to poor
construction practice and not from the properties of the concrete mixture itself. The
poor construction practices (construction factors) are including improper casting,
concrete placement, consolidation techniques, and inadequate curing regime which
eventually will lead to surface cracking, poor compaction, and high concrete
permeability. Of these factors will reduce the resistance of concrete for the aggressive
agents to ingress and consequently led to premature corrosion of reinforcing steel and
deterioration on the concrete structure.
2
Interestingly, the current construction specifications and codes
includingnormal vibrated concrete exposed to marine or aggressive environments are
only emphasize on the quality of the concrete mixture itself. The construction
specifications are including recommendations regarding the water to cement (w/c)
ratio, minimum cement content, and concrete cover thickness, however the effect of
construction factors is not highlighted. For example, the American Concrete Institute
(ACI) Committee 357 on Design and Construction of Fixed Concrete Offshore
Structures (ACI Committee 357 1994) has recommended that concrete with a
maximum w/c ratio of 0.45, a minimum cement content of 400 kg/m3 and minimum
cover thickness of 50 mm, can be used for marine structures. Similar requirements are
also specified in other codes such as British Standards and European Codes (British
Standard, BS 8110, 1985 and European Pre-Standard, ENV-206 1992). It should be
noted that the in-situ quality of such concrete is not solely a function of its w/c ratio,
cement content, cover thickness, but also a function of the construction factors.
Essentially, the durability of concrete structure is proven by the production of a
workable concrete mixture, its effective consolidation, and the application of proper
curing techniques. The latter is sometimes very difficult to specify due to the lack of
skilled workers and variations in construction techniques among the construction
companies.
The improper casting, placement, and consolidation of typical concrete
mixtures can lead to high concrete permeability and thus impair the durability of the
structures that exposed to aggressive environment. Additionally, the effect of high
temperature will cause poor fluidity of typical fresh concrete and therefore will create
difficulity in placing of such concrete at the field. This will need a considerable
amount of vibration and consolidation. There are few cases in which normal vibration
and consolidation techniques have not produced proper consolidation although a high
range water reducing admixtures has been applied. Such cases can be found especially
where structural members require congested reinforcement or when unusual shapes
and geometries are specified. If concrete is not properly consolidated, voids, gaps, and
cracks can be easily formed in the concrete structure. Furthermore, over vibration may
be applied if the concrete mixture is very stiff or in case of congested reinforcement,
which can result in bleeding and segregation. These defects may occur as a result of
poor vibration and will therefore reduce the permeability of concrete and will impair
3
the ability to resist aggressive agents. Consequently, it will reduce the concerete’s
serviceability.
A large number of concrete structures has been built in accordance with recent
codes with exposed to aggressive environments have showed considerable
deterioration before the end of their service lives due to poor construction practices.
Because the specifications and codes for vibrated concrete do not account for possible
effects of construction practices, it has been postulated that without adequate
compaction and curing, even correctly proportioned concrete will often not be as
impermeable as expected on the basis of its mixture composition.
Previous research have suggested that coal bottom ash as sand replacement
material which has particles appear similar to the natural size and, more recently, self-
compacting concrete has provided significant improvements in both its fresh and
hardened properties (Domone, 2006; Aggarwal et al., 2008; Pathak & Siddique, 2012;
Kadam & Patil, 2013). The incorporation of coal bottom ash as sand replacement
material was found to help self-compacting concrete in designing mix proportion
which contains extra fine particles content and fewer amounts of coarse aggregates
(Dubey & Kumar, 2012). On the other hand, self-compacting concrete was developed
to respond to the need for a self-compacting concrete with improved durability.
Therefore, the use of self-compacting concrete can minimize or even eliminate the
detrimental effects of construction factors. Additionally, the combination of the
benefits of coal bottom ash and self-compacting concrete can provide possible
durability advantages to the concrete structures in aggressive environments. There are
many issues which are lack of knowledge in its characteristics in relation to the
behaviour mainly in self-compacting concrete. Hence, further research about the self-
compacting concrete expose to aggressive environment, characterization of self-
compacting concrete using laboratory test methods, and construction issues related to
self-compacting concrete are practical.
4
1.2 Problem Statement
The durability of concrete has become a major concern in the construction industry. It
is also known that aggressive environments are the major factor affecting the
durability of concrete (Zuquan et al., 2007). The deteriorative of concrete is the resuted
from an ineffectiveness durability that might cause by physical, mechanical and
chemical factors and of these can be induced by external and internal factors to the
concrete structure. Physical and chemical deterioration are external influenced from
climate such as weathering, variation of temperature, wetting and drying cycles and
exposure to aggressive environment (Hekal et al., 2002; Mohr et al., 2005). Chemical
deterioration is usually determined by the rate at which concrete is decomposed as a
result of chemical reaction. The aggressive chemicals are greatly affected the concrete
durability which include chlorides and sulphates with their related cations.
Degradation consists of dissolution of calcium and hydroxide ions out of the
matrix when chloride dissolved in water, which causes an increase in porosity and
transport properties; and subsequently, affecting the strength and permeability of
concrete (Rozière et al., 2009). According to Bertolini et al. (2004), the increment of
coal bottom ash content in concrete shows a decreasing trend in the porosity of
concrete. As the degradation of chloride-water dissolved caused an increase in
porosity, potentially the coal bottom ash will be employed in the concrete due to pore
refinement. This process is vital to produce good quality of durable concrete. Calcium,
sodium, magnesium and ammonium sulphates may involve forming a progressive loss
of strength and loss of mass due to loss of cohesiveness in the cement hydration
products. Gypsum formation leads to reduction of stiffness and strength, then by
expansion and cracking. If concrete cracks, its permeability increases and the
aggressive chemical solution penetrate more easily into the interior, thus accelerating
the process of deterioration (Bassuoni & Nehdi, 2009; Monteiro & Kurtis, 2003).
Previous studies have suggested that coal bottom ash as sand replacement
material has particles appear similar size to natural river sand and, more recently, self-
compacting concrete provide concrete with significant improvements in both its fresh
and hardened properties (Domone, 2006; Aggarwal et al., 2008; Pathak & Siddique,
2012; Kadam & Patil, 2013). The incorporation of coal bottom ash as sand
replacement material is possible to help self-compacting concrete in designing mix
5
proportion which contains extra fine particles content and fewer amounts of coarse
aggregates (Dubey & Kumar, 2012). On the other hand, self-compacting concrete was
developed to respond to the need for a self-compacting concrete with improved
durability. Therefore, the use of self-compacting concrete can minimize or even
eliminate the detrimental effects of poor construction practices. The combination of
the benefits of coal bottom ash and self-compacting concrete can provide possible
durability advantages to the concrete structures in aggressive environments. There are
many issues which are lack of knowledge in its characteristics relation to the behaviour
mainly in self-compacting concrete. Hence, further research about the self-compacting
concrete expose to aggressive environment, characterization of self-compacting
concrete using laboratory test methods, and construction issues related to self-
compacting concrete are practical.
1.3 Research Objectives
This research is involves experimental study on self-compacting concrete. The aims
of this research are:-
i. To investigate the physical and mechanical properties of self-
compacting concrete incorporating coal bottom ash with different
percentage of sand replacement and optimum content of coal bottom as
sand replacement.
ii. To investigate the microstructure of self-compacting concrete
incorporating coal bottom ash with different percentage of sand
replacement.
iii. To evaluate the performance of coal bottom ash self-compacting
concrete with different percentages of sand replacement subjected to
aggressive environments (sodium chloride, sodium sulphate and
seawater) by wetting and drying cycles.
6
1.4 Research Significant
Self-compacting concrete signify the most important progress in concrete knowledge
for over decades. This type of concrete has been designed to make sure sufficient
compaction process and to ease the progress of concrete placement with complex
geometry areas and fully reinforced. The process is complicated or impracticable to
use mechanical compaction for fresh concrete. As the durability of concrete turns out
to be a crucial issue in exploring the potential cementitious materials, a good
compaction by expert workers was essential to get durable concrete structures
(Bouzoubaa & Lachemi, 2001; Zhu & Bartos, 2003).
Even there are advantages of utilization of self-compacting concrete; this type
of high performance concrete has not attracted local attention although it has been
introduced for the last 10 years especially in Malaysia. Mewah & Ehsan (2002)
acknowledged that the delivery of high strength concrete by the local ready mix
industry is not a current problem. There are many benefits from spectaculafdesin and
complex engineering whereby numerous high-rise structures have been constructed
such as Petronas Twin Tower and Menara Telekom Malaysia. The Menara Telekom
is a headquarters office that has been recognized as a noticeable project which
composed of excellence concrete technology and the use of high strength concrete.
The knowledge of high strength concrete and self-compacting concrete have
reached across the world, which driven by the concerned of poor compaction and
durability (Ahmadi et al., 2007; Madandoust & Mousavi, 2012; Azeredo & Diniz,
2013). However, the awareness about self-compacting concrete is still unfavourable
and this has showed the lack of commercial use of self-compacting concrete in the
Malaysia so far. The negative response in utilization of self-compacting concrete is
possibly due to limited research on locally utilizing this type of concrete. Moreover,
potential problems for the production and manufacturing self-compacting concrete
with local marginal aggregates due to accessibility of raw materials have an impact on
the self-compacting concrete consumerism in the industry as well as for environmental
concern by considering the construction cost, ecosystem and environmental aspect,
various option and alternative towards the utilization of local construction materials
are must be established. Mehta (2004) stated that one resolution to cut the cost of self-
7
compacting concrete is by using mineral admixtures or waste materials such as
limestone powder, natural pozzolans, ground granulated blast furnace slag and fly ash.
Malaysia is a country that hav hot and humid climate all the year, with an
average temperature of 27°C (80.6 °F) and small variability in the annual temperature.
The climate is characterized by high temperature and humidity with moderate
fluctuations in seasonal temperature and humidity. Conventional concrete admixtures
is greatly examined which subjected to aggressive environment such as sodium
chloride (NaCl), sodium sulphate (Na2SO4) solution and seawater. However, the
knowledge on exposure of fresh or harden self-compacting concrete to the harsh
condition are still limited Therefore, it is necessary to carry out a study on self-
compacting concrete using local admixture materials incorporating suitable
superplasticizer subjected to aggressive environment with wetting and drying cycles
that signify the region in Malaysja. Moreover, a preliminary standard mix design
nomograph of self-compacting concrete incorporating bottom ash will be produced
for future references.
1.5 Scope of Works
This study is focusing on the material performance of the self-compacting concrete.
The performance analysis were involved studying the characteristic of raw material of
coal bottom ash in terms of physical and mechanical properties to investigate the
durability and performance of self-compacting concrete containing coal bottom ash
with different proportion of fine aggregate replacement subjected to aggressive
sodium chloride, sodium sulphate solution and seawater with wetting and drying
cycles.
Standard strength concrete containing regular blended cement was designed
and prepared through a series of trial mixes to achieve a minimum compressive
strength of 40 MPa at the age of 28 days. The coal bottom ash replacement levels of
10%, 15%, 20%, 25% and 30% were used to replace sand. The experimental program
involved studying the characteristics of materials in terms of their physical and
mechanical properties, chemical compositions, particle morphology and phase
identification. The laboratory testing were conducted at the ages of 7, 28, 60, 90 and
8
180 days to study the effects of sodium chloride (NaCl), sodium sulphate (Na2SO4)
and seawater on the durability of self-compacting concrete containing coal bottom ash
with repetitive wetting and drying cycles including concrete exposed with normal
water. The selection of chemical is based on dominant chemicals in marine
environment, as the most is chloride, sodium and sulphate.
Results from laboratory testing of different mixture of self-compacting
concrete were analysed. There are 3 different mixture of self-compacting concrete
with different water/cement ratio which is 0.35, 0.4 and 0.45. The data obtained from
the experiment were analysed comprehensively to present a design mix nomograph of
self-compacting concrete and finally to meet the objective of this study.
9
1.6 Structure of Thesis
The thesis consists of eight chapters:
Chapter one discusses on the background of the study with a short overview
of the current situation, research and problem statement. Several research needs are
also identified. The objectives and scope of study are also presented.
Chapter two presents a background of the use of pozzolanic materials, its
characteristic and performance in concrete durability. The description on various
chemical solutions including chloride solution, sulphate solution and aggressive
seawater related to concrete were discussed.
Chapter three provides an overview of the research program and approach,
describes the preparation and testing of materials, discusses the selection and testing
of constituent materials, and highlights the procedures for experimental work,
apparatus and mixture design.
Details of finding and data about self-compacting concrete are presented in
chapter four. It has included various degrees of sand replacement on coal bottom ash
and different water-cement ratios on self-compacting concrete. Fresh and hardened
properties of concrete are analysed and presented in an appropriate forms. The chapter
discusses the significance of these results and determines the optimum percentage of
coal bottom ash incorporated in concrete. Additionally, mix design nomograph are
presented base on the results.
In chapter five, the influences of different replacement levels of coal bottom
ash to normal sand exposed to sodium chloride and sodium sulphate solution with
wetting and drying cycles are described. All results were presented in this chapter.
Chapter six discusses the performance of self-compacting concrete with coal
bottom ash subjected to seawater. Moreover, the chapter focuses on the exposure of
seawater from wetting and drying cycles and highlights the importance of these
results.
Finally, chapter seven provides a summary of the research findings, presents
the relationships and contributions, and present some recommendations for the future
study.
10
LITERATURE REVIEW
2.1 Introduction
Concrete is a man-made construction material and has been extensively used in the
world (Gambhir, 2006). According to Mehta & Monteiro (2006), concrete is made of
the basic ingredients of Portland cement, aggregates and water. Nowadays, the rapid
development in all areas of civil engineering has led to increase demand for concrete.
As a result many researchers have directed their attention towards developing concrete
that suits the contemporary requirements and proficient in the aggressive environment.
The concrete technology has been developing along with problem arises. This chapter
discusses the effect of aggressive environment and factors that influence the formation
of the crystallizing salt in the concrete structures. A general literature review of
research carried out on method for aggressive environment simulation and material of
coal bottom ash in self-compacting concrete are also presented.
2.2 Salt attack in concrete material
Salt attack is a controlled phenomenon to make the material more durable. The
exposure of salt attack for a longer period where the salt residue crystallised in the
pores of materials such as concrete and other masonry materials which can cause the
disintegration of concrete matrix and structure . The salt is transferred through water
11
that may be carried in the various surrounds of the material. When the water is
evaporated through dryer area, the salt residuals are deposited in the pores of the
concrete material. This reoccurrence of wetting and drying of the pores will eventually
cause a slow rise of salt in the pores and capillaries of the material resulting in a more
concentrated salt remnant. At this time, the crystals have formed. As the crystals grow,
micro-particles from the mortar will expand, thus exerting internal forces and stresses.
The internal forces exerted by the salt crystals exert may lead to the eventual damage
to the concrete material.
2.3 Factors affecting salt attack on concrete
The deterioration of concrete due to salt attack is considered as a complex problem
and it depends on many parameters related to materials and condition of exposure.
This can be found from Table 2.1 below.
Table 2.1: Parameters related due to salt attack
Dependence Parameters
Material properties Cement types and composition, mineral admixture
type, water binder ratio, degree of hydration and
curing conditions
Hydrated concrete properties Pore structure, permeability, diffusivity, mechanical
properties
Exposure conditions Temperature, type of ions and concentration
2.3.1 Cement type and composition
The salt attack caused by sulphate is depends on availability of Ca(OH)2 and C3A in
the hydrated concrete, hence chemical composition of binder have an important role
in the salt attack resistance. Cement that contains low C3A has good sulphate
resistance. Sulphate Resisting Portland Cement (SRPC) has less content of C3A,
therefore it is protected under sulphate attack. Too high cement content in the concrete
may cause increasein the sulphate resistance (Rodrıguez-Camacho & Uribe-Afif,
2002). Modern cement is made for rapid development of strength in which results to
an increase of tricalcium silicate (C3S) contentsin the cement. The susceptibility to
sulphate attack will be enhanced from the increase of calcium hydroxide content in
12
the hardened cement which resulted from the increased of C3S (Sancak, & Özkan,
2015).
Blending of mineral admixtures such as ground granulated blast furnace slag
(GGBFS), fly ash (FA), silica fume (SF) in cement increases resistance of concrete to
sulphate attack. The superior performance of blended cement over plain cement
concrete is attributedby the pozzolanic reactions that consumed the calcium hydroxide
and the reduction of the plain cement quantity in total binder will dilute the calcium
aluminate hydrates phase. Hekal et al. (2002) reported that the hardened cement paste
that contained 40% GGBFS shows a significant improvement in the sulphate
resistance.
2.3.2 Water binder ratio
Water to binder ratio is the key factor of the mechanism strength in the development
of concrete. The concrete with lower water/binder ratio is commonly denser and have
a higher strength. However, Prasad et al. (2006) stated that the assumption is not
always true for the concrete with low water/binder ratio to have a better sulphate
resistance. Al-Amaudi et al. (1995) investigated this effect and found that the lower
water/binder ratio may enhance the strength reduction. The possible reasons for such
behaviour could be due to sulphate attack that is not physically in nature hence it is
independent from permeability of mix. Furthermore, the expensive product formed
from the reaction between the cement and sulphate salts are not well accommodated
in the finer pore structure of low water/binder ratio mix. Thus dense concrete mixtures
have aggravated the deterioration process which attributed from the sulphate attack.
2.3.3 Curing condition
Curing of freshly placed concrete is an important requirement to achieve optimum
performance (Turk et al., 2007). The curing condition of the concrete has greatly
affected it’s hydration process. The complete hydration of binder and the influence
factor of strength development in the concrete are involved with the continuous and
moist curing process. Initial curing condition could affect the sulphate resistance of
13
concrete. Osborne (1999) reported that the beneficial effects of short initial air curing
are includingcontinuous moist curing, a long-term sulphate resistance of plain and
blended concrete. The possible reason for such behaviour may be due to the initial dry
curing that has reduces the calcium hydroxide concentration in the concrete surface
zone. In addition, the initial dry curing have caused minor carbonation and reduced
the availability of calcium hydroxide for the salt attack.
2.3.4 Type of sulphate and concentration
Deterioration rate of concrete under salt attack also depends on the type of sulphate.
Al-Amaudi et al. (2002) presented the results of sodium, magnesium, and mixed
sulphate solution attack on mortar and concrete specimen. The strength reduction was
almost comparable in both environments up to about 100 days of exposure and
subsequently the reduction is spread in the magnesium sulphate for all types of
specimens. The expansion data indicates that the sodium sulphate environment has
caused more expansion on all mortar specimens. Results showed a superior
performance of blended cement in the sodium sulphate solution. In mixed sulphate
environment, the mode of sulphate attack is mainly controlled by magnesium sulphate
due to the generation of magnesium hydroxide (brucite). The solubility of magnesium
hydroxide (its solubility is 0.01 g/litre compared to 1.37 g/litre for calcium hydroxide)
and it’s saturated solution with the ph about 10.5 will cause destabilization of both
ettringite and calcium silicate hydrate. Therefore, the formation of ettringite is
significantly hindered in such environment and the deterioration of concrete is
attributed mainly to the formation of gypsum.
Deterioration of concrete in the sulphate attack also depends on the Sulphate
concentration in the exposure solution. Higher concentration of sulphate will leads to
a quick deterioration. Al-Dulaijan et al. (2003) studied the performance of plain and
blended cement mortar cubes which exposed to sodium sulphate solution of varying
concentration for up to 24 months. The degree of deterioration was evaluated by
strength reduction and visual inspection. Result from their study has indicated that the
rate of deterioration increased with increase in sulphate concentration for both plain
and blended cement. The sample prepared by fly ash blended cement shows less
deterioration compared to other concentrations and at all time of exposure.
14
2.3.5 Presence of chloride
The chloride ions are inadvertently associated with the sulphate attack in the ground
water or marine environment on the concrete. It is commonly known that the chloride
ion reacts with the hydrates of cement and will form the Freidel’s salt that does not
have any harmful effects on the concrete. However, when chloride contents in the
concrete has reach more than the threshold value, the protective alkaline layer of steel
reinforcement in the concrete structure will be broken. Later, the presence of oxygen
and humidity will cause corrosion of of the steel reinforcement. The presence of
chloride in the sulphate solution will produce effects to the deterioration of concrete
under the sulphate attack. Al-Amoudi et al. (2002) studied this effect on plain and
blended cement mortar specimens, through the specimens exposure to 2.1% SO4
solution and 2.1% SO4 + 15.7% Cl solutions for 365 days. Deterioration was measured
on the basis of the strength reduction and expansion of specimens. Resultshows that
the deterioration was relatively more intense in the specimen that exposed to pure
sulphate solution compared to those that exposed to sulphate-chloride solution.
The increase of the sulphate resistance in the cement with the presence of
chlorides is attributed to (i) increased solubility of calcium aluminate hydrate phase
leading to calcium sulpho-aluminate crystallization i.e. ettringite formed in a non-
expensive form, (ii) a decrease in the lime concentration in the pure solution leading
conversion of the high insolubility of the basic aluminate hydrate phase to soluble low
basic compounds thus producing ettringite of liquid phase in the non-expensive forms,
(iii) a transformation of aluminate hydrate phase into chloro-aluminate phase, thereby
reducing the quantity of ettringite formed, (iv) the rate of diffusion of chloride ions is
much higher than the sulphate ions which allows the chloride to react with C3A to
form calcium chloro-aluminate hydrate,this will result the quantity of C3A to be
available for sulphate ions to react and the form ettringite will be reduced.
2.3.6 Temperature of exposure
The deterioration of mixes is influenced by the physical condition of sulphate solution
which related to its temperature and also by the submersed level of specimens. Hekal
et al. (2002) observed the sulphate exposure at 60°C temperature in the ambient
15
environment with drying-immersion cycle. The increase in temperature of sulphate
solution has accelerated the sulphate attack on all types of specimens of mortars. The
drying-immersion from the cyclic process at 60°C has accelerated the rate of sulphate
attack and this can be considered as an accelerated method to evaluate sulphate
resistance. Changes in compressive strength of ordinary Portland cement mortar cubes
over time at different exposure conditions is shown in Figure 2.1. The curve shows
more reduction in strength at higher temperature. Hence sulphate attack is more
aggressive in the summer or in a hot climatic area.
Figure 2.1: Effect of physical condition of exposure (Hekal et al., 2002)
2.4 Mechanism of salt attack
Over recent decades, several mechanisms have been proposed to explain the
phenomenon of damage due to crystallization in porous brittle materials. The most
widely accepted is the theory of salt attack by supersaturation proposed by Scherer
(2004). Salt attack is a crystal-forming process due to the presence of soluble salt in
moisture or water after evaporation. The salt concentration in the solution gradually
increases as the material dries. The presence of soluble salts can deteriorate the porous
brittle materials either directly or indirectly. Under this sub-section, mechanism of
crystallization and salt attack in the concrete material exposed to soluble salts are
discussed in details.
16
2.4.1 Salt crystallization
Porous and brittle materials such as stone, masonry or cement-based materials can be
deteriorated due to pressure induced by salt crystallization taken place in their pores.
The cracking and fracture can be formed as a result of the production of pressure which
has exceeded the tensile capacity of the material (Scherer, 2004). The advanced
damage can compromise the integrity and performance with cyclic exposure and
weathering of the affected material during a longer period. A phenomenon called as
“salt weathering”, “salt scaling”, “physical salt attack”, or “salt crystallization” when
the salt has crystallized in the absence of degrading chemical interation has caused
damage.
Researchers examining the salt crystallization damage on porous materials
have always focused on salt crystallization by sodium sulphate, sodium chloride, and
sodium carbonate (Lee & Kurtis, 2017; Haynes et al., 2010; Thaulow & Sahu, 2004).
For example, Scherer (2004) experimentally investigated the stress caused by
crystallization of sodium sulphate salt (thenardite and mirabilite) in the stone. This
phenomenon can be explained by precipitation of salt crystals from the liquid in pore
structure of a material and also related to the phase change from thenardite to
mirabilite, which contains 10 molecules of water. Chatterji & Thaulow (1997) also
experimentally demonstrated that the crystal growth pressure exerted by sodium
thiosulfate pentahydrate could break glass test tubes without confinement. Thaulow &
Sahu (2004) reviewed the mechanisms of surface scaling of concrete due to sodium
sulphate salt. There were three existing proposed damage mechanisms have been
compared- (i) solid volume change hypothesis, (ii) salt hydration pressure hypothesis,
and (iii) crystallization pressure hypothesis - concluding that damage can only be
explained by salt crystallization pressure theory. The damage mechanisms associated
with salt crystallization in porous materials have been reviewed by Valenza & Scherer
(2007).
Although not examined as often, other salts including nitrates, oxalates, and
acetates, are also known to damage porous materials (Lee & Kurtis, 2017). For
example, acetates is known to damage tiles of glazed ceramics by salt crystallization
(Linnow et al., 2007), and nitrate (NO3) salts, since they are derived from fertilizer
which known to damage masonry near agricultural regions. Conservationists have
17
found crystallization of calcium nitrate salts to be particularly damaging to brittle
materials such as plasters. In addition to their practical relevance in this application,
study of crystallization of various salts is desirable because it is essential to develop
accelerated laboratory tests to assess potential for damage in natural and engineered
porous materials. Salts are particularly damaging at a faster rate and it is also
potentially good candidate to be applied in the accelerated test methods. Cement-based
materials are brittle similar to stone and masonry and have a porous microstructure
which can exhibit salt crystallization damage in practice (Haynes et al., 2010).
However, the microstructure and hardened properties of cement-based materials are
different to the natural materials, thus the extent of damage, can be controlled or
tailored to enhance durability.
2.4.2 Chloride attack
The durability of concrete is depends to its capability to resist quality degradation
when exposed to aggressive environments which can cause deleterious effects to the
concrete (Glasser et al., 2008). It is known that the ingress of chloride ions in the
concrete is the most severe problem affecting the durability of the concrete
construction. Chloride ions may cause adverse effect on hardened concrete in various
ways. Generally, the effect is usually attributed to the formation of calcium
chloroaluminate or Friedel’s salt (Islam et al., 2010). This salt crystallization has a
low-medium expansion property and may increase concrete permeability by leaching
due to the formation of excessive calcium chloride. The process of chloride attack on
concrete may be explained by the following chemical reaction below.
NaOH2CaCl NaCl2Ca(OH) 22 Equation 2.1
O10HCaClOAl3CaOOH10OAlCaO3CaCl 22322322 Equation 2.2
The penetration of chloride ions may attack concrete in different ways and it
is usually associated with the corrosion process in the reinforced concrete. According
to Montemor et al. (2003), the common causes of corrosion are (i) an ingress of carbon
dioxide from the atmosphere decreasing the alkalinity of the pore solution and (ii) the
18
local depassivation of steel due to the presence of chlorides at the reinforcement level;
this has shown in Figure 2.2. Furthermore, chloride may also infiltrate into concrete
from the environment such as deicing salt and seawater (Xu et al., 2009).
Figure 2.2: Chloride attack on reinforced concrete (Kung, 2014)
2.4.3 Sulphate attack
Sulphate attack is a major problem which related to the durability of concrete
structures (Chatveera & Lertwattanaruk, 2009). The attack by solutions containing
sulphate can have different effects on concrete. Given that the influence of other
chemicals can affect the mechanism of the reaction, therefore the nature of the sulphate
solution is significant. Figure 2.3 shows the mechanism of sulphate attack. This is
particularly factual in the case of seawater, where the presence of a higher
concentration of chlorides can have a bearing on the action of the sulphates. Chlorides
have a high tendency to bind tricalcium alluminate (C3A) in the cement to produce
chloroaluminate compounds, such as Friedel's salt, which do not cause any expansion
(Ragab et al., 2016). The lowered accessibility of C3A can decrease the deterioration
by sulphate attack due to a direct decrease in the production of ettringite. Furthermore,
Mehta (1991) has stated that the ettringite formation in chloride-rich environments is
not related with expansion and cracking.
The extent of sulphate attack in concrete is influence by several factors
including type and concentration of sulphate solution, cement type and content,
presence of mineral admixture and permeability (Mehta & Monteiro, 2006; Neville,
2002). It was reported that the deterioration caused by sulphate attack may be due to
transformation of mono-sulphate to ettringite which resulted in ettringite formation,
19
formation of calcium sulphate upon reaction of calcium hydroxide with sulphate ions
lead to gypsum formation and mass or strength loss due to sulphate attack. Both
ettringite and gypsum formations are accompanied by large value expansions (Mehta
& Monteiro, 2006; Alexander et al., 2013; Mardani-Aghabaglou et al., 2015). The
reactions can be formulated (Santhanam et al., 2003) as follow:
OH8 NaOH2OH2CaSO O10HSONaCa(OH) 2242422 Equation 2.3
O17HNaOH62Al(OH)O31HCaSO3OAl3CaO
O10HSONaOH12.O3CaO.Al
232432
242232
Equation 2.4
Figure 2.3: Schematic diagram for sulphate attack (China Microsilica Union, 2011)
2.4.4 Seawater attack
Marine environments are very aggressive, since seawater mainly consists of chlorides
and sulphates. Both ions can be very harmful to the durability of concrete structures
which can affect the long-term durability and may cause a huge economic loss.
Furthermore, concretes are exposed to repeated drying–wetting cycles, such as in the
marine environment of splash and tidal zone which can accelerate the deterioration of
structures (Chen et al., 2016).
20
The main attack mechanism in marine environments is external sulphate
attack. This occurs when water contaminated with sulphates penetrates into the
concrete by means of diffusion or capillary suction. Sulphates are mostly found in the
form of sodium sulphate (Na2SO4) or magnesium sulphate (MgSO4). The cation
associated with SO42+ has an influence on the attack mechanism and the consequence
of deterioration (Maes & Belie, 2014). Sodium sulphate attack will result in expansive
reaction products while magnesium sulphate attack will result in reduction in strength.
Al-Amoudi (2002) describes the sequence of attack by magnesium sulphate in
seawater as follows:
Mg(OH)OH2CaSO O2HMgSOCa(OH) 224242 Equation 2.5
OHSiOMg(OH)OH2CaSO
OHMgSOH-S-C
22224
24
Equation 2.6
OHOH58SiOMgO OHSiO4Mg(OH) 222222 n Equation 2.7
Zacarias (2007) stated that calcium chloroaluminate hydrate or Fridel’s salt is
an important phase formed during exposure of concrete to seawater. Generally,
chloride and sulphate ion from seawater penetrate into concrete forming Fridels salt
and ettringite. However, magnesium sulphate also attacks calcium hydroxide and
calcium-silicate-hydrate (C-S-H) phases. According to Leng et al. (2000), magnesium
sulphate attacks calcium hydroxide and C-S-H, reacts with C-H to form secondary
gypsum and brucite. Apart from that, Islam et al. (2010) found that chloride reacting
with C-H of hydrated cement has led to weight loss and weakening the concrete
structures. Figure 2.4 illustrates the mechanism of deterioration act on concrete
exposed to seawater.
21
Figure 2.4: Concrete exposed to seawater (Malhorta, 2000)
2.5 Aggressive exposure condition
The most serious problem in concrete technology is the premature deterioration of
concrete structures that subjected to harsh environments. There is overwhelming
evidence from the field experience that many problems related to durability, such as
sulphate attack, reinforcement corrosion, carbonation and alkali-silica reaction in
concrete would not have occurred if the concrete is vulnerable to the environment and
during the intended service life at the time of exposure (Neville, 2004). The related
issue of durability, the selection of materials, aggregate mix proportions and
construction practices using concrete must be addressed. The industry must develop a
new comprehensive model of concrete deterioration and quantify the environmental
influences on the permeability of concrete.
Concrete bridge decks and parking structures are typically consist of concrete
deck, reinforced with steel bars, post or pre-tensioning tendons, which serve as the
finished wearing surface and can resist the abrasion of tires on surfaces. Some of these
22
decks are exposed to rain and snow, and others are subjected indirectly to moisture
carried on the undersides of cars. Moisture may also be associated with deck cleaning
and maintenance activities. De-icing salt is also brought from undersides of cars or
applied directly to the deck to melt ice and snow for improved traction. Virtually, all
de-icing salt used in the current road and highway maintenance contains chlorides
(Fortin et al., 2014). The water stands on the deck surface may worsen from the
exposure of chlorides. In offshore and marine areas, salty sand, salt-water spray,
seawater, and prevalent high moisture conditions can also lead to serious corrosion
problems.
The temperature follows seasonal and daily temperature cycles, although a
temperature lag always occurs in the structure materials. Differences in temperature
along cross-sections of a reinforced concrete structure result in volume changes in the
members, whereby changes that are greater than those within enclosed structures.
Such changes are frequently smaller in the plan dimensions and exist in an
environment with more constant temperature, humidity, and moisture. Restraint of
volume change can cause racking of decks and floor slabs, beams and columns, and if
unprotected itmay allow rapid ingress of water and chlorides leading to further
deterioration (Merritt & Ricketts, 2001). When de-icing salts are used, some of these
salts will be absorbed by the cover of the concrete. A high osmotic and hydraulic
pressure with a consequent movement of water toward the coldest zone which causes
freezing will be occurred under severe wetting, drying, freezing and thawing cycles.
Damage can occur when the tensile strain exceeds ithe capacity of the concrete, which
varies with the age of the concrete and the rate of application of strain. The extent of
damage varies from surface scaling to complete disintegration as the layers of ice is
formed, starting at the exposed surface of the concrete and progressing through its
depth (Yuan et al., 2003).
2.5.1 Wetting and drying
Wetting and drying cycles can cause constant moisture movement through concrete
pores (Hong & Hooton, 1999; Sahmaran et al., 2007; Jaya et al., 2014; Ye et al., 2016).
It is well-known that wetting and drying cycles may speed up concrete degradation
and durability problems because this has subjected the concrete to the motion and
23
accumulation of destructive elements, such as sulphates, alkalis, acids, and chlorides.
According to Hong & Hooton (1999), there are several mechanisms governing
chloride ingress into concrete such as absorption, diffusion, chloride binding,
permeation, wicking and dispersion. Absorption and diffusion are the most significant
mechanism of chloride ingress for the structures exposed to cyclic wetting-drying.
Chloride-induced corrosion of steel reinforcement is a major cause affecting the
service life of reinforced concrete structure exposed to aggressive environments.
Chloride ions ingression by pore diffusion is a rare occasion when the concrete
structure is exposed to continuous wetting–drying cycles by tidal and splash action
(Maekawa et al., 2003). Various model and analysis technology have been proposed
including the condition of cyclic wetting–drying for chloride ions transport in sound
concrete. Most of analyses were based on the condition of chloride penetration into
saturated concrete, however in reality, concrete was often found in an unsaturated
condition rather than a saturation condition especially when subjected to cyclic
wetting–drying (Ye et al., 2012).
Ye et al. (2016) have conducted an experiment on chloride penetration process
in concrete exposed to a cyclic drying-wetting and carbonation environment. Based
on the findings, the chloride penetration profile in concrete was produced by multiple
interactive deteriorating mechanisms, and was dependent on the properties and stress
status of the concrete itself. Their study also claimed that the incorporation of
supplementary cementitious materials have made concrete more vulnerable to chloride
attack under a combined deterioration of cyclic drying-wetting and carbonation, since
the deficiency of portlandite dominates the positive effects such as pore refinement.
2.5.2 Freeze and thaw
Freeze and thaw damages may be caused by internal frost damage or salt-scaling.
Resistance to internal frost damage is enhanced by providing an adequate air void
system—including proper total air void volume as well as proper air void size and
spacing. It can also be enhanced by using low water-cementitious materials ratios and
supplementary cementitious materials to reduce both permeability and, in particular,
24
the number of large pores. Increasing the concrete strength also enhances the
resistance to internal frost damage. Salt-scaling can be prevented by providing an
adequate entrained air void system, reducing the water-cementitious materials ratio,
and providing proper finishing and curing practices. There is some evidence that the
use of fly ash or slag may reduce salt-scaling resistance.
The freeze-thaw durability of self-compacting concrete is frequently
comparable to or better than conventionally placed concrete. The low water-
cementitious materials ratios and with adequate entrain air can enhance the freeze-
thaw resistance. The use of fly ash and slag, however, may reduce salt-scaling
resistance. Persson (2003) found the internal frost resistance of self-compacting
concrete to be better compared to conventionally placed concrete and it also found to
be similar to the salt-scaling resistance Heirman and Vandewalle (2003) found thatthe
freeze-thaw durability was similar however the salt-scaling resistance decreased in
relative to conventionally placed concrete when a variety of fillers were used and the
water-cement ratio was held constant. Audenaert, Boel, and De Schutter (2002) found
that the reduction of water-cement and water-powder ratios in self-compacting
concrete mixtures have improved internal frost resistance. The use of some high range
water reducing admixtures under certain conditions may detrimentally affect the air
content and characteristics of the air void system. Khayat and Assaad (2002), however,
found that the air void characteristics of self-compacting concrete were similar to those
of conventionally placed concrete and the air void stability could be improved by
increasing the cementitious materials content. These will reduce the water-
cementitious materials ratio or adding a viscosity modifying admixtures in mixtures
with low cementitious materials contents and high water-cementitious materials ratios.
2.5.3 Laboratory simulation of wetting and drying cycles
Generally, the mechanism of cyclic wetting and drying allow for deeper penetration
of aggressive ions. For example, the aggressive ions can cause corrosion at rate 20
times higher than the rate achieved by exposure to continuous immersion (McCarter
& Watson, 1997). Obviously, the rate of the ions penetration to the concrete is depends
on the duration of the wetting-drying periods. The simulation of wetting and drying
207
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