Conformity of Blended Cement Incorporating Ground Ceramic ... water for standard consistency, setting times and soundness tests were carried out on cement paste, while unit weight,

European Journal of Scientific Research ISSN 1450-216X / 1450-202X Vol. 148 No 2 January, 2018, pp. 265-276 http://www. europeanjournalofscientificresearch.com

Conformity of Blended Cement Incorporating Ground

Ceramic with Cement Standards

D.M. Sadek

Housing and Building National Research Center, Egypt

Sh.K. Amin

Corresponding Author, Associate Professor

Chemical Engineering and Pilot Plant Department

Engineering Research Division, National Research Centre (NRC)

33 El Bohouth St. (Former El Tahrir St.), Dokki, Giza, Egypt

PO box 12622, Dokki, Giza, Egypt

Affiliation ID: 60014618

Tel: 202 33335494; Fax: 202 33370931 E-mail: [email protected] or [email protected]

Abstract

In this study, ceramic powder derived from crushing and grinding rejected fired

glazed wall ceramic tiles was used as a supplementary cementing material to CEM I 42.5 N in the production of blended cement for sustainable construction. Cement was replaced by fine ceramic waste in ranges up to 35% wt. at an increasing increment of 5%. The characteristics of cement–ceramic blends were determined and compared with the requirements of both European and Egyptian standard specifications for cement. Standard water for standard consistency, setting times and soundness tests were carried out on cement paste, while unit weight, compression, flexural, water absorption, XRF, XRD, SEM and EDAX tests were carried out on cement mortar. The results demonstrate the effectiveness of using up to 35% ground ceramic waste in the production of blended cement satisfying the chemical, physical and mechanical requirements of both European and Egyptian standards for cement.

Keywords: Blended cement, ground ceramic waste, standard specifications, paste, mortar

1. Introduction Growth of population, increasing urbanization, rising standards of living due to technological innovations have contributed to an increase in the quantity and variety of wastes generated from industrial, mining, domestic and agricultural activities at an alarming rate. Huge quantities of solid wastes are generated and usually left as stockpiles, landfill material or illegally dumped, causing major environmental problems besides occupying a large area of land for their storage/disposal [1].

As a result, recent years have witnessed rising social concern about waste management problem. The environmental impact of these wastes can be reduced by making "Waste Hierarchy" concept for sustainable development. Its aim is to reduce, reuse, or recycle wastes. It offers three benefits: (i) reduce the demand upon new resources, (ii) reduce the demand of energy and (iii) use waste that would otherwise be disposed off in landfill sites [2]. The main potential market to utilize

Conformity of Blended Cement Incorporating Ground Ceramic with Cement Standards 266

recycled wastes is the construction industry. Many types of wastes have been investigated for use as coarse, fine aggregates or as supplementary cementing materials.

Ceramic industry is comprised of the following subsectors: floor and wall tiles, sanitary ware, bricks and roof tiles, refractory materials, technical ceramics and ceramic materials for domestic and ornamental use [3]. Ceramic tiles production has shown a great rate of increase in recent years. Globally, it increased from 8581 million m2 in 2009 to 11,913 million m2 in 2013 [4]. In Egypt, ceramic and refractory industries constitute about 7% of the industries, being one of the most important seven promising Egyptian industries [5]. Ceramic tile production was 20 million m2 in 1996, and reached 200 million m2 in 2009 [6, 7]. The increase in ceramic production is accompanied with a large increase of ceramic wastes; about 15–30% of the overall production goes as waste [8], which includes cracked, over-fired and under-fired ceramic. In addition, huge quantities of ceramic wastes are generated from construction and demolition activities [9].

For solving the ceramic waste disposal problem and at the same time helping in the achievement of sustainable development, several research works were carried out to find applications for ceramic wastes such as being used as road filler, and in the construction industry, as a partial substitute for coarse and/or fine aggregates, and as a partial substitute for cement [9–12].

On the other hand, cement industry faces a significant challenge related to energy and environment. It has been estimated that cement industry is responsible for the emission of about 6–7% of the planet’s total carbon dioxide emissions. Therefore, cement industry is looking for alternatives to overcome these problems by reusing wastes from other industries [4]. Hence, a new term "blended cement" is recently used to describe cement manufactured by inter-grinding clinker with one or more mineral additives such as ground-granulated blast furnace slag, pozzolan, fly ash, burnt shale, limestone, silica fume and meta-kaolin, etc [13], which reduces the environmental impact of plain cement.

In the same trend, some research works were carried out to investigate the influence of utilizing different ground ceramic wastes as a supplementary cementing material [14] in mortar [15, 16] and concrete [8, 11]. For ceramic/cement mortar, researchers confirmed that the presence of feldspars, quartz, and metal ions present in glazes do not interfere in the pozzolanic activity [15, 16]. Also, a systematic reduction in concrete compressive strength was noticed by increasing ceramic powder content. A concrete mix with 20% ceramic bricks waste provided the highest strength for all other studied ceramic wastes, while concrete mix with white stoneware one-fired waste gave the worst compressive strength, especially at early ages [8, 11].

It is obvious that although some researchers indicated the effectiveness of using ceramic powder as a partial replacement of cement, most researchers focused on the mechanical properties of mortar and concrete and there was no available research works were found concerning the evaluation of the influence of using ceramic powder with respect to the requirements of standard specifications of cement. Therefore, this research aims at investigating the conformity of blended cement containing 0–35% ground ceramic with the chemical, physical and mechanical requirements of both International and National cement standards [17, 18]. The replacement percentages by ceramic powder were selected to be in the range of blended cement CEM II according to cement standard specifications. Additional tests such as unit weight, water absorption, flexure, XRF, XRD, SEM and EDAX tests were also conducted to have a comprehensive evaluation of the potential recycling of ceramic waste in cement industry.

2. Experimental Work 2.1. Materials

CEM I 42.5 N from Qena Cement Company, Egypt, fulfilling both European and Egyptian cement standards [17, 18], was used for the preparation of all mixes. In this paper, ground ceramic waste was used as a supplementary cementing material to CEM I 42.5 N in manufacturing blended cement. It was

267 D.M. Sadek and Sh.K. Amin prepared by crushing and grinding rejected fired glazed wall ceramic tiles obtained from local factory in 10th Ramadan factory in Egypt. According to the factory's data sheet, the composition of ceramic was plastic clay from Aswan, potash feldspars from the Eastern desert, limestone from El–Menia quarries, kaolin from Sinai, bentonite from the north coast of Egypt and sand from the Eastern desert. Rejected fired glazed ceramic wall tiles were manually crushed then grinded and sieved on 75 µm (200 mesh) sieve.

Table (1) shows the chemical compositions of binding materials (i.e., cement and ceramic waste) as determined by X-ray fluorescence (XRF) technique, while Table (2) shows loss on ignition (LOI), chloride and sulfate contents for cement, ground ceramic waste and their blends, containing up to 35% ground ceramic waste as a replacement material to cement, as calculated by mass balance. It is obvious from Table (1) that cement is mainly composed of calcium and silica, while ground ceramic waste contains high levels of silica and alumina. The sum of the major components, SiO2, Al2O3 and Fe2O3, is higher than the minimum amount required for pozzolanic materials (i.e., 70% according to ASTM C618). Table (2) shows that while chloride content increases, sulfate content and LOI decrease by increasing the replacement percentage of CEM I 42.5 N by ground ceramic waste. According to cement standard specifications [17, 18], chloride content of cement should not be more than 0.1%, sulfate content should not be more than 3.5% for cement grade of 32.5 N and 42.5 N and 4% for cement grade of 42.5 R, while LOI should not be more than 5%. Accordingly, all blends conform to the requirement of standard specifications for all cement grades with respect to chemical requirements. On the other hand, although chloride content increased by using ground ceramic waste, which may be a risk in case of using ceramic-cement blend in reinforced concrete, the maximum chloride content found in the blend containing 35% waste ceramic powder is almost half the maximum allowable limit for chloride content according to cement standard specifications. Furthermore, using ground ceramic waste as a replacement material to cement was useful in decreasing sulfate content and LOI as required by standard specifications [17, 18]. Table 1: Chemical composition of cement and ground ceramic waste

Main constituents, (%) Cement Ground ceramic waste

SiO2 20.52 62.4 Al2O3 4.01 20.9 Fe2O3

tot. 3.27 4.02 CaO 62.57 7.01 MgO 1.75 0.45 Na2O 0.44 1.2 K2O 0.24 1.25 TiO2 1.18 ــــــ P2O5 0.58 ــــــ ZnO 0.11 ــــــ ZrO2 0.13 ــــــ Cr2O3 0.05 ــــــ MnO 0.03 ــــــ SO3

-2 3.15 0.23 Cl- 0.02 0.1 LOI 3.84 0.26

Table 2: Loss on ignition, chloride and sulfate contents for cement, ground ceramic waste, and their blends

Material LOI (%) Chloride content (%) Sulfate content (%)

CEM I 42.5 N 3.84 0.02 3.15 Ceramic waste powder 0.26 0.1 0.23 5% ceramic + 95% cement 3.66 0.02 3.00 10% ceramic + 90% cement 3.48 0.03 2.86 15% ceramic + 85% cement 3.30 0.03 2.71 20% ceramic + 80% cement 3.12 0.04 2.57


Material LOI (%) Chloride content (%) Sulfate content (%)

25% ceramic + 75% cement 2.95 0.04 2.42 30% ceramic +70% cement 2.77 0.04 2.27 35% ceramic + 65% cement 2.59 0.05 2.13

The mineralogical characterization of binding materials was determined by X-ray diffraction

(XRD) test using X-ray vertical diffractometer equipped with monochromatic Cu–Kα radiation source. The test was run at 40 kV and 30 mA. Scanning covered the range 0-50° with a scan rate of 2°/minute. XRD diagram (Fig. 1) indicates low crystallinity of ceramic waste. In addition, larnite, syn, brown-millerite, calcium silicate, calcium oxide and tri-calcium aluminate were the major crystalline phases detected in cement. On the other hand, as expected quartz and albite were the main crystalline minerals in ceramic, while hematite and montmorillonite were minor phases.

Figure 1: XRD of: (a) Cement and (b) Ground ceramic waste

Figure (2) shows the grading of binding materials determined by using laser analysis particle size distribution apparatus. It is obvious that the grading of ground ceramic is quite different from that of cement. The grading of cement ranged from 1.73 to 262.38 µm with mean, median and mode sizes of (28.97, 16.29, and 12.32) µm, respectively while the grading of ground ceramic ranged from 0.58 to77.34 µm, with mean, median and mode sizes of (14.78, 11.27, and 12.39) µm, respectively. Furthermore, D10 (i.e., size of particles passing 10% from sieves) for cement and ground ceramic was 6.25 and 2.45 µm, respectively, while D90 (i.e., size of particles passing 90% from sieves) for cement and ground ceramic was 68.96 and 32.58 µm, respectively, indicating finer grading of ground ceramic waste compared with cement. 2.2. Methods

For investigating the influence of utilizing ground ceramic waste in manufacturing of blended cement, ceramic powder substituted CEM I 42.5 N by 0, 5, 10, 15, 20, 25, 30, and 35%, respectively. Fresh and hardened characteristics of the blend were determined and checked for compliance with the chemical, physical and mechanical requirements of cement standard specifications [17, 18].

269 D.M. Sadek and Sh.K. Amin

Figure 2: Particle size distribution of: (a) Cement and (b) Ground ceramic waste

Chemical requirements include the maximum allowable limits for LOI, sulfate and chloride contents in cement as discussed earlier in the materials section. Physical requirements include initial setting time and soundness tests carried out on cement paste, while mechanical requirements include the determination of 2 and 28–days mortar compressive strength. Therefore, cement pastes were prepared with 0–35% ground ceramic waste to evaluate its effect on initial setting time and soundness as required by standard specifications. Additional tests were carried out on cement pastes including the determination of standard water required for standard consistency and final setting time of cement paste. Pastes were tested according to the standard test methods [19, 20]. Standard water required for standard consistency and setting times of cement paste were determined using Vicat apparatus, while soundness test was conducted using Le-Chatelier apparatus.

On the other hand, for the determination of compressive strength, mortar mixes with 0–35% ceramic waste powder were prepared. Additional tests were carried out on cement mortars including flexural, unit weight and water absorption tests. Compression and flexural tests were carried out at 2 and 28 days using (40 × 40 × 160) mm prisms according to the standard test methods [21, 22], while unit weight and water absorption tests were carried out at 28 days using 25 mm cubic specimens. Moreover, scanning electron microscope (SEM) test equipped with energy dispersive X-ray spectroscopy (EDAX), XRF and XRD tests were conducted for investigating the mineralogical phases and microstructure of selected mortar mixes. These tests were carried out after finishing water absorption test. Cubic specimens were sawed and one part was ground for XRF and XRD tests, while the second part was used in SEM and EDAX tests. Mortar specimens were prepared using natural sand complying with the requirements of standard specifications [21, 22]. The ratio between binder:sand:water was 1:3:0.5 (by weight). Specimens were de-molded after 24 h from cast and were then immersed in water until testing.

3. Results and Discussion 3.1. Effect of Ground Ceramic Waste on Cement Paste Characteristics

Table (3) shows the characteristics of cement pastes containing 0–35% ceramic powder. The investigated characteristics were the determination of the amount of required water for standard consistency as well as the determination of setting times and soundness. It is obvious from the table that the required water for standard consistency increases systematically by increasing ceramic powder substitution percentage. The percentage of increase was 12.7% at 35% ceramic powder compared with that for cement paste with plain cement. This is probably attributed to the finer grading of ceramic powder compared with that of cement as discussed previously. Kenna and Archbold [14] attributed the reduction in concrete consistency by increasing ceramic powder percentage to the higher water


absorption of ceramic. Consequently, in case of using blended cement with ground ceramic, additional amount of water or high range water reducing admixtures should be used to maintain the consistency of the mix.

The initial and final setting times were also found to increase by increasing the percentage of ground ceramic. At 5% replacement, the initial setting time slightly increased by 3.7%, while the final setting time remained unchanged at 185 minutes relative to the control mix without ground ceramic. Further increase in ground ceramic percentage increased setting times. At replacement percentage of 35%, the percentage of increase in initial and final setting times was 29.6% and 24.3%, respectively when compared with cement paste made using plain cement. Longer setting times of ceramic-cement pastes may be attributed to the higher amount of water needed for standard consistency of ground ceramic mixes. Hence, the influence of ground ceramic on setting times is likely a function of the substitution percentage and water content in the mix. According to cement standard specifications [17, 18], the initial setting time should not be less than 75 minute for cement grade of 32.5, 60 minute for cement grade of 42.5 and 45 minute for cement grade of 52.5, while no limit is set out for the final setting time. Accordingly, all the tested mixes conform to the requirement of the standard specifications for all cement grades with respect to setting times.

The results of soundness test indicate an increase in cement paste expansion by increasing the percentage of ground ceramic. The expansion of cement paste containing 5% ground ceramic was equal to that of plain cement paste, while at 35% ground ceramic, the expansion was four times that of plain cement paste. According to cement standard specifications [17, 18], the expansion should not exceed 10 mm for all cement types and grades. Accordingly, although the expansion at 35% ground ceramic was much higher than that for plain cement paste, this expansion value (4 mm) was still far below the standard specifications limit (i.e., 10 mm).

3.2. Effect of Ground Ceramic Waste on Cement Mortar Characteristics

In this section, the characteristics of cement mortar containing 0% to 35% ceramic waste are illustrated and discussed. The investigated characteristics were unit weight, water absorption, compressive strength and flexural strength. The physical properties were determined at 28 days, while the mechanical properties were determined at 2 and 28 days. Table 3: Characteristics of cement paste

Replacement

percentage

Water for standard

consistency (g)

Setting times (min.) Expansion

(soundness test) (mm) Initial Final

0% 136.8 135 185 1 5% 139.3 140 185 1

10% 140.1 145 190 1.5 15% 144.2 150 195 2 20% 146.1 150 195 2 25% 147.1 155 210 2.5 30% 147.5 165 215 3 35% 154.2 175 230 4

Figure (3) shows the physical properties of cement mortar as a function of the ground ceramic

replacement percentage. It found that the unit weight slightly increased by using up to 10% ground ceramic; thereafter the unit weight slightly decreased by increasing ground ceramic percentage. The highest unit weight of 2.176 g/cm3 was recorded at 10% ground ceramic percentage, while the lowest one was at 35% replacement percentage. The increased unit weight for 10% ground ceramic mix may possibly be attributed to the filler effect of ground ceramic that has finer grading than that of cement leading to denser microstructure. On the other hand, at higher percentages of ground ceramic, the dominant factor is the lower density of ground ceramic compared with cement. However, it is obvious that the unit weight of the investigated mixes ranges from 2.091 to 2.176 g/cm3, which falls within the

271 D.M. Sadek and Sh.K. Amin acceptable range for cement mortar. Similar findings were reported by Kenna and Archbold [14] that unit weight of concrete containing ceramic powder as a partial substitution of cement was slightly lower than that the control concrete mix, and a reduction of 7% was recorded at 30% replacement percentage.

Generally, the water absorption increases by increasing the percentage of ground ceramic. The highest water absorption was recorded at 30–35% ground ceramic percentage, with 21% increase relative to the control mix. The increased water absorption due to incorporating ground ceramic could be attributed to the morphological appearance of ground ceramic, as it has irregular shaped particles with a smooth surface and sharp edges [4]. Similar findings were reported by Vejmelková et al. [23] that the water transport parameters significantly increased by using ceramic powder as a partial substitution of cement in concrete. The authors recorded the highest water absorption value at 60% ceramic powder.

Figure 3: Physical properties of cement mortar: (a) Unit weight, (b) Water absorption

Figure (4) shows the mechanical properties of cement mortar as a function of both replacement percentage of ground ceramic and age. It was found that both of compressive and flexural strengths showed a continuous reduction by increasing the percentage of ground ceramic, regardless of mortar age. However, the reduction in strength at age of 2 days was more significant than that at 28 days. The reduction in compressive strength at 2 days increased from 10.6% to 21.6% by increasing ground ceramic percentage from 5% to 35%, respectively, while the reduction in flexural strength ranged from 5.4% to 25.1%, respectively. At the age of 28 days, the reduction in compressive and flexural strengths ranged from 3.3% to 9.3% and 3.5% to 11%, respectively. No significant difference was observed between the compressive strength of mortar mixes containing 10-20% ground ceramic. The lowest strengths were recorded at replacement percentage of 35%. Similar findings were reported by Kenna and Archbold [14] in which concrete compressive strength gradually decreased by increasing waste ceramic percentage. Mas et al. [4] also reported that although the compressive strength of mortar was reduced with increasing ceramic powder content, an excellent contribution of pozzolanic addition to the mechanical properties was observed after 28 days of curing.

According to cement standard specifications [17, 18], cement is classified into three grades 32.5, 42.5 and 52.5 based on its 28 days compressive strength. For each grade, cement is classified into three types based on the rate of gaining compressive strength; normal early compressive strength (N), rapid early compressive strength (R) and low early compressive strength (L), which is for blast furnace slag cement with low early compressive strength. Thus, (L) type is out of scope in this paper. Table (4) shows the required compressive strength for cement types (N) and (R) according to cement standard specifications. It is obvious from Table (4) that all the investigated mixes even those containing high percentages of ceramic waste powder (up to 35% replacement of cement) satisfied the requirements of the standard specifications for cement grade 42.5 N. The early compressive strength of the investigated


mixes (at 2 days) ranges from 17.4 to 22.2 N/mm2, which is higher than the required strength for cement grade 42.5 N (i.e., ≥ 10 N/mm2). Moreover, their standard compressive strength (at 28 days) ranges from 46.1 to 50.8 N/mm2, which is also within the required range for cement grade 42.5 N (i.e., ≥ 42.4 N/mm2 and ≤ 62.5 N/mm2).

Figure 4: Mechanical properties of cement mortar: (a) at the age of 2 days, (b) at the age of 28 day

Table 4: The required compressive strength (N/mm2) according to both European and Egyptian standards for

cement

Compressive strength grade Early compressive strength Standard compressive strength

2 days 7 days 28 days

32.5 N ≥ 16 ≥ 32.5 and ≤ 52.5 32.5 R ≥ 10 42.5 N ≥ 10 ≥ 42.5 and ≤ 62.5 42.5 R ≥ 20 52.5 N ≥ 20 ≥ 52.5 52.5 R ≥ 30

Based on the investigated characteristics of both cement paste and mortar, and the comparisons

made with the standard specifications, it was found that there is no significant difference between the characteristics of cement paste and mortar containing plain cement and those containing 5% ground ceramic. Beyond this percentage, any increase in ground ceramic content adversely affects the characteristics of cement paste and mortar. However, the characteristics of both cement paste and mortar containing up to 35% ground ceramic (as cement replacement material) still satisfy the requirements of standard specifications with respect to initial setting time, soundness and compressive strength for cement grade 42.5 N. Hence, ground ceramic waste could be used to substitute up to 35% of cement for manufacturing blended cement of grade 42.5 N. 3.3. Effect of Ground Ceramic Waste on the Mineralogical Composition and Microstructure of

Cement Mortar

Table (5) shows the elemental analysis of selected cement mortar mixes containing (0, 20, and 35) % ground ceramic as a partial substitution of cement. It was determined by XRF technique. It is obvious that while the content of silica, alumina and ferric oxides increased by increasing the substitution percentage of cement by ceramic waste, the content of calcium oxide decreases. This result was expected since silica and alumina, in addition to ferric oxides are the major elements found in ceramic powder as shown previously in Table (1). Furthermore, LOI and sulfate content showed a systematic

273 D.M. Sadek and Sh.K. Amin decrease by increasing the content of ceramic powder in mortar. This result is matched with that obtained in materials section. Table 5: Chemical composition of cement mortars containing 0%, 20% and 35% ground ceramic waste as a

replacement material

Main constituents, (%) 0% ground ceramic waste

mortar

20% ground ceramic

waste mortar

35% ground ceramic

waste mortar

SiO2 73 75.5 77.4 AlO3 2.03 2.6 3.19 Fe2O3

tot. 1.58 1.61 1.74 CaO 15.5 13 10.7 MgO 0.71 0.65 0.5 Na2O 0.24 0.15 0.2 K2O 0.23 0.33 0.32 TiO2 0.17 0.18 0.27 P2O5 0.1 0.07 0.11 ZnO 0.01 0.02 0.01 ZrO2 0.02 0.04 ــــــ Cr2O3 0.1 0.16 0.14 MnO 0.03 0.05 ــــــ SO3

-2 1.49 1.27 1.19 Cl- 0.09 0.1 0.08 LOI 4.55 4.28 3.85

Figure (5) shows the XRD patterns of selected cement mortar mixes containing (0, 20, and 35)

% ceramic powder as a partial substitution of cement. It is obvious that all mixes have almost the same phases with different intensities. They have portlandite, quartz, syn, larnite, calcite and calcium silicate. The intensity of portlandite peaks systematically decreases by increasing ground ceramic percentage in the mix, indicating the consumption of portlandite (Ca (OH)2) through the pozzolanic reaction. This result is consistent with that obtained from XRF test. On the other hand, the intensity of quartz, syn and larnite decreased due to using 20% ground ceramic, while it increased again due to using 35% ground ceramic. This indicates that the optimum percentage of ceramic powder is 20% of cement weight. At this percentage, most of very fine ceramic powder particles react with calcium hydroxide to form calcium silicate hydrate, while at 35% ground ceramic, large ceramic particles remained without reaction. Consequently, the content of quartz, syn and larnite increased in 35% ground ceramic mix when compared with 20% ground ceramic mix.

Figure 5: XRD of cement mortar: (a) 0% replacement, (b) 20% replacement, (c) 35% replacement


Figure 5: XRD of cement mortar: (a) 0% replacement, (b) 20% replacement, (c) 35% replacement - continued

Figure (6) shows SEM micrographs and EDAX for cement mortars containing (0, 20, and 35) % ceramic powder. It is obvious that the microstructure of cement mortar made with plain cement (Fig. 6-a) is denser than those of mixes containing 20 and 35% ground ceramic (Figs. 6-c and 6-e). This result is consistent with water absorption test results in which the absorption of mortar mixes increased by increasing the percentage of ceramic powder, indicating a more porous microstructure. Furthermore, calcium silicate hydrate and calcium hydroxide appear in Fig. (6-a) as the dominant hydration products in mortar mix with plain cement, while the amount of calcium hydroxide decreased in mortar mix with 20% ceramic powder (Fig. 6-c) and almost disappeared in case of using 35% ceramic powder (Fig. 6-e). It is well known that clay minerals are mainly formed from siliceous and aluminous compounds. Clay minerals become highly reactive by incineration at temperatures between 600–900 °C and grinding to appropriate fineness. Thus, if they are mixed with calcium hydroxide and water, they undergo pozzolanic reaction [23]. This is the case found in ground ceramic, as ceramic is made from natural materials containing a high proportion of clay minerals. These minerals through a process of dehydration followed by controlled firing at temperatures between 700 and 1000 ºC, acquire the characteristic properties of "fired clay". Thus, the manufacturing process of ceramic could activate the clay minerals, enhancing pozzolanic properties [9, 24]. Accordingly, ground ceramic possess characteristics making it suitable for use as a pozzolanic material, and thus when it is used as a replacement cementing material, it reacts with calcium hydroxide to form calcium silicate hydrate through pozzolanic reaction. However, not all ceramic powder grains were found to react with cement through pozzolanic reaction due to the existence of some ceramic powder crystals as shown in Figs. (6-c) and (6-e).

Figures (6-b) and (6-d) show EDX patterns for cement mortars made with plain cement and blended cement with 35% ground ceramic. The elemental analysis showed that mortar mix with plain cement composed of 53.1% O2, 1.5% Al, 16.2% Si, 28.3% Ca and 0.8% S, while mortar mix with 35% ground ceramic is composed of 55.7% O2, 2.1% Al, 28.1% Si and 14.0% Ca. Hence, mortar mix with 35% ground ceramic contains lower calcium content and higher silica and alumina contents. Lower calcium content indicates the conversion of calcium hydroxide to calcium silicate hydrate through pozzolanic reaction between ceramic powder and cement. Higher silica and alumina contents are from ground ceramic as silica and alumina are the major elements found in the fired ceramic tiles.

275 Figure 6:

4. ConclusionsIn this paper, ground ceramic from rejected fired glazed wall ceramic tiles was utilized as a replacement cementing material to CEM I 42.5 N in manufacturing of blended cement for sustainable cement mortar.

1) Groundreplacement level of up to 35%.

2) Using 5% ground ceramic does not have a significant influence on the characteristics of both cement paste and mortar. Further replacement levels acement paste and mortar. However, all blends containing ground ceramic, even those containing 35% replacement of cement, satisfied the chemical, physical and mechanical requirements according to national and internati

3) An increase of ground ceramic percentage in the blend results in an increase in chloride content and a decrease in both sulfate content and LOI.

4) Setting times and expansion of cement paste increased by increasing groundpercentage in the blend.

5) While water absorption of cement mortar increases systematically by increasing ground ceramic percentage, compressive and flexural strengths showed continuous reductions

6) The results of XRF, XRD, SEM and EDAX tests confirmto calcium silicate hydrate through the pozzolanic reaction of ground ceramic.

References[1] Batayneh, M., Marie, I., Asi, I., (2007), “Use of Selected Waste Materials in Concrete Mixes”,

Waste Manage, 27 (12):

SEM micrographs and EDAX patterns for selected cement mortars(a), (b) 0% replacement, (c) 20% replacement, (d) and (e) 35% replacement

Conclusions paper, ground ceramic from rejected fired glazed wall ceramic tiles was utilized as a

replacement cementing material to CEM I 42.5 N in manufacturing of blended cement for sustainable cement mortar. The main conclusions could be outlined as follows:

Ground ceramic could be utilized in the manufacturing of blended cement CEM II with replacement level of up to 35%.Using 5% ground ceramic does not have a significant influence on the characteristics of both cement paste and mortar. Further replacement levels acement paste and mortar. However, all blends containing ground ceramic, even those containing 35% replacement of cement, satisfied the chemical, physical and mechanical requirements according to national and internatiAn increase of ground ceramic percentage in the blend results in an increase in chloride content and a decrease in both sulfate content and LOI.Setting times and expansion of cement paste increased by increasing groundpercentage in the blend.While water absorption of cement mortar increases systematically by increasing ground ceramic percentage, compressive and flexural strengths showed continuous reductionsThe results of XRF, XRD, SEM and EDAX tests confirmto calcium silicate hydrate through the pozzolanic reaction of ground ceramic.

References Batayneh, M., Marie, I., Asi, I., (2007), “Use of Selected Waste Materials in Concrete Mixes”, Waste Manage, 27 (12):


paper, ground ceramic from rejected fired glazed wall ceramic tiles was utilized as a replacement cementing material to CEM I 42.5 N in manufacturing of blended cement for sustainable

The main conclusions could be outlined as follows:ceramic could be utilized in the manufacturing of blended cement CEM II with

replacement level of up to 35%.Using 5% ground ceramic does not have a significant influence on the characteristics of both cement paste and mortar. Further replacement levels acement paste and mortar. However, all blends containing ground ceramic, even those containing 35% replacement of cement, satisfied the chemical, physical and mechanical requirements according to national and internatiAn increase of ground ceramic percentage in the blend results in an increase in chloride content and a decrease in both sulfate content and LOI.Setting times and expansion of cement paste increased by increasing groundpercentage in the blend. While water absorption of cement mortar increases systematically by increasing ground ceramic percentage, compressive and flexural strengths showed continuous reductionsThe results of XRF, XRD, SEM and EDAX tests confirmto calcium silicate hydrate through the pozzolanic reaction of ground ceramic.

Batayneh, M., Marie, I., Asi, I., (2007), “Use of Selected Waste Materials in Concrete Mixes”, Waste Manage, 27 (12): 1870




replacement level of up to 35%. Using 5% ground ceramic does not have a significant influence on the characteristics of both cement paste and mortar. Further replacement levels acement paste and mortar. However, all blends containing ground ceramic, even those containing 35% replacement of cement, satisfied the chemical, physical and mechanical requirements according to national and internatiAn increase of ground ceramic percentage in the blend results in an increase in chloride content and a decrease in both sulfate content and LOI.Setting times and expansion of cement paste increased by increasing ground

While water absorption of cement mortar increases systematically by increasing ground ceramic percentage, compressive and flexural strengths showed continuous reductionsThe results of XRF, XRD, SEM and EDAX tests confirmto calcium silicate hydrate through the pozzolanic reaction of ground ceramic.

Batayneh, M., Marie, I., Asi, I., (2007), “Use of Selected Waste Materials in Concrete Mixes”, 1870–1876.




Using 5% ground ceramic does not have a significant influence on the characteristics of both cement paste and mortar. Further replacement levels acement paste and mortar. However, all blends containing ground ceramic, even those containing 35% replacement of cement, satisfied the chemical, physical and mechanical requirements according to national and international cement standard specifications.An increase of ground ceramic percentage in the blend results in an increase in chloride content and a decrease in both sulfate content and LOI. Setting times and expansion of cement paste increased by increasing ground

While water absorption of cement mortar increases systematically by increasing ground ceramic percentage, compressive and flexural strengths showed continuous reductionsThe results of XRF, XRD, SEM and EDAX tests confirmto calcium silicate hydrate through the pozzolanic reaction of ground ceramic.

Batayneh, M., Marie, I., Asi, I., (2007), “Use of Selected Waste Materials in Concrete Mixes”,

SEM micrographs and EDAX patterns for selected cement mortars(a), (b) 0% replacement, (c) 20%


The main conclusions could be outlined as follows: ceramic could be utilized in the manufacturing of blended cement CEM II with

Using 5% ground ceramic does not have a significant influence on the characteristics of both cement paste and mortar. Further replacement levels adversely affect the characteristics of cement paste and mortar. However, all blends containing ground ceramic, even those containing 35% replacement of cement, satisfied the chemical, physical and mechanical

onal cement standard specifications.An increase of ground ceramic percentage in the blend results in an increase in chloride content

Setting times and expansion of cement paste increased by increasing ground

While water absorption of cement mortar increases systematically by increasing ground ceramic percentage, compressive and flexural strengths showed continuous reductionsThe results of XRF, XRD, SEM and EDAX tests confirm the conversion of calcium hydroxide to calcium silicate hydrate through the pozzolanic reaction of ground ceramic.


D.M. Sadek and Sh.K. Amin



ceramic could be utilized in the manufacturing of blended cement CEM II with

Using 5% ground ceramic does not have a significant influence on the characteristics of both dversely affect the characteristics of

cement paste and mortar. However, all blends containing ground ceramic, even those containing 35% replacement of cement, satisfied the chemical, physical and mechanical

onal cement standard specifications.An increase of ground ceramic percentage in the blend results in an increase in chloride content


While water absorption of cement mortar increases systematically by increasing ground ceramic percentage, compressive and flexural strengths showed continuous reductions

the conversion of calcium hydroxide to calcium silicate hydrate through the pozzolanic reaction of ground ceramic.








onal cement standard specifications. An increase of ground ceramic percentage in the blend results in an increase in chloride content


While water absorption of cement mortar increases systematically by increasing ground ceramic percentage, compressive and flexural strengths showed continuous reductions

the conversion of calcium hydroxide to calcium silicate hydrate through the pozzolanic reaction of ground ceramic.








An increase of ground ceramic percentage in the blend results in an increase in chloride content

Setting times and expansion of cement paste increased by increasing ground ceramic

While water absorption of cement mortar increases systematically by increasing ground ceramic percentage, compressive and flexural strengths showed continuous reductions.

the conversion of calcium hydroxide



[2] Tam, V.M., Tam, C.M., (2006), “A Review on the Viable Technology for Construction Waste Recycling”, Resour. Conserv. Recycl, 47 (3): 209–221.

[3] Senthamarai, R.M., Manoharan, P.D, (2005), “Concrete with Ceramic Waste Aggregate”, Cem. Concr. Compos, 27 (9–10): 910–913.

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[7] El-Fadaly, E., Bakr, I.M., Abo-Breka, M.R., (2010), “Recycling of Ceramic Industry Wastes in Floor Tiles Recipes”, J. Am. Sci., 6 (10): 241–247.

[8] Raval, A.D., Patel, I.N., Pitroda, J., (2013), “Ceramic Waste: Effective Replacement of Cement for Establishing Sustainable Concrete”, Int. J. Eng. Trends Technol. (IJETT), 4 (6), 2324–2329.

[9] Juan, A., Medina, C., Guerra, M.I., Morán, J.M., Aguado, P.J., de Rojas, M.I.S., Frías, M., Rodríguez, O., (2010), “Re-use of Ceramic Wastes in Construction”, Ceram. Mater, 197–214.

[10] Martínez, C.M., Romero, MIG., Del Pozo, J.M.M., Valdés, A.J., (2009), “Use of Ceramic Wastes in Structural Concretes”, 1st Spanish National Conference on Advances in Materials Recycling and Eco–Energy, Madrid.

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[12] Amin, S.K., Sibak, H.A., El–Sherbiny, S.A., Abadir M.F., (2016), “An Overview of Ceramic Wastes Management in Construction”, Int. J. Appl. Eng. Res., 11 (4): 2680–2685.

[13] Wang, K., Ge, Z., (2003), “Evaluating Properties of Blended Cements for Concrete Pavements”, Center for Portland Cement Concrete Pavement Technology, Iowa State University, Ames, Final report.

[14] http://www.intrans.iastate.edu/reports/blendedcements.pdf [15] Kenna, F., Archbold, P., (2014), “Ceramic Waste Sludge as a Partial Cement Replacement”,

Civil Engineering Research in Ireland conference, Belfast, UK. [16] Ay, N., Ünal, M., (2000), “The Use of Waste Ceramic Tile in Cement Production”, Cem.

Concr. Res, 30 (3): 497–499. [17] Lavat, A.E., Trezza, M.A., Poggi, M., (2009), “Characterization of Ceramic Roof Tile Wastes

as Pozzolanic Admixture”, Waste Manage, 29 (5): 1666–1674. [18] EN 197–1/2011, “Composition, Specifications and Conformity Criteria for Common Cements”,

European Committee for Standardization (CEN), (2011). [19] ES 4756–1/2013, “Composition, Specifications and Conformity Criteria for Common

Cements”, Egyptian Organization for Standardization and Quality (EOS), Cairo, Egypt, (2013). [20] EN 196–3/2016, “Methods of Testing of Cement – Part (3): Determination of Setting Times

and Soundness”, European Committee for Standardization (CEN), (2016). [21] ES 2421–1/2005, “Physical and Mechanical Test of Cement – Part (1): Determination of

Setting Times and Soundness”, Egyptian Organization for Standardization and Quality (EOS), Cairo, Egypt, (2005).

[22] EN 196–1/2016, “Methods of Testing of Cement – Part (1): Determination of Strength”, European Committee for Standardization (CEN), (2016).

[23] ES 2421–7/2015, “Physical and Mechanical Test of Cement – Part (7): Determination of Strength using Prism”, Egyptian Organization for Standardization and Quality (EOS), Cairo, Egypt, (2015).

[24] Vejmelková, E., Kulovaná, T., Keppert, M., Konvalinka, P., (2012), “Application of Waste Ceramics as Active Pozzolana in Concrete Production”, IPCSIT, 28: 132–136.

[25] Zimbili, O., Salim, W., Ndambuki, M., (2014), “A Review on the Usage of Ceramic Wastes in Concrete Production”, Int. J. Civil, Environ, 8 (1): 91–95.

Documents

Conformity of Blended Cement Incorporating Ground Ceramic ... water for standard consistency, setting times and soundness tests were carried out on cement paste, while unit weight,