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Innovative Methods to Mitigate Alkali-Silica Reaction in Concrete Materials Containing Recycled Glass Aggregates

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Innovative Methods to Mitigate Alkali-Silica Reaction in Concrete Materials Containing Recycled Glass Aggregates The Pennsylvania State University The Graduate School College of Engineering INNOVATIVE METHODS TO MITIGATE ALKALI-SILICA REACTION IN CONCRETE MATERIALS CONTAINING RECYCLED GLASS AGGREGATES A Dissertation in Civil and Environmental Engineering by Seyed-Mohammad-Hadi Shafaatian Submitted in Partial Fulfillment of the Requirements for the Degree of Doctor of Philosophy December 2012 The dissertation proposal of Seyed-Mohammad-Hadi Shafaatian was reviewed and approved* by the following: Farshad Rajabipour (Chair) Assistant Professor off the civil and environmental engineering Dissertation advisor, Chair of Committee William Burgos Professor of Civil and Environmental Engineering Carlo Pantano Distinguished Professor of Materials Science and Engineering Barry Scheetz Professor of Civil and Environmental Engineering *Signatures are on file in the Graduate School. Peggy Johnson Civil and Environmental Engineering Department Head ABSTRACT Application of recycled glass as a cement or fine aggregate replacement in concrete could result in major benefits towards a more sustainable design of concrete materials. This is however only possible if the main obstacle, the alkali silica reaction (ASR), is properly addressed and the ASR damage is mitigated. ASR is a deleterious reaction that occurs between meta-stable silicate phases of aggregates and hydroxyl ions present in the pore solution of portland cement concrete. With the overall goal of developing effective methods to mitigate ASR in concrete containing recycled glass, the research objectives of this PhD study are: 1- To understand the mechanisms through which fly ash controls ASR in accelerated mortar bar test (AMBT). 2- To investigate the beneficial effects of high alkali content glass powder towards ASR mitigation and elucidate the underlying ASR controlling mechanisms in AMBT 3- To perform a preliminary study of the feasibility of using Al(OH)3 as a cement replacement to control ASR . As one potential mechanism, the effect of Al on the dissolution rate of glass aggregates in alkaline solutions is further researched. To achieve the first objective, a series of experiments were designed to assess different potential ASR mitigation mechanisms with the aid of computer modeling coupled with advanced material characterization techniques. Various properties (e.g., pore solution composition, ion diffusion coefficient, pore size distribution, strength, ASR gel production and its composition) of mortars with the minimum required fly ash dosage were compared with 100% portland cement mortars. The findings revealed that fly ash mainly reduces the ASR expansion of mortars, by reducing the rate of ingress of the attacking hydroxyl ions from the external alkali bath. This was linked to the pore refinement occurred due to pozzolanic reaction of fly ash. With a numerical study, simulating the adsorption of alkalis by cement hydration products as a sink term, it was shown that alkali binding was also effective. Application of fly ash increased tensile strength of the mortars and thus, could enhance their resistance against cracking. Variation in ASR gel composition and alkali dilution were found to have minor effect in AMBT conditions. Finally, a new mechanism was introduced and validated in which fly ash to reduce ASR by iii repressing the dissolution rate of silicate aggregates which occurs due to reduction of the effective hydroxyl ion to aggregate surface ratio. To achieve the second research objective, four types of glass powder (GP) with different sizes were experimented in AMBT. An approximately linear relationship was obtained between GP size and the required dosage to mitigate ASR. A set of material characterization techniques was designed to shed light on the ASR suppressing effects of GP. The findings revealed that cement replacement by glass powder leads to a decrease in the pH of the pore solution even if alkalis are released from the glass powder. Based on charge balance, it was speculated that some alkalis were present in non-ionic form which do not increase the pore solution’s pH and promote ASR. Application of glass powder leads to a significant reduction in the rate of ion transport from the external bath. During the test, portlandite content of GP mortar decreased due to the pozzolanic reaction which led to a reduction in the average pore size of the binder phase of GP mortar. GP enhanced the tensile strength of the mortars which could be beneficial in ASR mitigation. Finally, to achieve the third research objective, the replacement of 20% weight of cement with Al(OH)3 powder was shown to suppress ASR expansion during ASTM C1260 test. The study was then focused on one possible mechanism through which Al(OH)3 can mitigate ASR. The effect of soluble Al on the rate of silicate glass dissolution, at high pH was studied. Corrosion of glass slides in alkaline solutions significantly decreased in presence of Al in the solution. The cause of this phenomenon was further investigated and related to formation of a semi-crystalline Al-Si (zeolite) layer at the surface of glass slides as well as Al-poisoning of silica surface. Based on experimental results, it is speculated that the latter mechanism is more significant in reducing glass dissolution rate and the protective action of the zeolite layer is likely to be less effective. The presence of sufficient dissolved Al was found to be essential for minimizing the dissolution rate of silicate glass. iv TABLE OF CONTENTS LIST OF FIGURES ……………………………………………………………..ix LIST OF TABLES……………………………………………………………….xv CHAPTER 1: INTRODUCTION……...……………………...…………………1 1.1 The Problem of Waste Glass ....................................................................................................... 1 1.2 Alkali Silica Reaction (ASR) ...................................................................................................... 3 1.3 Research Significance and Needs: ............................................................................................... 4 1.4 Organization of Contents ............................................................................................................. 6 1.5 References: .................................................................................................................................. 9 CHAPTER 2: BACKGROUND……………...………………………………………………….10 2.1 Using Recycled Glass in Concrete: ........................................................................................... 10 2.2 Benefits of Using Recycled Glass in Concrete: ......................................................................... 14 2.3 Challenges to Use of Recycled Glass in Concrete: ................................................................... 16 2.4 Chemical Mechanism of ASR ................................................................................................... 17 2.4.1 Structure of soda-lime glass ...................................................................................................... 17 2.4.2 Glass dissolution ........................................................................................................................ 18 2.4.3 Silica gelation and swelling ....................................................................................................... 23 2.5 ASR Gel: ................................................................................................................................... 25 2.6 Controlling ASR: ....................................................................................................................... 26 2.7 Tests to Evaluate the ASR risk of Aggregate-Cement Combinations ....................................... 28 2.8 Summary: .................................................................................................................................. 33 2.9 References: ................................................................................................................................ 34 CHAPTER 3: HOW DOES FLY ASH MITIGATE ALKALI-SILICA REACTION (ASR) IN ACCELERATED MORTAR BAR TEST (ASTM C1567)?...................................................................................................................38 3.1 Introduction ......................................................................................................................................... 38 3.2 Existing Literature .............................................................................................................................. 40 3.3 Materials and Methods ........................................................................................................................ 44 v 3.3.1 Accelerated mortar bar test (ASTM C1567) ............................................................................. 45 3.3.2 Pore solution extraction and analysis ........................................................................................ 46 3.3.3 Measurement of ion diffusivity using electrical impedance spectroscopy ................................ 47 3.3.4 Tensile and compressive strength tests ...................................................................................... 48 3.3.5 SEM/EDS imaging .................................................................................................................... 49 3.3.6 Aggregate dissolution rate measurements ................................................................................. 50 3.3.7 Numerical Model to Simulate Alkali Transport and Binding ..................................................
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