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Gypsum Powder Recycled from Waste Drywalls As a Partial Cement Replacement in Concrete

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Gypsum Powder Recycled from Waste Drywalls As a Partial Cement Replacement in Concrete GYPSUM POWDER RECYCLED FROM WASTE DRYWALLS AS A PARTIAL CEMENT REPLACEMENT IN CONCRETE by Sarah Kathleen Aubierge Hansen Submitted in partial fulfilment of the requirements for the degree of Master of Applied Science at Dalhousie University Halifax, Nova Scotia March 2020 © Copyright by Sarah Kathleen Aubierge Hansen, 2020 DEDICATION I would like to dedicate this thesis to my mother, Kathy, who always encourages me to be my best and shows me immeasurable love and support. ii TABLE OF CONTENTS List of Tables ............................................................................................................ vi List of Figures ......................................................................................................... vii Abstract .................................................................................................................... x List of Abbreviations and Symbols Used .................................................................. xi Acknowledgements.................................................................................................. xiii Chapter 1 Introduction ........................................................................................ 1 1.1 General ................................................................................................................ 1 1.2 Research Objectives ............................................................................................ 1 1.3 Thesis Structure .................................................................................................. 2 1.4 References ........................................................................................................... 3 Chapter 2 Literature Review ............................................................................... 4 2.1 Concrete .............................................................................................................. 4 2.2 Gypsum ............................................................................................................... 6 2.2.1 Gypsum Mining in Canada ........................................................................................ 8 2.2.2 Other Uses for Gypsum .............................................................................................. 9 2.2.3 Gypsum Use in Portland Cement ............................................................................... 9 2.2.3.1 Chemical Hydration of Concrete with Gypsum .............................................. 10 2.2.3.2 Previous Research Using Gypsum in Portland Cement .................................. 12 2.3 Fly Ash .............................................................................................................. 17 2.3.1 Fly Ash as a Supplementary Cementing Material .................................................... 17 2.3.1.1 Previous Research Using Fly Ash as a Supplementary Cementing Material .. 18 2.4 Waste Management ........................................................................................... 20 2.4.1 Comparing Waste Gypsum and Natural Gypsum for Use in Concrete .................... 21 2.4.2 Gypsum in Landfills ................................................................................................. 23 2.5 Other Relevant Research................................................................................... 24 2.5.1 The Effect of SO3 Content on Concrete .................................................................... 24 2.5.1.1 Sulfate Attack .................................................................................................. 26 2.5.2 Particle Fineness ...................................................................................................... 27 2.5.3 Recycled Concrete as an Aggregate Replacement in Concrete ............................... 28 2.5.4 Cement-Free Binders Using Fluorogypsum ............................................................ 30 References ..................................................................................................................... 30 Chapter 3 Application of Recycled Gypsum Wallboards in Cement Mortar ..... 39 Abstract ......................................................................................................................... 39 3.1 Introduction ....................................................................................................... 40 3.2 Experimental Program ...................................................................................... 41 3.2.1 Test Matrix ............................................................................................................... 41 3.2.2 Material Properties .................................................................................................. 42 3.2.3 Specimen Preparation .............................................................................................. 44 iii 3.2.4 Test Setup and Instrumentation ................................................................................ 45 3.3 Results and Discussion ..................................................................................... 46 3.3.1 Compressive Behaviour ........................................................................................... 46 3.3.2 Effect of Gypsum Content ......................................................................................... 48 3.3.3 Effect of Fly Ash ....................................................................................................... 50 3.4 Conclusions ....................................................................................................... 52 Acknowledgements ....................................................................................................... 53 References ..................................................................................................................... 53 Chapter 4 Recycled Gypsum for Partial Cement Replacement in Concrete ...... 55 Abstract ......................................................................................................................... 55 4.1 Introduction ....................................................................................................... 56 4.2 Experimental Program ...................................................................................... 61 4.2.1 Test Matrix ............................................................................................................... 61 4.2.2 Material Properties .................................................................................................. 62 4.2.3 Specimen Preparation .............................................................................................. 64 4.2.4 Test Setup and Instrumentation ................................................................................ 66 4.3 Results and Discussion ..................................................................................... 67 4.3.1 Compressive Behaviour ........................................................................................... 67 4.3.2 Effect of Curing Time ............................................................................................... 69 4.3.3 Effect of Gypsum and Fly Ash on Physical Properties ............................................ 74 4.3.4 Stress-Strain Behaviour ........................................................................................... 76 4.3.5 Statistical Evaluations .............................................................................................. 79 4.4 Application and Future Research ...................................................................... 81 4.4.1 Advantages ............................................................................................................... 82 4.4.2 Disadvantages .......................................................................................................... 83 4.4.3 Future Research ....................................................................................................... 84 4.5 Conclusions ....................................................................................................... 84 Acknowledgements ....................................................................................................... 85 References ..................................................................................................................... 85 Chapter 5 Durability of Concrete with Fly Ash and Gypsum as Supplementary Cementing Materials ............................................................................................... 89 Abstract ......................................................................................................................... 89 5.1 Introduction ....................................................................................................... 90 5.2 Experimental Program ...................................................................................... 97 5.2.1 Material Properties .................................................................................................. 98 5.2.1.1 Scanning Electron Microscopy ...................................................................... 102 5.2.2 Specimen Preparation ............................................................................................ 106 5.2.2.1 Environmental Exposure ............................................................................... 107 5.2.3 Compression Tests ................................................................................................
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