Early Production of High Strength and Improved Water Resistance Gypsum Mortars from Used Plaster Mould and Cullet Waste
Publication: Journal of Materials in Civil Engineering
Volume 32, Issue 6
Abstract
This research aims at producing high-strength, water-resistant, gypsum-based materials (from used plaster moulds) with the additions of glass cullet and cements and investigating the influence of glass cullet contents on their properties. Block-shaped specimens of gypsum mortars containing 70–90 wt% -hemihydrate with up to 20 wt% cullet waste powder and a small amount of Portland and calcium aluminate cements, as early strength enhancer and setting time modifier, were cured under damp, ambient air for 7–90 days. Properties including setting times, water absorption, compressive strength, water resistance, volume change, and microstructure were observed. The results exhibited that all specimens could retain their original strength after cycles, while the volume shrinkage difference between 7 and 90 days was small (3%–7%), which is consistent with the minimal change of bulk densities at various curing times (densities ). Prolonged curing times led to lower water resistance due to a combination of hydration and pozzolanic reaction products. The mixture with 10 wt% cullet provided optimum characteristics and retained strength of 5.5 MPa with the smallest volume shrinkage of 7% at 90-day curing, suggesting possible applications for indoor and nonstructural outdoor applications.
Get full access to this article
View all available purchase options and get full access to this article.
Acknowledgments
This project was co-funded by Chulalongkorn University and the Thailand Research Fund (TRF), under the Project No. MRG5680176. Research Unit of Advanced Ceramics, Department of Materials Science, Faculty of Science, Chulalongkorn University was also appreciated for all apparatus and facilities.
References
Agarwal, S. K. 2006. “Pozzolanic activity of various siliceous materials.” Cem. Concr. Res. 36 (9): 1735–1739. https://doi.org/10.1016/j.cemconres.2004.06.025.
ASTM. 1992. Standard test method for compressive strength of hydraulic cement. ASTM C109. West Conshohocken, PA: ASTM.
ASTM. 2007a. Standard test method for evaluating the freeze-thaw resistance of manufactured concrete masonry units and related concrete units. ASTM C1262. West Conshohocken, PA: ASTM.
ASTM. 2007b. Standard test method for time of setting of hydraulic cement by Vicat needle. ASTM C191. West Conshohocken, PA: ASTM.
ASTM. 2008. Standard specification for coal fly ash and raw or calcined natural pozzolan for use in concrete. ASTM C618. West Conshohocken, PA: ASTM.
BSI. 2011. Gypsum blocks. Definitions, requirements and test methods. BS EN12859. London: BSI.
BSI. 2014. Gypsum binders and gypsum plasters. Test methods. BS EN13279-2. London: BSI.
Butakova, M. D., and S. P. Gorbunov. 2016. “Study of the influence of complex additives on properties of the gypsum-cement-pozzolan binder and concretes on its basis.” Procedia Eng. 150: 1461–1467. https://doi.org/10.1016/j.proeng.2016.07.082.
Camarini, G., and J. A. De Milito. 2011. “Gypsum hemihydrate-cement blends to improve renderings resistance.” Constr. Build. Mater. 25 (11): 4121–4125. https://doi.org/10.1016/j.conbuildmat.2011.04.048.
Değirmenci, N. 2008. “Utilization of phosphogypsum as raw and calcined materials in manufacturing of building products.” Constr. Build. Mater. 22 (8): 1857–1862. https://doi.org/10.1016/j.conbuildmat.2007.04.024.
Erbs, A., A. NAgalli, K. Q. Carvalho, V. Mymrin, F. H. Passig, and W. Mazer. 2018. “Properties of recycled gypsum plasterboards and commercial gypsum throughout recycling cycles” J. Cleaner Prod. 183 (May): 1314–1322. https://doi.org/10.1016/j.jclepro.2018.02.189.
Escalante-García, J. I., R. X. Magalanes-Riviera, and A. Gorokhovsky. 2009. “Waste calcium sulphate–blast furnace slag cement in mortar with granulated slag and silica sand as aggregates.” Constr. Build. Mater. 23 (8): 2851–2855. https://doi.org/10.1016/j.conbuildmat.2009.02.032.
Garg, M., and N. Jain. 2010. “Waste gypsum from intermediate dye for production of building materials.” Constr. Build. Mater. 24 (9): 1632–1637. https://doi.org/10.1016/j.conbuildmat.2010.02.029.
Geraldo, R. H., S. M. M. Pinheiro, J. S. Silva, H. M. C. Andrade, J. Dweck, J. P. Gonçalves, and G. Camarini. 2017. “Gypsum plaster waste recycling: A potential environmental and industrial solution.” J. Cleaner Prod. 164 (Oct): 288–300. https://doi.org/10.1016/j.jclepro.2017.06.188.
Geraldo, R. H., J. D. Souza, S. C. Campos, L. F. R. Fernandes, and G. Camarini. 2018. “Pressured recycled gypsum plaster and wastes: Characteristics of eco-friendly building components.” Constr. Build. Mater. 191 (Dec): 136–144. https://doi.org/10.1016/j.conbuildmat.2018.09.193.
giSCI Technical University of Madrid. 2016. “Resource efficient uses of mixed wastes case study: GtoG from production to recycling: A circular economy for the European gypsum industry with the demolition and recycling industry, task 2.” Accessed April 1, 2016. http://ec.europa.eu.
Idir, R., M. Cyr, and A. Tagnit-Hamou. 2011. “Pozzolanic properties of fine and coarse color-mixed glass cullet.” Cem. Concr. Compos. 33 (1): 19–29. https://doi.org/10.1016/j.cemconcomp.2010.09.013.
Indian Standards. 1981. Methods of test for gypsum plaster, concrete and products. Part II: Gypsum products. IS 2542. New Delhi, India: Bureau of Indian Standards.
Jiang, L., C. Li, C. Wang, N. Xu, and H. Chu. 2018. “Utilization of flue gas desulfurization gypsum as an activation agent for high-volume slag concrete.” J. Cleaner Prod. 205 (Dec): 589–598. https://doi.org/10.1016/j.jclepro.2018.09.145.
Jiménez Rivero, A., R. Sathre, and J. García Navarro. 2016. “Life cycle energy and material flow implications of gypsum plasterboard recycling in the European Union.” Resour. Conserv. Recycl. 108 (Mar–Apr): 171–181. https://doi.org/10.1016/j.resconrec.2016.01.014.
Jørgensen, K. D. 1960. “The hygroscopic setting expansion of gypsum.” Acta Odontol. Scand. 18 (4): 461–477. https://doi.org/10.3109/00016356009043878.
Kondratieva, N., and M. Sanytsky. 2017. “Study of modified gypsum binder.” Constr. Build. Mater. 149 (Sep): 535–542. https://doi.org/10.1016/j.conbuildmat.2017.05.140.
Kovler, K. 1998a. “Setting time and hardening of gypsum-Portland cement and cement-silica fume blends. Part I: Temperature and setting expansion” Cem. Concr. Res. 28 (3): 423–437. https://doi.org/10.1016/S0008-8846(98)00005-2.
Kovler, K. 1998b. “Setting time and hardening of gypsum-Portland cement and cement-silica fume blends. Part II: Early strength DTA, XRD and SEM observations.” Cem. Concr. Res. 28 (4): 523–531. https://doi.org/10.1016/S0008-8846(98)00004-0.
Liu, S., S. Wang, W. Tang, N. Hu, and J. Wei. 2015. “Inhibitory effect of waste glass powder on ASR expansion induced by waste glass aggregate.” Materials 8 (10): 6849–6862. https://doi.org/10.3390/ma8105344.
Lushnikova, N., and L. Dvorkin. 2016. “Sustainability of gypsum products as a construction material.” In Sustainability of construction materials: Woodhead publishing series in civil and structural engineering. 2nd ed., 643–681. Cambridge, UK: Woodhead Publishing.
Magallanes-Rivera, R. X., and J. I. Escalante-García. 2014. “Anhydrite/hemihydrate-blast furnace slag cementitious composites: Strength development and reactivity.” Constr. Build. Mater. 65 (Aug): 20–28. https://doi.org/10.1016/j.conbuildmat.2014.04.056.
Mármol, G., H. Savastano Jr., J. M. Monzó, M. V. Borrachero, L. Soriano, and J. Payá. 2016. “Portland cement, gypsum and fly ash binder systems characterization for lignocellulosic fiber-cement.” Constr. Build. Mater. 124 (Oct): 208–218. https://doi.org/10.1016/j.conbuildmat.2016.07.083.
Matos, A. M., and J. Sousa-Coutinho. 2012. “Durability of mortar using waste glass powder as cement replacement.” Constr. Build. Mater. 36 (Nov): 205–215. https://doi.org/10.1016/j.conbuildmat.2012.04.027.
Murat, M. 1983. “Hydration reaction and hardening of calcined clays and related minerals. Part I: Preliminary investigation on metakaolin.” Cem. Concr. Res. 13 (2): 259–266. https://doi.org/10.1016/0008-8846(83)90109-6.
Nawi, A. M., and N. A. Badarulzaman. 2015. “Effect of plaster of Paris waste and sintering temperatures on physical properties of pottery.” Procedia CIRP 26: 752–755. https://doi.org/10.1016/j.procir.2014.08.019.
Ogawa, K., and D. M. Roy. 1982. “ hydration, ettringite formation, and its expansion mechanism. Part II: Microstructural observation of expansion.” Cem. Concr. Res. 12 (1): 101–109. https://doi.org/10.1016/0008-8846(82)90104-1.
PCA (Portland Concrete Association). 2011. Concrete information: Ettringite formation and performance of concrete. Skokie, IL: PCA.
Péra, J., J. Ambroise, and T. Kuryatnyk. 2007. “Development of insoluble gypsum using calcium sulfoaluminate cement.” Constr. Build. Mater. 10: 37–43.
Pimraksa, K., and P. Chindaprasert. 2009. “Lightweight bricks made of diatomaceous earth.” Ceram. Int. 35 (1): 471–478. https://doi.org/10.1016/j.ceramint.2008.01.013.
Punsukumtana, L., and P. Wattanopas. 2010. “Effects of additives on properties of used ceramic plaster mould.” J. Sci. Serv. 181 (52): 44–48.
Shao, Y., T. Lefort, S. Maras, and D. Rodrigues. 2000. “Studies on concrete containing ground waste glass.” Cem. Concr. Res. 30 (1): 91–100. https://doi.org/10.1016/S0008-8846(99)00213-6.
Shi, C., Y. Wu, C. Riefler, and H. Wang. 2005. “Characteristics and pozzolanic reactivity of glass powders.” Cem. Concr. Res. 35 (5): 987–993. https://doi.org/10.1016/j.cemconres.2004.05.015.
Shi, C., and K. Zheng. 2007. “A review on the use of waste glass in the production of cement and concrete.” Resour. Conserv. Recycl. 52 (2): 234–247. https://doi.org/10.1016/j.resconrec.2007.01.013.
Singh, M., and M. Garg. 2005. “Study of anhydrite plaster from waste phosphogypsum for use in polymerized flooring composition.” Constr. Build. Mater. 19 (1): 25–29. https://doi.org/10.1016/j.conbuildmat.2004.04.038.
Singh, N. B., and B. Middendorf. 2007. “Calcium sulphate hemihydrate hydration leading to gypsum crystallization.” Prog. Cryst. Growth Charact. Mater. 53 (1): 57–77. https://doi.org/10.1016/j.pcrysgrow.2007.01.002.
Sobolev, K., P. Türker, S. Soboleva, and G. Iscioglu. 2007. “Utilization of waste glass in ECO-cement: Strength properties and microstructural observation.” Waste Manage. (Oxford) 27 (7): 971–976. https://doi.org/10.1016/j.wasman.2006.07.014.
Suárez, S., X. Roca, and S. Gasso. 2016. “Product-specific life cycle assessment of recycled gypsum as a replacement for natural gypsum in ordinary Portland cement; application to the Spanish context.” J. Cleaner Prod. 117 (Mar): 150–159. https://doi.org/10.1016/j.jclepro.2016.01.044.
Taylor, H. F. W. 1964. Vol. 2 of The chemistry of cements. London: Academic Press.
Tounchuen, K., P. Umponpanarat, W. Buggakupta, and P. Panpa. 2013. “Effect of diatomite and glass cullet in the waste-based gypsum building materials.” Key Eng. Mater. 545: 122–128. https://doi.org/10.4028/www.scientific.net/KEM.545.122.
Universidad Politécnica de Madrid. 2013. “Inventory of current practice: GtoG from production to recycling: A circular economy for the European gypsum industry with the demolition and recycling industry.” Accessed September 1, 2013. http://ec.europa.eu.
Vedalakshmi, R., A. Sundara, and N. Palaniswamy. 2008. “Identification of various chemical phenomena in concrete using thermal analysis.” Indian J. Chem. Technol. 15 (4): 388–396.
Yu, Q. L., and H. J. H. Brouwers. 2012. “Development of a self-compacting gypsum-based lightweight composite.” Cem. Concr. Compos. 34 (9): 1033–1043. https://doi.org/10.1016/j.cemconcomp.2012.05.004.
Zhong, L., J. Qu, X. Li, X. He, and Q. Zhang. 2016. “Simultaneous synthesis of ettringite and absorbate incorporation by aqueous agitation of a mechanochemically prepared precursor.” RSC Adv. 6 (42): 35203–35209. https://doi.org/10.1039/C6RA01253A.
Information & Authors
Information
Published In
Journal of Materials in Civil Engineering
Volume 32 • Issue 6 • June 2020
Copyright
©2020 American Society of Civil Engineers.
History
Received: Jul 26, 2018
Accepted: Oct 29, 2019
Published online: Mar 19, 2020
Published in print: Jun 1, 2020
Discussion open until: Aug 19, 2020
Authors
Metrics & Citations
Metrics
Citations
Download citation
If you have the appropriate software installed, you can download article citation data to the citation manager of your choice. Simply select your manager software from the list below and click Download.