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The African environment for the construction with concrete differs greatly from the Situation that can be found in Europe, Japan or North America. Europe can look back upon a concrete tradition of more than 150 years. Standardising documents and guidelines exist since more than 100 years, which formed the foundation of modern Standards that are adopted and applied and in many regions of the world. The technological developments in cement production are also strongly influenced by environmental conditions of the Northern hemisphere. In contrast, with the exception of South Africa, in most countries of sub-Saharan Africa, cement production started in the 1950s to 1960s, followed by a period of political and economical disturbances in many countries. As a result, there have not been serious approaches towards customised Solutions for the construction with concrete for the specific boundary conditions of sub-Saharan Africa. In most countries Standards from overseas are applied. Today, most African economies are growing at a rapid pace and construction activities in infrastructure and housing are urgently required to support and keep up the economic verve. Concrete technology will become of major interest in this context, since no other material can be produced similarly efficiently based on raw materials, which can be found largely only locally. In order to produce concrete with high efficiency, the local boundary framework has to be taken into account. Sub-Saharan Africa exhibits special peculiarities that are not covered by the recently applied technological guidelines and Standards. These need to be addressed to in local codes of practice in order to maximise the benefit of concrete technology.
Innovative admixture technology has significantly widened up the ränge of possibilities of concrete engineers. For many decades the water to cement ratio (w/c) was the major influencing factor for the performance of concrete. Due to the need to adjust a consistency, which still allowed reasonable workability, the w/c was typically significantly higher than technologically reasonable. Rheology modifying admixtures Support adjusting the concrete consistency largely independent of the w/c. It was only after the invention of the first superplasticizers that modern concrete technology significantly evolved in terms of flowability, strength, and durability, and only due to the steady evolution of the technology modern innovations, such as Self-Compacting Concrete, Ultra-High-Performance Concrete, or Engineered Cementitious Composites were made possible. Today’s superplasticizers are extremely versatile and can be adjusted to individual technological specifications. However, the other side of the coin of versatility is that cementitious Systems incorporating superplasticizers have become more sensitive against environmental influences, such as the environmental temperature, which may cause unwanted effects or demand for supplementary admixture use such as stabilizing admixtures. Hence, concrete mixture composition with admixtures demands for a high level of expertise and offen there is lack of awareness about the mode of Operation of rheology modifying admixtures among concrete technologists. The paper gives a comprehensive overview about rheology modifying admixtures such as superplasticizers or stabilizing agents, and how they can be used depending upon the application in the most favourable way. Based on experiences with the sub-Saharan African concreting boundary conditions, which exhibit many challenges in terms of environmental boundary conditions and construction site logistics, conclusions are finally drawn, how admixtures can be used in the most beneficial way to improve the concrete casting Situation.
Influence of the type of viscosity-modifying admixtures and metakaolin on the rheology of grouts
(2013)
The Viscosity-modifying admixtures (VMAs) contribute to the control of the rheology of grouts and are used to enhance plastic viscosity, cohesion, stability, and resistance to bleeding of cement-based systems. This paper reports the results of an investigation on the effect of type of VMAs, namely two types of diutan gums and a welan gum and metakaolin (MTK), plus a superplasticiser, on the rheology behaviour of cement grouts. All mixes were made with polycarboxylic superplasticiser at 0.6% and 0.9%. The dosages of VMAs were 0.05%, and 0.10%, with a fixed water-to-binder ratio of 0.40. The investigated fresh properties of the grouts included the mini-slump flow, plate cohesion, and rheology parameters: namely yield value and plastic viscosity. The rheological parameters were obtained using a vane viscometer. Control grouts (with and without superplasticiser and VMA) were also tested and compared to mixes containing VMAs. The results indicated that the incorporation of MTK reduced the fluidity and increased the plate cohesion and yield stress, and plastic viscosity due to the higher surface area of MTK. The diutan gum grouts improved the grout fresh properties and rheology compared to the welan gum grouts.
African cement inffastructure is quite complex. Apart from Northern Africa and South Africa in particular, cement plants are scarce resulting in highly unstable cement pricing. Clinker and cement are imported from overseas, e.g. from Portugal, Turkey, Pakistan, Indonesia, and China. Imports are typically determined by the lowest price, and as a result the countries of origin of products vaiy regularly yielding large scatter of properties. Quality control and a good quality infrastructure are thus of utmost importance for the safety of the popuiace, an issue, which is actually often neglected. With funding of the German Metrology Institute (PTB) and Support of the SPIN project, a proficiency testing scheme for cement testing according to EN 196 was set up for African laboratories. Proficiency testing schemes, also called round robins. are interlaboratory performance comparisons allowing participants to evaluate themselves against pre-established criteria. Thev are a powerful tool to help laboratories improve their performance as well as demonstrate their competences to accreditation bodies or Customers. 26 laboratories from 20 nations, 18 of which from Africa, participated. The BAM Federal Institute for Materials Research and Testing acted as coordinator and provider of the scheme. The aim of the round robin was to interpret the submitted data further beyond the pure statistic analyses. The data provided a positive picture of the performance of the participants in general, but it also exhibited a number of technical fields that need improvement. The paper provides the general results of the scheme and analyses identified strengths and weak points based on the submitted and non submitted data as well as on discrepancies from the EN 196 procedures during measurements. The application of EN Standards for material testing is critically discussed and since quality infrastructure is also always an issue between industrial and political stakeholders, suggestions for the mitigation of the identified shared problems are given.
ln order to observe the influence of stabilising agents (STA) based on starch and diutan gum, rheometric experiments and setting tests were conducted on cement pastes with and without PCE superpiasticizers. The results show that with regard to yield stress both STAs show differing behaviours in Systems without PCE. In presence of PCE, yield stress infiuences of the STAs retreat into the background. The Vicat results exhibit that STAs can reduce the retard ing effect of PCE.
The economic use of chemical admixtures depends on supply chains. Therefore, in most regions ins sub-Saharan Africa (SSA), the use of admixtures is not common practice. This amplifies the unfavorable framework for concrete construction such as fragmentary supply chains, high local cement prices, and unfavorable construction site facilities in this region significantly. The use of superplasticizer (SP) and stabilizing agents (STA) can enhance the concrete technology in SSA, since they can disassociate the concrete quality from external boundary influences. After providing a general overview of the peculiarities of the SSA boundary framework, economic concepts are provided, how existing material solutions can be significantly improved by the use of SPs and STAs based on locally available materials such as lignosulphonates and cassava starch. Finally a three step optimization process is described that helps developing flowable concrete based on materials that can be accessed in most locations in SSA.
Polysaccharides modify the rheological properties of cement based systems. Depending upon their chemistry, molecular architecture, and adsorption tendency, they have different modes of action. Some polysaccharides like diutan gum have strong effect on the fluid phase; others like starch strongly interact with particles. This paper presents effects of diutan gum and starches in presence of polycarboxylates. Rheometric investigations with varied particle volume fractions and increasing coarse aggregate diameters were conducted. The results show that starches have stronger influence on the rheology at high particle volume fractions than diutan gum. At lower particle volume fractions this trend is inverted. Experiments with aggregates sizes up to 16 mm (0.63 in.) indicate that stabilizing agent influences on the effects of aggregates on yield stress were small; however up to 1.0 mm (0.04 in.), a significant effect on the plastic viscosity could be observed, which levelled off at larger diameters.
Chemical admixtures like superplasticisers or stabilising agents are of ever increasing importance for modern concrete technology. They liberate the workability of concrete from its dependency on water content, and thus, open the gate towards innovative and future oriented concrete technologies such as self-compacting concrete. Today, admixture addition has become common practice in concrete technology, but the understanding of their highly complex mode of operation is extremely difficult and demands for understanding of processes within the range between nanometres and centimetres. Due to its complex time-dependent, multi-phase and multi-scale behaviour, flowable concrete systems are highly complicated and cannot be described comprehensively by simple models. It is therefore extremely challenging to identify the relevant parameters that predominantly control flow phenomena on different size scales, since these may occur on any scale between the nano scale (e.g. superplasticizer adsorption) and macro scale (e.g. grading of the aggregates). The present study discusses fundamental mechanisms at the interface between particle or hydrate surfaces and the fluid phase at a very early stage of concrete formation, and links these effects to macroscopic flow phenomena. Methods are discussed that appear promising interdisciplinary tools for enhancement of the understanding of the relevant interactions that are responsible for the macroscopic flow of flowable concrete.
Chemical admixtures like superplasticisers or stabilising agents are of ever increasing importance for modern concrete technology. They liberate the workability of concrete from its dependency on water content, and thus, open the gate towards innovative and future oriented concrete technologies such as self-compacting concrete.
Today, admixture addition has become common practice in concrete technology, but the understanding of their highly complex mode of operation is extremely difficult and demands for understanding of processes within the range between nanometres and centimetres.
Due to its complex time-dependent, multi-phase and multi-scale behaviour, flowable concrete systems are highly complicated and cannot be described comprehensively by simple models. It is therefore extremely challenging to identify the relevant parameters that predominantly control flow phenomena on different size scales, since these may occur on any scale between the nano scale (e.g. superplasticizer adsorption) and macro scale (e.g. grading of the aggregates). The present study discusses fundamental mechanisms at the interface between particle or hydrate surfaces and the fluid phase at a very early stage of concrete formation, and links these effects to macroscopic flow phenomena. Methods are discussed that appear promising interdisciplinary tools for enhancement of the understanding of the relevant interactions that are responsible for the macroscopic flow of flowable concrete.
South Africa and recently Nigeria are the only net exporter of cement in Africa, yet cements are imported into the country mainly on the basis of price competitiveness. This poses potential for scatter in the properties of the cements in the South African market as pricing seems to be the only determining factor that affects Portland cements imported. A survey of cements of grade 42.5N in the South African cement market was carried out to identify major players in the industry. The identified cements, which included four locally produced and one imported cement were then analysed for both chemical composition and physical properties in line with the Eurocode EN 196. Tests carried out include loss on ignition, chloride content, sulphate content, specific surface (Blaine), standard consistence, initial setting time, final setting time, soundness and flexural and compressive strength at 2, 7 and 28 days. The testing program was initiated as part of on-going Africa-wide cement testing competency program in partnership with BAM and PTB in Germany. The performance of the identified cements from the different local manufacturers and the imported cement were analysed and are presented in this paper. These results reveal some similarities and differences in the properties. Particularly of interest is the marked difference in the 28 days compressive strength of the cements. This paper shows that there is need for further tests across the cement industry as some of the cements failed to meet certain requirement as set by EN 196. The paper also recommends the use of proficiency testing schemes in the cement industry of the country to ensure the cement laboratories are providing results of high quality and at the same time act as a check to make sure these laboratories are not failing to meet standard requirements.
Interactions between waste paper sludge ashes and superplasticizers based on polycarboxylates
(2016)
In many industrial nations, about two third of the paper demand is covered by recovered paper. A major process step within the treatment of waste paper is the de-inking. It is a floating process yielding paper sludge as a waste product. About 50 % of this residue is used as a fuel. In several cases it is burnt at temperature of about 850 °C and thereafter the accrued ashes are collected in the flue gas filter. During the combustion, kaolinite and calcium oxide generate gehlenite and larnite. Calcite is the main component of waste paper sludge ash (PA).The chemical and mineralogical composition of PA suggests using it as a supplementary cementitious material.
In modern construction materials technology, workability aspects gain importance, since for most modern materials the rheology and compaction ability are relevant for the operation at a hardened state. It was observed that PA significantly increases the water demand of powder systems, which can cause serious problems during the casting of mineral binder systems containing PA. It is therefore obvious that binder systems containing PA might demand for the use of superplasticizers. Superplasticizers are polymers with anionic backbone that cause electrostatic and steric repulsion effects upon adsorption on surfaces of particles and hydration phases.
In this paper interactions between superplasticizers and waste paper sludge ashes are discussed and analysed. Based on observations of changes in the zeta potential and the dispersion of the particle system, the influence of the charge density of superplasticizers is observed and time dependent effects are demonstrated.
The use of starch and its derivatives in concrete as an admixture to modify relevant properties of concrete is on the increase in recent times. It is known to modify the rheology, to affect the hydration kinetics of cement, and influence on initial and final setting time of cement. This paper examines the effect of cassava starch on concrete. shrinkage properties of concrete, with and without starch addition, were studied. Various percentages (0, 0.5, 1.0, 1.5 and 2 %) of starches by weight of cement were added to concrete mixes prepared in the laboratory. Shrinkage tests were conducted for duration of up to one year. The result show that concretes with starch additions exhibit lower shrinkage, which is an indication the addition of starch as admixture in concrete improves the ability of the concrete reduce shrinkage problems.
There is a wide range of research worldwide on supplementary cementitious materials (SCMs) such as fly ash and slag for substituting pure cement. Such materials are suitable to be considered in a cementitious system with ordinary Portland cement (OPC) due to their high pozzolanic properties. In addition, majority of the SCMs are said to significantly improve concrete properties especially in terms of increased strength and durability. Unfortunately, the production of such SCMs is not entirely eco-friendly and also limited to certain parts of the world, hence one has to look at alternative options.
The issue of availability of resources is a strong concept that is ever-increasing, and the use of more eco-friendly SCMs in a cementitious system is furthermore attractive. Hence this paper addresses the use of eco-friendly SCMs in concrete such as rice husk ash (RHA). Despite the fact that extensive research has been done on this material, its application in a cementitious system to obtain sufficient concrete properties is still rather limited. In a country like Tanzania, high strength concrete construction is applicable in special construction cases but certainly not a high priority. Majority of construction is still undertaken using normal strength concrete. In a ternary cementitious system consisting of OPC, RHA and other readily available resources such as limestone filler (LSF), normal strength concrete can still be produced having good performance and suitable for regular on-site construction. This paper explains a possible application of obtaining sufficient concrete properties from the available resources.
Chemical admixtures like superplasticisers or stabilising agents are of ever increasing importance for modern concrete technology. They liberate the workability of concrete from its dependency on water content, and thus, open the gate towards innovative and future oriented concrete technologies such as selfcompacting concrete. Meanwhile admixtures have become common practice in concrete technology, but the understanding of these highly complex polymers in the entire concrete system lags far behind their application. Due to its complex time-dependent, multi-phase and multi-scale behaviour, flowable concrete systems are highly complicated and cannot be described comprehensively by simple models. It is therefore extremely challenging to identify the relevant parameters that predominantly control flow phenomena on different size scales, since these may occur on any scale between the nano scale (e.g. superplasticizer adsorption) and macro scale (e.g. grading of the aggregates). The present study discusses fundamental mechanisms at the interface between particle or hydrate surfaces and the fluid phase at a very early stage of concrete formation, and links these effects to macroscopic flow phenomena. Methods are discussed that appear promising interdisciplinary tools for enhancement of the understanding of the relevant interactions that are responsible for the macroscopic flow of flowable concrete.
Over the course of the last decades, concrete construction has significantly changed from mass application towards sophisticated more innovative, future oriented, and performance based materials technology. Today concrete no longer consists of cement, water, and aggregates, but can be enhanced significantly by using supplementary additions and chemical admixtures. Advancements in admixtures eventually facilitated the development of new concrete types such as self-compacting concrete (SCC) and high performance concrete (HPC) by uncoupling the workability from the water-cement ratio (w/c).
While for traditional concrete types the major mixture parameter for the workability and strength were the w/c and the grading of the aggregates, for SCC and HPC the performance parameters are more complicated and the performance depends highly on the powder components. This makes the system more sophisticated and in parallel more prone to scatter during the production. The complexity and difficulty to predict the effects of changes in the process and mixture makes it very difficult to identify the right potentials for savings.
Selbstverdichtender Beton (SVB) findet kaum Anwendung als Transportbeton. Ein wesentlicher Grund hierfür ist, dass die Außentemperaturen auf der Baustelle nicht gesteuert werden können. Während des Betonierens können allerdings Schwankungen in der Umgebungstemperatur die rheologischen Eigenschaften aber auch das Erstarrungsverhalten signifikant beeinflussen, wodurch in der Folge auch Veränderungen im Festbeton auftreten können. Durch geeignete Wahl der Komponenten kann die Robustheit von SVB gegenüber Einflüssen aus den Umgebungsbedingungen deutlich verbessert werden.
In der vorgestellten Arbeit werden anhand von Untersuchungen am Betonrheometer, am Setzfließmaß und am Erstarren nach Vicat die Einflüsse von veränderlichen Umgebungstemperaturen auf die frühen Eigenschaften von SVB dargestellt. Der Fokus liegt auf Effekten, die durch die Modifikation von Polycarboxylatether-Fließmitteln und durch Stabilisierer eingetragen werden. Darüber hinaus wird der Einfluss des Mischungsentwurfes gezeigt. Die Ergebnisse werden mit Relevanz für praktische Betonanwendungen analysiert und es werden die wichtigen Einflussgrößen zur Verbesserung der Robustheit von SVB gegenüber Temperaturschwankungen herausgearbeitet.
Today polycarboxylate ether based superplasticizer (PCE) is commonly used in concrete technology when high flow properties and water reduction are specified. The ionic strength of the polymers’ backbones determines the adsorption behaviour of polymers on clinker and early hydration products. The amount of required polymers for specified flow properties and the performance over the time of casting is thus determined by the molecular structure of the superplasticizer. The time depending consumption of polycarboxylate ether polymers strongly affects the reaction of aluminates and sulphate ions as well as the hydration process in general. Hence, the choice of polymers for particular flow properties greatly affects the very early properties of cementitious materials such as setting, heat evolution and autogenous deformations.
In order to better understand how PCEs influence the early properties, mixes from cement, limestone filler, viscosity modifying agent and water were varied with a high and a low charge density superplasticizer in differing amounts. Results are presented from measurements with an automatic Vicat device, an isothermal heat flow calorimeter, and shrinkage cones. Tests were conducted at 5, 20, and 30 °C.
It is shown that in presence of PCE the final set correlates well with the inflexion point of the heat flow curve, which emphasises the interrelation between C-S-H formation and setting. No such clear correlation can be found for the initial set, which is attributed to the fact that the initial set is rather a rheological than a structural phenomenon, so that other effects overlap with C-S-H formation. The results demonstrate that for a given polymer concentration low charge density polymers yield earlier setting than high charge polymers. However, this influence is overridden by the influence of the total amount of polymers in a cementitious system. Since PCE is typically added according to rheological specifications, and low charge PCE typically requires higher amounts of polymers than high charge PCE for comparable flow performance, low charge PCE retards setting more than high charge PCE.
The paper furthermore points out that there is no significant influence of the polymer type or amount on the early deformations. Since type and amount strongly affect the hydration, it is demonstrated that early setting causes higher strain after the final set. It is hence concluded that higher PCE solid contents reduce the risk of early cracks that occur at time of setting, when a solid structure has already been formed but without resistance against cracks yet.
The cement and concrete market in East, Central and Southern Africa is highly fragmented. The concrete industry in this area consists of multiple parties, including producers and suppliers of construction materials, formal and informal contractors, engineers and architects, unions of trades persons and workmen, governmental bodies and formal institutions of research and education. All these institutions mostly do not interact adequately, which makes building with cementitious materials susceptible to damage and failures. Completely opposed to the situation in Europe or North America, cement in Africa is often unaffordable, while manpower is cheap, which results in a questionable economisation of cement. Typically, there is not sufficient awareness of methods to sensibly reducing the cement content in concrete or replace Ordinary Portland Cement by adequate alternative materials. Research activities in this field of technology are often missing completely. Only few countries in the area, such as South Africa, are exempted from these issues.
This paper presents the SPIN project, which is a joint project of a consortium of 8 African and 3 European partners within the ACP Science and Technology Programme. The project is funded by the EC and ACP Secretariat is the project body. The main objective of the current project is to strengthen the cement and concrete industry in the East and Central African regions. The project shall generate reasonable solution strategies to implement clean, safe and sustainable cement and concrete technology on the African continent, including general and specific guidelines for sensible application. Furthermore it shall be the kick-off for future projects, research activities and the world-wide expansion of a European-African network.
The paper addresses special problems the cement and concrete market in Eastern, Central and Southern African countries has to face. Several options are presented in detail, which shall help overcoming the current situation. Customized solutions for the African market include rational methods for reducing the amount of cement used and the replacement of Ordinary Portland Cement with cheaper alternatives. The use of recycled concrete through a new and economically effective method, as well as the opportunity of using locally available resources is also discussed.