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6CCVD Research

Use of Waste from Granite Gang Saws to Manufacture Ultra-High Performance Concrete Reinforced with Steel Fibers

At a Glance

Section titled “At a Glance”
MetadataDetails
Publication Date2021-02-17
JournalApplied Sciences
AuthorsFernando LĂłpez Gayarre, JesĂșs SuĂĄrez GonzĂĄlez, ĂĂ±igo LĂłpez Boadella, Carlos LĂłpez-Colina PĂ©rez, Miguel A. Serrano
InstitutionsUniversidad de Oviedo
Citations3
AnalysisFull AI Review Included

Executive Summary

Section titled “Executive Summary”

This analysis evaluates the feasibility of using ultra-fine waste from granite cutting gang saws (GCW-GS) as a partial substitute for micronized quartz (MQ) in Ultra-High Performance Fiber Reinforced Concrete (UHPFRC).

  • Core Value Proposition: GCW-GS waste, characterized by high Fe2O3 (14.6%) and CaO (4.5%) content, is a viable and performance-enhancing alternative to natural MQ in UHPFRC manufacturing.
  • Optimal Performance: Mechanical properties showed significant improvement up to 35% substitution of MQ by GCW-GS.
  • Strength Gains (35% Substitution): Tensile strength increased by 35% (from 8.7 MPa to 11.8 MPa), and flexural strength increased by 12% (from 23 MPa to 25.7 MPa) compared to the control mix.
  • Maximum Compressive Strength: Peak compressive strength reached 134 MPa at 70% substitution, representing a 14% increase over the control (117 MPa).
  • Mechanism of Improvement: The presence of Fe2O3 and CaO promotes favorable pozzolanic reactions and reduces autogenous shrinkage, contributing to a denser, more compact matrix.
  • Density and Workability Trade-offs: Density increased due to the higher particle density of GCW-GS (2856 kg/m3). However, workability decreased due to the reaction of CaO with water, necessitating higher superplasticizer dosages.
  • Overall Feasibility: Even at 100% substitution, mechanical properties remained within 10% of the control concrete values, confirming the material’s viability across all tested ratios.

Technical Specifications

Section titled “Technical Specifications”
ParameterValueUnitContext
Control Compressive Strength117 ± 2.9MPaControl UHPFRC mix (0% GCW-GS).
Peak Compressive Strength134 ± 4.6MPaAchieved at 70% GCW-GS substitution.
Peak Flexural Strength25.7 ± 0.3MPaAchieved at 35% GCW-GS substitution (12% increase).
Peak Tensile Strength11.8 ± 0.1MPaAchieved at 35% GCW-GS substitution (35% increase).
Modulus of Elasticity (Control)45 ± 1.0GPaControl UHPFRC mix.
Modulus of Elasticity (Max Loss)8.5%Observed at 100% GCW-GS substitution.
GCW-GS Particle Density2856kg/m3Higher than Micronized Quartz (2609 kg/m3).
GCW-GS Fe2O3 Content14.59%Chemical composition of the waste powder.
GCW-GS CaO Content4.53%Chemical composition of the waste powder.
Cement Dosage800kg/m3Constant across all mixes (CEM I 42.5 R/SR).
Steel Fiber Dosage160kg/m3Constant across all mixes (0.2 mm diameter, 13 mm length).
Curing Temperature20°CCured for 28 days at 95% Relative Humidity.
Density (100% GCW-GS)2500 ± 14kg/m3Increased density compared to control (2410 kg/m3).

Key Methodologies

Section titled “Key Methodologies”

The experimental program involved manufacturing four UHPFRC mixes (Control, 35%, 70%, and 100% GCW-GS substitution) and testing their fresh and hardened properties according to European and French standards.

  1. Material Selection:

    • Cement: CEM I 42.5 R/SR.
    • Aggregates: Two fractions of silica sand (0/0.5 mm and 0.5/1.6 mm).
    • Additions: Densified silica fume (0.15 ”m), Micronized Quartz (max 40 ”m), and GCW-GS waste (substitute).
    • Reinforcement: Short steel fibers (0.2 mm diameter, 13 mm length).
    • Admixture: Polycarboxylate superplasticizer (SP).

  2. Mix Design Strategy:

    • The control mix was established to achieve self-compacting UHPFRC with compressive strength > 110 MPa.
    • GCW-GS replaced Micronized Quartz by volume at 35%, 70%, and 100% ratios.
    • SP dosage was increased proportionally with GCW-GS substitution (10 kg/m3 for Control up to 18 kg/m3 for 100% GCW-GS) to compensate for workability loss caused by CaO hydration.

  3. Mixing Procedure:

    • Sands and MQ/GCW-GS were added first, followed by silica fume and cement.
    • Dry mixing occurred for 30 seconds before water addition.
    • SP and steel fibers were added 2 minutes 30 seconds after water introduction.
    • Total mixing time was 25 minutes.

  4. Specimen Preparation and Curing:

    • Specimens (prisms 10x10x40 cm, cubes 10x10x10 cm, cylinders 15x30 cm) were cast per EN 12390-1.
    • Curing involved 24 hours in molds, followed by 28 days in a humid chamber at 20 °C and 95% relative humidity (EN 12390-2).

  5. Mechanical Testing:

    • Workability (Consistency): Slump test (NF P 18-470).
    • Compressive Strength: Tested on cubes (EN 12390-3).
    • Modulus of Elasticity: Tested on cylinders (EN 12390-13).
    • Flexural Strength: Tested on prisms (NF P 18-470).
    • Tensile Strength: Determined indirectly via inverse analysis of the stress-strain curves obtained during the flexural test [27].

Commercial Applications

Section titled “Commercial Applications”

The successful incorporation of GCW-GS waste into UHPFRC offers significant commercial advantages, particularly in sustainable construction and high-performance material production.

  • Sustainable Infrastructure Development: Provides a high-volume, high-value recycling solution for granite processing waste, reducing landfill burden and lowering the carbon footprint of concrete production by replacing virgin quartz.
  • High-Performance Precast Elements: The enhanced tensile and flexural strengths (up to 35% improvement at 35% substitution) make this UHPFRC ideal for precast applications requiring extreme durability, such as bridge components, tunnel segments, and protective barriers.
  • Specialized Repair and Overlay Materials: The dense matrix and high strength achieved through the pozzolanic activity of Fe2O3 and CaO are beneficial for manufacturing specialized repair mortars and overlays used in industrial floors or corrosive environments.
  • Cost Reduction in UHPC Production: Utilizing an abundant industrial waste stream (GCW-GS) as a substitute for expensive micronized quartz powder lowers raw material costs for UHPC manufacturers.
  • Dense Matrix Applications: The increased density and improved particle packing (due to GCW-GS granulometry) are advantageous for structures requiring high resistance to water penetration and abrasion.
View Original Abstract

The purpose of this study is to analyze the feasibility of using the ultra-fine waste coming from the granite cutting waste gang saws (GCW-GS) to manufacture ultra-high performance, steel-fiber reinforced concrete (UHPFRC). These machines cut granite blocks by abrasion using a steel blade and slurry containing fine steel grit. The waste generated by gang saws (GCW-GS) contains up to 15% Fe2O3 and up to 5% CaO. This is the main difference from the waste produced by diamond saws (GCW-D). Although this waste is available in large quantities, there are very few studies focused on recycling it to manufacture any kind of concrete. In this study, the replaced material was the micronized quartz powder of natural origin used in the manufacture of UHPRFC. The properties tested include workability, density, compressive strength, elasticity modulus, flexural strength, and tensile strength. The final conclusion is that this waste can be used to manufacture UHPFRC with a better performance than that from diamond saws given that there is an improvement of their mechanical properties up to a replacement of 35%. Even for higher percentages, the mechanical properties are within values close to those of control concrete with small decreases.

Tech Support

Section titled “Tech Support”

Original Source

Section titled “Original Source”

References

Section titled “References”
  1. 2017 - Using glass sand as an alternative for quartz sand in UHPC [Crossref]
  2. 2017 - Partial substitution of silica fume with fine glass powder in UHPC: Filling the micro gap [Crossref]
  3. 2016 - Development of ultra-high-performance concrete using glass powder—Towards ecofriendly concrete [Crossref]
  4. 2014 - Utilization of iron ore tailings as fine aggregate in ultra-high performance concrete [Crossref]
  5. 2015 - The Influences of Iron Ore Tailings as Fine Aggregate on the Strength of Ultra-High Performance Concrete
  6. 2009 - Performance of high strength concrete made with copper slag as a fine aggregate [Crossref]
  7. 2015 - Studies on ultra high performance concrete incorporating copper slag as fine aggregate [Crossref]
  8. 2018 - Performance of mortar and concrete incorporating granite sludge as cement replacement [Crossref]
  9. 2016 - Performance of sustainable concrete containing granite cutting waste [Crossref]

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