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Concrete structures placed in aggressive aqueous environments are vulnerable to degradation. Majority of studies have linked structural failures to the ingress of deleterious ions into the cement matrix. Some microbial activities may accelerate the penetration of harmful materials into the cement matrix and hence cause pronounced deterioration. This work reports a laboratory-simulated study carried out to determine the extent of chloride ingress in cement mortars exposed to Acidithiobacillus thiooxidans. Test prisms were cast from Portland pozzolana cement (PPC) and ordinary Portland cement (OPC) with water-to-cement ratio maintained at 0.5. Acidithiobacillus thiooxidans bacterial solution of concentration 1.0 × 10 7 cell/mL was used to prepare microbial mortar prisms, whereas distilled water was used to prepare the control mortar prisms. The test prisms were subjected to porosity and accelerated chloride ingress after 28th day of curing. Compressive strength was determined after the 2nd, 7th, 28th, and 56th days of curing. Apparent diffusion coefficients (Dapp) were estimated from the solutions to Fick's second law of diffusion. After the 56th day of curing, the microbial-treated mortars exhibited a significant reduction in compressive strength. The resultant percentage decrease in compressive strength was 30.74% and 19.88% for OPC and PPC, respectively. Further, microbial-treated mortars demonstrated both high porosity and chloride ingress as compared to the control test mortars. Scanning electron microscopy (SEM) and X-ray diffraction (XRD) analyses showed the formation of new deleterious products in the microbial-exposed mortars. [ABSTRACT FROM AUTHOR]

Cement-made materials face durability and sustainability challenges. This is majorly caused by the presence of cracks. Cracking affects the mechanical strength of cement-based materials. Microbiologically induced calcite precipitation (MICP) has been found to enhance compressive strength, thus enhancing on the mechanical and durability properties of these materials. This paper presents the findings of a study conducted to investigate the effect of Bacillus cohnii on compressive strength development of OPC mortar prisms and the effect of Bacillus cohnii on cement setting time and soundness. Microbial concentration of 1.0 × 107 cells·ml−1 was used. Compressive strength tests analyses were carried out for each category of mortar prisms. Compressive strength tests were carried out on the 2nd, 7th, 14th, 28th, 56th, and 90th day of curing in distilled water and microbial solutions. All microbial mortars exhibited a greater compressive strength compared to the control with the highest observed at 90 days. Highest percentage gain in compressive strength was observed at 90 days which is 28.3%. Microstructural analysis was carried out using a scanning electron microscope (SEM) after 28 days of curing. The results indicated the presence of calcium carbonate and more calcium silicate hydrate (CSH) deposits on the bacterial mortars. The bacteria did not have an effect on cement soundness. Setting time was significantly accelerated. [ABSTRACT FROM AUTHOR]

Pyroprocessing is an important stage in cement manufacturing. In this process, materials are subjected to high temperatures so as to cause a chemical or physical change. Its control improves efficiency in energy utilization and hence enhances production for good quality assurance. Kilns used in cement manufacturing are complex in nature. They have longer time constants, and raw materials used have variable properties. They are therefore difficult to control. Additionally, the inclusion of various alternative fuels in burning makes the process more complex as the fuel characteristics remain inconsistent throughout the kiln operation. Fuel intensity standards for kilns using fuel oil are very high, ranging from 2.9 GJ to 7.5 GJ/ton of clinker produced. Grinding of clinker consumes power in the range of 2.5 kWh/ton of clinker produced. These and other pyroprocessing parameters make cement production costly. The pyroprocessing process in kilns and the grinding technologies therefore have to be optimized for best processing. This paper discusses the cement manufacturing and grinding processes. The traditional kiln technologies and the current and emerging technologies together with general fuel and energy requirements of cement manufacturing have been discussed. From the discussion, it has been established that the cement manufacturing and grinding technologies are capital-intensive investments. The kiln processes are advanced and use both electricity and natural fuels which are expensive and limited factors of production. The raw materials used in cement manufacturing are also limited and sometimes rare. The calcination of the raw materials requires external energy input which has contributed to the high cost of cement especially to low-income population in the developing countries. Self-calcining materials, in which the pozzolanic materials burn on their own, are potential pozzolanic materials with great potential to lower the cost of cement production. Such materials, as shown from the previous research study, are rice husks, broken bricks, spent bleaching earth, and lime sludge. There is a need, therefore, for research to look into ways of making cement using kiln processes that would use this property. This will be cost-effective if successful. It can be done at micro- and small-scale enterprise. [ABSTRACT FROM AUTHOR]

The concrete/mortar durability performance depends mainly on the environmental conditions, the microstructures, and its chemistry. Cement structures are subject to deterioration by the ingress of aggressive media. This study focused on the effects of Bacillus megaterium and Lysinibacillus sphaericus on flexural strength and chloride ingress in mortar prisms. Microbial solutions with a concentration of 1.0 × 107 cells/ml were mixed with ordinary Portland cement (OPC 42.5 N) to make mortar prisms at a water/cement ratio of 0.5. Four mortar categories were obtained from each bacterium based on mix and curing solution. Mortar prisms of 160 mm × 40 mm × 40 mm were used in this study. Flexural strength across all mortar categories was determined at the 14th, 28th, and 56th day of curing. Mortars prepared and cured using bacterial solution across all curing ages exhibited the highest flexural strength as well as the highest percent flexural strength gain. Lysinibacillus sphaericus mortars across all mortar categories showed higher flexural strength and percent flexural strength gain than Bacillus megaterium mortars. The highest percent flexural strength gain of 33.3% and 37.0% was exhibited by the 28th and 56th day of curing, respectively. The mortars were subjected to laboratory prepared 3.5% by mass of sodium chloride solution under the accelerated ion migration test method for thirty-six hours using a 12 V Direct Current power source after their 28th day of curing. After subjecting the mortar cubes to Cl media, their core powder was analyzed for Cl content. From these results, the apparent diffusion coefficient, Dapp, was approximated from solutions to Fick's 2nd Law using the error function. Bacillus megaterium mortars across all mortar categories showed lower apparent diffusion coefficient values with the lowest being 2.6456 × 10–10 while the highest value for Lysinibacillus sphaericus mortars was 2.8005 × 10–10. Both of the test bacteria lowered the ordinary Portland cement Cl-ingress but Bacillus megaterium was significantly more effective than Lysinibacillus sphaericus in inhibition. [ABSTRACT FROM AUTHOR]

Cement-based materials are subject to degradation during their service life. Most of the structural failures have been associated with corrosion of the rebar due to chloride ingress, alkali aggregate reaction, and/or sulfate attack. Microbial activities, especially in waste water collection points such as sewer lines, may compromise the integrity of concrete structures. This study reports an experimental work carried out to determine the effect of Starkeya novella bacteria species on mechanical and microstructural properties of cement mortars. Mortar prisms were prepared from selected ordinary Portland cement (OPC) and Portland pozzolana cement (PPC) in Kenyan markets. Bacterial solution of 1.0 × 107 cell/mL concentration was used as either mix water, curing media, or both. Distilled water was used to prepare mortar prisms for control samples. Compressive strength was determined after the 7th, 28th, 56th, and 90th day of curing. Scanning electron microscopy (SEM) was tested on both bacterial and control mortar prisms after the 28th day of curing. Both PPC and OPC exhibited significant decrease in compressive strength for bacterial-prepared mortars as compared to controls. SEM analysis showed extreme erosion on the microstructure of the microbial mortars. This was denoted by massive formation of ettringite and gypsum which are injurious to mortar/concrete. [ABSTRACT FROM AUTHOR]

The durability of cement-based structures majorly depends on their resistivity to the aggressive media in the construction environment. The most aggressive ions commonly encountered in construction environment are chloride (Cl−) and sulphate (SO42−). The interactions of these ions with hydrated cement influence their durability and ultimate service life. This paper reports the experimental findings on an investigation on the diffusivity of Cl− and SO42− ions into mortars made from two mixtures: one made from ground calcined clay bricks (GB) and commercial ordinary Portland cement (OPC) and the other consisting of GB and Portland pozzolana cement (PPC). The test media were 3.5% Cl− and 1.75% SO42− solutions. For comparison, commercial OPC and PPC were also investigated. GB was blended with OPC at replacement levels of 25, 35, 45, and 50% to make OPCGB. Similar blends were also made with PPC replacement levels of 15, 20, and 25% to make PPCGB. Mortar prisms measuring 160 mm × 40 mm × 40 mm were cast at the water-to-cement ratios (w/c) of 0.40, 0.50, and 0.60 using each category of cement and cured in water for 3, 7, and 28 days. Compressive strength measurements were taken at each of the curing ages. The 28-day cured mortar prisms were subjected to compressive strength analysis and accelerated Cl− and SO42− ingress for 36 hours at 12 V. Ion profiling was done on the mortars, and diffusion coefficients of the Cl− and SO42− ions were approximated. The results showed that there was an increase in compressive strength after exposure to Cl− and SO42− ions. In addition, the ingress of Cl− and SO42− ions decreased with an increase in depth of cover. Blended cement exhibited lower Cl− and SO42− ingress than OPC. The ingress of Cl− was observed to be higher than that of SO42− ions. The ingress of Cl− and SO42− ions increased with an increase in w/c ratio. The results further showed that there was a drop in the ingress of Cl− and SO42− ions with an increase in replacement up to 35 percent for OPC. A 15 percent replacement showed a better compressive strength development compared with 20 and 25 percent replacement for PPC. Blended cement showed lower apparent diffusion coefficients (Dapp) compared with OPC. PPC, OPCGB-35, and PPCGB-15 exhibited similar performance in terms of strength development, aggressive ions ingress, and Dapp. In conclusion, it was found that the test cements, PPCGB-15 and OPCGB-35, can be used in similar tested environments as commercial PPC. [ABSTRACT FROM AUTHOR]

Cement structures are major capital investments globally. However, exposure of cement-based materials to aggressive media such as chloride- and sulphate-laden environments such as coastal areas affects their performance. Ordinary Portland cement (OPC) is the main cement used in buildings and civil structures such as dams and bridges. This paper reports the findings of an experimental investigation on the effect of ingress of Cl− and SO42− on compressive strength development and the ions' diffusivity in selected OPC brands in Kenya. The aggressive media used included seawater (SW) and wastewater from leather industry (WLI). Three brands of commonly used cements of OPC in Kenya were used. Mortar prisms were prepared from each brand of cement at different water-to-cement ratios (w/c) of 0.5, 0.6, 0.65, and 0.7 and allowed to cure for 28 days in a highly humid environment. The aggressive ions' ingress in the mortar prisms was accelerated using a potential difference of 12 V ± 0.1 V. Analysis of diffusivity and diffusion coefficient of Cl− and SO42− was finally done. Compressive strength analysis was done before (at the 2nd, 7th, 14th, and 28th day) and after exposure to the aggressive ions. The results showed that the diffusivity of chlorides was more pronounced than that of sulphates. Diffusivity was observed to be higher at higher w/c ratios for all cement categories. It was observed that compressive strength increased with curing age, with the highest observed at 28 days. Cement A was generally found to have the highest compressive strength for all w/c ratios. The compressive strength was observed to increase after the mortar prisms were exposed to SW as opposed to the ones exposed to WLI. Generally, it was also observed that the strength gain increased with increase in w/c. The loss in strength was also observed to increase with increase in w/c. [ABSTRACT FROM AUTHOR]

This paper reports study findings on the diffusivity of chloride ions in potential blended cement. The cement, abbreviated as PCDC, was made from blending ordinary Portland cement (OPC) with dried calcium carbide residue and an incinerated mix of rice husks, spent bleaching earth, and broken bricks. The aim of the study was to investigate the ability of PCDC to withstand aggressive chloride environment. 10 cm × 10 cm mortar cubes were prepared using PCDC and cured for 28 days in saturated calcium hydroxide solution. The cured mortar cubes were subjected to aggressive chloride media in a laboratory set up. The test cement was subjected to chloride profile analysis with depth of cover as a function of w/c ratio and curing period in alternate dry and wet environments of 3.5 percent sodium chloride solution. The experiments were carried alongside neat OPC and OPC + 25% pulverised fuel ash (OPC + 25% PFA). Results showed that PCDC exhibited lower chloride ingress as the depth of cover increased. In conclusion, the study showed that PCDC was a potential cementitious material with high ability to withstand aggressive environment of chlorides. [ABSTRACT FROM AUTHOR]

This paper reports leach and/or intake of SO42−, Cl−, Ca2+, Na+, and K+ from and/or into cement mortar cubes made from a novel cementious material in naturally encountered environmental simulated media. The paper also reports changes in pH of the media over time of exposure to the cement mortar cubes. The compressive strength changes of the test cement in simulated media are also reported. The novel cement, labelled PCDC, made from intermixing ordinary Portland cement (OPC) with waste materials which included rice husks, waste bricks, acetylene lime sludge, and spent bleaching earth was previously tested and found to meet the Kenyan Standard requirements for Portland pozzolana cement (PPC). 100 mm mortar cubes were prepared, and their compressive strengths were determined after exposure to the sea water. The media included sea water, distilled water, and solutions of sulphates and chlorides separately for a period of six months. The tests were carried alongside commercial PPC and OPC. The results showed that the PCDC exhibited comparable selected ions intake and/or leach to PPC in sea water, sulphate solutions, and distilled water. In chloride solutions, the cement exhibited the highest leach in the selected ions except K+ and Na+ ions. The results further showed that PCDC exhibited lower pH in all the media compared to OPC and PPC. The tests showed that the novel cement can be used for general construction work in the tested media in a similar manner to PPC. [ABSTRACT FROM AUTHOR]

Cementitious materials are subject to degradation when subjected to corrosive chloride media. This paper reports the experimental results on corrosion studies conducted on a potential cementitious material, PCDC, made from a blend of 55 % Ordinary Portland Cement (OPC), Dried Calcium Carbide Residue (DCCR), and an incineration mix of Rice Husks (RH), Spent Beaching Earth (SBE), and Ground Reject Bricks (BB). The experiments were run along 100 % OPC. Different w/c were used. Corrosion current densities using linear polarisation resistance (LPR) and corrosion potentials measurements versus saturated calomel electrode were used for the determination of corrosion rates and potentials, respectively, for simulated reinforcement at different depths of cover in the cement mortars. The results showed that PCDC exhibited higher corrosion current densities over all depths of covers and early attainment of active corrosion than the control cements. In conclusion, PCDC and OPC can be used in a similar corrosive media during construction. [ABSTRACT FROM AUTHOR]

Blended cements are preferred to Ordinary Portland Cement (OPC) in construction industry due to costs and technological and environmental benefits associated with them. Prevalence of significant quantities of carbon dioxide (CO2) in the atmosphere due to increased industrial emission is deleterious to hydrated cement materials due to carbonation. Recent research has shown that blended cements are more susceptible to degradation due to carbonation than OPC. The ingress of CO2 within the porous mortar matrix is a diffusion controlled process. Subsequent chemical reaction between CO2 and cement hydration products (mostly calcium hydroxide [CH] and calcium silicate hydrate [CSH]) results in degradation of cement based materials. CH offers the buffering capacity against carbonation in hydrated cements. Partial substitution of OPC with pozzolanic materials however decreases the amount of CH in hydrated blended cements. Therefore, low amounts of CH in hydrated blended cements make them more susceptible to degradation as a result of carbonation compared to OPC. The magnitude of carbonation affects the service life of cement based structures significantly. It is therefore apparent that sufficient attention is given to carbonation process in order to ensure resilient cementitious structures. In this paper, an indepth review of the recent advances on carbonation process, factors affecting carbonation resistance, and the effects of carbonation on hardened cement materials have been discussed. In conclusion, carbonation process is influenced by internal and external factors, and it has also been found to have both beneficial and deleterious effects on hardened cement matrix. [ABSTRACT FROM AUTHOR]

Chloride-laden environments pose serious durability concerns in cement based materials. This paper presents the findings of chloride ingress in chemically activated calcined Clay-Ordinary Portland Cement blended mortars. Results are also presented for compressive strength development and porosity tests. Sampled clays were incinerated at a temperature of 800°C for 4 hours. The resultant calcined clay was blended with Ordinary Portland Cement (OPC) at replacement level of 35% by mass of OPC to make test cement labeled PCC35. Mortar prisms measuring 40 mm × 40 mm × 160 mm were cast using PCC35 with 0.5 M Na2SO4 solution as a chemical activator instead of water. Compressive strength was determined at 28th day of curing. As a control, OPC, Portland Pozzolana Cement (PPC), and PCC35 were similarly investigated without use of activator. After the 28th day of curing, mortar specimens were subjected to accelerated chloride ingress, porosity, compressive strength tests, and chloride profiling. Subsequently, apparent diffusion coefficients (Dapp) were estimated from solutions to Fick’s second law of diffusion. Compressive strength increased after exposure to the chloride rich media in all cement categories. Chemically activated PCC35 exhibited higher compressive strength compared to nonactivated PCC35. However, chemically activated PCC35 had the least gain in compressive strength, lower porosity, and lower chloride ingress in terms of Dapp, compared to OPC, PPC, and nonactivated PCC35. [ABSTRACT FROM AUTHOR]