white csa cement - calumex
TRANSCRIPT
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April 3, 2017 The 6th International Drymix Mortar Conference Nürnberg
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agenda
INTRODUCTION White cement , production , phase formation
ADJUST calcium aluminate CAC , CSA WHITE ,ACA calcium sulfate
SHRINKAGE DRY-MIX problems and how to overcome them
CONCLUSION closing
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White Portlandcement
raw feed ; limestone + kaolin + sand high energy consumption (~1600°C )
sintering
low impurity raw materials
clinker cooled quickly (water quenching)
decorative use
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main phase composition
C3S alite
C2S belite
C3A tri calcium aluminate
CaSO4 calcium sulfate (≤ 5%)
(added at grinding stage )
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hydration
high alkali
fCaO (efflorescence , lime bloom)
shrinkage
long setting time
slow strength development
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replacement or part replacement of White Portlandcement
by source of high aluminum containing cement ;
reduce alkalinity
prevent efflorescence (lime bloom)
accelerate set
increase early strength
improve color consistency / sustainability
adjust
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alumina cement
White calcium aluminate cement (CAC)
White calcium sulfo aluminate cement (CSA)
Amorphous calcium aluminate (ACA)
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CAC WHITE
raw feed ; refined alumina+ limestone refractory cement
sintering calcination temperature ( ~1550° C.)
grinding clinker (blaine 4200-4600 g/cm2)
main phase composition CA +CA2 (monocalcium aluminate+calcium di-aluminate)
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CSA WHITE raw feed ; white bauxite + limestone + calcium sulphate choice of high purity raw materials
sintering
tight control calcination (1250~1300° C.)
cooling of clinker
grinding clinker high fineness (blaine 4800-5200 g/cm2)
main phase composition C4A3Š +C2S (calcium aluminum sulfate hydroxide+belite)
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ACA
raw feed ; bauxite + limestone fused
calcination temperature ( ~1700° C.)
rapid cooling
grinding clinker (blaine 6000 g/cm2)
main phase composition C12A7 + CA (mayenite+monocalcium aluminate)
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calcium sulfate
a chemical reaction of aluminum , calcium and sulphate
ions forms calcium aluminum sulfate hydroxide , ettringite crystals (Aft)
tetra calcium tri aluminate sulfate (C4A3Š)
3(CaO.Al2O3.3CaSO4.32H2O)
ettrinigite crystals;
needle-rod-, hexagonal, shaped
average size 1 ~ 7 μ
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early ettringite formation
ternary cement matrix ; compensation of shrinkage – expanding in volume
increase of initial strength – sulfate ions go in solution more rapid than aluminate and silicate phase
accelerated drying - mobs up excess water ,32 water molecules
higher density - filling pores and cavities amount and type of sulfate variable
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shrinkage dry-mix
volume change
plastic chemical (autogenous) drying carbonation
water evaporation smaller volume through hydration loss of water from gel pores CO2 carbonation of calcium hydroxide
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practical
3 white formulations; tile grout
fast setting tile adhesive
self leveling topping mortar Mix 1 based on CAC White and Mix 2 on CSA WHITE
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tile grout
sub
stra
te
tile adhesive
grout shrinks leaving voids
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water enters
sub
stra
te
water penetrating
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bond strength reduced
loss of strength adhesive
sub
stra
te
grout falls out
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tile grout
Tile Grout - white Mix 1.
Tile Grout - white Mix 2.
OPC white 258 OPC white 275
CAC white 88,5 CSA white 75
Calcium sulfate 36 Calcium sulfate 26
Limestone filler 591 Limestone filler 601
Cellulose ether 1 Cellulose ether 1
Polymer powder 20 Polymer powder 20
Accelerator 1 Accelerator 1
Retarder 1,5 Retarder 1
Shrinkage compensation agent 3 Shrinkage compensation agent
Total 1000 Total 1000
open time 30~40 min.- final set 3~4 hrs.
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compressive strength MPa
0
5
10
15
20
25
1 day 7 day 28 day
Mix 1.
Mix 2.
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flexural strength MPa
0
1
2
3
4
5
6
1 day 7 day 28 day
Mix 1.
Mix 2.
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shrinkage/expansion 28 days
-0,045
-0,04
-0,035
-0,03
-0,025
-0,02
-0,015
-0,01
-0,005
0
Mix 1.
Mix 2.
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tile grout
low porosity (low water absorption) low alkali – (effluoresence , colour fading)
shrinkage compensation early gelling allows fast and easy cleaning
rapid strength development
reduction of pigments
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tile adhesive
substrate
tile adhesive
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wet / dry cycle
substrate
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loss of strength
substrate
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natural stone
substrate
mortar bed / tile adhesive
marble stone
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alkali
substrate
mortar bed / tile adhesive
soluble alkali from mortar bed or adhesive migrate to the surface dissolving impurities
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stains
substrate
mortar bed / tile adhesive
stains on surface
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tile adhesive
Tile Adhesive - white Mix 1.
Tile Adhesive - white Mix 2.
OPC white 256 OPC white 256
CAC white 154 CSA white 154
Calcium sulfate 31 Calcium sulfate 51
Sand 513 Sand 493
Cellulose ether 1,9 Cellulose ether 1,9
Polymer powder 40 Polymer powder 40
Accelerator 1 Accelerator 1
Retarder 3,1 Retarder 3,1
Total 1000 Total 1000
open time 45 ~ 60 min.
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compressive strength MPa
0
5
10
15
20
25
6 hrs 7 days 28 days
Mix 1.
Mix 2.
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flexural strength MPa
0
1
2
3
4
5
6
7
8
6 hrs. 7 days 28 days
Mix 1.
Mix 2.
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shrinkage/expansion 28 days
-0,06
-0,05
-0,04
-0,03
-0,02
-0,01
0 Mix 1 Mix 2
Mix 1
Mix 2
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improved adhesion to substrate
low shrinkage less risk of de-bonding
reduced porosity low alkaline – (efflorescence)
rapid strength development
reduced porosity and low alkaline
prevent stains on surface marble
tile adhesive
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decorative SLO
screed
self leveling overlay
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loss of water
substrate
evaporation
suction substrate
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curling / debonding
substrate
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self leveling overlayment
SLO - white Mix 1.
SLO - white Mix 2.
OPC white 300 OPC white 300
CAC white 60 CSA white 75
Calcium sulfate 37,5 Calcium sulfate 25
Limestone filler 150 Limestone filler 150
Sand 400 Sand 402,5
PCE 4 PCE 4
Cellulose ether 1 Cellulose ether 1
Polymer powder 40 Polymer powder 40
Accelerator 2 Accelerator 2
Retarder 0,5 Retarder 0,5
Shrinkage compensator 5 Shrinkage compensator
Total 1000 Total 1000
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compressive strength MPa
0
10
20
30
40
50
60
70
1 day 7 day 28 day
Mix 1.
Mix 2.
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flexural strength MPa
0
2
4
6
8
10
12
14
16
18
1 day 7 day 28 day
Mix 1.
Mix 2.
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shrinkage
-0,08
-0,07
-0,06
-0,05
-0,04
-0,03
-0,02
-0,01
0 Mix 1 Mix 2
28 day
Mix 1
Mix 2
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self leveling overlay
stable base color easy to pigment
no effluoresence
rapid strength development high abrasion resistance
shrinkage compensated
short walk-on time
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CSA WHITE CSA WHITE proofs to be a good cost effective alternative acting as cementious binder it features; lower temperature on hydration stable white color fast set high early strength no loss of strength in time reduced shrinkage elevated bond strength rapid drying reduced porosity no free lime low alkali
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whiteness Y
CSA WHITE
White Portland
ACA CAC
~85 ~89
~89 ~93
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glass fiber reinforced concrete
low alkali binder improves durability glass fibers
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recycled glass
low alkali allows glass as filler
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decorative concrete
fast de-moulding prefab elements
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terrazzo
quick polishing
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decorative screed / overlayment
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enviroment
CSA White cement “green binder label” having a ;
decreased amount of limestone reduces release of CO2 (CSA=3CaO·3Al2O3·CaSO4 (36.7%) opposed to OPC=3CaO·SiO2 (73.7%)
lower calcination temperature (~300 °C lower than OPC clinker) clinker is more friable than other clinker lower grinding cost
possible use of industrial by-products
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acknowledgements
I would like to express my thanks and gratitude to
Dr.Torsten Kowald and his team at the Institut für Bau- und Werrkstoff chemie
University of Siegen
and my colleagues at Caltra Lab
for their research and assistance
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thank you for your kind attention You are happily invited to visit us at ECS hall 7 booth 422
and at ECS CONFERENCE Tomorrow afternoon at 13:30-14:00 “Choosing right Sulphate”