4.1 Influence of SCBA and SD on properties of concrete
4.1.1 Influence on compressive strength
The compressive strength of ES-28 mixes with varying levels of SD and BA content at 28 days is presented in Fig. 18 (a). The results show that with 3%, 6%, and 9% BA replacements, as the SD content varies from 20% to 40%, the compressive strength exhibits a consistent upward trend, ultimately reaching 27.54 MPa, 27.77 MPa, and 27.93 MPa, respectively, which closely align with the compressive strength of the control mix at 27.58 MPa. This occurs because BA serves as a supplementary cementitious material, contributing to gradual strength improvement through pozzolanic reactions. These reactions become more significant over time, with their impact being more apparent at 28 days compared to 7 days. The marginal strength reduction of 28 MPa concrete at earlier ages due to higher BA content might result from factors like delayed hydration and potential alterations in water-cementitious material ratios, attributed to the finer particle size of BA. On the other hand, SD affects concrete's density, impacting strength development. The strength reduction observed with increased SD content could be due to heightened porosity and changes in particle packing, influencing strength formation. Notably, the combination of 9% BA and 40% SD yields the highest strength enhancement (1.26%). This enhancement can be attributed to the cumulative effects of both BA and SD after 28 days in comparison to the control mix. The higher BA content may contribute to increased pozzolanic reactions and further strength development over the 28-day curing period. However, with a further increase in SD content to 50%, there is a subsequent decrease in compressive strength.
Similarly, the compressive strength of ES-34 mixes with varying levels of SD and BA content at 28 days is presented in Fig. 18 (b). The findings indicate that, with 3%, 6%, and 9% BA replacements, as the SD content fluctuates from 20% to 50%, there is a consistent upward trajectory in compressive strength. Ultimately, this leads to values of 35.77 MPa, 37.34 MPa, and 38.11 MPa, respectively, signifying increases of 4.29%, 8.31%, and 10.16% compared to the compressive strength of the control mix at 34.24 MPa. The increase in strength can be attributed to the relatively high silica content in SCBA, which chemically reacted with calcium hydroxide and water, resulting in the formation of a strong C–S–H gel. This finding aligns with the research of Fairbairn et al. [63]. Previous studies have also noted a common trend: the strength tends to decrease in the early curing stages but improves as the curing duration increases. This pattern is likely due to the delayed pozzolanic activity of SCBA [64, 65]. This trend underscores the importance of thoughtful mix design and the potential benefits of leveraging supplementary materials to achieve desirable concrete strength outcomes.
4.1.2 Influence on split tensile strength
The split tensile strength of ES-28 mixes with varying levels of SD and BA content at 28 days is presented in Fig. 19 (a). The results demonstrate that, with 3%, 6%, and 9% BA replacements, the split tensile strength consistently increases as the SD content varies from 20% to 40%. This ultimately leads to values of 2.74 MPa, 2.77 MPa, and 2.79 MPa, respectively, which closely match the split tensile strength of the control mix at 2.74 MPa. However, as the SD content is further increased to 50%, there is a subsequent reduction in split tensile strength. Nonetheless, these values still align with those of the control mix. Mixes with 6 % or 9 % BA and 30 % or higher SD could potentially result in split tensile strengths equal to or higher than the control mix. It's possible that higher percentages of SD in certain cases could improve tensile strength by filling voids or enhancing the interlocking effect. This possibility aligns with the findings of Balamurugan et al. [66].
Similarly, the split tensile strength of ES-34 mixes with varying levels of SD and BA content at 28 days is presented in Fig. 19 (b). The findings indicate that, with 3%, 6%, and 9% BA replacements, as the SD content fluctuates from 20% to 50%, there is a consistent upward trajectory in split tensile strength. Ultimately, this leads to values of 3.57 MPa, 3.74 MPa, and 3.84 MPa, respectively. These figures signify increases of 5.07%, 9.43%, and 11.63% when compared to the split tensile strength of the control mix, which stands at 3.39 MPa. The observed increases in split tensile strength could be attributed to a synergy between the pozzolanic effect of BA and the improved particle packing resulting from SD. When combined, these factors lead to an overall enhancement in the concrete's performance. The pozzolanic reactions initiated by BA contribute to the development of additional cementitious compounds within the concrete matrix, effectively binding the particles together. Simultaneously, the improved packing and densification of the mixture, facilitated by SD, further enhance the concrete's structural integrity. Achieving the observed increases in split tensile strength likely requires careful mix design, where the proportions of BA and SD are balanced to harness their beneficial effects. The optimal mix design may vary depending on factors such as the specific properties of the BA and SD, the cementitious materials used, and the project's requirements.
4.1.3 Influence on flexural strength
Fig. 20 (a) illustrates the 28-day flexure strength of ES-28 mixes, showcasing the impact of varying SD and BA content. The results demonstrate that, with 3%, 6%, and 9% BA replacements, the flexure strength consistently increases as the SD content varies from 20% to 40%. This ultimately results in values of 5.76 MPa, 6.80 MPa, and 7.05 MPa, respectively. These figures indicate an increase in flexural strength up to 0.26%, 15.46%, and 18.39%, respectively when compared to the flexural strength of the control mix at 5.75 MPa. However, with a further increase in SD content to 50%, there is a subsequent reduction in flexural strength. The same phenomenon was observed in ES-34 mixes, as depicted in Fig. 20 (b). It showcased an increase in flexural strength of up to 0.17%, 6.29%, and 8.92% for 3%, 6%, and 9% BA replacements, respectively, in comparison to the flexural strength of the control mix at 7.65 MPa. The test data suggests that the presence of SD, particularly at higher percentages, appears to counteract the reduction in flexural strength caused by the inclusion of BA. This suggests that the combination of these two materials can produce concrete mixes that are at least as strong as the control mix, which is a promising outcome for sustainable construction practices.
The w/c ratios have a significant influence on the mechanical properties of concrete. A well-chosen w/c ratio can optimize the reaction between cementitious materials (cement and BA) and water, forming a stronger matrix. It also affects the workability of the mix, which is crucial for proper compaction and curing. If the mix is too dry (too low w/c ratio), it may not be workable enough, leading to poor compaction and thus lower strength. Conversely, if the mix is too wet (too high w/c ratio), it may lead to segregation and excessive shrinkage upon drying, also reducing strength.
A lower w/c ratio in ES-34 generally makes concrete stronger because it leads to a denser matrix and fewer pores within the hardened cement paste, which means that there are fewer weak points in the structure. The finer particles of SD fill the voids more effectively, leading to a denser and more cohesive matrix that can withstand compressive and tensile stresses better. BA, containing silica, can react with calcium hydroxide released during cement hydration to form an additional calcium silicate hydrate (C-S-H), the primary compound responsible for strength in concrete. As the percentage of BA increases, the trend of increasing compressive and split tensile strength with SD content is maintained, suggesting that BA, up to a point, is also contributing positively to the compressive strength, potentially due to its pozzolanic properties which can enhance the microstructure of the hardened concrete. Unlike compressive and tensile strengths, a decrease in flexural strength was observed with a 50% replacement of sand with SD, as flexural strength is a measure of the material's ability to resist deformation under load. The decrease in flexural strength suggests that while the internal cohesion of the material is improved (as indicated by increased compressive and tensile strengths), the material's ability to distribute stress across the composite is compromised. This might occur because the flexural strength is more sensitive to the bond between the aggregates and the cement paste. SD, despite its positive effects on void filling and possibly initial inter-particle strength, might not bond as effectively with the cement paste in bending. The different trends in these strength measures can also be due to the angularity and surface texture of SD particles, which may lead to an improved mechanical interlock for compression and tension, but create stress concentrations under bending loads that promote crack initiation and propagation. Moreover, at 50% replacement, there might be a threshold beyond which the benefits of finer SD particles and pozzolanic reaction of BA are overshadowed by the negative effects on the concrete’s flexural performance, like altered aggregate-paste bond strength and the effectiveness of the SD particles in the matrix.
Similarly, In ES-28 a higher w/c ratio is used, which would generally reduce strength. However, up to the optimal point of SD content, the mix may still be workable and cohesive enough to achieve good compaction and strength. Past the optimal point, the excess SD might be making the mix too stiff or causing segregation, resulting in weaker concrete. The peak and subsequent decrease in compressive, split tensile, and flexural strength with higher SD content could also be due to the dilution of the cement paste, as more SD means less cementitious binder relative to aggregates, leading to a less effective paste that binds aggregates together.
4.1.4 Influence on water absorption
Fig. 21 illustrates the 28-day water absorption of ES-28 and ES-34 mixes, respectively, showcasing the impact of varying SD and BA content. The results indicate that the inclusion of both BA and SD in Mix-28 and Mix-34 leads to an increase in water absorption within the concrete. This is due to the effect of BA in the mixes when used in higher percentages, may introduce porosity and affect the binding properties of the concrete, leading to increased water absorption and enhanced durability. Similarly, SD especially at higher percentages, can also increase the porosity of the concrete, which in turn leads to higher water absorption. These findings emphasize the importance of selecting the right mix proportions based on project requirements, particularly when aiming to achieve superior water resistance in concrete structures.
Higher water absorption suggests increased porosity within the concrete. The SD particles may not pack as densely as the sand particles they are replacing, potentially due to their size, shape, or surface texture. With a higher w/c ratio, the increased water in the mix also contributes to a higher porosity, as excess water leaves behind more voids when it evaporates from the concrete. The compressive and split tensile strengths improved with the addition of SD and BA. This does not necessarily correlate with a decrease in porosity. The finer particles of SD may fill the spaces between the coarser aggregates, leading to denser packing and a higher compressive strength. However, the increased porosity indicated by higher water absorption rates suggests that these finer particles may not be bonding as effectively with the cement paste, which can negatively impact the durability and flexural strength of the concrete. The BA, despite providing a pozzolanic reaction, does not seem to reduce the porosity sufficiently to counteract the effects of SD on water absorption.
4.2 Microstructure analysis
To study the microstructure of control concrete and concrete mixture which gives higher compressive strength value i.e. 9BA:50SD having w/c ratio of 0.45, the SEM analysis was carried out to provide a close-up view of the microstructure of concrete mixes, which can give us insights into the differences in mechanical strength between the control mix and the mix with cement replaced by 9% BA and sand replaced by 50% SD. The variation in properties of concrete so far studied was validated with the micrographs of SEM. Fig. 22 collectively provides insight into the structural composition of concrete and its implications for strength. Fig. 22 (a) illustrates a large aggregate with a clearly defined contact zone, emphasizing the significance of a well-bonded interface between aggregate and cement paste for enhanced strength. In contrast, Fig. 22 (b) exposes the presence of pores within this contact zone, highlighting their potential to weaken the concrete by serving as initiation points for cracks. Fig. 22 (c) captures hydrated particles in the cement paste, underscoring the importance of hydration level for strength, with more complete hydration correlating to a stronger matrix. Finally, Fig. 22 (d) reveals the presence of calcium hydroxide (Ca(OH)2) and calcium-silicate-hydrate (C-S-H) gel, the latter being the primary contributor to concrete's strength, while the former is a by-product of the hydration process. Together, these figures depict the complex interplay of components and processes that determine the strength of concrete.
It was observed that the micrographs of 9BA:50SD showed better properties as far as the dense matrix is concerned. Fig. 23 (a) presents the aggregate and its contact zone, suggesting a possibly more defined or densely packed area with hydration products compared to the control mix, potentially contributing to increased strength. Fig. 23 (b), showing pores within the contact zone, reveals fewer and smaller pores relative to the control mix, indicative of a denser matrix that could account for heightened strength. In Fig. 23 (c), the presence of hydrated particles alongside pores is observed, with the hydration appearing more complete and the distribution of particles more uniform, factors that are advantageous for strength. Lastly, Fig. 23 (d) displays the calcium-silicate-hydrate (C-S-H) gel and calcium hydroxide (Ca(OH)2), similar to the control mix, but with a possibly greater presence of C-S-H gel due to the pozzolanic reaction of BA, enhancing the concrete's strength.
The modified mix displays a denser microstructure with more C-S-H gel, which is the strength-giving phase in concrete. BA, as a pozzolan, reacts with the Ca(OH)2 to form additional C-S-H gel, which fills pores and makes the cement matrix more homogenous and less permeable, hence increasing the compressive strength. Furthermore, the SD particles could be filling the voids between the larger aggregate particles more effectively than the sand, leading to a denser packing and better particle interlock. The reduction in porosity, as evidenced by the lower prevalence of pores and the denser packing of hydrated particles, is likely a significant contributor to the increased compressive strength observed in the modified mix. In addition, the pozzolanic reaction of BA consumes the Ca(OH)2, which is relatively weak and can be leached out, transforming it into additional C-S-H gel, thereby enhancing the durability and mechanical properties of the concrete.
4.3 Response surface analysis
In this research Design Expert software [67] was used for Response Surface Analysis in which Compressive strength, Tensile strength, Flexural strength, and Water absorption tests (for both mixes) were the factors for which response surface methodology was used for the optimization of any of these parameters keeping other factors constant. For illustration Compressive strength, Tensile strength, Flexural strength, and Water absorption have been taken as response and w/c ratio, % replacement ratio of cement with BA, and sand with SD as factors. The test results were subjected to response surface methodology independently to obtain the best ratios for each property as shown in Fig. 24, Fig. 25, Fig. 26, and Fig. 27. The optimization process aimed to determine the best ratios of BA and SD replacement that would yield the most favorable outcomes in terms of concrete's mechanical properties and durability as indicated by water absorption.
The analysis of the optimized mix compared to the control mix across various parameters—compressive strength, split tensile strength, flexural strength, and water absorption—shows varying degrees of difference. The optimized mix demonstrates values of 34.28 MPa, 3.43 MPa, 7.97 MPa, and 5.45% respectively. The values obtained using response surface methodology are indicated in Table 1 for 34 MPa, which shows the best ratio of replacements of cement with BA and sand with SD for the targeted results of each property. These figures represent differences of 0.12%, 1.18%, 4.18%, and a significant 27.34% in each parameter respectively. Such variations indicate that the optimized mix largely matches the control mix in mechanical strengths, underscoring its suitability for structural use. However, the notable 27.34% increase in water absorption in the optimized mix points to increased porosity or reduced density, which might adversely affect its long-term durability. This increased water absorption, while a drawback, is a consequence of optimizing the mix for mechanical strengths, highlighting a potential compromise in the material's overall performance and durability in structural applications.
Table 1 Optimization Outcomes for Concrete Mix Properties Utilizing Response Surface Analysis
Property
|
W/C Ratio
|
Replacement ratio of BA (%)
|
Replacement Ratio of SD (%)
|
Value (With Response Surface)
(A)
|
Value (Control Mix)
(B)
|
Percent difference b/w A & B
|
Compressive Strength (MPa)
|
0.50
|
9
|
50
|
34.28
|
34.24
|
0.12 %
|
Split tensile Strength (MPa)
|
3.43
|
3.39
|
1.18 %
|
Flexural Strength (MPa)
|
7.97
|
7.65
|
4.18 %
|
Water absorption (%)
|
5.45
|
4.28
|
27.34 %
|
In short, optimizing one property does not necessarily lead to improvements across all properties; trade-offs must be considered. While the mechanical properties show favorable increases, the durability indicated by water absorption is compromised, which could lead to longer-term issues such as increased permeability and potential for damage from freeze-thaw cycles or chemical attacks.