Performance evaluation of self-leveling mortars using phosphogypsum and white ceramic waste

Gruber, Elayne Thais; Effting, Carmeane; Schackow, Adilson; Mendes, Gabriela Azambuja

doi:10.1590/S1983-41952024000100003

Elayne Thais Gruber

conceptualization

data curation

formal analysis

investigation

methodology

validation

visualization

writing original draft

Universidade do Estado de Santa Catarina - UDESC, Center of Technological Sciences, Department of Civil Engineering, Graduate Program in Civil Engineering, Joinville, SC, Brasil

https://orcid.org/0000-0002-3183-1048

Carmeane Effting

conceptualization

formal analysis

investigation

methodology

project administration

resources

supervision

validation

visualization

writing review and editing

Universidade do Estado de Santa Catarina - UDESC, Center of Technological Sciences, Department of Civil Engineering, Graduate Program in Civil Engineering, Joinville, SC, Brasil

https://orcid.org/0000-0001-5457-5457

Adilson Schackow

conceptualization

investigation

methodology

visualization

writing original draft

writing review and editing

Universidade do Estado de Santa Catarina - UDESC, Center of Technological Sciences, Department of Civil Engineering, Graduate Program in Civil Engineering, Joinville, SC, Brasil

https://orcid.org/0000-0003-2561-5231

Gabriela Azambuja Mendes

conceptualization

methodology

validation

Universidade do Estado de Santa Catarina - UDESC, Center of Technological Sciences, Department of Civil Engineering, Graduate Program in Civil Engineering, Joinville, SC, Brasil

https://orcid.org/0000-0003-3087-1424

Corresponding author: Adilson Schackow. E-mail: adilson.schackow@udesc.br

Conflict of interest: Nothing to declare.

Author contributions: ETG: Conceptualization, Data curation, Formal analysis, Investigation, Methodology, Validation, Visualization, Roles/Writing - original draft; CE: Conceptualization, Formal analysis, Investigation, Methodology, Project administration, Resources, Supervision, Validation, Visualization, Writing - review & editing; AS: Conceptualization, Investigation, Methodology, Visualization, Roles/Writing - original draft, Writing - review & editing; GAM: Conceptualization, Methodology, Validation.

Editors: Vladimir Haach, Guilherme Aris Parsekian.

Material (%)	Natural phospho-gypsum	Natural phospho-gypsum	Natural phospho-gypsum	Natural phospho-gypsum	Natural phospho-gypsum	Phosphogypsum calcined at 450°C (Anhydrite II)	Phosphogypsum calcined at 450°C (Anhydrite II)
Material (%)	Natural phospho-gypsum	Natural phospho-gypsum	Natural phospho-gypsum	Natural phospho-gypsum	Natural phospho-gypsum	Phosphogypsum calcined at 450°C (Anhydrite II)	Phosphogypsum calcined at 450°C (Anhydrite II)	Author	[ ²⁴24 X. Gong, J. Liu, Z. Sun, and F. Li, "Effects of phosphogypsum and calcined phosphogypsum content on the basic physical and mechanical properties of Portland Cement Mortar," J. Test. Eval., no. 48, no. 5, pp. 1-13, 2019, http://dx.doi.org/10.1520/JTE20180380. http://dx.doi.org/10.1520/JTE20180380... ]	[ ²⁵25 S. Oumnih, N. Bekkouch, E. Gharibi, N. Fagel, K. Elhamouti, and M. El Ouahabi, "Phosphogypsum waste as additives to lime stabilization of bentonite," Sustain. Environ. Res., vol. 29, pp. 35, 2019, http://dx.doi.org/10.1186/s42834-019-0038-z. http://dx.doi.org/10.1186/s42834-019-003... ]	[ ²⁶26 W. Hyung, D. Han, and D. Seo, "Basic properties of non-sintered cement mortar using industrial byproducts as activators," J. Asian Archit. Build. Eng., vol. 14, pp. 649-656, 2015, http://dx.doi.org/10.3130/jaabe.14.649. http://dx.doi.org/10.3130/jaabe.14.649... ]	[ ²⁷27 C. O. Schaefer, M. Cheriaf, and J. C. Rocha, "Production of synthetic phosphoanhydrite and its use as a binder in Self-Leveling Underlayments (SLU)," Materials (Basel), vol. 10, pp. 958, Aug. 2017, http://dx.doi.org/10.3390/ma10080958. http://dx.doi.org/10.3390/ma10080958... ]	The author (2022)	[ ²⁷27 C. O. Schaefer, M. Cheriaf, and J. C. Rocha, "Production of synthetic phosphoanhydrite and its use as a binder in Self-Leveling Underlayments (SLU)," Materials (Basel), vol. 10, pp. 958, Aug. 2017, http://dx.doi.org/10.3390/ma10080958. http://dx.doi.org/10.3390/ma10080958... ]	The author (2022)
CaO	35.62	31.51	32.28	38.56	56.21	53.53	71.75
SiO₂	2.39	0.5	1.08	0.82	1.67	0.92	1.05
Al₂O₃	0.03	0.11	0.07	0.41	0	0.10	0
Fe₂O₃	0.83	0.05	0.21	0.89	1.07	1.03	2.06
SO₃	47.10	46.9	43.29	24.59	39.76	34.10	22.18
MgO	0.62	1.59	0.05	0	0	0.00	0
TiO₂	0	0	0.04	0	1.29	0.00	1.92
Na₂O	0	0.03	0	3.99	0	3.85	0
P₂O₅	1.14	0.35	0.58	1.13	0	1.01	0.98
Other	12.27	18.96	22.4	29.61	0	5.46	0.05

Material (%)	White Ceramic	White Ceramic	White Ceramic	White Ceramic	White Ceramic	White Ceramic
Material (%)	White Ceramic	White Ceramic	White Ceramic	White Ceramic	White Ceramic	White Ceramic	Author	[ ²⁸28 J. R. S. Melo, "Recycling ceramic waste for use in the mortar process", M.S. thesis, Univ. Fed. Pará, Belém, PA, Brasil, 2017. [in Portuguese] ]	[ ²⁹29 E. Lasseuguete et al., "Chemical microstructural and mechanical properties of ceramic waste blended cementitious systems," J. Clean. Prod., vol. 211, pp. 1228-1238, 2019, http://dx.doi.org/ 10.1016/j.jclepro.2018.11.240. http://dx.doi.org/ 10.1016/j.jclepro.201... ]	[ ³⁰30 C. Medina, P. F. G. Banfill, M. I. Sánchez de Rojas, and M. Frías, "Rheological and calorimetric behaviour of cements blended with containing ceramic sanitary ware and construction/demolition waste," Constr. Build. Mater., vol. 40, pp. 822-831, 2013, http://dx.doi.org/10.1016/j.conbuildmat.2012.11.112. http://dx.doi.org/10.1016/j.conbuildmat.... ]	[ ³¹31 F. Pacheco-Torgal, and S. Jalali, "Compressive strength and durability properties of ceramic wastes based concrete," Mater. Struct., vol. 44, pp. 155-167, Apr. 2011. https://doi.org/10.1617/s11527-010-9616-6. https://doi.org/10.1617/s11527-010-9616-... ]	[ ³²32 H. Higashiyama, F. Yagishita, M. Sano, and O. Takahashi, "Compressive strength and resistance to chloride penetration of mortars using ceramic waste as fine aggregate," Constr. Build. Mater., vol. 26, pp. 96-101, 2012, http://dx.doi.org/10.1016/j.conbuildmat.2011.05.008. http://dx.doi.org/10.1016/j.conbuildmat.... ]	The author (2022)
CaO	1.42	7.00	2.41	0.20	0.76	2.47
SiO₂	66.62	68.9	67.91	65.00	70.90	62.63
Al₂O₃	15.58	19.8	22.01	21.30	21.10	29.83
Fe₂O₃	8.18	0.90	1.41	1.30	0.81	1.71
SO₃	0	0	0.07	0	0	0
MgO	1.79	0.30	0.29	0.30	0.24	0
TiO₂	0.83	0.70	0.45	0.20	0.33	0.65
Na₂O	1.18	0.30	1.91	2.50	1.47	0
K₂O	3.84	1.70	2.79	3.70	3.57	2.69
Other	0.56	0.40	0.75	5.50	0.82	0.02

Mortar	Proportion of materials	Flow test images
AR	1 : 1 : 0.33 : 0.0033 : 0.0067 (cement; sand; water; superplasticizer; viscosity modifying additive)
FN	1 : 1.5 : 0.5 : 0.65 : 0.0090 : 0.010 (cement; sand; waste; water; superplasticizer; viscosity modifying additive)
FN	(50% of the cement mass replaced by natural phosphogypsum)
FC	1 : 1.5 : 0.5 : 0.65 : 0.0050 : 0.010 (cement; sand; waste; water; superplasticizer; viscosity modifying additive)
FC	(50% of the cement mass replaced by calcined phosphogypsum)
CB	1 : 1.5 : 0.5 : 0.65 : 0.0050 : 0.010 (cement; sand; waste; water; superplasticizer; viscosity modifying additive)
CB	(50% of the cement mass replaced by ceramic waste)

Mixtures	C (kg/m³)	FN (kg/m³)	FC (kg/m³)	CB (kg/m³)	S (kg/m³)	W (kg/m³)	SP (kg/m³)	VA (kg/m³)	W/C
AR	948.18	-	-	-	948.18	312.89	3.12	6.35	0.33
FN	474.09	474.09	-	-	1422.27	616.31	8.53	9.48	0.65
FC	474.09	-	474.09	-	1422.27	616.31	4.74	9.48	0.65
CB	474.09	-	-	474.09	1422.27	616.31	4.74	9.48	0.65

Evaluated mortar	Initial spreading diameter (mm)	Spreading diameter 20 min. (mm)	Spreading diameter 30 min. (mm)	Regeneration time (minutes)
AR	125	125	125	15-20
FN	135	125	125	10-15
FC	125	125	125	15-20
CB	125	125	125	15-20

Evaluated mortar	Initial setting time (h:min)	Final setting time (h:min)	Difference (h:min)
AR	08:40	09:15	00:35
FN	05:25	14:35	09:10
FC	08:20	08:50	00:30
CB	06:10	06:30	00:20

Variable	Sum of Squares			Degrees of Freedom			F			p-value
Variable	1 day	7 days	28 days	1 d	7 d	28 d	1 d	7 d	28 d	1 d	7 d	28 d
Between Groups	1595	1885.12	2949.36	3	3	3	127.43	49.77	192.00	4.31	1.61	8.62
Between Groups	1595	1885.12	2949.36	3	3	3	127.43	49.77	192.00	.10^-7	.10^-5	.10^-8
Within Groups	33.38	101,00	40.96	8	8	8
Total	1628.37	1986.12	2990.33	11	11	11

Mortars compared	Age	Difference	Inferior Limit	Superior Limit	p-value
AR-FN	01 day	-28.07	-33.41	-22.72	0.0000007
AR-FC		-28.34	-33.68	-22.99	0.0000007
AR-CB		-20.11	-25.45	-14.76	0.0000097
FC-FN		-0.27	-5.61	5.07	0.9983603
CB-FN		7.96	2.61	13.30	0.0061194
CB-FC		8.23	2.88	13.57	0.0050084
AR-FN	07 days	-34.11	-43.40	-24.81	0.0000118
AR-FC		-25.18	-34.47	-15.89	0.0001118
AR-CB		-17.91	-27.20	-8.61	0.0012047
FC-FN		8.92	-0.36	18.21	0.0596687
CB-FN		16.20	6.90	25.49	0.0023185
CB-FC		7.27	-2.01	16.56	0.1331075
AR-FN	28 days	-42.85	-48.77	-36.94	0.0000000
AR-FC		-30.58	-36.49	-24.66	0.0000009
AR-CB		-21.02	-26.94	-15.11	0.0000150
FC-FN		12.27	6.36	18.19	0.0007346
CB-FN		21.83	15.91	27.74	0.0000113
CB-FC		9.55	3.63	15.46	0.0037627

Variable	Sum of Squares		Degrees of Freedom		F		p-value
Variable	3 days	28 days	3 days	28 days	3 days	28 days	3 days	28 days
Between Groups	25.35	121.29	3	3	6.12	45.94	0.018117	2.18.10^-5
Within Groups	11.03	7.04	8	8
Total	36.39	128.33	11	11

Mortars compared	Age	Difference	Inferior Limit	Superior Limit	p-value
AR-FN	03 days	-3.72	-6.79	-0.65	0.0194316
AR-FC		-2.73	-5.80	0.33	0.0822377
AR-CB		-0.99	-4.06	2.07	0.7328111
FC-FN		0.99	-2.07	4.06	0.7346940
CB-FN		2.73	-0.34	5.80	0.0826423
CB-FC		1.73	-1.33	4.80	0.3352774
AR-FN	28 days	-3.84	-6.29	-1.39	0.0045020
AR-FC		-7.94	-10.39	-5.49	0.0000301
AR-CB		-0.49	-2.94	1.95	0.9131918
FC-FN		-4.10	-6.55	-1.64	0.0030318
CB-FN		3.35	0.89	5.80	0.0101720
CB-FC		7.45	4.99	9.90	0.0000486

Evaluated mortar	Water absorption (%)	Void ratio (%)	Specific mass (g/cm³)
AR	9.79 ± 0.13	20.32 ± 0.21	2.08 ± 0.01
FN	18.65 ± 0.34	32.33 ± 0.17	1.74 ± 0.02
FC	15.59 ± 0.29	28.65 ± 0.24	1.85 ± 0.01
CB	15.03 ± 0.15	27.34 ± 0.32	1.82 ± 0.03

Evaluated mortar	Average rupture strength (N)	Average tensile adhesion strength (MPa)
AR	3122	1.59
FN	810	0.41
FC	1519	0.77
CB	1295	0.66

[1] Corresponding author: Adilson Schackow. E-mail: adilson.schackow@udesc.br

Brasil

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Abstract