BIOMASS WASTE MATERIALS AS A SET-RETARDATION AGENT IN CEMENT OR CONCRETE

Abstract

A concrete mixture is provided. The mixture includes cement powder, a plant biomaterial in a solid form, wherein the plant biomaterial does not comprise ash, and concrete aggregate, wherein a ratio of cement powder to the biomaterial ranges from 10:1 to 100:1. Methods of controlling concrete setting by adding a plant biomaterial in a solid form to a concrete mixture are also provided.

Claims

1. A concrete mixture, comprising: cement powder; a plant biomaterial in a solid form, wherein the plant biomaterial does not comprise ash; and concrete aggregate, wherein a ratio of cement powder to the biomaterial ranges from 10:1 to 100:1.

2. The concrete mixture of claim 1, wherein the ratio of cement powder to the plant biomaterial ranges from 10:1 to 25:1.

3. The concrete mixture of claim 1, wherein the plant biomaterial is obtained from a plant selected from the group consisting of hemp, kenaf, and combinations thereof.

4. The concrete mixture of claim 1, wherein the plant biomaterial is obtained from a plant part selected from the group consisting of a stalk, stem, flowering material, hurd, bast, and combinations thereof.

5. The concrete mixture of claim 1, wherein the solid form is selected from the group consisting of powder, chips, fibers, and nanoparticles.

6. The concrete mixture of claim 1, wherein the mixture further comprises one or more materials selected from siliceous or calcareous fly ash, slag cement, and silica fume.

7. A method of controlling concrete setting, comprising adding a plant biomaterial in a solid form to a concrete mixture, wherein the plant biomaterial does not comprise ash.

8. The method of claim 7, wherein the plant biomaterial replaces 1 to 10 wt % of cement powder in the concrete mixture.

9. The method of claim 7, wherein the plant biomaterial is obtained from a plant selected from the group consisting of hemp, kenaf, and combinations thereof.

10. The method of claim 7, wherein the plant biomaterial is obtained from a plant part selected from the group consisting of a stalk, stem, flowering material, hurd, bast, and combinations thereof.

11. The method of claim 7, wherein the solid form is selected from the group consisting of powder, chips, fibers, and nanoparticles.

12. The method of claim 7, further comprising adding one or more materials selected from siliceous or calcareous fly ash, slag cement, and silica fume.

13. The method of claim 7, wherein the plant biomaterial is treated with an alkaline extraction agent prior to being added to the concrete mixture.

14. The method of claim 13, wherein the plant biomaterial is washed with water after being treated with the alkaline extraction agent.

15. The method of claim 13, wherein at least a portion of the alkaline extraction agent used to treat the plant biomaterial is added to the concrete mixture.

16. The method of claim 14, wherein at least a portion of the water used to wash the plant biomaterial is added to the concrete mixture.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] FIGS. 1A-C. Images of (a) hemp leaves; (b) fine hemp powders; and (c) coarse hemp powders.

[0012] FIGS. 2A-B. TGA and DTGA curves of (a) fine; and (b) coarse hemp powders.

[0013] FIGS. 3A-B. (a) Heat evolution; and (b) heat evolution rate during hydration of portland cement paste without and with hemp powders.

[0014] FIG. 4. Degree of hydration of 7-day cement paste samples.

[0015] FIGS. 5A-B. (a) Heat evolution; and (b) heat evolution rate during hydration of RTN-incorporated cement paste.

[0016] FIGS. 6A-B. (a) Heat evolution; and (b) heat evolution rate during hydration of portland cement paste with 5% fine hemp powders.

[0017] FIGS. 7A-B. (a) Heat evolution; and (b) heat evolution rate during hydration of portland cement paste with 10% washed treated hemp powders.

[0018] FIG. 8. FTIR spectra of (a) OPC; (b) control; (c) PU5; (d) PTN5; (e) PTW5; (f) RTN5; (g) RTW5; (h) PU10; (i) PTN10; (j) PTW10; (k) RTN10; and (1) RTW10.

[0019] FIGS. 9A-E. Microstructure of (a) unhydrated cement powder; (b) control; (c) PU10; (d) PTN10; and (e) PTW10.

[0020] FIG. 10. Schematic of weight-loss correction of cement paste.

DETAILED DESCRIPTION

[0021] Embodiments of the disclosure provide biomass-derived materials (e.g. plant powders) that are useful as multifunctional additives for cement and concrete applications. The biomaterials act as set-retardation agents while also enhancing the toughness of the cement paste/concrete. Concrete mixtures disclosed herein may comprise cement powder, a plant biomaterial in a solid form, and concrete aggregate.

[0022] A cement is a substance used for construction that sets, hardens, and adheres to other materials to bind them together. For example, cement may be used to bind aggregate (e.g. sand and gravel) together to form concrete. Cements used in construction are usually inorganic, often lime or calcium silicate based. The mixtures of the present disclosure are compatible with any type of hydraulic cement which set and become adhesive due to a chemical reaction between the dry ingredients and water. The chemical reaction results in mineral hydrates that are not very water-soluble and so are quite durable in water and safe from chemical attack. This allows setting in wet conditions or under water and further protects the hardened material from chemical attack. Hydraulic cements are made of a mixture of silicates and oxides. Suitable hydraulic cements include, but are not limited to, Portland cement, Blended Portland cement, pozzolan-lime cement, white cement, oil well cement, calcium aluminate cement, calcium sulfoamluminate cement, polymer modified/impregnated cement, expansive cement, and cements for ultra high performance concrete, etc. Cement powder may comprise 5-50 wt % of the concrete mixture.

[0023] Concrete aggregates are an inert filler in a concrete mixture. Exemplary concrete aggregates include, but are not limited to, gravel, sand, recycled concrete, slag, topsoil, ballast, and geosynthetic aggregates. Concrete aggregates may comprise 50-90 wt % of the concrete mixture.

[0024] Cement starts to set when mixed with water, which causes a series of hydration chemical reactions. Water generally comprises 10-20 wt % of the mixture, e.g. 14-18 wt %. The constituents slowly hydrate and the mineral hydrates solidify and harden. The interlocking of the hydrates gives cement its strength. Hydraulic cement does not set by drying out. Instead, proper curing requires maintaining the appropriate moisture content necessary for the hydration reactions during the setting and the hardening processes. If hydraulic cements dry out during the curing phase, the resulting product can be insufficiently hydrated and significantly weakened. Suitable temperatures for curing generally range from 5° C. to 30° C. During the curing process, the concrete should be protected against water evaporation due to direct insolation, elevated temperature, low relative humidity, and wind.

[0025] The plant biomaterials described herein provide a delaying effect on cement hydration. Thus, they are useful in serving as retardation agents to adjust cement hydration rates, particularly when rapid hydration needs to be avoided. The biomaterials allow for controlling the heat of hydration and may be used in special applications such as oilwell cementing under elevated temperature and pressure, hot weather construction, to stabilize hydration of returned plastic concrete by post-addition of biomass materials, etc.

[0026] In some embodiments, a ratio of cement powder to the biomaterial ranges from 10:1 to 1000:1, e.g. 10:1 to 100:1, e.g. 10:1 to 25:1. The plant biomaterial may be obtained from a variety of plants including, but not limited to, hemp (Cannabis sativa), kenaf (Hibiscus cannabinus), tobacco leaves, agricultural wastes (e.g. wheat straw, rice straw, corn stover, etc.), dedicated crops (e.g. switchgrass, miscanthus, etc.), woody biomass (e.g. pine, eucalyptus, spruce, etc.), and combinations thereof. In some embodiments, the plant biomaterial is any organic matter/material, e.g. as obtained from recycled papers, yard wastes, or other municipal solid wastes. A dry biomass or a wet biomass with a moisture content between 0-90% can be used. Any part of the plant may be used including, for example, the stalk, stem, flowering material (flowers and leaves), hurd, bast, and combinations thereof. The plant biomaterial is incorporated into the concrete mixture in a solid (i.e. non-liquid) form such as a powder, chips, fibers, and nanomaterials such as nanoparticles and nanocellulose. The plant materials may be waste materials left over after an initial processing, such as cannabidiol (CBD) oil extraction.

[0027] To prepare a plant-derived powder, the plant part (e.g. dried flowering materials) may be chopped and blended or ground into a powder. In some embodiments, the powder is then passed through a No. 200 sieve having openings of about 0.074 mm. The powders passing through the sieve (fine powders) or those retained on the sieve (coarse powders) may be utilized in cement mixtures as described herein. Accordingly, the present disclosure provides the direct use of plant-based powders without a previous combustion to form an ash. Since the powder may be on the same size scale of cement powders, it helps refining cement paste to have a denser micro-structure. The plant powders also enhance the toughness of the paste/concrete.

[0028] In some embodiments, the plant materials, e.g. in a powder form, are surface treated with an alkaline agent such as an aqueous solution containing calcium hydroxide or sodium hydroxide prior to inclusion in the cement mixture.

[0029] Optionally, the alkaline treated plant material may be washed with water prior to inclusion in the cement mixture. The alkaline agent and/or the water used to pre-treat/wash the plant material may also be included in the cement mixture.

[0030] In some embodiments, the plant material is not pre-treated with an alkaline extraction agent and/or is not pre-washed with water or other solvents.

[0031] Cement mixtures as described herein may further comprise one or more additional materials such as concrete additives. For example, the mixture may include siliceous or calcareous fly ash, slag cement, and/or silica fume.

[0032] Further embodiments provide a method of controlling concrete setting comprising adding a plant biomaterial in a solid form to a concrete mixture. In some embodiments, the plant biomaterial replaces 1 to 20 wt % of cement powder in the concrete mixture, e.g. 1-15 wt % or 1-10 wt %.

[0033] Before exemplary embodiments of the present invention are described in greater detail, it is to be understood that this invention is not limited to particular embodiments described, as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting, since the scope of the present invention will be limited only by the appended claims.

[0034] Where a range of values is provided, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limit of that range and any other stated or intervening value in that stated range, is encompassed within the invention. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges and are also encompassed within the invention, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the invention.

[0035] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can also be used in the practice or testing of the present invention, representative illustrative methods and materials are now described.

[0036] All publications and patents cited in this specification are herein incorporated by reference as if each individual publication or patent were specifically and individually indicated to be incorporated by reference and are incorporated herein by reference to disclose and describe the methods and/or materials in connection with which the publications are cited. The citation of any publication is for its disclosure prior to the filing date and should not be construed as an admission that the present invention is not entitled to antedate such publication by virtue of prior invention. Further, the dates of publication provided may be different from the actual publication dates which may need to be independently confirmed.

[0037] It is noted that, as used herein and in the appended claims, the singular forms “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise. It is further noted that the claims may be drafted to exclude any optional element. As such, this statement is intended to serve as antecedent basis for use of such exclusive terminology as “solely,” “only” and the like in connection with the recitation of claim elements, or use of a “negative” limitation.

[0038] As will be apparent to those of skill in the art upon reading this disclosure, each of the individual embodiments described and illustrated herein has discrete components and features which may be readily separated from or combined with the features of any of the other several embodiments without departing from the scope or spirit of the present invention. Any recited method can be carried out in the order of events recited or in any other order which is logically possible.

[0039] The invention is further described by the following non-limiting examples which further illustrate the invention, and are not intended, nor should they be interpreted to, limit the scope of the invention.

Example

Summary

[0040] In this study, the residual of hemp products as biomass wastes has been ground into powders to be used in cement-based materials. The effect of untreated and alkaline treated hemp powders on the hydration of Portland cement paste was studied by isothermal calorimetry analysis, thermogravimetric analysis, Fourier transform infrared spectroscopy analysis, and scanning electron microscopy analysis. The results show that partially replacing cement with untreated and alkaline treated hemp powders can delay cement hydration and reduce the degree of hydration. Compared to untreated hemp powders, alkaline treated (washed or non-washed) hemp powders show less set delay effect on cement hydration; moreover, distilled water washed treated hemp powders delay less than non-washed treated hemp powders. The study also shows that coarse hemp powders exert a less set delay effect on cement hydration than fine hemp powders. Generally, the distilled water washed treated coarse hemp powders exert the minimum delay effect on cement hydration.

Materials and Methods

Hemp Powder Preparation

[0041] Hemp powders were prepared from flowering materials (flowers and leaves) and used to partially replace cement in this study. These flowering materials were provided by Green Remedy, Inc. (Louisville, Ky., USA). Cannabidiol (CBD) was extracted from them prior to hemp powder preparation. To prepare the hemp powders, oven dried flowering materials (shown in FIG. 1(a)) were firstly chopped and blended into powders by using a high-speed blender and then sieved through a No. 200 sieve. The powders passing through the sieve were called fine hemp powders, as shown in FIG. 1(b), and those retained on the sieve were called coarse hemp powders, as shown in FIG. 1(c).

Chemical Treatment

[0042] The fine and coarse hemp powders were chemically treated by using the same procedure as introduced below. Saturated calcium hydroxide solution (saturated lime water) was prepared in a beaker at room temperature. Hemp powders were introduced to the prepared solution (hemp-to-solution mass ratio=0.1) and stirred by using an AREX-6 Digital PRO (a kind of hot plate stirrer) (Velp Scientifica, Usmate, Italy) to assure good dispersion. The beaker was then covered to avoid water evaporation. After 24 h, a centrifuge was used to filter out hemp powders from the calcium hydroxide solution. A part of treated hemp powders was collected without washing. The remaining part of the treated hemp powders was further washed by distilled water several times until the pH was close to neutral. The collected wet hemp powders (both washed and non-washed) were dried in an oven for 24 h at 40° C. And finally, the dried hemp powders were ground by using a mortar and pestle to eliminate the clumping. Based on the hemp powder size and treatment method, six types of hemp powders were obtained, as listed in Table 1.

TABLE-US-00001 TABLE 1 Classification of hemp powders Sample Specification RU Untreated hemp powders retained on No. 200 sieve PU Untreated hemp powders passing through No. 200 sieve RTN Nonwashed treated hemp powders retained on No. 200 sieve PTN Nonwashed treated hemp powders passing through No. 200 sieve RTW Distilled-water-washed treated hemp powders retained on No. 200 sieve PTW Distilled-water-washed treated hemp powders passing through No. 200 sieve Note: P = passing; R = retained; U = untreated; T = treated; N = nonwashed; and W = washed.

Cement Paste Preparation

[0043] The chemical compositions and the mineral clinker compounds of the Type I/II cement used are shown in Table 2 and Table 3 (Shang and Sun 2019). The water/binder ratio was kept at 0.50, and hemp powders were used to replace 5.0% and 10.0% of cement by weight. The corresponding mix proportion is shown in Table 4. The samples are named after the hemp powder type and dosage. For example, RTW10 denotes the paste with 10% of cement replaced by distilled water washed treated hemp powders that were retained on the No. 200 sieve.

TABLE-US-00002 TABLE 2 Chemical composition of Type I/II low alkaline (LA) portland cement Chemical compound Weight (%) CaO 63.30 SiO.sub.2 19.70 Al.sub.2O.sub.3 5.00 Fe.sub.2O.sub.3 3.47 MgO 3.59 SO.sub.3 2.50 Na.sub.2O 1.55 K.sub.2O 0.45 Loss on Ignition 0.54

TABLE-US-00003 TABLE 3 Major compounds of Type I/II LA portland cement Clinker phase Weight (%) C.sub.3S 59.32 C.sub.2S 11.81 C.sub.3A 7.39 C.sub.4AF 10.55

TABLE-US-00004 TABLE 4 Mix proportions of cement paste Cement Hemp Sample Water (Type I/II) powder Specification Control 0.5 1 0 Cement paste with no hemp powders PU5 0.5 0.95 0.05 Cement paste with 5% PU RTN5 0.5 0.95 0.05 Cement paste with 5% RTN PTN5 0.5 0.95 0.05 Cement paste with 5% PTN RTW5 0.5 0.95 0.05 Cement paste with 5% RTW PTW5 0.5 0.95 0.05 Cement paste with 5% PTW PU10 0.5 0.90 0.10 Cement paste with 10% PU RTN10 0.5 0.90 0.10 Cement paste with 10% RTN PTN10 0.5 0.90 0.10 Cement paste with 10% PTN RTW10 0.5 0.90 0.10 Cement paste with 10% RTW PTW10 0.5 0.90 0.10 Cement paste with 10% PTW Note: P = passing; R = retained; U = untreated; T = treated; N = nonwashed; W = washed; 5 = 5%; and 10 = 10%.

Isothermal Calorimetry Test

[0044] In order to evaluate the hydration of cement, Isothermal calorimetry (IC) test was conducted on cement paste according to ASTM C1702 (ASTM. 2009). TAM Air (TA Instruments, New Castle, Del.), a commercial calorimeter, was adopted in this study (Sun et al. 2017). It is an eight-channel isothermal heat conduction calorimeter with an operating temperature range of 5-60° C. Before the testing, the equipment was carefully calibrated based on the calibration procedures specified by the manufacturer's manual. The energy change during hydration was collected and registered by an automated data-acquisition program. The energy value was calculated based on the unit weight of cementitious materials' mass.

Thermogravimetric Analysis

[0045] Thermogravimetric analysis (TGA) was conducted on each type of hemp powders under nitrogen atmosphere with a flow rate of 40 ml/min from 25° C. to 600° C., with a heating rate of 10° C./min. Around 10 mg of hemp powders were used for each run. The purpose of this step was to study the decomposition of hemp powders within the temperature range and thus evaluate the effectiveness of calcium hydroxide treatment on the removal of hemicellulose.

[0046] TGA was also conducted on 7-day paste mixtures under nitrogen atmosphere, with a flow rate of 40 ml/min from 25° C. to 1100° C. The temperature profile includes increasing from room temperature to 105° C. by 20° C./min and then keeping the temperature at 105° C. for 12 h to remove the evaporable water in the sample. Subsequently, the sample was heated from 105° C. to 1100° C. by 20° C./min, and then the temperature was kept at 1100° C. for 6 h to extract all chemically bound water (CBW). Around 20 mg paste sample was used for each run. The TGA tests were also conducted on pure cement powder and each type of hemp powders by adopting the same test procedure in order to correct the weight loss between 105° C. and 1100° C. for chemically bound water calculation.

[0047] For cement paste without hemp powders, the calculation of chemically bound water (CBW) is regularly defined as the weight loss of the tested cement paste between 105° C. and 1100° C., corrected for the loss on ignition (LOI) of the dry cement powder itself (Cao et al. 2015; Feng et al. 2004). However, for cement pastes with hemp powders, the calculation of chemically bound water is more complicated and needs to be additionally corrected to take account for the decomposition of hemp powders involved.

Fourier Transform Infrared Spectroscopy Analysis

[0048] Fourier transform infrared spectroscopy (FTIR) test was conducted on pure cement powder and 7-day cement pastes by using a PerkinElmer Spectrum 100® series spectrometer (Shelton, Conn.). The sampling technique of Attenuated Total Reflection (ATR) was adopted to enable samples to be examined directly without further preparation (Elmer 2005). The background spectrum was collected at ambient atmosphere, and then the samples were directly analyzed. The spectra were recorded in the range of 650-4000 cm.sup.−1 with the resolution of 4 cm.sup.−1 (Horgnies et al. 2013). The purpose of the FTIR test is to evaluate the effect of hemp powders on cement hydration qualitatively by observing the change of functional groups of cement pastes.

Scanning Electron Microscopy Analysis

[0049] Scanning electron microscopy (SEM) analysis was conducted on the powdered cement pastes using NOVA NANOSEM 600™ provided by FBI (Hillsboro, Oreg.). Before testing, in order to suppress charging effect, gold sputtering was applied to the surface of specimens. While testing, the Everhart Thornley detector (ETD) in the secondary electron mode was adopted. The beam current and voltage were 0.32 nA and 10 kV, respectively. The purpose of SEM analysis is to observe the microstructure of cement pastes with hemp powders and then identify the effect of hemp powders on cement hydration.

Degree of Hydration Calculation Procedure Based on TGA

Correction for Chemically Bound Water Calculation

[0050] TGA test was conducted on pure cement powder and on each type of hemp powder and paste mixture according to the procedure introduced above. The weights of pure cement powder at 105° C. and 1100° C. are denoted as C.sub.1 and C.sub.2, respectively. The weights of hemp powders at 105° C. and 1100° C. are denoted as H.sub.1 and H.sub.2, respectively. The weights of cement paste mixtures at 105° C. and 1100° C. are denoted as W.sub.1 and W.sub.2, respectively. The loss on ignition of pure cement powder between 105° C. and 1100° C. is (C.sub.1−C.sub.2)/C.sub.1, denoted as L.sub.c. The weight loss percentage of hemp powders between 105° C. and 1100° C. is (H.sub.1−H.sub.2)/H.sub.1, denoted as L.sub.h. The weight loss of the tested cement paste between 105° C. and 1100° C. is calculated as shown in eq. (1).

W.sub.t=W.sub.1−W.sub.2  (1)

where W.sub.1 is the weight of cement paste at 105° C.; W.sub.2 is the weight of cement paste at 1100° C.

[0051] The weight loss of cement paste between 105° C. and 1100° C. (W.sub.t) includes several main parts: (1) decomposition of chemically bound water; (2) loss on ignition of cement powder used; (3) decomposition of hemp powders if involved; and (4) calcium carbonate decomposition. Therefore, to calculate chemically bound water, W.sub.t needs to be modified. It should be noted that the calcium carbonate decomposition correction is not considered because it is hard to be exactly quantified in this study. Therefore, the calculated degree of hydration should be a little bit higher than its real value, but it does not affect the comparative analysis of all samples. Other steps for weight correction of W.sub.t are shown as follows:

(1) Hemp Powder Decomposition Correction (W.SUB.h.)

[0052] For cement paste with hemp powders, W.sub.t needs to be modified by considering the decomposition of hemp powders. Assuming the total weight of hemp powders used in cement paste is H.sub.t. Based on the weight loss percentage of hemp powders between 105° C. and 1100° C., L.sub.h, the remaining weight of hemp powders incorporated into cement paste will be (1−L.sub.h)×H.sub.t when cement paste is heated to 1100° C. Because the weight of cement paste at 1100° C. is W.sub.2, the weight of ignited cement will be W.sub.2−(1−L.sub.h)×H.sub.t by excluding the remaining hemp powders. Based on the loss on ignition of pure cement powder, L.sub.c, the total weight of cement powder used will be deduced as [W.sub.2−(1−L.sub.h)×H.sub.t]/(1−L.sub.a). If the replacement percentage of cement powder with hemp powders is denoted as r, then the total weight of hemp powders used will be [W.sub.2−(1−L.sub.h)×H.sub.t]/[(1−L.sub.c)×(1−r)]. Finally, an equilibrium can be achieved as shown in eq. (2), by which H.sub.t can be solved (shown in eq. (3)). The total weight of cement powder used can be calculated by substituting H.sub.t into [W.sub.2−(1−L.sub.h)×H.sub.t]/(1−L.sub.a), as shown in eq. (4), which is denoted as C.sub.t. If no hemp powders are used in cement paste, the replacement content r is 0, then C.sub.t will be simplified into W.sub.2/(1−L.sub.c).

[00001]$\begin{array}{cc}\frac{\left[W_2-\left(1-L_h\right)\times H_t\right]\times r}{\left(1-L_c\right)\times \left(1-r\right)}=H_t& \left(2\right)\\ H_t=\frac{W_2\times r}{\left(1-L_h\right)\times r+\left(1-L_c\right)\times \left(1-r\right)}& \left(3\right)\\ C_t=\frac{W_2\times \left(1-r\right)}{\left(1-L_h\right)\times r+\left(1-L_c\right)\times \left(1-r\right)}& \left(4\right)\end{array}$

where H.sub.t is the total weight of hemp powders used in cement paste; C.sub.t is the total weight of cement powder used in cement paste; W.sub.2 is the weight of cement paste at 1100° C.; r is the replacement percentage of cement powder with hemp powders; L.sub.h is the weight loss percentage of hemp powders between 105° C. and 1100° C.; L.sub.c is the loss on ignition of pure cement powder (between 105° C. and 1100° C.).

[0053] Based on the total weight of hemp powders used in cement paste, H.sub.t, and the weight loss percentage of hemp powders between 105° C. and 1100° C., L.sub.h, the weight loss of hemp powders used in cement paste between 105° C. and 1100° C. can be obtained as shown in eq. (5), denoted as W.sub.h. W.sub.h is hemp powder decomposition correction content, which will be subtracted from W.sub.t for calculating chemically bound water if hemp powders involved.

W.sub.h=H.sub.t×L.sub.h  (5)

where W.sub.h is the weight loss of hemp powders used in cement paste between 105° C. and 1100° C.; H.sub.t is the total weight of hemp powders used in cement paste; L.sub.h is the weight loss percentage of hemp powders between 105° C. and 1100° C.

(2) Loss on Ignition Correction (W.SUB.1.)

[0054] Based on the loss on ignition of pure cement powder, L.sub.c, the weight loss of cement powder used between 105° C. and 1100° C. will be C.sub.t×L.sub.c as shown in eq. (6), denoted as W.sub.I. W.sub.l is the loss on ignition correction content, which will be subtracted from W.sub.t for calculating chemically bound water.

W.sub.l=C.sub.t×L.sub.c  (6)

where W.sub.l is the weight loss of cement powder used between 105° C. and 1100° C.; C.sub.t is the total weight of cement powder used in cement paste; L.sub.c is the loss on ignition of pure cement powder.

[0055] With the abovementioned correction, the chemically bound water (w.sub.b) of cement paste with hemp powders can be calculated by using eq. (7). FIG. 10 also schematically plots the correction procedure of weight loss of cement paste.

W.sub.b=W.sub.t−W.sub.l−W.sub.h  (7)

where W.sub.t is the total weight loss of cement paste between 105° C. and 1100° C.; W.sub.1 is loss on ignition correction, namely the weight loss of cement powder used between 105° C. and 1100° C.; W.sub.h is hemp powder decomposition correction, namely the weight loss of hemp powders used between 105° C. and 1100° C.

Degree of Hydration Calculation

[0056] For cement paste with hemp powders, the weight of ignited cement is corrected to be W.sub.2−(1−L.sub.h)×H.sub.t that has been introduced in “Hemp powder decomposition correction” section. The chemically bound water per unit gram of ignited cement then can be calculated by using W.sub.b/[W.sub.2−(1−L.sub.h)×H.sub.t], denoted as W.sub.bg. By substituting H.sub.t obtained in eq. (3) into W.sub.b/[W.sub.2−(1−L.sub.h)×H.sub.t], W.sub.bg can be obtained as shown in eq. (8). If no hemp powders are used in the paste mixtures, the replacement content r is 0, and then W.sub.bg will be simplified into W.sub.b/W.sub.2.

[00002]$\begin{array}{cc}{W}_{bg}=\frac{W_b\times \left[\left(1-L_h\right)\times r+\left(1-L_c\right)\times \left(1-r\right)\right]}{W_2\times \left(1-r\right)\times \left(1-L_C\right)}& \left(8\right)\end{array}$

where W.sub.bg is the chemically bound water per unit gram of ignited cement; W.sub.b is the chemically bound water of cement paste; W.sub.2 is the weight of cement paste at 1100° C.; r is the replacement percentage of cement powder with hemp powders; L.sub.h is the weight loss percentage of hemp powders between 105° C. and 1100° C.; L.sub.c is the loss on ignition of pure cement powder (between 105° C. and 1100° C.).

[0057] For completely hydrated Type I Portland cement, the chemically bound water per unit gram of ignited cement ranges from 0.23-0.25 (Pane and Hansen 2005). In this study, 0.25 is adopted. Therefore, the degree of hydration (DoH) can be calculated by using W.sub.bg divided by 0.25, as shown in eq. (9). If no hemp powders are used in paste mixtures, the replacement content r is 0, and then DoH will be simplified into W.sub.b/(0.25×W.sub.2).

[00003]$\begin{array}{cc}DoH=\frac{W_b\times \left(\left(1-L_h\right)\times r+\left(1-L_c\right)\times \left(1-r\right)\right)}{0.25\times W_2\times \left(1-r\right)\times \left(1-L_c\right)}& \left(9\right)\end{array}$

where DoH is degree of hydration of cement paste; W.sub.b is the chemically bound water of cement paste; W.sub.2 is the weight of cement paste at 1100° C.; r is the replacement percentage of cement powder with hemp powders; L.sub.h is the weight loss percentage of hemp powders between 105° C. and 1100° C.; L.sub.c is the loss on ignition of pure cement powder (between 105° C. and 1100° C.).

Results and Discussion

Thermogravimetric Analysis on Hemp Powders

[0058] The TGA test has been applied to various types of hemp powders as listed in Table 1. The TGA results on fine hemp powders (PU, PTN, and PTW) and coarse hemp powders (RU, RTN, RTW) are shown in FIG. 2(a) and FIG. 2(b), respectively. For each figure, the weight loss and the weight loss rate (denoted as derivative weight (%/min)) are plotted.

[0059] In both figures, it can be seen that there is a large weight loss between 200 and 300° C., which is indicative of high hemicellulose content (Lv et al. 2010; Yang et al. 2007). Even a clear shoulder peak at 200-300° C. exists in DTGA curves for both figures, which is mainly attributed to the decomposition of hemicellulose (Wang et al. 2016). Between 200 and 300° C., the weight losses of PU, PTN, and PTW are 22.53%, 17.35%, and 16.04%, respectively, and the weight losses of RU, RTN and RTW are 21.87%, 17.00% and 15.18%, respectively, as shown in Table 5. Compared to untreated hemp powders, for chemically treated hemp powders, the hemicellulose content decreases, and also the shoulder peaks in DTGA curves become less obvious. In addition, both PTW and RTW have much smoother DTGA curves at 200-300° C. than PTN and RTN. It can be attributed to the washing process after the chemical treatment that further removes hemicellulose. The weight loss of fine hemp powders is slightly more than that of the coarse hemp powders, which may be because fine hemp powders with the larger specific surface area are much easier to be decomposed than coarse hemp powders.

[0060] From both figures, a significant peak can be seen between 300 and 400° C. on the derivative weight curve, which is mainly due to the decomposition of cellulose (Yang et al. 2007). In this temperature range, the weight losses of PU, PTN, and PTW are 18.68%, 21.12% and 23.40%, respectively, and the weight losses of RU, RTN and RTW are 19.03%, 23.92% and 26.25%, respectively, as shown in Table 5. It can be seen that the weight loss of cellulose correlates to the weight loss of hemicellulose. That is because chemical treatment and washing process remove some hemicellulose, resulting in the increased relative content of cellulose. Bilba et al. reported that hemicellulose could be decomposed into saccharides in an alkali medium that can have a negative impact on cement hydration (Bilba et al. 2003). The TGA results indicate that the chemical treatment and the further washing process can assist the removal of hemicellulose, which is helpful to minimize the set delay effect of the hemp powders. By comparison of the weight losses, it is expected that the descending order of set delay effect is PU, PTN, and PTW for fine hemp powders, and RU, RTN, and RTW for coarse hemp powders. In addition, the set delay effect on the hydration of RU, RTN, and RTW is expected to be less than that of PU, PTN, and PTW, respectively, due to the smaller specific surface area.

TABLE-US-00005 TABLE 5 Weight loss (W.sub.L) of all types of hemp powders W.sub.L (%) Sample 200-300° C. 300-400° C. PU 22.53 18.68 PTN 17.35 21.12 PTW 16.04 23.40 RU 21.87 19.03 RTN 17.00 23.92 RTW 15.18 26.25

Isothermal Calorimetry and Thermogravimetric Analysis on Cement Pastes

[0061] Based on the calorimetric analysis, the heat evolution and heat evolution rate during hydration of Portland cement pastes without and with hemp powders are shown in FIG. 3(a) and FIG. 3(b), respectively. The hydration time corresponding to the peaks in FIG. 3(b) is listed in Table 6. The degree of hydration (DoH) of 7-day cement paste is calculated as summarized in FIG. 4.

[0062] From FIG. 3(b), two peaks next to each other (corresponding to C.sub.3S (the 1.sup.st peak from the left side) and C.sub.3A hydration (the 2.sup.nd peak), respectively) of the control sample can be clearly seen; however, for any other sample, the second peak disappears, showing the C.sub.3A hydration and ettringite conversion are much affected. This may be because saccharides from hemp powders prevent the formation of ettringite. It has been reported that saccharides influence the morphological evolution of hydrating aluminate particles, such as C.sub.3A (Smith et al. 2011). Moreover, the microstructure analysis introduced in this study shows the formation of needle-like ettringites is much influenced by hemp powders.

[0063] Compared to the control, FIG. 3(a) and FIG. 3(b) show that the heat evolution and heat evolution rate of other samples with hemp powders are all reduced, and Table 6 shows that the hydration time corresponding to the maximum peak of heat evolution rate curve increases (except for PU10 and PTN10). That indicates the addition of hemp powders in cement delays the hydration, which is supported by the reduced degree of hydration (DoH) at 7 days as shown in FIG. 4. For PU10 and PTN10, the heat evolution amount (FIG. 3(a)) is very low, and no peaks exist in their heat evolution rate curve (FIG. 3(b)). The calculated DoH values shown in FIG. 4 are very small. When 10% of the cement powder is replaced, the delay effect of hemp powders is so significant that the dormant period of the samples is very much extended.

[0064] The delay effect of hemp powders on cement hydration could be mainly due to the fact that some saccharides are possibly leached out (Vaickelionis and Vaickelioniene 2006). The delaying mechanism of saccharides for cement hydration has not been identified clearly, however, some possible reasons are proposed. One reason is that saccharides can form a complex with the metal ions present in the cement through chelation (Chakraborty et al. 2013a). A protective layer around the partially reacted cement grain is formed to prevent further hydration of cement, which can delay the nucleation and the growth of the hydrated products (Jo and Chakraborty 2015). The second reason may be that some saccharides are unstable in cement paste and can be degraded into some sugar acids, which can inhibit cement hydration (Kochova et al. 2017). The third possible reason can be that organic retarders have strong calcium binding capacity that can prevent the formation of calcium-silicate-hydrate (C-S-H) (Kochova et al. 2017).

TABLE-US-00006 TABLE 6 Hydration time corresponding to peaks of heat evolution rate curves Sample Peak 1 (h) Peak 2 (h) Control  9.91 12.45 PU5 65.72 — RTN5 20.01 — PTN5 36.64 — RTW5 15.74 — PTW5 18.01 — PU10 — — RTN10 65.15 — PTN10 — — RTW10 33.56 — PTW10 45.37 — Note: M-dashes indicate no peak

The Effect of Replacement Content on Cement Hydration

[0065] In this study, 5% and 10% hemp powders were used to replace cement, respectively. Since for cement pastes with any type of hemp powders, the effect of replacement content on cement hydration is similar, RTN incorporated cement pastes are taken as an example for analysis. The heat evolution and heat evolution rate of RTN incorporated cement paste with different replacement contents are shown in FIG. 5(a) and FIG. 5(b), respectively. It can be noted that compared to RTN5, the heat evolution and heat evolution rate of RTN10 is lower. Also, Table 6 and FIG. 4 show that with the increase of replacement content, the hydration time corresponding to the maximum peak of heat evolution rate curve increases, and the DoH value decreases. This is not only because higher replacement content can dilute cement and thus undoubtedly reduce the heat evolution, but also more hemp powders can be possibly decomposed to generate more saccharides in cement paste, inhibiting cement hydration.

The Effect of Treatment Method on Cement Hydration

[0066] In this study, different treatment methods were applied to hemp powders. The cement pastes with 5% fine hemp powders are taken as an example for analysis. FIG. 6(a) and FIG. 6(b) plot the heat evolution and heat evolution rate of the pastes with 5% fine hemp powders, respectively. PTN5 and PTW5 both have higher heat evolution amount and heat evolution rate than those of PU5, and PTW5 has the highest amount among the three. Moreover, the hydration time corresponding to the maximum peak of the heat evolution rate curve is reduced, and the corresponding DoH value is improved, as shown in Table 6 and FIG. 4, respectively. This indicates that compared to untreated hemp powders (PU), the addition of treated hemp powders (PTN or PTW) to cement paste can mitigate the delay effect on the hydration of cement. The reason can be after calcium hydroxide treatment, much hemicellulose, lignin, and other extractives that can be decomposed into saccharides are removed from hemp powders (Lu and Oza 2011; Sawpan et al. 2011). This is also confirmed by the TGA test on hemp powders in this research. Compared to non-washed treated hemp powders (PTN), the washing process after chemical treatment can further mitigate the delay effect on the hydration of cement, resulting in a higher degree of hydration for washed treated hemp powders (PTW). This can be attributed to the further removal of hemicellulose during the washing process. This can also be due to the removal of some remaining saccharides during washing.

The Effect of Hemp Powder Size on Cement Hydration

[0067] To study the size effect, cement pastes with 10% washed treated hemp powders are compared. The heat evolution and heat evolution rate of Portland cement paste with 10% washed treated hemp powders is shown in FIG. 7(a) and FIG. 7(b), respectively. It can be seen that compared to RTW10, PTW10 can lower the heat evolution amount and heat evolution rate. Moreover, Table 6 and FIG. 4 demonstrate that PTW10 has an increased hydration time corresponding to the maximum peak of the heat evolution rate curve and a lower DoH value, respectively. This indicates that the addition of fine hemp powders (PU, PTN, and PTW) can intensify the delay effect on the hydration of cement compared to coarse hemp powders (RU, RTN, and RTW). The possible reason may be that finer hemp powders (PU, PTN, and PTW) have higher specific surface area than coarse hemp powders (RU, RTN, and RTW), and they can be much easier to be dissipated in cement paste to produce saccharides, delaying the hydration of cement.

FTIR Analysis on Cement Pastes

[0068] The FTIR spectra of original Portland cement (OPC) and hydrated cement pastes at 7 days are shown in FIG. 8. There are four important regions that include water region (>1600 cm.sup.−1), carbonate region (1400-1450 cm.sup.−1), sulfate region (1100-1150 cm.sup.−1), and silicate region (<1000 cm.sup.−1) (Mollah et al. 2000). The FTIR spectral data of each region are shown in Table 7.

Water Region

[0069] From FIG. 8(a), it is shown that for OPC, there are no significant peaks in the water region. However, for all hydrated cement pastes (FIG. 8(b-1)), three important peaks appear in this region, and the corresponding spectral data are shown in Table 7. The first peak appears between 3612 and 3645 cm.sup.−1, which corresponds to the OH band from Ca(OH).sub.2 (Mollah et al. 2000; Ylmén et al. 2009). This is attributed to the hydration of C.sub.3S and C.sub.2S. The second peak appears between 3409 and 3435 cm.sup.−1, which corresponds to hydrogen-bonded OH species (OH—OH) adsorbed on the surfaces (Mollah et al. 2000). This is due to the symmetric and asymmetric stretching vibration (ν.sub.1 and ν.sub.3) of H.sub.2O in the hydrated cement paste (Chakraborty et al. 2013a; Choudhary et al. 2015; Ylmén et al. 2009). The third peak appears between 1641 and 1670 cm.sup.−1, which may be attributed to the bending vibration ν.sub.2 of water in sulphates, mainly gypsum (Ylmén et al. 2009).

Carbonate Region

[0070] For OPC, FIG. 8(a) does not show any significant peaks in the carbonate region. However, for all hydrated cement pastes (FIG. 8(b-1)), a peak between 1416 and 1425 appears, which is due to the reaction of atmospheric CO.sub.2 with the calcium hydroxide produced by cement hydration (Liu and Sun 2013).

Sulfate Region

[0071] The sulfates present in OPC are gypsum (CaSO.sub.4.2H.sub.2O), hemihydrate (CaSO.sub.4.0.5H.sub.2O) and anhydrite (CaSO.sub.4), and the sulfate region in FTIR spectrum is located between 1100-1150 cm.sup.−1, corresponding to the ν.sub.3 vibration of the SO.sub.4.sup.2− group in sulphates (Choudhary et al. 2015; Ylmén et al. 2009). FIG. 8(a) shows that two peaks (1143 cm.sup.−1 and 1126 cm.sup.−1 listed in Table 7) appear in the sulfate region of OPC, which may be because different forms of sulfates lead to different peaks. Upon hydration, these two peaks become one peak that is between 1114 and 1120 cm.sup.−1 for all hydrated cement pastes, as shown in FIG. 8(b-1) and Table 7. The shift of sulfate band towards a lower wavenumber is due to the formation of ettringite (Mollah et al. 2000).

Silicate Region

[0072] FIG. 8(a) shows that OPC has a significant peak at 917 cm.sup.−1 in the silicate region, which is due to Si—O asymmetric stretching vibration (ν.sub.3) of C.sub.3S and C25 phase (Choudhary et al. 2015). For hydrated cement pastes (except for PU10 and PTN110), this peak significantly shifts towards a higher wavenumber that is between 954 and 965 cm.sup.−1 as shown in Table 7. The shifting of the Si—O stretching vibration is indicative of the polymerization of silicate units (SiO.sub.4.sup.2−), with the formation of C-S-H phase as a result of cement hydration (Govin et al. 2006; Mollah et al. 2000; Peschard et al. 2004). However, FIG. 8(h) shows the silicate peak of PU10 does not shift and FIG. 8(i) shows the peak of PTN10 only shifts 6 cm.sup.−1, which may be because the degree of hydration for these two samples is so low that very few C-S-H is formed. This is confirmed by IC and TGA tests that PU10 and PTN10 are still in the dormant period after 7 days.

TABLE-US-00007 TABLE 7 FTIR spectral data for original portland cement and hydrated cement pastes Carbonate Sulfate Silicate Water region region region region Samples Peak 1 Peak 2 Peak 3 Peak 1 Peak 1 Peak 1 OPC — — — — 1143 & 1126 917 Control 3644 3419 1641 1424 1118 962 PU5 3643 3422 1650 1420 1119 961 PTN5 3644 3419 1648 1424 1117 960 PTW5 3644 3419 1658 1420 1120 965 RTN5 3644 3427 1657 1425 1115 961 RTW5 3645 3418 1649 1420 1118 964 PU10 3626 3409 1670 1424 1114 917 PTN10 3612 3414 1653 1419 1114 923 PTW10 3645 3435 1655 1422 1115 964 RTN10 3645 3423 1650 1421 1114 954 RTW10 3645 3419 1643 1416 1114 959 Note: M-dashes indicate no peak.

Microstructure

[0073] In order to examine the effect of untreated and chemically treated hemp powders on the microstructure of cement paste, the control, PU10, PTN10, and PTW10 samples at 7 days are taken as an example for analysis. In addition, the SEM image on unhydrated cement powders is also adopted to assist analysis. For unhydrated cement powders, some large irregular particles can be clearly seen, as shown in FIG. 9 (a). For the control cement paste, FIG. 9(b) shows that some needle-like ettringites and C-S-H are formed after cement hydration. For PU10, some large unhydrated cement particles and rod-like ettringites can be seen in FIG. 9(c). This could be due to large amounts of decomposition products (most possibly much saccharides) of untreated hemp powders delaying the hydration of cement, as confirmed by TGA and IC tests in this study. Moreover, the seriously delayed cement hydration prevent the further development of rod-like ettringites into needle-like ettringites. It has been reported that at a very early stage, ettringites are formed as hexagonal rods, and the relatively slender ettringites can be observed with the hydration progress (Liu 2014). Also, Cody et al. reported that the presence of sugars can lead to the morphology of ettringites to be short thick hexagonal prisms rather than needles (Cody et al. 2001). For PTN10, many unhydrated cement particles are clearly shown in FIG. 9(d). Compared to PU10, PTN10 has some small needle-like ettringites instead of rod-like ettringites on the surface, which indicates that some needle-like ettringites start to form. The reason may be chemically treated hemp powders have fewer saccharides inside, which makes the hydration of cement less delayed. For PTW10, although a small quantity of unhydrated cement particles can still be identified, they are not obvious in FIG. 9(e). Compared to PU10 and PTN10, more hydration products are formed, and the hydration of PTW10 seems to be the least delayed.

CONCLUSIONS

[0074] In this research, untreated and calcium hydroxide treated hemp powders were used to partially replace cement. Compared to pure cement paste, IC test shows that the incorporation of hemp powders in cement paste can reduce heat evolution amount and slow down heat evolution rate; also, the degree of hydration (DoH) calculated based on TGA test matches the IC results. This confirms the delayed effects of hemp powders on cement hydration. SEM analysis shows that the formation of hydration products are significantly influenced if hemp powders are involved.

[0075] The research also shows that the 10% replacement content delays the hydration of cement significantly. Particularly, for PU10 (untreated fine powders) and PTN10 (treated but non-washed fine powders) samples, the hydration is almost completely inhibited, and the degree of hydration is significantly low compared to others (e.g. 5% replacement). This indicates that 10% is the limit replacement if hemp powders are used.

[0076] Compared to the pastes with untreated hemp powders, treated hemp powders can reduce the delay effect when used. Also, the washed treated hemp powders had the minimum delay effect on cement hydration. The reduced delay effect may be attributed to the fact that much hemicellulose is removed after calcium hydroxide treatment and washing process, as confirmed by TGA test in this study.

[0077] In addition, the study also shows that fine hemp powders can delay the hydration of cement paste more than coarse hemp powders, which can be attributed to the higher specific surface area of fine hemp powders that can be easily decomposed into saccharides to delay the hydration of cement.

[0078] Generally, regardless of replacement content, treatment method, and hemp powder size, the delaying effect of hemp powders on cement hydration is clear, which can reduce the mechanical properties of cementitious materials significantly. However, hemp powders can be useful in serving as powder-type retardation agents to adjust cement hydration rate as needed, particularly in some extreme occasions where rapid hydration needs to be avoided.

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[0123] While the invention has been described in terms of its preferred embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the appended claims. Accordingly, the present invention should not be limited to the embodiments as described above, but should further include all modifications and equivalents thereof within the spirit and scope of the description provided herein.