BASALTIC LAVA FOR PRODUCING GREEN CONTROLLED LOW STRENGTH MATERIAL (CLSM)

Abstract

Disclosed is a composition for a Controlled Low Strength Material (CLSM) including cementitious materials, water, and fine aggregate. The cementitious materials include powdered basaltic lava and Ordinary Portland Cement (OPC). In the composition, the basaltic lava replaces some of the ordinary Portland cement in the CLSM as compared to a conventional CLSM. The basaltic lava replaces 25% to 90% of the OPC in a conventional CLSM. The CLSM can be used as a compacted fill for structural and non-structural construction applications.

Claims

1. A controlled low strength material (CLSM) having reduced environmental impact, the CLSM comprising: a first fine aggregate comprising sand; a second fine aggregate comprising limestone; a water; and a cementitious material, wherein the cementitious material comprises ordinary Portland cement (OPC) and powdered basaltic lava; wherein the ratio of OPC to powdered basaltic lava is selected to produce a compressive strength equal to or below a target compressive strength.

2. The CLSM of claim 1, wherein the powdered basaltic lava has a composition comprising between 35 to 45 wt % SiO.sub.2, between 7 to 18 wt % Al.sub.2O.sub.3, between 12 to 23 wt % Fe.sub.2O.sub.3, and between 6 to 17 wt % CaO.

3. The CLSM of claim 1, wherein the CLSM comprises between 10.5 wt % powdered basaltic lava and 14.5 wt % powdered basaltic lava.

4. The CLSM of claim 1, wherein the ratio of OPC to powdered basaltic lava is in the range of 1:3 to 1:9.

5. The CLSM of claim 1, wherein the powdered basaltic lava is gathered from Saudi Arabia.

6. The CLSM of claim 1, wherein the second fine aggregate is sized between 2.38 mm and 4.75 mm.

7. The CLSM of claim 1, wherein the target compressive strength is a 28 day compressive strength of 8.3 MPa.

8. The CLSM of claim 1, wherein the target compressive strength is a 28 day compressive strength of 2.1 MPa.

9. A controlled low strength material (CLSM) having reduced environmental impact, the concrete material consisting essentially of: a first fine aggregate comprising sand; a second fine aggregate comprising limestone; water; and a cementitious material, wherein the cementitious material comprises ordinary Portland cement (OPC) and powdered basaltic lava; wherein the ratio of OPC to powdered basaltic lava is selected to produce a compressive strength equal to or below a target compressive strength.

10. The CLSM of claim 9, wherein the CLSM comprises between 10.5 wt % powdered basaltic lava and 14.5 wt % powdered basaltic lava.

11. The CLSM of claim 9, wherein the ratio of OPC to powdered basaltic lava is in the range of 1:3 to 1:9.

12. The CLSM of claim 9, wherein the second fine aggregate is sized between 2.38 mm and 4.75 mm.

13. The CLSM of claim 9, wherein the target compressive strength is a 28 day compressive strength of 8.3 MPa.

14. The CLSM of claim 9, wherein the target compressive strength is a 28 day compressive strength of 2.1 MPa.

15. A method for forming a concrete material having reduced environmental impact, the method comprising the step of: mixing together constituent materials to form a controlled low strength material (CLSM), the constituent materials comprising: a first fine aggregate comprising sand; a second fine aggregate comprising limestone; a water; and cementitious materials, wherein the cementitious material comprises ordinary Portland cement (OPC) and powdered basaltic lava; wherein the ratio of OPC to powdered basaltic lava is selected to produce a compressive strength equal to or below a target compressive strength.

16. The method of claim 15, wherein the CLSM comprises between 10.5 wt % powdered basaltic lava and 14.5 wt % powdered basaltic lava.

17. The method of claim 15, wherein the ratio of OPC to powdered basaltic lava is in the range of 1:3 to 1:9.

18. The method of claim 15, wherein the second fine aggregate is sized between 2.38 mm and 4.75 mm.

19. The method of claim 15, wherein the target compressive strength is a 28 day compressive strength of 8.3 MPa.

20. The method of claim 15, wherein the target compressive strength is a 28 day compressive strength of 2.1 MPa.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] These and other features, aspects, and advantages of the present disclosure will become better understood with regard to the following descriptions, claims, and accompanying drawings. It is to be noted, however, that the drawings illustrate only several embodiments of the disclosure and are therefore not to be considered limiting of the scope as it can admit to other equally effective embodiments.

[0014] FIG. 1A is a photograph of pyroclastic cones in lava fields which can be a source of material, according to an embodiment.

[0015] FIG. 1B is a photograph of pyroclastic cones in lava fields which can be a source of material, according to an embodiment.

[0016] FIG. 2 is a photograph of a scanning electron microscope (SEM) result from raw basaltic lava, according to an embodiment.

[0017] FIG. 3 is a photograph of basaltic lava powder after grinding, according to an embodiment.

DETAILED DESCRIPTION

[0018] While the disclosure will be described with several embodiments, it is understood that one of ordinary skill in the relevant art will appreciate that many examples, variations and alterations to the systems and methods described are within the scope and spirit of the disclosure. Accordingly, the embodiments of the disclosure described are set forth without any loss of generality, and without imposing limitations, on the claims.

[0019] The terms comprising, including, having, and the like, as used with respect to embodiments of the present disclosure, are synonymous and are each intended to have an open, non-limiting meaning that does not exclude additional elements or steps. In this disclosure the terms about and approximately can include a deviation of 5% of the given value unless the deviation changes the nature or effect of the value such that it is not operable to achieve its intended purpose. The terms optional or optionally mean that an element can be used for some embodiments, but can be omitted in other embodiments. The singular forms a, an, and the include plural referents, unless the context clearly dictates otherwise.

[0020] Compositions, methods of generation, and methods of use are provided for a CLSM made with natural materials. Specifically, a CLSM generated with powdered basaltic lava which replaces a portion of the cementitious material is disclosed. The powdered basaltic lava is a natural material that replaces a portion of the OPC in the mixture, thus reducing the negative environmental impact of the CLSM.

[0021] The CLSM disclosed herein provides numerous benefits over conventional CLSM. Advantageously, basaltic lava is generally inexpensive, widely available in portions of the world, and can be utilized in areas where conventional fly ash is not widely available or where conventional fly ash production is diminishing. The present CLSM utilizes less OPC than conventional CLSM, which also reduces costs and decreases the negative environmental impact. The use of natural basaltic lava also reduces the greenhouse gas emissions of CLSM, since OPC production generates large quantities of greenhouse gases. Additionally, the CLSM of the present invention does not utilize fly ash, which in some parts of the world may be banned due to the negative environmental impact. Basaltic lava is free of many hazardous materials, such as crystalline silica, which may be found in other CLSM additives or components.

[0022] Beneficially, the powdered basaltic lava utilized in the embodiments disclosed herein is not processed outside of grinding and optionally sieving, and the powdered basaltic lava does not require any heat treatment. The addition of basaltic lava to CLSM advantageously reduces bleeding and segregation considerably. The use of powdered basaltic lava also reduces the heat of hydration, which can reduce the likelihood of thermal cracking and is advantageous for large CLSM applications. Additionally, it has been found to be easier to control the strength gain of CLSM when utilizing powdered basaltic lava than when utilizing fly ash or only OPC.

[0023] To be considered a CLSM, once cured, the mix must not have an unconfined compressive strength exceeding 8.3 MPA (1200 psi). However, excavatable CLSM generally has an unconfined compressive strength that does not exceed 2.1 MPa (300 psi). Additionally, CLSM must have a flow spread diameter of more than 200 mm to be classified as a CLSM. CLSM must generally have a hardening time of less than or equal to 12 hours, a bleeding rate of less than or equal to about 5%, and a segregation rate of less than or equal to about 15%.

[0024] As used herein, powdered basaltic lava is a powdered form of volcanic rock. Basaltic lava is widely available around the world. Basaltic lava is also widely available on the coast of the Red Sea in the western region of Saudi Arabia. In some embodiments, the basaltic lava is gathered from the Red Sea coast in the western region of Saudi Arabia. Referring to FIG. 1A, a photograph is provided of pyroclastic cones of lava fields on the coast of the Red Sea, which can be a source of basaltic lava which can then be processed into powdered basaltic lava and utilized in embodiments disclosed herein. Referring to FIG. 1B, a second photograph is provided of different pyroclastic cones of lava fields on the coast of the Red Sea, which can be a source of basaltic lava which can then be processed into powdered basaltic lava and utilized in embodiments disclosed herein.

[0025] Referring to FIG. 2, a photograph of the result of an SEM of basaltic lava powder after grinding is provided, showing the irregular shape and size of the material. Referring to FIG. 3, a photograph of basaltic lava powder after grinding is provided. To generate the powdered basaltic lava, raw basaltic lava aggregate or fines in various sizes are collected. The raw basaltic lava aggregate or fines are ground in grinders known in the art to the fineness required for the intended purpose. The ground powder can be sieved. In the present disclosure, the powdered basaltic lava is a mixture of various shapes and sizes of particles, like what is shown in FIG. 2. The powdered basaltic lava has an irregular morphology and primarily consists of non-spherical particles. In some embodiments, the powdered basaltic lava has a specific surface area of about 442 m.sup.2/kg and an average particles size of about 30 m.

[0026] The powdered basaltic lava is a natural pozzolan. Pozzolans are siliceous and aluminous materials which in their natural form are not cementitious or exhibit little cementitious value, but, when powdered and added to water, react chemically with calcium hydroxide to form compounds with cementitious properties. Natural pozzolans are naturally occurring or are derived directly from naturally occurring deposits, and are not generated by industrial or chemical processes.

[0027] Artificial pozzolans are man-made in industrial or chemical processes, are usually generated through heat treatment, and are not derived from naturally occurring materials. Artificial pozzolans can include fly ash, blast furnace slag, silica fume, and other industrial by-products. Both natural and artificial pozzolans have variable compositions and chemical characteristics. Thus, pozzolans cannot simply be substituted one for one in cementitious mixtures due to their varying characteristics. The oxide quantities of SiO.sub.2, Al.sub.2O.sub.3, and CaO vary between artificial and natural pozzolans, and between types and sources of pozzolans. For example, blast furnace slag can have a SiO.sub.2 content of between about 20 to about 35 wt % and a CaO content of about 28 to about 40 wt %, fly ash can have a SiO.sub.2 content of between about 50 to about 55 wt % and an Al.sub.2O.sub.3 content of between about 25 to about 30 wt %, and silica fume can have a SiO.sub.2 content of between about 85 to about 98 wt %.

[0028] In contrast, the powdered basaltic lava in the embodiments disclosed herein can have between about 35 to about 45 wt % SiO.sub.2, between about 7 to about 18 wt % Al.sub.2O.sub.3, between about 12 to about 23 wt % Fe.sub.2O.sub.3, between 6 about to about 17 wt % CaO, between about 3 to about 14 wt % MgO, between about 0 to about 7 wt % K.sub.2O, between about 0 to about 9 wt % Na.sub.2O, between about 0 and about 5 wt % P.sub.2O.sub.5, and between about 0 and about 5 wt % TiO.sub.2. The powdered basaltic lava can have the chemical composition and loss on ignition (LOI) value shown in Table 1:

TABLE-US-00001 TABLE 1 Chemical Composition of Basaltic Lava Compound SiO.sub.2 Al.sub.2O.sub.3 Fe.sub.2O.sub.3 CaO MgO K.sub.2O Na.sub.2O P.sub.2O.sub.5 TiO.sub.2 LOI Weight % 40.48 12.90 17.62 11.83 8.33 1.67 3.60 1.37 0.60 1.6

[0029] The basaltic lava utilized in the present disclosure can have the physical properties shown in Table 2:

TABLE-US-00002 TABLE 2 Physical Properties of Basaltic Lava Property Value ASTM C 618 Fineness: Amount Retained 3.798 34 (max) when wet-sieved on 45-m (No. 325) Sieve, Max, % Strength Activity Index: with 80.14 75 (min) OPC, at 7 days, Min 5 of Control Water Requirement, Max, 5 of 105 115 (max) Control Soundness: Autoclave 0.274 0.8 (max) Expansion or Contraction, Max, 5

[0030] The present CLSM comprises a first fine aggregate substantially containing sand, cementitious materials including OPC, powdered basaltic lava, water, and a second fine aggregate substantially containing limestone. Basaltic lava is utilized as a portion of the present CLSM binder, partially replacing the OPC in the mixture. The present CLSM utilizes less OPC than a comparable conventional CLSM that does not contain powdered basaltic lava. In other words, the powdered basaltic lava replaces some of the OPC in the CLSM to generate the present mixture. In some embodiments, the basaltic lava replaces between approximately 25% to approximately 90% of the OPC in a conventional CLSM. In some embodiments, the 25% substitution of OPC by the powdered basaltic lava resulted in an improvement of both fresh and hardened properties. In some embodiments, the basaltic lava replaces between approximately 75% to approximately 90% of the OPC in a conventional CLSM. In some embodiments, the CLSM can have between 10.5 wt % powdered basaltic lava and 14.5 wt % powdered basaltic lava. In some embodiments, the CLSM can have between 10.5 wt % powdered basaltic lava and 12.5 wt % powdered basaltic lava. The ratio of the OPC to the powdered basaltic lava in the range of 1:3 to 1:9. The ratio of OPC to powdered basaltic lava can be selected such that the CLSM has a compressive strength equal to or below a target compressive strength.

[0031] The first fine aggregate substantially contains sand, which can be dune sand. The sand can primarily contain quartz. The first fine aggregate is able to pass through a #4 (4.75 mm) sieve. The first fine aggregate can have a particle size less than or equal to about 4.75 mm. The second fine aggregate substantially contains limestone. The second fine aggregate is able to pass through a #4 (4.75 mm) sieve. The second fine aggregate can have a particle size in the range of about 2.38 mm to 4.75 mm. In some embodiments, the second fine aggregate is about 2.38 mm in size. In some embodiments, the second find aggregate is sourced from limestone quarries in Saudi Arabia.

[0032] In order to form the CLSM, the constituents of the CLSM can be batched in stationary concrete batch plants in general conformance with ASTM C94, or mixed in mobile volumetric mixing plants in accordance with ASTM C685. In each case, there may be necessary adjustment or modifications to the plant fixtures or process to allow for introducing the HOFA and recycled concrete powder or recycled concrete aggregates in accurately-measured amounts.

Experimental Example

[0033] A variety of experimental CLSM mixes were prepared utilizing powdered basaltic lava as a cementitious material. The powdered basaltic lava was utilized as a binder, replacing varying quantities of the OPC in the mixture. The mixtures vary in powdered basaltic lava and OPC quantities. References in the following tables to basaltic lava refer to powdered basaltic lava. Dune sand containing primarily quartz was utilized as the first fine aggregate, having a specific gravity of about 2.56 and a water absorption of about 0.5%. The second fine aggregate substantially containing limestone was sized between 2.38 mm and 4.75 mm.

[0034] The mixture composition can be shown in Table 3, below:

TABLE-US-00003 TABLE 3 Experimental Mixture Composition Mix # M0 M10 M15 M20 M25 OPC Percent of 100 10 15 20 25 Cementitious Material, % OPC, kg/m.sup.3 110 40 60 80 100 Basaltic Lava, 0 360 340 320 300 kg/m.sup.3 OPC 0 90 85 80 75 Replacement, % Percent 0 12.5 11.9 11.4 10.8 Basaltic Lava in Total Mixture, % Water, kg/m.sup.3 310 337 337 337 337 First Fine 1066 1290 1266 1242 1218 Aggregate, kg/m.sup.3 Second Fine 711 860 844 828 812 Aggregate, kg/m.sup.3 OPC to N/A 1:9 3:17 1:4 1:3 Basaltic Lava (approximately Ratio 1:5.7)

[0035] M0 is a control mixture which shows a typical concrete mix. The OPC Replacement percent refers to the amount of OPC replaced by the powdered basaltic lava.

[0036] Table 4 shows the density of the experimental mixtures:

TABLE-US-00004 TABLE 5 Density of Mixtures OPC Percent of Unit Avg. unit Mix Cementitious Trial L, W, H, Weight, weight, weight, # Material, % # mm mm mm g kg/m.sup.3 kg/m.sup.3 M0 100% 1 50.7 51.3 50.7 260.2 1973 1971 2 51.2 50 51.5 262.9 1994 3 51.2 50.3 51.1 255.9 1945 M10 10% 1 51.3 55.6 50.9 285.7 1969 1998 2 52.6 49.6 51.2 272 2038 3 54.3 51.3 50.7 280.5 1988 M15 15% 1 51.7 50.4 52.3 278.2 2043 2023 2 51.3 51.5 52.7 279.8 2011 3 51.3 51.6 53.0 282.4 2015 M20 20% 1 49.3 52 52.9 273.2 2016 2044 2 50.2 50.5 53 279.8 2081 3 50.9 50.3 52.8 275 2036 M25 25% 1 50.2 49.7 51 270.3 2124 2088 2 50.7 50 49.9 260.9 2063 3 49.5 50.6 51.2 266.3 2077

[0037] The density of the experimental mixes were lower than the conventional concrete mixtures. Conventional concrete mixtures have wet mix densities that are generally in the range of 2200 to 2400 kg/m.sup.3.

[0038] Table 5 shows the compressive strength of the experimental mixtures:

TABLE-US-00005 TABLE 5 Compressive Strength of Mixtures Compressive Strength, MPa Mix # 3-Days 7-Days 28-Days M0 1.96 3.36 3.84 M10 0.47 0.51 1.12 M15 0.95 1.11 1.80 M20 1.03 2.01 2.71 M25 2.03 3.51 5.44

[0039] The M10 and M15 CLSM mixtures qualify as excavatable CLSM as their 28 day compressive strength is below 2.1 MPa. In the mixtures above, the compressive strength increased with increasing OPC content, such that the M20, M25, and M0 mixes are considered non-excavatable CLSM.

[0040] Table 6 shows the flow of the experimental mixtures:

TABLE-US-00006 TABLE 6 Flow of Mixtures Flow of CLSM, mm Mix # Run 1 Run 2 Run 3 Run 4 Avg. M0 203 201 197 205 202 M10 210 209 215 209 211 M15 209 213 215 212 212 M20 213 215 212 216 214 M25 214 217 215 218 216

[0041] CLSM must have a flow spread diameter of more than 200 mm to be classified as a CLSM. All of the experimental mixtures met the 200 mm minimum for flow required for CLSM. The experimental mixtures also showed favorable results in segregation.

[0042] Table 7 shows the bleeding and setting time of the experimental mixtures:

TABLE-US-00007 TABLE 7 Bleeding and Setting Time of Mixtures Mix # Bleeding % Initial Setting Time M0 4.44 7 hrs, 32 mins M10 1.39 7 hrs, 46 mins M15 1.45 6 hrs, 48 mins M20 1.57 6 hrs, 19 mins M25 1.69 6 hrs, 7 mins

[0043] All of the experimental mixtures met the 5% maximum bleeding percentage required for CLSM. Advantageously, the experimental mixtures with powdered basaltic lava had bleed rates significantly lower than the control mixture with 100% OPC. Lower bleeding rates are advantageous as mixtures with lower bleed rates have higher flowability and experience less segregation between the paste and aggregates. Additionally, bleeding rates affect the final yield of the mixture. Higher bleeding rates results in less volume and more settlement when the mixture is utilized in the field. Advantageously, the setting time of the experimental mixtures with powdered basaltic lava were lower than the control mixtures with 100% OPC. A 1.5 hour decrease in setting time is particularly advantageous in construction applications.

[0044] Embodiments of this disclosure, therefore, are well adapted to carry out the objects and attain the ends and advantages mentioned, as well as others that are inherent. While embodiments of the disclosure have been given for purposes of disclosure, numerous changes exist in the details of procedures for accomplishing the desired results. These and other similar modifications will readily suggest themselves to those skilled in the art, and are intended to be encompassed within the spirit of the present disclosure and the scope of the appended claims.