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New mathematical modelling for grain size distribution adjustment in

concrete

Article in Cerâmica · January 2019

DOI: 10.1590/0366-6913201965s12567

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Caroline Moraes Cruz Eduardo Morais

University of São Paulo São Paulo State University
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 Cerâmica 65 (2019) Suppl.1 54-57 http://dx.doi.org/10.1590/0366-6913201965S12567 54

New mathematical modelling for grain size distribution

adjustment in concrete
C. M. Cruz1*, E. M. Morais2, R. H. F. Grillo3, C. D. Roveri4, S. C. Maestrelli4
1
University of São Paulo, FZEA, Av. Duque de Caxias Norte 225, Pirassununga, SP, Brazil
2
Institute for Theoretical Physics, UNESP, São Paulo, SP, Brazil
3
Federal Institute of Sul de Minas, Pouso Alegre, MG, Brazil
4
Federal University of Alfenas, Poços de Caldas, MG, Brazil

Abstract

Concrete used in civil engineering is a composite obtained from the combination of coarse and fine aggregates, cement and water,
and its cost and quality are normally associated to the proportion of its constituents (ceramic formulation), as well as the reduction
of water consumption. The aggregates used in concrete may have diverse origins, and the syenite extracted at Pedra Branca Alkaline
Massif is one of the materials that can be used for this substitution. In order to do so, a reference formulation of concrete was
calculated and optimized using the mathematical models of Andreasen, and syenite was added substituting 25, 50, 75 and 100% of the
fine aggregate. In order to maintain the original granulometric distribution, an algorithm was developed to compensate the different
particle size distributions. The grain size correction guaranteed the maintenance of the original properties of the concrete, reaching
values of mechanical strength above 35 MPa.
Keywords: concrete, packing equations, algorithm, syenite, mechanical properties.

INTRODUCTION as an attempt of diminishing the impact of urbanization on the

environment, has led to several researches on the incorporation
Concrete is one of the cheapest and most easily produced of disposals in concrete, such as tire rubber, coal ashes and
materials in the world, besides being one of the most common casting sand [6-8]. Syenite is an igneous rock with high levels
structural materials. Concrete may be considered a composite, of sodic and potassic feldspars, which may contain 80% to
in which the matrix is formed by the combination of cement 95% of feldspars and feldspathoids in its totality [9]. The
and water, in order to form a binder, and the reinforcement is syenite from ‘Maciço da Pedra Branca’, in Minas Gerais State,
presented in the form of particulate and fragmented aggregates, Brazil, has been used as ornamental rocks due to its brown
from which natural sand, gravel, boulder, hail, among others, color resulting from the mineralogical composition. Due to the
can be highlighted [1, 2]. The aggregates may be classified low exploitation during its extraction, this material is currently
as coarse or fine. Coarse aggregates refer to the material with being accumulated in the environment; thus, it was evaluated
a grain size larger than 4.75 mm (sieve 4 mesh). The fine for the substitution of fine gravel in concretes.
aggregate, together with the binder system (cement and water), The adequate formulation of concretes, resulting in
forms the mortar, while with the coarse aggregates concrete is efficient packing of its particles, exerts a direct effect in many
formed [1]. The choice of the aggregate is important, since it of its properties. In the case of concretes, as well as structural
has an impact in cost and workability of the fresh concrete, and ceramics, electronics, nuclear and powder metallurgy, for
may also influence mechanical strength, dimensional stability, example, it is desirable that the product presents a dense
and durability of the hardened concrete. The granulometric packing [5]. There are several models to determine the
distribution affects directly the workability of the concrete, ideal packing of particles. The purpose of this work was to
seeing that it is directly linked to particle packing [1, 3]. In develop a formulation of concrete using Andreasen’s model
addition, the roundness of the particles must also be considered, and, subsequently, substitute fine gravel by syenite. Since
i.e. the relative sharpness or the angularity of the edges and/or fine gravel and syenite had different grain size distributions,
corners of a particle [4]. The rounder the particle, the better an algorithm was developed in order to keep the original
its packing in the mix. However, a higher roughness of the distribution as determined by Andreasen’s equation.
aggregate surface and angularity of the edges/corners may lead
to better anchoring between the particles; thus, there must be MATERIALS AND METHODS
an equilibrium in order to have good particle packing, but also
fine anchoring [5]. Andreasen’s method: this model considers the particle
The scarcity of some raw materials such as sand, as well distributions as continuous. In his model, in an ideal particle
packing, the neighborhood of two specific particles with
*[email protected] very different sizes presents conditions of similarity, which
https://orcid.org/0000-0001-5712-4766 defines the grain size distribution in terms of a power law, as
55 C. M. Cruz et al. / Cerâmica 65 (2019) Suppl.1 54-57

indicated in Eq. A [5]:

W = P -B + w (B-S )
(H)
V = C -B + w (B-S )
Dp
CPFT= .100 (A) Minimizing Eq. G leads to:
DL
∂O2
=2a W1
2
W1 = 0 (I)
∂a
in which CPFT is the accumulated percentage of particles
smaller than Dp, Dp is the particle diameter, DL is the diameter Thus, the optimum proportion of fine gravel is:
of the larger particle and q is the module or distribution
coefficient. The Andreasen distribution with better possible W1 V1
packing is, theoretically, the one using q=0.37 [5]. a= (J)
W1
2
Algorithm: given a determinate reference formulation of
concrete, composed by fine and coarse gravel, it is desirable
the use of disposal to replace a determinate proportion of fine and the optimum proportions of coarse gravel and
gravel, keeping the grain size distribution of the concrete as substituting material may be calculated by Eq. F.
close as possible to the original distribution as calculated using Experimental: it was used as raw materials gravel in
the packing equation of Andreasen. Grain size distribution grains and powder from Pouso Alegre region as coarse and
curves of all compounds must be taken in the same sieves, and fine aggregates, respectively, syenite from Pedra Branca
with the same quantity N of sieves, and they are represented Alkaline Massif, cement type CP II-E 32 (Holcim Brazil)
by vectors containing the cumulative distribution. Consider and superplasticizer additive Glenium 51 (Basf), with
CS the cumulative grain size distribution of the reference density of 1067 to 1107 kg/m³. Initially, the aggregates were
concrete; the same way, P is the distribution of fine gravel, classified according to their physical properties, through
B is the one for coarse gravel and S is the distribution for the determination of bulk density, solid bulk density, water
the substituting material. Thus, the distribution of the concrete absorption and apparent porosity using the Archimedes’
containing the substituting material is: method. The grain size distribution of the aggregates was
determined using sieves with openings between 25 and
CS= aP + bB + gS (B) 0.15 mm for the coarse aggregate and between 9.5 and
0.15 mm for the fine aggregates. It was also performed
in which the coefficients α, β, and γ designate the proportions semiquantitative chemical analysis by X-ray fluorescence
of fine gravel, coarse gravel and substituting material, and determined the pH for each aggregate.
respectively. These variables must respect the constraint: The reference formulation of the concrete, denominated
C1, was calculated using the equation of Andreasen. The
α+β+γ=1 (C) amount of cement used was calculated in order to obtain
mechanical strength of 35 MPa after 28 days [10]. It was
reducing one degree of freedom of the optimization calculated four formulations with the substitution of fine
problem. The proportion of substitution ω is pre-determined gravel by syenite, in the proportions of 25% (C1-25), 50%
so that the engineer has total control in order to minimize (C1-50), 75% (C1-75) e 100% (C1-100). The proportion
production cost or maximize logistical advantages in the of the aggregates was determined using the algorithm
supply of raw materials. It is defined as: previously detailed, using as a target the accumulated
g g grain size distribution of formulation C1. The formulations
=
b+g 1-a (D) obtained are listed in Table I. The content of additive was
w=
fixed at 0.4 wt% of cement, due to good results presented in
which supply another constraint to the optimization problem, [10], and the water content was determined at the moment
diminishing another degree of freedom of the problem. To of mixing, in order to obtain a self-compacting concrete.
optimize, it was used the method of ordinary least squares: For each formulation, it was analyzed the properties in
the fresh and hardened state. For the fresh concrete, it
02= N
i=1 (CSi- Ci )2= N
i=1
(aP1 + bB1+gS1 - Ci )2 (E) was performed a visual analysis of the cohesion through
a slump test, according to Brazilian standard NBR NM 67
Using Eqs. B and C to rewrite β and γ in terms of α: [11]. Then, cylindrical specimens of 0.01 m in diameter
b = (1-a)(1-w) and 0.02 m in height were prepared for evaluation of
(F) compressive strength of the hardened concrete. For each of
g = (1-a)w
the formulations analyzed, 6 specimens were prepared for
the least squares sum may be written as: each age (7, 14 and 28 days). After 24 h of casting, curing
was made through the immersion of the specimens in water
W1 V1 a2 W1
2
W1 (G) with an average temperature of 21 °C until evaluation
of compressive strength. Preparation of specimens and
being W1and V1 elements of vectors defined by: evaluation of compressive strength were performed
 C. M. Cruz et al. / Cerâmica 65 (2019) Suppl.1 54-57 56

Table I - Concrete formulations (kg) with syenite additions. Table III - Physical properties of the aggregates.
Raw material C1 C1-25 C1-50 C1-75 C1-100 Bulk Solid bulk Water Apparent
Coarse gravel 40.383 40.463 40.149 39.893 39.701 Material density density absorption porosity
Fine gravel 35.112 26.274 17.673 8.901 - (kg/m³) (kg/m³) (%) (%)
Syenite - 8.758 17.673 26.702 35.794 Gravel 2570 2590 0.35 0.89
Cement 27.696 27.696 27.696 27.696 27.696 Syenite 2710 2780 0.91 2.46
Water 11.130 11.130 11.130 11.130 11.130
Additive 0.111 0.111 0.111 0.111 0.111 Table IV - Chemical composition (wt%) and pH of
aggregates.
according to Brazilian standards NBR 5738:2015 [12] and Compound Gravel Syenite
NBR 5739:2007 [13].
Loss on ignition 2.71 0.58
RESULTS AND DISCUSSION Al2O3 19.79 14.15
SiO2 54.44 55.08
Aggregate characterization: the accumulated grain
TiO2 0.75 2.95
size distribution data of syenite may be seen in Table II,
comparatively with those of coarse and fine gravels. The Fe2O3 3.72 4.65
results of the physical tests are presented in Table III. It CaO 2.09 5.75
can be seen that the grain size distribution of syenite was MgO 0.48 2.61
different from that of the fine gravel, being distributed in a
larger range of diameters, and with a lower fraction of fines. Na2O 7.32 3.14
This factor may contribute to concrete segregation and K 2O 7.41 7.79
lower mechanical strength. It was noted density difference F - 1.02
between fine gravel and syenite, so it was expected that
P2O5 0.08 0.87
the concrete with syenite could present increasing values
of density as the level of syenite increased. However, the BaO 0.23 0.50
higher porosity of the syenite may lead to higher water SrO 0.20 0.44
consumption in the concrete, which can lower its final
ZrO2 0.12 0.12
mechanical strength.
Results of chemical analysis and pH evaluation can MnO 0.27 0.10
be seen in Table IV. The chemical compositions of both SO3 0.08 0.08
materials presented differences as well; such differences Cr2O3 - 0.06
may impact directly the deflocculating process of the
material. For example, the SiO2:Na2O relation in the gravel Nb2O5 0.03 0.05
Cs2O 0.25 -
ZnO 0.02 -
Table II - Accumulated grain size analysis of the aggregates.
Au - 0.05
Opening Coarse Fine gravel Syenite
Y2O3 - 0.01
(mm) gravel (%) (%) (%)
pH 9.60 10.14
25.00 0.00 0.00 0.00
19.00 1.59 0.00 0.00 was 7.43, while in syenite was 17.54. This difference
12.50 50.47 0.00 0.78 may affect the required amount of water and/or additive,
9.50 80.87 0.00 1.84 interfering in the final properties of the concrete [14]. pH
also has its influence, and the change may lead to concrete
6.30 97.03 0.04 4.22
segregation depending on the amount of additive used.
4.80 99.09 0.29 6.73 Cohesion evaluation: for all formulations, cohesion
2.40 99.82 15.07 23.15 was visually analyzed. The appearance of the material may
1.20 99.82 36.33 41.32 be seen in Fig. 1. From these images, it can be noted that
keeping the same level of water, there was no segregation in
0.60 99.82 59.81 56.50 the concretes due to the adjustment made with the algorithm.
0.30 99.82 90.86 72.32 It was possible to substitute 100% of fine gravel by syenite,
0.15 99.82 97.97 87.18 which could have caused segregation in levels superior to
50%, as observed in [15].
Pan 100.00 100.00 100.00
Compressive strength: compressive strength results may
 57 C. M. Cruz et al. / Cerâmica 65 (2019) Suppl.1 54-57

a) b) c) the grain size distribution. It affects the required water and

concrete cohesion, which have a direct impact on mechanical
strength. This was proved by the values of compressive
strength found after 28 days: the expected value of
compressive strength according to the cement dosage used
d) e) was 35 MPa, and values 27% to 47% higher were found for
all formulations tested. All formulations analyzed presented
good properties for concrete, such as good cohesion and
mechanical strength, resulting possibly in the reduction of
cost with the increase of syenite content.

Figure 1: Cohesion evaluation for formulations: a) C1; b) C1-25; c) ACKNOWLEDGMENTS

C1-50; d) C1-75; and e) C1-100.
The authors are thankful to FAPEMIG and CAPES-
Brazil for the financial support for this work.
Cold crushing strength (MPa)

C1 C1-25 C1-50 C1-75 C1-100

55
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45
40
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