Materials and Design 31 (2010) 4039–4042

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Materials and Design

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Technical Report

Utilization of waste marble dust as an additive in cement production

_
Hüseyin Yılmaz Aruntasß a,*, Metin Gürü b, Mustafa Dayı a, Ilker Tekin c
a
Department of Construction, Faculty of Technical Education, Gazi University, Ankara 06500, Turkey
b
Department of Chemical Engineering, Faculty of Engineering, Gazi University, Ankara 06570, Turkey
c
Yatağan Vocational High School, Muğla University, Muğla 48500, Turkey

a r t i c l e i n f o a b s t r a c t

Article history: In this experimental study, the usability of waste marble dust (WMD) as an additive material in blended
Received 14 November 2009 cement has been investigated. For this purpose, waste marble dust added cements (WMDCs) have been
Accepted 22 March 2010 obtained by intergrinding WMD with Portland cement clinker at different blend ratios: 2.5%, 5.0%, 7.5%
Available online 27 March 2010
and 10% by weight. 40  40  160 mm mortar prisms have been produced with the obtained cements.
Strength tests have been carried out on mortar specimen at 7, 28, and 90 days. WMDCs have been com-
pared to each other as well as to control cements of CEM I and CEM II with respect to their physical,
chemical and mechanical properties. Obtained results showed that WMDCs conform to EN 197-1 stan-
dard and thus 10% WMD can be used as an additive material in cement manufacturing.
Ó 2010 Elsevier Ltd. All rights reserved.

1. Introduction material or raw material in various areas and applications, such

as ceramic [17], brick [18], building material [14], infiltration
New developments in construction technologies and growing [19] and desulphurization processes [20]. In addition, the waste
population give rise to more building constructions and thus ce- marble dust has been used in the manufacturing of mosaics, mor-
ment consumption. Since the cement industry demands vast tar, tile, plaster and white cement [21]. A 90% of dried marble slur-
amount of energy, any increase in cement manufacturing also in- ry having very fine dust is smaller than 200 lm in size [14].
creases energy needs and causes additional environmental pollu- Moreover, it was reported that the wastes of marble and granite
tion [1]. The important portion of cost in cement manufacturing can be used in the production of clay based materials [17]. Coarse
results from the energy consumption during the clinker produc- marble wastes were used as aggregate [16] and as filler in asphalt
tion. Therefore, alternative investigations for solution have been cement [22]. Artificial marble waste was used as a fine aggregate in
ongoing in the ignition of clinker and raw material milling. The polymer-modified mortar [23]. Also, marble dust can be used in
manufacturing of cement with additive is an economic and feasible the production of polymer based composite material [24,25]. It
method due to the decreasing of clinker ratio in cement and energy was reported that waste marble sludge can be used to produce
consumption in an oven and ball milling. For this purpose, gener- clinker [26] and as an additive material in mortar [27].
ally pozzolans are used in the cement production. The studies on The purpose of this study was to investigate the usability of
cement additives such as pumice [2], nut shell, wood and tea waste waste marble dust as an additive in composite cement production
[3], fly ash [4–6], blast furnace slag [7], silica fume [8], rice husk and determine its performance properties as a function of waste
ash [9,10], diatomite [11,12], perlite [13] and others were carried marble dust addition.
out by researchers.
Marble is one of the most extensively used aesthetic stones
[14]. Turkey has approximately 3872,000,000 m3 of valuable mar- 2. Materials and method
ble reserve [15]. On the other hand, marble manufacturing indus-
try produces high amount of waste [16]. Waste generation 2.1. Materials
continues from mining process to finished product and is about
50% of mineral mined; the dried slurry product is quiet fine. 90% The Portland cement (PC) and pozzolan containing Portland
of the particles are below 200 lm [14]. The waste of marble dust composite cement (PCC) used in the experimental study were
can cause environmental problem and economic loss if the waste CEM I and CEM II type cements (control cements), respectively.
is not used. The marble dust is generally used as reinforcement The chemical composition and physical properties of the cements
are given in Table 1. Waste marble dust (WMD) supplied from Af-
yon region of Turkey was used as an additive material in cement
* Corresponding author. Tel.: +90 312 2028873; fax: +90 3122120059. production. WMD used consists of basically SiO2, Al2O3, and CaO
E-mail address: [email protected] (H.Y. Aruntasß). with minor contents of MgO, Fe2O3, K2O and Na2O according to

0261-3069/$ - see front matter Ó 2010 Elsevier Ltd. All rights reserved.
doi:10.1016/j.matdes.2010.03.036
4040 H.Y. Aruntasß et al. / Materials and Design 31 (2010) 4039–4042

Table 1 3. Results and discussion

Properties of WMD and cement used.

Oxide (%) PC PCC WMD The chemical constituents and physical properties of cements
CaO 61.39 47.64 54.43 produced with WMD are given in Tables 3 and 4.
SiO2 19.55 30.53 0.67 As seen from Table 1, WMD contains mainly CaO (54.43%) and
Al2O3 4.82 7.63 0.12 calcination products (43.4%). On the other hand, percentage of
Fe2O3 3.52 3.63 0.08
chemical constituents except calcination products decreases by
MgO 1.83 1.86 0.59
SO3 2.76 2.71 – increasing WMD ratio in the cement. The reason is that there are
K2O 0.74 1.03 – little metal oxides except CaO in chemical composition of WMD.
Na2O 0.14 0.80 0.14 As given in Table 4, specific gravity decreases related to control
Loss on ignition 2.18 4.52 43.4 cements by increasing WMD proportion in the cement. The cause
Insoluble residue 0.38 – –
of this is the specific gravity of WMD being less than the specific
Physical and mechanical properties gravity of cement.
Specific gravity, g/cm3 3.10 2.91 2.60
It can be seen from Table 4, the specific surface decreases re-
Specific surface (Blaine), cm2/g 3238 3456 3097
Initial setting time, min 140 155 – lated to control cement by increasing WMD ratio in cement. The
Final setting time, min 240 250 – reason of this is the specific surface of WMD being less than the
Soundness, mm 2 3 – specific surface of cement. At the same time, the water require-
Compressive strength, MPa ment values decrease related to control cement by increasing
7 days 41.1 27.0 – WMD ratio in cement. This status illustrates the need of water
28 days 48.8 38.0 –
for WMD to be less. On the other hand, the initial setting time
and the final setting time of cements were not affected by increas-
ing WMD ratio in cement. As known, increase in C3S content and
XRD analysis. The physical properties and chemical constituents of especially C3A content reduce the initial setting time. In order to
WMD are given in Table 1. form C3A, Al2O3 and CaO compounds are necessary. As seen from
The sand used in the composition of Portland cement mortars Table 1, the content of Al2O3 is very low (0.12%) in the WMD. Be-
was standard CEN type conforming to EN 196-3 [28]. The water sides, the content of gypsum is constant in the WMDCs, as seen
used in mortar production was regular tap water. in Table 2. Although the content of CaO changes in the WMDCs,
setting times do not change considerably due to the trace amount
of Al2O3.
2.2. Method
However, WMD increased slightly the soundness values of ce-
ments according to PC and PCC control cements. On the other hand,
The WMD was used as partial replacement of PC clinker in the
there is a linear relationship among WMD additive ratio and quan-
amount of 0%, 2.5%, 5.0%, 7.5% and 10% by weight and grounded to-
tities of cement retained on 90-lm sieve and retained on 40-lm
gether with PC clinker and gypsum in order to produce composed
sieve.
cement with additive. Amount of gypsum was fixed as 5% by
As seen in Fig. 1, when the tensile strengths of cement mortar
weight in the cement manufacturing in this study. Amount of
that was cured for 7 days were examined, strengths of WMDC were
WMD was substituted with the same amount of Portland cement
lower than the strength of PC control cement and higher than the
clinker. The mixture proportions of constituents used for produc-
strength of PCC control cement. The strengths of WMDC1, WMDC2,
tion of composed cement with WMD are given in Table 2.
WMDC3 and WMDC4 were lower compared to strength of PC as
Portland cement clinker, WMD and gypsum were separately
13%, 5%, 11% and 5%, respectively. However, strengths of WMDCs
grounded at specified proportions by means of ball milling. Grind-
were higher than the strength of PCC produced with the same
ing period was fixed as 1 h in the experiments.
manner as 15%, 26%, 17% and 26%, respectively.
The cement pastes were prepared by using laboratory type mix-
In the similar form of cement mortars cured for 7 days, the
er. Initial and final setting times and standard consistency of ce-
strengths of cement cured for 28 days were lower than the
ment pastes were determined using a Vicat apparatus and
strength of PC control cement and higher than the strength of
following EN 196-3 procedure. Specific gravity of cement was
PCC control cement. The strengths of WMDC1, WMDC2, WMDC3
investigated using Le Chatelier flask. Soundness of cement pastes
and WMDC4 were lower compared to strength of PC as 10%, 10%,
was determined by Le Chatelier method. The values presented in
12% and 13%, respectively. However, strengths of WMDCs were
this work are the mean value of the three replicates.
higher than the strength of PCC produced with the same manner
Dimensions of mortar sample were 160  40  40 mm. Pre-
as 13%, 13%, 11% and 9%, respectively.
pared cement mortars were placed into the steel moulds and after
As seen in the similar strength results of cement mortars cured
24 h, samples were removed from moulds. They were cured at
for 7 and 28 days, the strengths of cement cured for 90 days were
20 ± 2 °C temperatures in water until the test day. Samples cured
for 7, 28, and 90 days were tested for tensile strength and compres-
sive strength in accordance with EN 196-1 standard [30]. Table 3
Chemical compositions of WMDCs produced.

Table 2 Oxide (%) WMDC1 WMDC2 WMDC3 WMDC4

Mixture proportions of agents for production of cement, %(w/w). CaO 58.73 57.37 56.43 55.00
SiO2 20.22 19.50 20.36 19.61
Cement PC clinker (%) WMD (%) Gypsum (%) Total (%)
Al2O3 5.16 4.95 5.19 4.99
type
Fe2O3 3.64 3.43 3.69 3.46
WMDC1 92.5 2.5 5.0 100 MgO 3.24 3.11 3.14 3.01
WMDC2 90.0 5.0 5.0 100 SO3 4.24 4.08 3.84 3.91
WMDC3 87.5 7.5 5.0 100 K2O 0.59 0.57 0.60 0.58
WMDC4 85.0 10.0 5.0 100 Na2O – – – –
PC EN 197-1 CEM I [29] Loss on ignition 2.40 3.55 4.48 6.00
PCC EN 197-1 CEM II [29] Insoluble residue – – – –
 H.Y. Aruntasß et al. / Materials and Design 31 (2010) 4039–4042 4041

Table 4
Physical properties of the cements.

Properties WMDC1 WMDC2 WMDC3 WMDC4 PC PCC

3
Specific gravity, g/cm 3.06 3.02 2.98 2.94 3.10 2.91
Specific surface (Blaine), cm2/g 3111 3087 3054 3012 3238 3456
Retained on 90 lm,% 2.6 3.0 3.3 3.4 3.8 3.6
Retained on 40 lm,% 21.4 22.5 23.3 23.4 24.8 25.4
Water requirement,% 36.0 35.7 35.7 35.0 36.7 37.3
Initial setting time, min 135 135 135 135 140 155
Final setting time, min 205 205 205 205 240 250
Soundness, mm 4 6 6 5 2 3

8 control cement and higher than the strength of PCC control ce-
ment. The strengths of WMDC1, WMDC2, WMDC3 and WMDC4
7 were recorded lower than the strength of PC as 20%, 17%, 19%
Tensile strength (MPa)

and 16%, respectively. However, the strengths of MWDCs were

6
measured higher than the strength of PCC produced with the same
5 manner as 23%, 28%, 25% and 30%, respectively.
When the cement mortars cured for 28 days were compared
4 with the others, the compressive strengths of WMDC1 and
WMDC2 were recorded equal to the strength of PC control cement.
3 7 days
Their strengths were determined higher than the strengths of oth-
28 days
2 90 days
ers. The results of this research are in agreement with those ob-
tained by Pereira et al. [26] and Arslan et al. [27]. The strengths
1 of WMDC3 and WMDC4 were obtained lower compared to the
strength of PC as 10% and 14%, respectively. However, the strengths
0
PC PCC WMDC1 WMDC2 WMDC3 WMDC4
of WMDCs were measured higher than the strength of PCC pro-
duced with the same manner as 27%, 29%, 16% and 10%, respec-
Cement type tively. Furthermore, increasing of WMD ratio in the cement
Fig. 1. Comparisons of tensile strengths of cement type.
affects the strength of cement negatively.
When the cement mortars cured for 90 days were compared
with the others, the compressive strengths of WMDC1 and
lower than the strength of PC control cement and higher than the WMDC2 were obtained higher as 2% and 5%, the strengths of
strength of PCC control cement. The strengths of WMDC1, WMDC2, WMDC3 and WMDC4 lower as 3% and 4% than the strength of PC
WMDC3 and WMDC4 were lower compared to strength of PC as control cement, respectively. It is obvious that the strengths of
10%, 6%, 6% and 9%, respectively. On the other hand, strengths of WMDC3 and WMDC4 were close to the strength of PC. On the
WMDCs were higher than the strength of PCC produced with the other hand, the strengths of WMDCs were determined higher than
same manner as 7%, 13%, 13% and 9%, respectively. As seen from the strength of PCC produced with the same manner as 17%, 20%,
Fig. 1, addition of WMD in order to form composed cement does 11% and 9%, respectively. The higher strengths of the WMDC mor-
not change the tensile strengths considerably. tars can be explained by their higher PC contents than that of the
Similar results as observed in tensile strengths were recorded PCC. Moreover, increasing of WMD ratio in the cement affects
for compressive strength tests. As shown in Fig. 2, when the com- the strength of cement negatively. As seen from Fig. 2, addition
pressive strengths of cement mortars cured for 7 days were exam- of WMD in order to form composed cement increases the compres-
ined, strengths of WMDC were lower than the strength of PC sive strength slightly.

4. Conclusions
60
Compressive strength (MPa)

Based on the experimental results obtained from this study, the

50 following conclusions can be drawn:

40  A 10% WMD can be used as an additive material in production

of cement.
 Use of WMD in production of WMDCs does not affect the setting
30
time.
 The ratio of WMD in the cements increases the values of specific
20 gravity and specific surface decrease.
7 days
 There is a linear relationship between WMD and quantities of
28 days
10 cement retained on sieve.
90 days
 The compressive strength of WMDC2 is higher than those of PC.
0 The compressive strengths of all WMDCs are higher than those
PC PCC WMDC1 WMDC2 WMDC3 WMDC4 of PCC strengths at all ages. All WMDCs can be used instead of
PCC.
Cement type  Cost of cement production can be decreased by use of 10%
Fig. 2. Comparisons of compressive strengths of cement type.
WMD.
4042 H.Y. Aruntasß et al. / Materials and Design 31 (2010) 4039–4042

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