Strain-hardening cement-based composites (SHCC) are a special class of fiber-reinforced concrete which develop multiple, fine cracks when subjected to increasing tensile loading, reaching strain capacities of up to several percent. The tensile behavior of SHCC is a result of a purposeful material design accounting for the mechanical and physical properties of the cementitious matrix, of the reinforcing fibers and of their interaction. The exceptionally high energy dissipation through inelastic deformations before reaching tensile strength makes SHCC suitable for manufacturing or strengthening of structural elements which may be subjected to impact loading. However, the tensile behavior of SHCC is highly strain rate dependent, both in terms of tensile strength and strain capacity. The different strain rate sensitivities of the constitutive phases of SHCC (matrix, fiber and interfacial bond) lead to disproportionate dynamic alteration of their mechanical properties under increasing strain rates and, consequently, to an impairment of the micromechanical balance necessary for strain-hardening and multiple cracking. Thus, high energy dissipation under impact loading can only be ensured through a targeted material design. This work presents a series of mechanical experiments at different strain rates and different scales of investigation with the goal of developing a qualitative and quantitative basis for formulating material design recommendations for impact resistant SHCC. Three different types of SHCC were investigated, consisting of two types of polymer fibers (polyvinyl-alcohol and high-density polyethylene) and cementitious matrices (normal-strength and high-strength). Uniaxial tension experiments were performed on SHCC specimens and on non-reinforced matrix specimens with different testing setups at strain rates ranging from 10-4 to 150 s-1. Besides the measured mechanical properties, special attention was paid to the crack patterns and the condition of fracture surfaces. Additionally, micro-scale investigations were performed to quantify the strain rate dependent changes in the mechanical behavior of individual component phases, i.e., matrix, fibers and fiber-matrix bond. The results obtained from the micromechanical investigations were used in an analytical model for crack bridging. The model links the micromechanical parameters and their strain rate sensitivities to the single-crack opening behavior under increasing displacement rates, making it useful for material design purposes. If given an extensive experimental basis for the fracture mechanical properties of the non-reinforced cementitious matrices, the model can be extended for predicting the strain capacity (multiple cracking) of SHCC under different strain rates. / Die hochduktilen Betone (Engl.: Strain-Hardening Cement-based Composites – SHCC) bilden eine besondere Klasse von Faserbetonen, die eine multiple Rissbildung unter zunehmenden Zugspannungen aufweisen, was zu einer sehr hohen Bruchdehnung führt. Das dehnungsverfestigende, hochduktile Zugverhalten der SHCC wird durch eine gezielte Materialentwicklung erreicht, die die mechanischen und physikalischen Eigenschaften der zementgebundenen Matrizen, der Kurzfasern und deren Zusammenwirkung berücksichtigt. Das außergewöhnliche Energieabsorptionsvermögen der SHCC durch plastische Verformungen vor dem Erreichen der Zugfestigkeit qualifiziert diese Verbundwerkstoffe für die Herstellung oder Verstärkung von Bauteilen, die Impaktbeanspruchungen ausgesetzt sein könnten. Jedoch weisen SHCC sowohl bezüglich deren Zugfestigkeit als auch deren Dehnungskapazität ein ausgeprägtes dehnratenabhängiges Verhalten auf. Unter zunehmenden Dehnraten führen die unterschiedlichen Dehnratensensitivitäten der gestaltenden Phasen von SHCC (Matrix, Faser und deren Verbund) zur Beeinträchtigung des mikromechanischen Gleichgewichts, welches für die Dehnungsverfestigung und multiple Rissbildung erforderlich ist. Eine hohe Energiedissipation unter Impaktbeanspruchungen kann deshalb nur durch eine gezielte Materialentwicklung der SHCC hinsichtlich deren Verhaltens unter hohen Dehnraten gewährleistet werden. Die vorliegende Arbeit umfasst eine Reihe von experimentellen Untersuchungen mit verschiedenen Dehnraten und an unterschiedlichen Betrachtungsebenen, mit dem Ziel eine qualitative und quantitative Basis für Empfehlungen zur Materialentwicklung von Impakt-resistenten SHCC zu schaffen. Drei verschiedene SHCC-Zusammensetzungen wurden untersucht. Die Referenz-Zusammensetzung aus einer normalfesten zementgebundenen Matrix und Polyvinyl-Alkohol-Kurzfasern wurde mit zwei unterschiedlichen SHCC verglichen (hochfest und normalfest), die mit Kurzfasern aus hochdichtem Polyethylen bewehrt wurden. Einaxiale Zugversuche wurden an SHCC-Proben und unbewehrten Matrix-Proben mit verschiedenen Prüfvorrichtungen bei Dehnraten von 10-4 bis 150 s-1 durchgeführt. Zusätzlich zu den gemessenen mechanischen Eigenschaften wurden die Rissbildung und die Bruchflächen detailliert untersucht. Darüber hinaus wurden mikromechanische Untersuchungen durchgeführt, um die Dehnratensensitivität der einzelnen Phasen, d.h. Matrix, Faser und deren Verbund zu beschreiben. Die aus den mikromechanischen Untersuchungen erzielten Ergebnisse wurden als Eingangswerte in einem analytischen Einzelriss-Modell verwendet. Das entwickelte Modell verbindet die mikromechanischen Parameter und deren Dehnratenabhängigkeit mit dem Rissöffnungsverhalten von SHCC bei zunehmenden Verschiebungsraten. Das macht es vorteilhaft für Materialentwicklungszwecke. Das Modell kann für die Vorhersage der Dehnungskapazität von SHCC bei diversen Dehnraten weiterentwickelt werden, wenn eine umfassende experimentelle Basis für die bruchmechanischen Eigenschaften der Matrizen vorliegt.

Le manque de granulats de qualité dans certaines régions françaises tend à devenir un problème majeur pour les entreprises de travaux publics. En effet, avec une consommation annuelle de 200 millions de tonnes de granulats, la route se doit de faire face en imaginant de nouvelles solutions comme la valorisation de certains matériaux.La craie, située entre roche et sol, possède une place particulière dans le monde des travaux publics. En effet, si son usage est relativement bien maîtrisé en vue de la réalisation de remblais ou de couches de forme, il en est tout autrement des couches d’assise de chaussées.Ce type de matériau est usuellement rejeté de la conception des assises de chaussées car il ne s’insère pas dans les guides normatifs utilisés par les professionnels de la route. Les performances mécaniques et la grande sensibilité à l’eau de ce matériau ne lui permettent pas d’entrer dans les spécifications requises par les normes. Cependant, il est tout à fait envisageable que la craie trouve sa place de manière totale ou partielle en assise de chaussée.Ce matériau que l’on trouve en abondance dans certaines régions françaises pauvres en granulats "haut de gamme" (Nord-Pas de Calais, Champagne-Ardenne…), pourrait ainsi palier un certain manque, participer à la préservation de ressources naturelles et économiser frais et pollution générés par un approvisionnement lointain.Ces travaux menés en partenariat entre le Laboratoire de Génie Civil de l’Ecole Centrale de Lille et le Laboratoire Routier Eurovia de Loos ont donc pour but de proposer des pistes d’amélioration des performances mécaniques de la craie en vue de sa valorisation en assise de chaussée routière / The lack of high quality aggregates in some French regions seems to become a main issue for road work firms. With an annual consumption of 200 millions tonnes of aggregates, road professionals must square up finding new solutions like the valorisation of some forgotten materials. Between rock and soil, chalk has a particular position in road work. While its use is relatively well managed for the realisation of fills and subgrade courses, the same certainly cannot be said for base courses. This kind of material is usually rejected for the design of road base courses because it is not approved within the current standards used by road professionals. Indeed, the low mechanical performances and the high water sensibility of chalk do not allow this material to be used. However, it seems possible to find some pre-treatments to harden chalk for a use in road base courses.This material is found profusely in some French regions otherwise limited in upscale aggregates (Nord-Pas de Calais, Champagne-Ardenne…). Therefore, valorising chalk may overcome the lack of aggregates, contribute to the preservation of natural resources, save up money and avoid pollution due to distant supplying.The study presented here is conducted in partnership between the Ecole Centrale de Lille Civil Engineering Laboratory and the Eurovia Roadworks Laboratory of Loos. We provide several trails aimed at improving the mechanical properties of chalk for its use in road base courses

La prédiction du comportement à long terme des matériaux cimentaires est un enjeu majeur pour contribuer à l'étude de la durabilité des structures précontraintes. Le présent travail porte sur l'utilisation de la méthode de l'inclusion équivalente, approche d'homogénéisation multi-échelle simplifiée, pour la prédiction du fluage dans ces matériaux. Le fluage est modélisé par la viscoélasticité linéaire sans vieillissement. La méthode de l'inclusion équivalente permet de contourner certaines difficultés et limitations que présentent les approches classiques. Pour les matériaux cimentaires, fortement hétérogènes, les approches multiéchelles classiques sont ou bien numériquement lourdes et très complexes à mettre en œuvre, ou bien pas suffisamment détaillées pour prendre en compte les spécificités d'une microstructure. La méthode de l'inclusion équivalente présente un juste-milieu et permet de calculer des microstructures simplifiées de type matrice-inclusions et de fournir des estimations ou des bornes sur le comportement homogénéisé. Sous sa forme variationnelle, la méthode de l'inclusion équivalente n'a jusqu'alors été mise en œuvre que pour des inclusions de forme sphérique. Le présent travail propose d'étendre cette méthode à des inclusions de forme ellipsoïdale dont la variation de l'élancement permet de modéliser de nouveaux éléments asphériques tels que les fissures, les fibres et les cristaux de portlandite. Cette complexification de la géométrie a un impact sur le temps de calcul, qui est amplifié dans le cadre du fluage. Le second volet du travail porte alors sur l'extension de la méthode de l'inclusion équivalente à la viscoélasticité linéaire sans vieillissement par l'intermédiaire de la transformée de Laplace-Carson. Une méthodologie efficace (tant du point de vue de la précision que de celui du temps de calcul) est finalement proposée pour effectuer l'inversion numérique de cette transformée / The prediction of long-term behaviour of cementitious materials is a major concern which contributs to the study of the durability of prestressed structures. This work focuses on the use of the equivalent inclusion method, simplified multi-scale homogenization approach, for the prediction of creep in these materials. Creep is modelled by the non-ageing linear viscoelasticity. The equivalent inclusion method overcomes certain difficulties and limitations posed by conventional approaches. For cementitious materials (highly heterogeneous), conventional multi-scale approaches are, either digitally heavy and complex to implement, or not sufficiently detailed to take into account the specificities of a microstructure. The equivalent inclusion method presents a middle way and allows the calculation of simplified matrix-inclusion type microstructures and to provide estimates or bounds on the homogenized behaviour.Under its variational form, the equivalent inclusion method has, up to now, been implemented only for spherical inclusions. This work proposes to extend this method to ellipsoidal inclusions whose variation of slenderness allows the modelling of new aspheric elements such as cracks, fibers and portlandite crystals. Such enrichment of the geometry has an impact on the computation time, that is amplified in the context of creep. The second aspect of the work then applies to the extension of the equivalent inclusion method to the non-ageing linear viscoelasticity by means of the Laplace-Carson transform. An effective methodology (both from the viewpoint of precision and calculation time) is finally proposed to perform the numerical inversion of this transform

La durabilité des structures en béton armé ainsi que leur durée de vie sont étroitement liées à la mise en œuvre simultanée de nombreux phénomènes physiques et chimiques. Ceux-ci sont de diverses natures mais restent, en général, fonction des propriétés hydriques des matériaux étudiés. Ainsi, la prédiction des dégradations potentielles d'un matériau cimentaire requiert l'étude du transport de l'eau liquide et des phases gazeuses à travers ce dernier, considéré comme un milieu poreux. En milieu naturel, les structures subissent des variations périodiques de l'humidité relative extérieure (HR). Cependant, la plupart des modèles de transfert hydrique préexistants dans la littérature, s'intéresse uniquement au processus de séchage. Il existe peu de modèles décrivant à la fois l'humidification et le séchage du matériau (ces deux phénomènes se produisent dans le matériau en condition naturelle d'humidité relative (HR)). Tenir compte des phénomènes d'hystérésis dans les transferts hydriques réduit à nouveau le nombre de modèles à disposition. Ainsi, cette thèse s'attache à proposer une meilleure compréhension de l'état hydrique du béton en fonction des variations d'humidité relative extérieure, sur la base d'une nouvelle campagne expérimentale et de modélisations numériques. Un soin sera apporté afin de tenir compte dans les modèles numériques des effets d'hystérésis. Dans ce travail, nous détaillerons, tout d'abord, un modèle multi-phasiques complet. Un modèle simplifié est obtenu, sur la base de considérations théoriques et de vérifications expérimentales dans le cas où la perméabilité intrinsèque à l'eau liquide reste très inférieure à la perméabilité intrinsèque au gaz. Une étude comparative des modèles d'hystérésis couramment utilisés permet d'obtenir un jeu de modèles proposant les meilleures prédictions d'isothermes de sorption d'eau et de leurs hystérésis. Par la suite, le modèle de transport simplifié est couplé avec les modèles d'hystérésis sélectionnés afin de simuler les transferts hydriques dans des bétons soumis à des cycles d'humidification-séchage. La comparaison avec des données expérimentales révèle que la prise en compte de l'hystérésis de l'isotherme de sorption d'eau ne peut pas être négligé. De plus, il est montré que les prédictions obtenues avec des modèles d'hystérésis théoriques, sont les plus cohérentes avec les résultats expérimentaux, en particulier, pour des chemins secondaires d'hystérésis. Plusieurs scénarios (conditions environnementales, bétons différents) sont également simulés. Les résultats obtenus pointent à nouveau la nécessité de tenir compte de l'hystérésis lors de la modélisation des transferts hydriques à travers des matériaux cimentaires soumis à des variations d'humidité relative. La définition d'une profondeur pour laquelle le profil hydrique du béton est modifié par les variations périodiques d'humidité relative permet de mieux comprendre comment la modélisation de la pénétration des espèces ioniques est influencée par les cycles d'humidification-séchage. Par ailleurs, notre analyse révèle qu'il est pertinent de considérer l'effet de Knudsen pour la diffusion de la vapeur afin d'améliorer la prédiction de la diffusivité apparente / The durability of reinforced concrete structures and their service life are closely related to the simultaneous occurrence of many physical and chemical phenomena. These phenomena are diverse in nature, but in common they are dependent on the moisture properties of the material. Therefore, the prediction of the potential degradation of cementitious materials requires the study of the movement of liquid-water and gas-phase transport in the material which is considered as a porous medium. In natural environment, structures are always affected by periodic variations of external relative humidity (RH). However, most moisture transport models in the literature only focus on the drying process. There are few researches considering both drying and wetting, although these conditions represent natural RH variations. Even few studies take into account hysteresis in moisture transport. Thus, this work is devoted to better understand how the moisture behaviour within cementitious materials responds to the ambient RH changes through both experimental investigations and numerical modelling. In particular, hysteretic effects will be included in numerical modelling. In this thesis, we first recalled a complicate multi-phase continuum model. By theoretical analysis and experimental verification, a simplified model can be obtained for the case of that the intrinsic permeability to liquid-water is smaller than the intrinsic permeability to gas-phase. The review of commonly-used hysteresis models enabled to conclude a set of best models for the prediction of water vapour sorption isotherms and their hysteresis. After that, the simplified model was coupled with selected hysteresis models to simulate moisture transport under drying and wetting cycles. Compared with experimental data, numerical simulations revealed that modelling with hysteretic effects can provide much better results than non-hysteresis modelling. Among different hysteresis models, results showed that the use of the conceptual hysteresis model, which presents closed form scanning loops, can provide more accuracy predictions. Further simulations for different scenarios were also performed. All comparisons and investigations enhanced the necessity of considering hysteresis to model moisture transport for varying relative humidity at the boundary. The investigation of moisture penetration depth could provide a better understanding of how deep moisture as well as ions can move into the material. Furthermore, the analysis revealed that the consideration of Knudsen effects for diffusion of vapour can improve the prediction of the apparent diffusivity

Concrete is a brittle material prone to cracking due to its low tensile strength. Crack repairs are not only expensive and time-consuming but also increase the carbon footprint. Designing a novel concrete material possessing the ability to self-repair cracks would enhance its sustainability. Self-healing can be defined as a material’s ability to repair inner damage without any external intervention. In the case of concrete, the process can be autogenous, based on an optimized mix composition, or autonomous, when additional capsules containing some healing agent and/or bacteria spores are incorporated into the binder matrix. The first process uses unhydrated cement particles as the healing material while the other utilizes a synthetic material or bacteria precipitating calcite which are released into the crack from a broken capsule or activated by access to water and oxygen. The main disadvantages of the autonomous method are the loss of the fresh concrete workability, worsened mechanical properties, low efficiency, low survivability of the capsules and bacteria during mixing and the very high price. On the other hand, the autogenous self-healing was found to be more efficient, more cost effective, safer, and easier to implement in full-scale applications. Knowledge related to mechanisms and key factors controlling the autogenous self-healing is rather limited. Therefore, the aim of this research work was to better understand the autogenous self-healing process of concrete and to optimize the mix design and exposure conditions to maximize its efficiency. This licentiate thesis summarizes the main findings of the first 2.5 years of the PhD project. Several factors affecting autogenous self-healing were studied, including the amount of unhydrated cement, mix composition, age of material, self-healing duration and exposure conditions. The process was investigated both externally, at the surface, and deeper inside of the crack, by evaluating the crack closure and chemical composition of formed self-healing products. In addition, the flexural strength recovery was also studied. It was observed that a large amount of cement in the concrete mix does not ensure an efficient autogenous self-healing of cracks. A very dense and impermeable binder microstructure limited the transport of calcium and silicone ions to the crack and diminished the precipitation of the healing products. Addition fly ash increased the crack closure ratio close to the crack mouth, but its presence did not support the recovery of the flexural strength, presumably due to a very limited formation of load bearing phases inside the crack. Calcium carbonate was detected mainly at the crack mouth, whereas calcium silicate hydrate (C-S-H) and ettringite were found deeper inside the crack. The formation of C-S-H and ettringite presumably resulted in a regain of the flexural strength. On the other hand, calcite crystals formed close to the surface of the specimen controlled conditions inside the crack through its external closure. Healing exposure based on pure water appeared to be inefficient even despite the application of different temperature cycles and water volumes. The application of a phosphate-based retarding admixture in the curing water resulted in the highest self-healing efficiency. The admixture presumably inhibited the formation of a dense hydration shell on the surface of the unhydrated cement grains and promoted the precipitation of calcium phosphate compounds inside the crack. In addition, water mixed with microsilica particles caused a regain of the flexural strength through formation of C-S-H in the crack.

Doctoral thesis „Ballistic-proof concretes“ deals with description, design and development of material based on ultra-high performance fibre reinforced cementitious composite with increased ballistic resistance i.e. increased resistance against high-strain rate dynamic loading induced by interaction of high-velocity moving objects. High mechanical properties, essential for such a material, are reached especially by maximal reduction of water-to-binder coefficient using high-range water reducing agents, high-strength aggregates and dense structure by precise selection and dosage of raw materials in the recipe. The main goal is to prepare a methodology for design of such a materials, observation of material behaviour on ballistic loading and quantitative description of material response for protective structures design. Properties of designed materials within this thesis are comparing with properties of commercially available and commonly used cementitious composites in order to create a concept for material limits in the field of ballistic protection. This concept enables to estimate ballistic protection of present or newly-designed materials and structures.

<p>Developing a reliable in-situ non-destructive testing method to determine the strength of in-place concrete is critical because a fast-paced construction schedule exposes concrete pavement and/or structures undergoing substantial loading conditions, even at their early ages. Conventional destructive testing methods, such as compressive and flexural tests, are very time-consuming, which may cause construction delays or cost overruns. Moreover, the curing conditions of the tested cylindrical samples and the in-place concrete pavement/structures are quite different, which may result in different strength values. An NDT method that could directly correlate the mechanical properties of cementitious materials with the sensing results, regardless of the curing conditions, mix design, and size effect is needed for the in-situ application.</p><p>The piezoelectric sensor-based electromechanical impedance (EMI) technique has shown promise in addressing this challenge as it has been used to both monitor properties and detect damages on the concrete structure. Due to the direct and inverse effects of piezoelectric, this material can act as a sensor, actuator, and transducer. This research serves as a comprehensive study to investigate the feasibility and efficiency of using piezoelectric sensor-based EMI to evaluate the strength of newly poured concrete. To understand the fundamentals of this method and enhance the durability of the sensor for in-situ monitoring, this work started with sensor fabrication. It has studied two types of polymer coating on the effect of the durability of the sensor to make it practical to be used in the field.</p><p>The mortar and concrete samples with various mix designs were prepared to ascertain whether the results of the proposed sensing technique were affected by the different mixtures. The EMI measurement and compressive strength testing methods (ASTM C39, ASTM C109) were conducted in the laboratory. The experimental results of mortar samples with different water-to-cement ratios (W/C) and two types of cement (I and III) showed that the correlation coefficient (R²) is higher than 0.93 for all mixes. In the concrete experiments, the correlation coefficient between the EMI sensing index and compressive strength of all mixes is higher than 0.90. The empirical estimation function was established through a concrete slab experiment. Moreover, several trial implementations on highway construction projects (I-70, I-74, and I-465) were conducted to monitor the real-time strength development of concrete. The data processing method and the reliable index of EMI sensing were developed to establish the regression model to correlate the sensing results with the compressive strength of concrete. It has been found that the EMI sensing method and its related statistical index can effectively reflect the compressive strength gain of in-place concrete at different ages.</p><p>To further investigate the in-situ compressive strength of concrete for large-scale structures, we conducted a series of large concrete slabs with the dimension of 8 feet × 12 feet × 8 inches in depth was conducted at outdoor experiments field to simulate real-world conditions. Different types of compressive strength samples, including cast-in-place (CIP) cylinder (4” × 6”) – (ASTM C873), field molded cylinder (4” × 8”) – (ASTM C39), and core drilled sample (4” × 8”) – (ASTM C42) were prepared to compare the compressive strength of concrete. The environmental conditions, such as ambient temperatures and relative humidity, were also recorded. The in-situ EMI monitoring of concrete strength was also conducted. The testing ages in this study were started from 6 hours after the concrete cast was put in place to investigate the early age results and continued up to 365 days (one year) later for long-term monitoring. The results indicate that the strength of the CIP sample is higher than the 4” x 8” molded cylinder , and that core drilled concrete is weaker than the two aforementioned. The EMI results obtained from the slab are close to those obtained from CIP due to similar curing conditions. The EMI results collected from 4 × 8-inch cylinder samples are lower than slab and CIP, which aligns with the mechanical testing results and indicates that EMI could capture the strength gain of concrete over time.</p><p>The consequent database collected from the large slab tests was used to build a prediction model for concrete strength. The Artificial Neuron Network (ANN) was investigated and experimented with to optimize the prediction of performances. Then, a sensitivity analysis was conducted to discuss and understand the critical parameters to predict the mechanical properties of concrete using the ML model. A framework using Generative Adversarial Network (GAN) based on algorithms was then proposed to overcome real data usage restrictions. Two types of GAN algorithms were selected for the data synthesis in the research: Tabular Generative Adversarial Networks (TGAN) and Conditional Tabular Generative Adversarial Networks (CTGAN). The testing results suggested that the CTGAN-NN model shows improved testing performances and higher computational efficiency than the TGAN model. In conclusion, the AI-guided concrete strength sensing and prediction approaches developed in this dissertation will be a steppingstone towards accomplishing the reliable and intelligent assessment of in-situ concrete structures.</p><br>

This paper focuses on two experimental methods that give indicators linked to the impregnation level of the yarn / matrix interface, in the case of Textile Reinforced Concrete (TRC). These methods have been tested on three different glass yarns laid in a cementitious matrix, with three different impregnation levels resulting from the manufacturing process. The first method (comparative mercury intrusion porosity test) is based on the evaluation by mercury intrusion porosity of the pores volume associated to the porosity inside and near the yarn. The second method (flow test) consists in measuring the flow rate of water along the yarn, with imposed flow conditions. The physical parameters measured by these two methods are both related to the pore size and to the porosity of the yarn / matrix interface. The results of the two methods are discussed and drawn in parallel to a qualitative characterization of the yarn matrix interface made by scanning electron microscopy. As a result, the connection between the results of the two methods and the SEM characterization is studied. It is shown how these methods can participate to characterize the yarn impregnation. Limitations of the methods are also discussed.

Zementklinker ist der Hauptbestandteil von Zement und verbraucht zu dessen Herstellung signifikante Mengen von natürlichen Ressourcen und trägt gleichzeitig zu seiner sehr ungünstigen Treibhausgasbilanz bei. In dieser Arbeit wird gezeigt, dass Zementersatzstoffe mit spezifischen Eigenschaften aus Abfallstoffen wie Kieswaschschlämmen, Strassenwaschschlämmen und Gipskartonplatten ohne Leistungseinbußen auf Produktseite, bei geringeren Temperaturen und geringerer CO2 Emission hergestellt werden können. Entsprechend den angestrebten Eigenschaften solcher zum Teil anthropogener Zementbestandteile wurden lokal verfügbare geeignete Abfallstoffe ausgewählt und thermisch aktiviert. Eine industriell anwendbare Methode zur Aktivierung solcher Stoffe bei Temperaturen von 700 °C – 850 °C wurde entwickelt und patentiert. Es basiert auf einem neu entwickelten Trocknungsverfahren und der Kombination von zwei Produktionslinien, um durch die Verknüpfung der Gasströme beider Systeme eine energieeffiziente thermische Behandlung von Abfallstoffen zu ermöglichen sowie auf umweltfreundliche Weise einen Zementersatzstoff herzustellen.:Table of Contents List of Tables List of Figures List of Abbreviations Glossary Chapter 1: Introduction 1.1 Motivation 1.2 Research hypotheses and objectives 1.3 Research methodology 1.4 Thesis outline Chapter 2: State of the art in SCM production 2.1 Supplementary cementitious materials 2.2 Classification of SCMs 2.2.1 Classification according to origin 2.2.2 Classification according to reaction behaviour 2.3 Chemical composition of SCMs 2.4 Formation of hydraulic or pozzolanic minerals in thermal processes 2.4.1 Cement clinker 2.4.2 Burnt oil shale 2.4.3 Fly ash 2.4.4 Calcined clay 2.5 Performance of composite cements 2.6 Calcining technologies 2.6.1 Flash calciner 2.6.2 Rotary calciner 2.7 Comparison of process technologies 2.8 Summary of Chapter 2 Chapter 3: Alternative SCMs and a new method for activation 3.1 Introduction 3.2 Target of alternative SCM 3.3 Waste materials 3.3.1 Aggregate washing sludge 3.3.2 Road cleaning sludge 3.3.3 Deconstruction gypsum 3.4 Producing alternative SCMs 3.5 Thermal activation of alternative SCMs 3.6 Limitations in current calcining technology 3.6.1 Difficult emission control 3.6.1.1 Particulate emission 3.6.1.2 Gaseous emission 3.6.2 Challenging material preparation 3.6.3 Demand for noble fuels 3.6.4 Difficult colour control 3.6.5 Strict temperature control 3.6.6 CO2 footprint of calciners 3.7 Proposed new method of calcination 3.7.1 Feed material handling 3.7.2 Thermal heat-exchange system 3.7.3 Clay calciner design 3.7.4 Grinding 3.8 Summary Chapter 3 Chapter 4: Theoretical Considerations 4.1 Material considerations 4.1.1 Composition of alternative SCM 4.1.2 Anticipated products and characteristics 4.2 Process considerations 4.2.1 System capacity 4.2.2 Material characteristics 4.2.3 Material receiving, crushing and handling 4.2.4 Thermodynamic modelling 4.2.4.1 Mass balance 4.2.4.2 Drying and cooling heat balance 4.2.4.3 Calcination heat balance 4.2.4.4 Gas balance 4.2.4.5 Impact on clinker kiln line 4.2.4.6 Impact of calcite on the gas balance 4.2.5 Calciner design 4.2.6 Colour control 4.2.7 Emission prediction 4.2.7.1 Emission during drying 4.2.7.2 Emission during calcination 4.2.8 CO2 footprint of produced material 4.2.9 Grinding requirements 4.3 Summary of Chapter 4 Chapter 5: Experimental tests and proof of concept 5.1 Introduction 5.2 Sampling and characterization 5.2.1 Kaolinitic AWS from France 5.2.2 Non-kaolinitic AWS from Switzerland 5.2.3 Road cleaning sludges from Switzerland 5.2.4 Deconstruction gypsum from Switzerland 5.2.5 Sample preparation and shipping 5.3 Drying screw conveyor testing 5.4 Calcination testing 5.4.1 Mineralogy of activated products 5.4.1.1 Non-kaolinitic SCM 5.4.1.2 Kaolinitic AWS from France 5.4.2 Colour 5.5 Crushing tests 5.6 Grinding tests 5.7 Mortar compressive strength testing 5.8 Water demand testing 5.9 Summary of Chapter 5 Chapter 6: Experimental results 6.1 Characteristics of activated materials 6.2 Concrete performance and colour 6.2.1 Thermally activated kaolinitic AWS from France 6.2.2 Thermally activated non-kaolinitic alternative SCM from Switzerland 6.3 Equipment dimensioning 6.3.1 Process mass flow 6.3.2 Heat-exchanging screws and thermal oil system 6.3.3 Rotary calciner dimensioning 6.3.4 Ball mill dimensioning 6.4 CO2 reduction 6.5 Summary of Chapter 6 Chapter 7: Conclusion and outlook 7.1 Conclusions 7.2 Outlook. Literature

Concrete, the second most consumed material on earth after water, is a source of environmental problems due to global urbanization. The production of this construction material requires a large amount of natural resources, and portland cement (PC) is responsible for around 8 % of planet-warming CO2 emissions. Producing 1 ton of PC will release roughly 1 ton of CO2 into the atmosphere. In 2021, around 92 million metric tons of PC were produced in the U.S., and a total of 4.4 billion tons were manufactured worldwide. While there was a yearly increase of around 1.5 % in the direct CO2 intensity of cement production from 2015 to 2021, urgent annual declines of 3 % until 2030 are necessary to be in line with the Net Zero Emissions by 2050 Scenario. This dissertation presents different approaches and technologies to offset the CO2 footprint of the production of cement clinker, concrete, and cementitious materials in general. First, this dissertation investigated the possibility of using end-of-life tire (ELT) rubber powder and its zinc-recovered residual (treated ELT rubber) to partially replace fine aggregates of different construction and infrastructure materials including stabilized soft soil (0 %, 10 %, 30 %, and 50 % ELT rubber added by clay volume), portland cement concrete (0 %, 10 %, 20 %, and 30 % ELT rubber added by sand volume), and asphalt concrete (20 % ELT rubber added by sand volume). This work was discussed through aspects of engineering properties and environmental impacts. The results reveal that the ELT rubber had both negative and positive effects on the engineering properties of the three materials while this waste posed a huge leachability of zinc and total organic carbon (TOC) content when being subjected to aqueous environments. However, the findings indicate that all three materials' matrices could effectively immobilize most leachable zinc from the ELT rubber by more than 90 %. Meanwhile, only stabilized soft soil and asphalt concrete could effectively deal with leachable TOC content from ELT rubber, and portland cement concrete needed the addition of silica fume to reduce TOC concentration in its leachate. Second, while previous studies have shown that steel furnace slag (SFS) can stabilize clay soils, the evidence is not clear if the stabilization mechanism is chemical and/or mechanical. This dissertation used isothermal calorimetry (IC) to quantify the heat of hydration of the mixture to assess the chemical aspects of the stabilization. Specifically, kaolin and bentonite clays were each blended with 40 % SFS by mass at water-to-binder ratios ranging from 1.0 to 1.5. The hydration properties of stabilized mixtures using lime or PC were also tested for comparison at the same experimental conditions. The obtained thermal power and total heat curves of stabilized mixtures confirmed that, for the specific SFS in this study, there is a hydration process taking place in clay stabilized by SFS. Relative to lime and PC, the SFS performed similarly in terms of heat of hydration behavior. When blended into clays, SFS provided a more significant heat of hydration behavior than cement, but that was much milder than lime. X-ray diffraction (XRD) and thermogravimetric analysis (TGA) were also employed to qualitatively analyze the mineralogy of the stabilized mixtures. Finally, this dissertation adopted a Digestion-Titration Method (DTM) for the determination of CO2 content in cementitious materials that has been mineralized in the form of calcium carbonate (CaCO3). This method was modified based on tests that were originally developed in the early 1900s. The method uses hydrochloric acid to digest CaCO3 under vacuum conditions. The CO2 released is captured by a barium hydroxide solution, which is then titrated to quantify the amount of CO2 absorbed. A design of experiments approach was used to optimize the experimental conditions. Samples of known CaCO3 content were first evaluated to establish the baseline test performance, and additional tests were performed on portland cement and various rock samples. The results were also compared to TGA, including a discussion to compare the two test methods. The data suggest that the new test method is feasibly applicable to chemically determine the CO2 captured in cementitious materials, and it can be an alternative method for TGA with lower experimental cost and easier access. Overall, it is evident that cement, concrete, and construction materials are essential to the functionality of civilization. Dealing with CO2 emissions and natural resource depletion induced by the production of these construction materials is urgent for sustainable development. Attempts toward construction materials with lower embodied CO2 by using low-carbon aggregates (e.g., waste aggregates, recycled aggregates) and alternative cementitious binders while controlling the environmental effects of the utilized waste materials are currently viable sustainable approaches. In addition, tools or new test methods that can support measuring the effectiveness of these reduced carbon cementitious materials are necessary. This dissertation investigates the feasibility of the use of ELT rubber waste in construction materials to reduce the exploitation of natural resources considering engineering properties and environmental impacts. It also provides a deeper understanding of the hydration behavior of stabilized soil using SFS which is expected to partially or fully replace PC in the material. Experimentally, it develops a chemical test model as an alternative method for TGA with lower experimental cost, less interference, and easier access to determine the CO2 captured in cementitious materials. / Doctor of Philosophy / Concrete, the second most consumed material on earth after water, is a source of environmental problems due to global urbanization. The production of this construction material requires a large amount of natural resources, and portland cement (PC) is responsible for around 8 % of planet-warming CO2 emissions. This dissertation presents different approaches and technologies to offset the CO2 footprint of the production of construction materials (i.e., cement clinker, concrete, and general cementitious materials). First, this dissertation investigated the possibility of using end-of-life tire (ELT) rubber powder in different construction materials including stabilized soft soil, portland cement concrete, and asphalt concrete. This work was discussed through aspects of engineering properties and environmental impacts. The results reveal that the ELT rubber had both negative and positive effects on the engineering properties of the three materials. In return, all three materials' matrices could effectively immobilize most leachable zinc and total organic carbon (TOC) from the ELT rubber, which are detrimental to aquatic animals, plants, and humans. Second, this dissertation used isothermal calorimetry (IC) for the first time to study the heat of hydration of soil stabilized by steel furnace slag (SFS) to assess the chemical aspects of the stabilization. The work compared the hydration behavior of SFS in clayey soil with traditional stabilizers such as lime or portland cement. The results demonstrated that there were chemical reactions taking place during the hydration of stabilized soil using SFS, explaining the improvement in engineering properties of the stabilized soil. Moreover, this dissertation adopted a Digestion-Titration Method (DTM) for the determination of mineralized CO2 content in cementitious materials. The method uses hydrochloric acid to digest CaCO3 under vacuum conditions. The CO2 released is captured by a barium hydroxide solution, which is then titrated to quantify the amount of CO2 absorbed. The data suggest that the new test method is feasibly applicable to chemically determine the CO2 mineralized in cementitious materials, and it can be an alternative method for thermogravimetric analysis with lower experimental cost and easier access. Overall, it is evident that cement, concrete, and construction materials are essential to the functionality of civilization. Dealing with CO2 emissions and natural resource depletion induced by the production of these construction materials is urgent for sustainable development. This dissertation is expected to fill the knowledge gap in carbon neutral construction materials research, including increasing the use of low-carbon aggregates (e.g., waste aggregates, recycled aggregates) and alternative cementitious binders as well as developing new test methods that can support measuring the effectiveness of these reduced carbon cementitious materials.