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Carbonation curing of concrete products has shown potentials for CO2 capture and storage with environmental, technical and economical benefits in global greenhouse gas mitigation exercise. The primary objective of this study is to investigate the effect of early age carbonation on mechanical performance and pH of concrete in an attempt to understand the process and promote large scale applications. / It was found that significant early strength was developed in cement and concrete through early age carbonation curing. The early strength could be maintained and improved due to subsequent hydration. Twenty-eight-day strength of carbonated cement and concrete was comparable to that of hydrated reference if subsequently cured in the air in a sealed bag, but was lower if subsequently cured in water. Treatment with either internal curing using lightweight aggregates or chemical admixture can effectively enhance late strength development in carbonated concrete. / For three typical cement-based products including cement paste compacts, concrete compacts and precast concrete, two-hour carbonation reduced pH value from 12.8 to 11.8 as the lowest and subsequent 28-day hydration could slightly increase pH by 2% as maximum. At any time pH of early age carbonated concrete was always higher than 11.5, a threshold value under which the corrosion of reinforcing steel is likely to occur in concrete. The high pH in early-age carbonated concrete was likely attributed to the fact that early age carbonation was an accelerated hydration process, which was totally different from weathering carbonation in which pH of concrete could be neutralized due to the decomposition of calcium hydroxide and calcium silicate hydrates gel. Therefore, early age carbonation technology is applicable not only to concrete products such as masonry units and paving stones, but possibly to precast concrete with steel reinforcement as well.

Recycled concrete aggregate (RCA) is a construction material, which is being used in the Canadian construction industry more frequently than it was in the past. The environmental benefits associated with RCA use, such as reduced landfilling and natural aggregate (NA) quarrying, have been identified by industry and government agencies. This has resulted in some incentives to use RCA in construction applications. Some properties of RCA are variable and as a result the material is often used as a structural fill, which is a low risk application. The use of RCA in this application is beneficial from an overall sustainability perspective but may not represent the most efficient use of the material. Efficient use of a material means getting the most benefit possible out of that material in a given application. The initial step in efficient material use is evaluating how a material affects its potential applications. In the case of RCA, this includes its use in concrete as a coarse aggregate. RCA is made up of both aggregate and cement mortar from its original application. Its make-up results in absorption capacities, which are higher than NA. Its high absorption capacity indicates that RCA can retain a relatively large proportion of water. Internal curing of concrete is the practice of intentionally entraining reservoirs of water within concrete. This water is drawn into the cement at a beneficial point in the cement hydration process. This water allows for a more complete hydration reaction, less desiccation, a less permeable concrete pore system, and less susceptibility to the negative effects of poor curing. The potential for RCA to act as an internal curing agent was evaluated in this research. Two RCA types were studied in the course of this research, one RCA of high-quality and one low-quality. These were compared to one NA type, which served as experimental control. Neither RCA type was found to desorb significant amounts of entrained water at relative humidity levels between 85% and 93%. This behaviour indicates that they would not behave as a traditional internal curing agent. Within concrete, the initial saturation levels of these RCAs were 0%, 60% and 100% of their full absorption capacity. The mixtures ranged from 30% RCA (by volume of coarse aggregate) to 100% RCA. These mixtures were subjected to two curing regimes, MTO-specified curing conditions and moist curing, in order to gauge the internal curing potential of the RCA. Fully saturated RCA mixtures were found to retain water throughout the course of testing. They were also found to increase the rate of compressive strength gain at early ages in comparison to similarly cured NA mixtures. Full saturation was found to have a negative effect on the thermal expansion behaviour of the concrete at 28 days concrete age. Permeable porosity of concrete was measured as an indicator of more thorough hydration in RCA concrete, but any potential benefits were masked by the increase in permeable porosity associated with permeable RCA. When compared with NA control mixtures and RCA mixtures cured under ideal conditions, it was found that saturated RCA mixtures provided compressive strength benefits. Low-quality RCA, which lost entrained water earlier in the testing period than high-quality RCA, benefitted in terms of early age compressive strength gains under specified curing conditions. High-quality RCA, which retained a relatively higher proportion of its entrained water throughout the early testing period, improved later age compressive strength under spec-curing conditions. Mixtures with 30% RCA (by volume of coarse aggregate) were generally found to not significantly affect the tensile strength, elastic modulus, and permeable porosity of the concrete. Tensile strength and elastic modulus were found to be consistently lower in RCA concretes, while permeable porosity was consistently higher. However, the magnitudes of these changes were not large enough to be statistically significant based on the testing regime employed. Compressive strength was significantly improved at 28 days when the 30% RCA was fully saturated. 30% RCA mixtures significantly reduced the thermal expansion of concrete at 28 days, which could provide particular benefit to concrete pavement applications. Overall, RCA saturation in new concrete had both positive and negative effects on the properties of concrete, which should both be considered in the context of the application for which RCA concrete is being considered. Specifically, concrete applications with the potential for poor curing and the need for reduced thermal expansion could benefit through the inclusion of coarse RCA. For example, these benefits could manifest in reduced thermal cracking at slab joints and reduced thermal stresses due to temperature gradients in pavements.

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Sustainable resource management and development have been at the forefront of important issues concerning the construction industry for the past several years. Specifically, the use of sustainable building materials and the reuse and recycling of previously used building materials is gaining acceptance and becoming common place in many areas. As one of the most commonly used building materials in the world, concrete, composed of aggregate, sand, cement and water, can be recycled and reused in a variety of applications. Using crushed concrete as fill and subgrade material under roads, sidewalks and foundations has been the most common of these applications. However, research has been ongoing over the past 50 years in many countries including Germany, Canada, Japan, the United States, China, and Australia investigating the use of crushed concrete from demolished old concrete structures to fully or partially replace the virgin aggregate used to produce new concrete for use in building and pavement applications. Producing concrete using recycled concrete aggregates (RCAs) has several advantages, namely, the burden placed on non-renewable aggregate resources may be significantly decreased, the service life and capacity of landfill and waste management facilities can be extended, and the carbon dioxide emissions and traffic congestion associated with the transport of virgin aggregates from remote sites can be reduced. This research is directed at benchmarking typical RCA sources for usage in structural concrete and investigating the inter-relationships between aggregate properties, concrete properties and the bond properties between reinforcing steel and RCA concrete. The experimental program focused on four main areas: aggregate properties testing, development of concrete mixture proportions, concrete fresh and hardened properties testing, and beam-end bond testing. Four coarse aggregate sources were investigated including one virgin or natural aggregate (NA) source, and three RCA sources. Two RCA sources were derived from the crushing of decommissioned building and pavement structures (RCA-1 and RCA-2) while the third source was derived from the crushing of returned ready-mix concrete (RCA-3). A variety of typical and non-typical aggregate tests were performed to provide a basis for correlation with fresh and hardened concrete properties results. A total of 24 concrete mixtures were developed and divided into three separate categories, 1) control, 2) direct replacement, and 3) strength-based mixtures. The control mixtures were proportioned to achieve compressive strengths of 30, 40, 50 and 60MPa with slump values between 75 and 125 mm and served as a basis for comparison with the RCA concrete mixtures. The direct replacement mixtures were developed to investigate the effect that fully replacing (i.e., 100% replacement by volume) virgin coarse aggregate with RCA has on the fresh and hardened properties of the resulting concrete. The strength-based mixtures were developed to investigate the influence of aggregate properties on reinforcement bond in concrete having the same compressive strength. In addition, two separate experimental phases were carried out which had varying compressive strength ranges, different RCA sources, and different suppliers of the same type GU cement. Concrete properties such as slump, compressive strength, splitting tensile strength, modulus of elasticity, Poisson’s ratio, linear coefficient of thermal expansion (LCTE), modulus of rupture and fracture energy were all measured. In total, 48 beam-end specimens were tested that incorporated three bonded lengths (125, 375, and 450 mm) and four concrete compressive strengths (30, 40, 50 and 60 MPa). Based on the results of the aggregate testing it was found that concrete incorporating pre-soaked (i.e., fully saturated) RCA as a 100% replacement for natural aggregate had slump values between 22% and 75%, compressive strengths between 81% and 137%, splitting tensile strengths between 78% and 109%, modulus of elasticity values between 81% and 98%, LCTE values in the same range, flexural strengths between 85% and 136%, and fracture energies between 68% and 118%, of the equivalent control (natural aggregate) concrete mixture. Overall, reductions in bond strength between natural aggregate and RCA concrete ranged between 3 and 21%. The strength of coarse aggregate as quantified by the aggregate crushing value (ACV) was found to be the most significant aggregate property for influencing bond strength. A regression model (based on the beam-end specimens test results) was developed to extrapolate the experimental development lengths as a function of f’c1/4 and ACV. The model, while not intended for use as a design equation, predicted that the required development lengths for the RCA concrete tested as part of this research study were up to 9% longer as compared to the natural aggregate concrete. A detailed flowchart of the various inter-relationships between aggregate properties, concrete properties and reinforced concrete bond properties was compiled based on the results of this research. A comprehensive guideline for use of RCA in concrete was developed based on the findings of this research. It includes a systematic decision tree approach for assessing whether a particular RCA source can be categorized into one of three performance classes. The range of allowable applications of a concrete which incorporates the RCA source as replacement of natural coarse aggregate will depend on the RCA performance class.

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