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Articles • Matéria (Rio J.) 30 • 2025 • https://doi.org/10.1590/1517-7076-RMAT-2024-0781 linkcopy

Open-access Rheological and mechanical behavior of self-compacting mortars containing marble waste as a partial replacement of sand

AuthorshipSCIMAGO INSTITUTIONS RANKINGS

    ABSTRACT

    Materials recycling presents a compelling economic case for waste disposal sites and the conservation of natural resources. This study delves into the substitution of cement with varying percentages of marble waste (0%, 10%, 20%, 30%, 40% and 50%). The water-to-binder ratio is consistently set at 0.44 for all mixes. Chemical admixtures such as superplasticizers or viscosity agents are frequently added to the mortar to improve its flow and strength. We conducted mini-slump flow and rheometer tests to assess the fresh mixes' rheological properties, as well as tests to measure the compressive and tensile strength of the mixes. The findings indicate that including marble powder enhances the mechanical properties of self-compacting mortar. A substantial 29% enhancement was achieved for a mixture incorporating 30% marble waste. The most favorable rheological properties, including slump flow, yield stress, and superior mechanical performance in compressive and tensile strength, were observed in the mix containing 30% marble powder waste. Furthermore, the investigation showed that the self-compacting mortar with a yield stress of 0.98 MPa at a 50% MW replacement rate and a viscosity of 1.4 Pa.S can achieve a slump flow of 25–31 cm. These findings illustrate marble waste potential as a valuable addition to self-compacting mortar (SCM) manufacturing, delivering improved performance and structural integrity. However, specific application scenarios and long-term endurance restrictions require further investigation. Practical effects include the possibility of developing inventive, sustainable, and economic SCM compositions, which will help to advance construction practices and sustainability. The social ramifications include reducing environmental impact and increasing resource efficiency in the construction industry.

    Keywords:
    Mortar; Workability; Compressive strength; Flexural strength; Marble waste

    1. INTRODUCTION

    In recent years, in the concrete industry, self-compacting concrete (SCC) has made significant technological progress through the advantages affected by the latter, ease of implementation, prefabrication, and the needless vibration ensured by the concrete fluidity, also due to the workability characteristics of self-compacting concrete [1, 2]. Adding admixtures and utilizing adjuvants in SCC mixes affect its characteristics [3, 4]. Various studies by DHIYANESHWARAN et al. [5] and Messaoudi et al. [6] have devised individual mix proportion techniques.

    Incorporating different types of waste in self-compacting concrete blends affects their properties in fresh and hardened states [6, 7]. Multiple research investigations have concentrated on formulating a method to forecast the rheological characteristics of these concrete mixes s[8, 9, 10].

    Using marble powder is a practical and cost-effective way to enhance the qualities of various types of concrete [11]. Numerous studies have outlined the benefits of marble powder. TOPÇU et al. [12] and SARDINH et al. [13] have examined its impact on the properties of concrete, both in its fresh state and once hardened. These studies concluded that substituting marble powder improved the workability and mechanical strength of the mortar.

    The literature suggests that mortar containing marble waste can be produced with properties similar to standard mortar as long as the marble powder content does not exceed 30% [2]. Some studies have also investigated the impact of this experimental material on the shear threshold and viscosity of mixtures using a Herschel-Bulkley model [2, 14]. Furthermore, the influence of mineral additives on concretes’ rheological and mechanical properties is discussed in [15]. Results from rheological and mechanical tests indicate that, depending on the type and amount of mineral additions, it is feasible to adjust rheological parameters to align with the used rheology assessments. The research discovered that replacing sand with limestone waste enhances the rheological properties of concrete. The study noted a rise in mechanical strength for fine aggregates with 25%, 50%, and 75% substitution ratios, exceeding the strength attained with natural aggregates [16]—However, a complete 100% replacement led to decreased strength values [17].

    GADO [18] reported improvements in the properties of polymer-modified cementitious adhesive mixture formulations with the optimal addition of sludge. SIDDIQUE and MEHTA [19] demonstrated that using waste marble with a 5–20% replacement ratio in self-compacting concrete can increase its durability—additionally, reusing marble in concrete offers economic interest. AYDIN and AREL [20] noted that the concrete slump decreased with increasing amounts of marble waste. Similarly, KARAKURT and DUMANGÖZ [21] showed that slump test results extended between 55–72 cm with a 10–30% substitution of marble dust. Sharma et al. [22] found that the highest slump flow value was achieved with a 20% replacement of marble dust with cement, resulting in a slump value of 12 cm. According to JARUGUMALLI and MADUPU [23], the slump flow increases up to a 40% replacement with marble waste powder, after which it begins to decrease.

    In this study, the influence of replacing natural sand with marble waste up to 50%, based on the literature review on the fresh and hardened properties of mortar, including porosity and water absorption, is considered. The main objective is to evaluate the rheological parameters such as yield stress and plastic viscosity, slump flow, compressive and flexural strength, bulk density, and microstructural properties.

    2. MATERIALS AND METHODS

    The experimental program used CEM I/A-L 42.5 cement sourced from Blida. The mineralogical and chemical composition of the cement are given in Tables 1 and 2. The particle size distribution of cement was determined by laser granulometry and is shown in Figure 1. Marble powder waste, primarily composed of calcium carbonate (98.8%), was obtained from recycled marble waste in the Blida region. Semi-crushed sand (0/4) was employed as the fine aggregate. The physical properties of the sand and marble waste are summarized in Table 3. The particle size distribution of the sand and marble waste particles is shown in Figure 2.

    Thumbnail
    Table 1
    The mineralogical constitution of cement.
    Thumbnail
    Table 2
    Chemical composition of the cement used.
    thumbnail of Figure 1
    Figure 1
    Particle size distribution of cement.
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    Table 3
    Physical characteristics of sand and marble waste.
    thumbnail of Figure 2
    Figure 2
    Particle size distribution of sand and marble waste.

    Figure 3 presents the SEM images of natural sand and marble waste. The shape of sand grains is spherical with a regular surface. Meanwhile, the marble waste grains are angular and have relatively rough surfaces.

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    Figure 3
    SEM (Scanning Electron Microscopy) images of (a) sand and (b) marble waste.

    The mineral composition of the marble powder was assessed through X-ray diffraction (XRD) analysis. Figure 4 shows the XRD diffractogram, revealing predominant components, including Calcite (Ca), Dolomite (D), and Quartz (Q).

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    Figure 4
    XRD (X-ray diffraction diffractogram) of marble.

    The superplasticizer this research utilizes is a high-range water reducer, specifically a polycarboxylate. It had a density of 1.07 and has a pH of approximately 6.0. Notably, this superplasticizer’s chloride ion (CI−) and sodium oxide (Na2O) contents are maintained below 0.1% and 1%, respectively. Figure 5 illustrates the various materials used in the mix design. Some papers may include a bibliographic review between the introduction, materials, and methods.

    thumbnail of Figure 5
    Figure 5
    Materials used in mix design.

    To conduct this investigation and assess the rheological and mechanical properties of mortar incorporating marble waste, five distinct mixtures were formulated with varying proportions of marble waste (0, 10, 20, 30, and 40%) using the methodology proposed by FARIH et al. [24]. The compositional details of these mixtures are presented in Table 4.

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    Table 4
    Composition of different mixtures.

    The rheological properties of the mixtures were evaluated using two methods: the slump flow test (Figure 6), conducted by EN 12350-8 standard and described by AFNOR [25], and the rheometer test (Figure 7). The latter was employed to quantify specific rheological parameters. These complementary tests comprehensively assess the mixtures’ flow behavior and rheological characteristics.

    thumbnail of Figure 6
    Figure 6
    Slump flow test.
    thumbnail of Figure 7
    Figure 7
    Rheometer AR 2000 test.

    The mechanical performance of the mixtures was characterized through compressive and flexural strength tests. These mechanical evaluations were conducted using a TE 300 kN press (Figure 8) in compliance with the NF EN 196-1 standard [26]. The values are obtained by crushing the average of four specimens of the size of 4 × 4 × 16 cm3 at different curing times: 7, 28, and 90 days. The flexural strength was measured using a three-point bending test. The distance between supporting pins is 10 cm. This testing protocol ensures a standardized assessment of the mortar’s mechanical properties, allowing for reliable comparisons between different mixture compositions.

    thumbnail of Figure 8
    Figure 8
    Electromechanical universal press.

    3. RESULTS

    3.1. Slump flow test

    Figure 9 illustrates the relationship between the five mixtures’ slump flow and the marble powder replacement ratio. A consistent decrease in slump flow was observed with increasing proportions of marble waste in the mortar. The control self-compacting mortar (0MW, without marble powder) exhibited a slump flow of 33.5 cm. Mixtures containing 10%, 20%, 30%, 40%, and 50% marble demonstrated reductions in slump flow of 2.8%, 6.4%, 9.4%, 14.2 and 33.1%, respectively. A notable decrease in spread diameter was observed when the marble powder content reached 40%, corroborating the negative impact of marble powder on workability, as reported in previous studies by MESSAOUDI et al. [2].

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    Figure 9
    Slump flow of mixes according to MW substitution ratio.

    3.2. Rheological parameters

    Figure 10 illustrates the impact of marble waste incorporation on the yield stress of mortar mixtures. The results demonstrate that mortars containing marble powder exhibited higher yield stress values than the control mixture (0MW). A progressive increase in yield stress was observed with increasing marble powder content. Relative to MMP0, the yield stress increased by 30.1%, 49,4%, 53.5%, 59.1 and 70% for 10MW, 20MW, 30MW, 40MW and 50MW, respectively.

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    Figure 10
    Influence of MW substitution ratio on yield stress.

    Figure 11 depicts the relationship between viscosity and marble powder content, with other parameters constant (W/C = 0.44, SP dosage = 1.30). The viscosity of the mixtures increased gradually with increasing marble powder content. Compared to 0MW, the viscosity increased by 9.99%, 19.9%, 27.3%, 69.7%, and 78.2 for 10MW, 20MW, 30MW, 40MW and 50MW, respectively.

    thumbnail of Figure 11
    Figure 11
    Influence of MW substitution ratio on viscosity.

    These findings are consistent with previous research. GÜNEYISI et al. [27] reported that the addition of marble powder increased the plastic viscosity of mortars, while ÇINAR et al. [28] observed that increasing the marble powder waste content in cement-based Grout (CBG) mixtures led to higher plastic viscosity values.

    3.3. Mechanical properties

    Figure 12 illustrates the relationship between mechanical properties, marble powder content, and curing age. The compressive strength exhibited an initial increase up to a threshold value (30% marble powder), beyond which it decreased with further additions of marble powder waste. Compared to the control mixture (0MW), the compressive strength increased by 2.8%, 4.5%, 9.4%, 1.1 and 0.2% for mixtures 10MW, 20MW, 30MW, 40MW and 50MW, respectively. This enhancement in mechanical performance may be attributed to the chemical effects of marble powder, a finding that aligns with previous research by OMAR et al. [16].

    thumbnail of Figure 12
    Figure 12
    Influence of MW on compressive strength at 7, 28, and 90 days.

    Figure 13 depicts the progression of flexural strength in hardened mixtures based on varying amounts of marble powder waste. All mixtures containing marble powder exhibited significantly higher flexural strength compared to the reference mixture without marble powder (MMP0). Specifically, at 28 days, the flexural strength increased by 11.1%, 15.9%, 28.4%, and 28.4% for mixtures 10MW, 20MW, 30MW, 40MW, and 50MW, respectively, in comparison to 0MW. This observation validates the effectiveness of utilizing marble powder waste in self-compacting mortar [29, 30]. Furthermore, over time, the enhanced flexural strength is primarily attributed to the continuous cement hydration and the interaction between limestone fillers in cement type CEMII and the aluminates from the marble powder, leading to monocarboaluminates. PATEL et al. [31] showed that including ground granulated blast slag (GGBS) in mixes increased compressive strength. In related research, AIDJOULI et al. [32] demonstrated that including waste marble powder in mixed concrete requires a significant quantity of superplasticizer to improve the workability, increasing the compressive strength of this concrete. Another analysis has suggested that an optimal cement substitution of 10% marble powder maintains the best mechanical and environmental characteristics in friendly concrete [33]. Furthermore, BOURZIK et al. [34] studied the influence of waste marble powder on the properties of concrete. Based on workability, density, and compressive strength, their results show that the inclusion of waste marble powder at 15% does not negatively influence the mixes’ properties. On the other hand, AHMED et al. [35] concluded that using an adequate quantity (20%) of Waste Marble increases self-compacting concrete’s compressive strength, tensile strength, and durability. In related research, FILALI and NASSER [36] examined the influence of marble powder and fly ash as a function of workability and compressive strength of concrete. They show that the incorporation of marble powder at 20% and 30% of fly ash as a partial substitution for sand increases the compressive strength of this concrete. Several researchers have observed similar findings [37, 38, 39]. KORE and VYAS [40] focused their study on the compressive strength of all the mixtures containing marble raised by 40% and 18% at 7 and 28 days, respectively, and comparable results have been mentioned by DEMIR et al. [41].

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    Figure 13
    Influence of MW on flexural strength at 7, 28, and 90 days.

    3.4. The bulk density of SCM

    The bulk density in mixed materials is influenced by multiple parameters, including grain morphological characteristics, mixture porosity, mineralogical and chemical admixture types, cement composition, curing temperature, and water-to-cement ratio (W/C). The bulk density of hardened mortar was studied according to the European standards NF EN 1015-18 [42]. The effects of the marble waste on the bulk density of SCM are presented in Figure 14. The bulk density results show that the enhancement of mortar with marble waste results in a continuous rise in the bulk density. The SCM formulated with MW exhibited bulk density between 1.8 and 2.5 g/cm3%. The minimum bulk density value (1.8 g/cm3) was observed at 0% and 10% MW. The mortar’s highest value was given by incorporating 50% MW (SCM–50MW); the substitution of MW can lead to an essential increase in bulk density of 39% compared to the mixture without marble waste (MW). This indicates that the inclusion of MW in the mixes reduces the porosity. This is consistent with findings from [43], who reported that the density increased with up to 50% substitution of marble.

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    Figure 14
    Influence of the incorporation of MW on bulk density.

    3.5. Microstructure

    Figure 15 shows SEM microstructure images in SCM mixes at 90 days. SEM images of the control mortar (SCM-0MW) and SCM-50MW are presented in Figure 15(a) and (b), respectively. These scanning pictures illustrate an apparent propagation of (C-S-H) gel. Figure 14(a) presents the SCM-0MW. It is observed that the mortar is comprised of micro-voids. This can be explained by the reference mortar’s modest compressive and flexural strength compared to mixes containing 10% MW, 20% MW, 30% MW, 40% MW, and 50% MW, respectively. It is recorded that the micro-voids were decreased to improve the hydration action. Mixes containing 50% MW present extended spreading compared to the control mortar (SCM0-MW), which presents a compact structure compared to the reference mortar [24]. These observations align with the experimental values for compressive strength illustrated in Figure 12. Similar results have been documented by ADITTO et al. [44] and SINGH et al. [45] studied the influence of partial substitution of cement by waste marble. Their findings indicate that the marble mixes were denser than the reference mixes. Further, observing the specimens via SEM by ALAKARA et al. [46] showed that calcined marble powder increases hydration and microstructure densification and demonstrated improved mechanical properties.

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    Figure 15
    SEM images of the SCM.

    4. CONCLUSIONS

    Based on the experimental study of the impact of marble waste on the rheological and mechanical properties of SCM, the results presented and discussed the following conclusions have been reached:

    • The quantity of marble waste significantly influences the properties of mixtures in the fresh and hardened state.

    • The incorporation of marble waste (MW) decreased the slump flow of all mixes.

    • The dosage of SP significantly impacted the plastic viscosity values, yield stress, and slump flow. Reduced flowability and rheological metrics resulted from an increase in SP dosage.

    • Substitution of 40% of natural sand with marble powder improved compressive strength by around 13% by densifying the microstructure.

    • The replacement of sand with 40% marble powder improves the flexural strength of SCM, mainly at 28 days, by 21%.

    Finally, based on the main findings from this experimental study, the incorporation of marble waste as sand substitution in the mortar composition can provide an alternative material for producing any concrete class for different construction with low environmental impacts.

    5. ACKNOWLEDGMENTS

    In this section, credits for all received support may be given.

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    Publication Dates

    • Publication in this collection
      03 Mar 2025
    • Date of issue
      2025

    History

    • Received
      10 Nov 2024
    • Accepted
      27 Dec 2024
    Creative Common - by 4.0
    This is an Open Access article distributed under the terms of the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
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