Replacement of Clinker with Dune Sand

1. INTRODUCTION
Portland cement is one of the most important materials in the construction industry
because of its multiple applications and mechanical and physical properties. The
current production rate for Portland cement is about 3.8 billion tons per year and is
increases in every year. A problem with the use of Portland cement is that its
production is highly energy intensive and cause significant environmental impact. For
example, the production of one ton of Portland cement produces about one ton of
carbon dioxide into the atmosphere. Therefore, there is a pressing need for
developing green building materials to fulfil the increase in demand for Portland
cement.
Dune sand powder considered as partial replacement material in cement. The Dunes
are considered as an important natural source and making them a major component in
concrete and mortar mixes. A Dune is a hill of sand built by either wind or water
flow. It occurs in different forms and sizes. The Dune sand is material of great
availability found in deserts or near lakes and oceans. It is common in Algeria, Egypt,
Western desert, Saudi Arabia etc. The sand is rich in silicon dioxide (SiO2), but in the
less reactive form. The milled or ground dune sand has a particle size of about 45
microns or less and is used as a partial replacement of up to 20 percent of the cement
to provide concrete with comparable strength to plain concrete. The 20 percent
replacement of cement by milled dune sand was considered to provide a sufficient
amount of silica (SiO2) that can react with Ca(OH)2 generated from the 80 percent of
cement to produce products having cementious properties. DSP consist of SiO2
quartz well crystallized type low quartz.
The effect of addition of the Dune Sand Powder (DSP) on development of
compressive strength and hydration of cement pastes was achieved as a function of
water/binder ratio, percentage and fineness of DSP. A cheaper alternative for cement
made of local natural resources has become a big concern to compensate the deficit in
the manufacture of cement. In 1970, major researches were carried out on the use of
materials that can be added to cement as a partial substitution to Portland cement.
These addition comes from the natural resources or other industrial by product. The
binding activity of the new obtained material depend on their amount, fineness
mineralogical composition and type of cement.
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The contribution of addition of dune sand powder on the cement binding activity
results primarily from three effects. They are granular effect, physico -chemical effect
and chemical effect. Granular effect relates to mineral addition in the granular
structure of cementing material in a fresh state. It becomes positive and leads either to
improve the consistency of fresh mixture maintain a constant water content or
decrease the water content for a given consistency by improving the compactness of
the mixture and the mechanical performance of hardened material. It related to the
changes induced by the presence of the fine particles in the solid skeleton of the
mixture. Physico -chemical effect relates to all the modification generated by the
multiple interaction between the mineral addition particles on the hydration process
of cement, and on structuring the hydrated products. Physico-chemical effect of the
mineral additions acts primarily on the evolution of the mechanical strengths at early
age and on the physical and microstructural properties of hardened cementing
materials. Chemical effect relates to pozzolanic or hydraulic properties, to react with
water and the anhydrous or hydrated components of cement to form new mineral
phases which can contribute to the mechanical strength and hydrated products of
cement. The analysis by X-ray diffraction highlighted the role of pozzolanic dune
sand powder. DSP can be used for replacement of clinker present in the cement
production. 5%,10%,15%,20% replacement of clinker by DSP is commonly adopted.
Figure 1.1 shows Barchan sand dune to the east of El- Bagawat cemetery.

Fig. 1.1 Barchan sand dune to the east of El- Bagawat cemetery.

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2. CONCRETE
A composite material that consists essentially of a binding medium, such as a mixture
of Portland cement and water, which contains fragments of aggregate, usually a
combination of fine and coarse aggregate. The tensile strength of concrete is very less
than that of its compressive strength. Because of that it is typically reinforced with
steel bars, in which case it is known as reinforced concrete.
2.1. CEMENT
There are many different kinds of cements. In concrete, the most commonly used is
Portland cement, a hydraulic cement which sets and hardens by chemical reaction
with water and is capable of doing so under water.Modern Portland cement was
invented in 1824 by Joseph Aspdin of Leeds, England. The name derives from its
resemblance of the natural building stone quarried in Portland, England.The raw
ingredients of Portland cement are iron ore, lime, alumina and silica. These are
ground up and fired in a kiln to produce a clinker. Clinker is stored at the construction
site until it is required for grinding into cement. Gypsum and supplementary
cementitious material added to get fine cement powder. Gypsum is added to regulate
the setting time of cement.
2.1.1 Clinker
Clinker is an artificial rock made by heating limestone and other raw materials in
specific quantities to a very high temperature in a specially made kiln. Portland
cement is hydraulic cement made by finely pulverizing the clinker produced by
calcincing to incipient fusion a mixture of argillaceous and calcareous materials. It is
the fine grey powder that is the most important ingredient of concrete. Hence the
name cement concrete. A cement kiln, a huge inclined rotating furnace is a
continuous stream process vessel in which the feed and fuel are held in dynamic
balance. As the raw materials combine toward the 1500 0C flame, the chemical
reaction transforms them into clinker. Clinker production require high temperatures,
which are generated by the combustion of coal. Clinker is stored at the construction
site until it is required for grinding into cement. It is ground with gypsum and
supplementary cementitious materials to form fine cement powder. Addition of DSP
reduce the requirement of clinker in cement.
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Fineness is the measure of the size of the cement particles.

2.2. AGGREGATE
The aggregate is a granular material, such as sand, gravel, crushed stone, or iron-blast
furnace slag. It is graded by passing it through a set of sieves with progressively
smaller mesh sizes. All material that passes through 4.75 mm sieve conventionally
referred to as fine aggregate or sand, while all material that is retained on the 4.75
mm sieve is refered to as coarse aggregate, gravel, or stone. By carefully grading the
material and selecting an optimal particle size distribution, a maximum packing
density can be achieved, where the smaller particles fill the void spaces between the
larger particles. Such dense packing minimizes the amount of cement paste needed
and generally leads to improved mechanical and durability properties of the
concrete.The aggregate constitutes typically 75% of the concrete volume, or more,
and therefore its properties largely determine the properties of the concrete. For the
concrete to be of good quality, the aggregate has to be strong and durable and free of
silts, organic matter, oils, and sugars. Otherwise, it should be washed prior to use,
because any of these impurities may slow or prevent the cement from hydrating or
reduce the bond between the cement paste and the aggregate particles.

3. DUNE SAND POWDER

Dune is a hill of sand formed by wind or due to flow of water. Dune occurs in
different shapes and size. Dune sand is greatly available in desert regions. The
contribution of addition DSP on the cement binding activity results primarily from
two effects. They are physical-chemical effect and chemical effect.
3.1. CHARACTERISTICS OF MATERIALS
Very fine particles of dune sand is used for the replacement. Crushing of dune
sandand clinker is carried out using a ball crusher. DSP, Portland cement, Water are
the materials.
3.1.1. Chemical nature
Dune sand powder contain high percentage of silica SiO2 , therefore the dune sand is
siliceous sand. The presence of high percentage of silica SiO2 is greater than 74%
and therefore the dune sand is siliceous sand. Table 3.1 Chemical analysis of dune
sand powder (%)
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Table 3.1 Chemical analysis of dune sand powder (%)

Element SiO2 Al2O3 Fe2O3 CaO MgO SO3 K2O Cl- PAF
Percentage
(%) 74.61 1.35 0.86 17.3 0.29 0.04 0.47 0.005 5.04

3.1.2. Mineralogical nature

DSP shows a crystalline structure siliceous (low quartz). The crystalline silica shows
a regular three-dimensional structure. It is a tetrahedron an oxygen atom and center
occupies each summit by a silicon atom. The atomic structure changes when the
temperature is above 8700 C. Mineralogical nature is observed by using X
diffractogram.
Figure 3.1 shows the mineralogical nature of dune sand powder.

Fig. 3.1 X diffractogram (DSP) as a function of time

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4. CASE STUDY
The experimental work has done for checking the possibility of use of dune sand
powder additions as a partial substitution to Portland cement. These additions come
from natural sources or by products of other industries. The addition increases
binding activity of the cement and it depends on amount, fineness, mineralogical
compositon and the type of cement also. The compactness of the cement paste can be
improved by the formation of calcium silicate hydrates.
4.1. EXPERIMENT
For studying the effect of different percentages of dune sand powder. Dune sand
powder of fineness F1=3000cm2/g and F2=4000cm2/g and the effect of water binder
ratio w/b= 0.4,0.3 and 0.25 on the compressive strength of cement paste. The mass
percentages (5%,10%,15%,20%) were taken for the addition to ordinary Portland
cement. Cubes of size 20 mmx20 mm x20 mm prepared with pure cement paste. The
cement pastes were prepared in a mixer standard EN 196-1 by following procedure
described by European Standard EN 196-3. The hardening was under natural
conditions, the specimens are subjected to water curing. It is useful in identifying
minerals. Spectrum of X diffraction reflects internal structure and nature of minerals.

4.2. MATERIALS
The materials used are dune sand, Portland cement and water. The crushing of dune
sand and clinker are carried out using a conventional ball crusher.
4.2.1. Dune Sand
Addition of dune sand powder depends on its local availability at acceptable cost and
silica content .Dune sand in the region of Biskra. Apparent density is 1300kg/m3 and
specific density is 2770kg/m3. Figure 4.1 shows Grading curve of sand and gravel.

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 Replacement of Clinker with Dune Sand

Fig. 4.1 Grading curve of sand and gravel

4.2.2. Gravel
Gravel is of crushed stone fraction in the region Ain-Touta (Batna).
Apparent density = 1420 kg/m3
Specific density = 2610 kg/m3
4.2.3. Portland Cement
The cement used is OPC. It consist of 95% clinker and 5% gypsum, for regulationof the
setting time. Apparent density is 1120 kg/m3 and specific density is 3050 kg/m3.
4.2.3.1. Chemical and Mineralogical nature
The chemical and mineralogical composition of clinker is shown below in the table 4.1 and
4.2

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Table 4.1 Chemical composition of clinker (%)

Free
Elements SiO2 Al2O3 Fe2O3 CaO MgO IR SO3 CaO LOI

Percentage
(%) 22 5.02 2.94 64.36 2.07 0.73 1.94 0.30 0.64

Table 4.2 Mineralogical composition of clinker (%)

Element C3 S C2 S C3 A C4AF

Percentage
(%) 51.28 24.68 8.33 8.94

4.2.3. Water
The water is drinking water that contains little sulphate and having a temperature of 20±100
C. Its quality conforms to the requirements of standard NFP 18-404.

4.3 MIX PROPORTIONS

The details of the mixtures proportions are given in the table.

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4.4. RESULTS AND DISCUSSIONS

The results obtained from the case study is as follows.
4.4.1. Pozzolanic reactivity of dune sand powder
The superposition of X diffractograms shows that the dune sand powder does not change the
nature of hydrate after 14 days of hydration. The portlandite formed during reactions of
cement hydration in the presence of DSP has been partially consumed, the peak
corresponding decreased compared to the reference (peak appearing at 9°θCu Kα (P is
centered in the reticular distance d = 4.9Å)). The choice of this stripe is the fact that it is
distinct from those of other minerals. The higher the percentage of DSP content in the paste
increases the intensity of the line corresponding to 4.9Å increases. This result confirms that
the DSP is not inert and participates in training new C-S-H II that make the paste thicker and
more compact. The dune sand powder, despite its crystalline nature, presents a partial
pozzolanic reactivity. Figure 4.2 shows X Diffractograms of cement pastes in the presence of
DSP in 14 days.

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Fig. 4.2 X Diffractograms of cement pastes in the presence of DSP in 14 days

4.4.2 Compressive Strength

During the first seven days compressive strength is low. Whereas the compressive strengths
increases significantly in some period. It is due to the kinetics of the reaction of cement
hydration and reaction of dune sand powder with portlandite as a function of time. The rate of
development of compressive strength of the OPC alone at 28 and 90 days is 56% and 68%
respectively. When DSP added to the cement the compressive strength at 28 days is 69% and
97% to 90 days. These increase in compressive strength is resulted primarily from three
effects. They are physical effect, physico – chemical effect and chemical effect. These effects
acts simultaneously on the compressive strength of cement pastes. Physical effect is an
improvement of the compressive strengths by a thickening of the cement pastes. Physical -

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chemical effect is a physical process which produces a chemical activation of cement

hydration and depends on the content and fineness of the DSP, which acts on the evolution on
the compressive strengths at early age. The presence of DSP accelerates the reaction of
cement hydration. It is also combined with physical effect and hydration leads to better short
term compressive strengths. Chemical effect in which lime provided in Portland cement are
consumed by the pozzolanic reaction, caused by the addition of DSP to cement. Cement is the
expensive ingredient in the composition of the concrete. Therefore reducing the cement
content by maintaining a given strength for a given slump. It is also makes the cement to
continue its development of compressive strength even after the 28 days period. Compressive
strength of all hardened cement paste at any age decreases with the increase in w/b ratio .The
w/b ratio influences the porosity of the cement paste hydrated. Therefore cement with low
w/b ratio is adopted. Since cement pastes with low w/b ratio develops compressive strength
quickly by a high concentration in C-S-H. Figure 4.3 shows the Variation in compressive
strength as a function of time and w/b ratio (F1=3000 cm2/g). Figure 4.4 shows the Variation
in compressive strength as a function of time and w/b ratio (F1=4000 cm2/g).

Fig. 4.3 Variation in compressive strength as a function of time and w/b ratio (F1=3000
cm2/g)

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Fig. 4.4 Variation in compressive strength as a function of time and w/b ratio (F1=4000
cm2/g)

The DSP can change the structure of pores which means that it reduce the number of large
pores and increase the small pores. The role of fine particles in DSP is very important and

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more effective. Increasing the fineness of 3000 cm2/g to 4000 cm2/g the compressive
strengths at all ages were improved by 12%. The addition of 20% DSP with fineness of 4000
cm2/g in OPC gives a new variety of cement with a compressive strength comparable to
OPC. Figure 4.5 shows the Variation in compressive strength at 28 days of cement pastes
with 20% DSP as a function of fineness and w/b ratio. Figure 4.6 shows the Effect of DSP on
the compressive strength( Fineness= 4000 cm2/g , w/b=0.25).

Fig. 4.5 Variation in compressive strength at 28 days of cement pastes with 20% DSP as a
function of fineness and w/b ratio.

Fig. 4.6 Effect of DSP on the compressive strength( Fineness= 4000 cm2/g , w/b=0.25)

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4.4.3. Effect of Dune Sand on Workability

When the dune sand content increases slump increases initially, and slump start decreasing
when the dune sand content is above 50%.Higher the workability of mix higher the dune sand
content .The optimum dune sand content is above 50% in higher workability mixes of
O1,O2,O3. All the fine aggregates are replaced by dune sand, there is a sharp decrease in the
slump. The decreasing in slump is due to the resulting particle size distribution when more
normal sand is replaced by dune sand. This is due to finer the fine aggregate less workable the
concrete. Figure 4.7 shows the Effect of dune sand content on workability

Fig.4.7 Effect of dune sand content on workability

4.4.4. Physical Properties
Consistency and Setting Time
DSP percentage has no significant effect on the setting time of mixtures. The addition of DSP
decreased their initial consistency by reducing the Inter granular vacuum .Amount of water
to obtain a normal consistency of the cement paste varies from 23% to 35%.The dune sand
powder fill the inter granular vacuums that decreases the demand of water.Therefore the dune
sand powder plays a role of lubricant. Table 4.4 shows Consistency and Setting time of
mixtures.

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Table 4.4 Consistency and Setting time of mixtures.

Tests( T=27 C) OPC+0 % OPC+ 5% OPC+

Porosity
From the volume of specimen, calculate the porosity. On the experimental basis hydrostatic
weighing of a saturated specimen, then determines the porosity from the following equation.
€exp (%) = ((MSDS – MS) / (MSDS – MD)) × 100%
Where
€exp: Porosity determined experimentally by hydrostatic weighing, excluding the volume of
trapped air and/or trained (%).
MSDS: Mass of saturated surface dry specimen (g).
MS: Dry mass of specimen (g).
MD: Mass of saturated surface dry specimen, weighing in water (g).
The specimens are dried in an oven at 105°C for 24 hours, and then immersed in water for 48
hours, the sample is then placed in a boiling water bath for 5 hours, and the tubes are
withdrawn to be weighed in air and water (hydrostatic weighing). The method used in this test
is that established by ASTM designation C 624 [21]. The porosity is estimated after 28 and
180 days of hardening on cubic specimens (10×10×10) cm3. The results obtained are shown

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in Figure 4.4.3.1. The porosity of the material is the first indicator of durability, because
porosity is the seat of external aggression, the material is more porous, more penetration of
agents is facilitated, and therefore its durability is limited. Figure 4.8 shows Porosity of
concrete as a function of time .

Fig. 4.8 Porosity of concrete as a function of time

OC: Ordinary concrete based OPC
C10: Concrete OPC + 10% DSP
C20: Concrete OPC + 20% DSP
At 28 days, the concrete porosity C10 is lower than other concretes, which is explained by the
high quality of the interface mortar/gravel. At 180 days, the porosity decreases.The addition
of 10% DSP caused a reduction of 32% porosity compared to ordinary concrete. Concrete
porosity improve their long term confirms the continuity of hydration reactions, leading to the
development of the internal structure byproduction of new hydration products which
precipitate to close the pores existing in the structure, making reduce the number of large
pores and increase the small pores.

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5. CONCLUSION

The use of the dune sand powder as a substitute of the clinker in Portland cement
reduces carbon dioxide emissions. It improves the compressive strength. The contribution of
addition of DSP to cement binding activity results from three effects. Increasing the fineness
of 3000 cm2/g to 4000 cm2/g, the compressive strength at all ages is improved by 12%.
Compressive strength of all hardened cement paste at any age decreases with the increase of
w/b ratio. After 28 days, the compressive strength at 5,10 and 15% of the DSP is superior to
the Portland cement with an optimum effect for percentage of the order 5% to 10%
irrespective of the w/b ratio and fineness of the DSP. DSP has partial pozzolanic reactivity.
The results proved that up to 20% DSP as Portland cement, replacement could be used with a
fineness of 4000cm2/g without affecting adversely the compressive strength. Compressive
strength at early age develop due to the acceleration of cement hydration combined with the
physical effect. The XRD analysis revealed the role of pozzolanic DSP. The small content of
portlandite detected in the cement pastes in the presence of the DSP, reflects the partial
pozzolanic reaction, which contributes to increased strength and improves compacting cement
pastes by three effects: physical, physical-chemical and chemical. The compressive strengths
at earty-age develop due to the acceleration of cement hydration, combined with the physical
effect, while those at average and especially long-term develop through the partial pozzolanic
effect, which cause the replacement of lime by the calcium silicate hydrate C-S-H semi-
crystallized of second generation and transformation of large crystals of lime CH into a
product of hydration slightly crystallized Average or long term strength develop through the
partial pozzolanic effect which cause the replacement of lime by calcium silicate hydrate C-S-
H. The use of the dune sand powder improves overall porous structure of concrete and also
contributes to the thickening of the interface (mortar/gravel). Thus, the dune sand powder
change the fracture characteristics (deformability), this allows an increase net in durability of
concrete. So DSP is used as a partial replacement upto 20% and it will reduce the emission of
carbon dioxide.

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