Latest Trends in Sustainable and Green Development

Use of Green cement in concrete for friendly building construction

KLARA KRIZOVA, RUDOLF HELA
Faculty of Civil Engineering
Brno University of Technology
Veveri 331/95, Brno
CZECH REPUBLIC
krizova.k@fce.vutbr.cz, hela.r@fce.vutbr.cz, http://www.fce.vutbr.cz

Abstract: - The paper presents a summary of current state of cement industry and possibilities of reduction of
CO2 by means of using waste materials and production of so-called Green cements, which are becoming very
popular worldwide. Practical part includes results of experimental work with Green cement CEM II/A-LL 42,5
R and CEM II/A-M 42,5 R compared to common Portland cement CEM I 42,5 R. Mix-designs were identical
with the only difference in the type of cement. Basic characteristics of concrete were examined, like
workability, compressive strength and static elasticity modulus. The aim of this research is introduction of
Green cements and concrete made from them. The focus is on positive technical aspects of concrete as well as
generally accepted fact of lower energetic and ecological demands of their production. There are efforts to
introduce these cements in common construction practice and contribute to Green buildings.

Key-Words: - Green buildings, CO2 emission, Cement industry, Portland cement, Limestone, Green cement

1 Introduction Usually, properties are the same as those of

Many sectors of science focus on ecological design
and production of ecologically friendly materials.
One of the main reasons is awareness of global
warming. The aim is changing to ecological
manufacturing processes and introduction of
ecologically friendly materials in every day practice
[1]. As regards construction industry, production of
cement is one of the most energetically demanding
industrial production processes. Cement, the main
component of concrete, is still popular and most
frequently used construction material worldwide,
even though it was found about 200 years ago.
Production of Portland cement requires raw
materials (clays, slates and limestone), which are
accessible in most countries. However, production
or Portland clinker is consumes a lot of energy.
Cement industry produces 5 % of worldwide
production of CO2 [1,2]. The goal is energetic
saving of the whole production process. Energy can
be saved by appropriate production process in rotary
furnace. It is also possible to use municipal waste,
old tires, waste oil or similar wastes for heating the
furnace systems. Technology of production of
Portland clinker has changed. Nowadays, waste
products of other industrial branches are added to
clinker. In particular fly ash, blast furnace slag and
limestone. With such additions, the product is not
clean Portland cement; it is blended cement with
various percentage proportions of waste materials.
common Portland cement. Properties of blended
cement, in particular durability of concrete
structures, can be better than those of common
cement [4,6,8].
Green cement or Green concrete represents a
modern trend in current concrete technology.
Production of cement with addition of selected
waste materials is very important with respect to
decrease of CO2 production in cement industry.
Development of alternative cementitious binders
and their application in building industry are
necessary for sustainable development. Such
cements are advantageous from both ecological and
economical point of view. Waste materials are used
as partial replacement of cement clinker and thus
energy demand for manufacture of cement and CO2
emissions are lower.
2 Cement industry
Current scheme of cement plants with respect to
environmental problems is following [6]:
• Reduction of emissions
• Use of waste materials as additions in input
materials, cement and alternative fuel
• Reduction of noise emissions
Cement industry belongs to most demanding
branches of industry as regards consumption of
energy. Cost of energy is the most important part of
total cost of cement. The aim is decreasing demands

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 Latest Trends in Sustainable and Green Development
for fuel and electrical energy. In the 90th of 20th
century, environmental requirements joined
previous requirements of energy savings.
Consumption of energy and amount of emissions is
influenced particularly by the process of production
of cement clinker. In recent years, most of modern
cement plants converted to dry production process
with multistage exchanger and precalcination. This
dry production process has been used since 1990 in
the Czech Republic together with using alternative
fuels, which saves so-called clean fuels like natural
gas and heavy oil. However, content of carbon in
alternative fuels is usually higher. Therefore, these
fuels often go against reduction of CO2 emissions.
There is a possibility of using biomass as fuel;
however, it is still limited in particular by its lower
heating capacity compared to other types of fuels
[8,9].
2.1 Emission of greenhouse gasses
Declared emission of CO2 to one ton of cement
clinker is 900 to 1000 kg at specific consumption
3500 to 5000 MJ/t of clinker, depending on the type
of fuel [4,7].
Fig.1 Overview of CO2 emissions of cement
industry
ISBN: 978-1-61804-132-6
Emission of CO2 to one ton of cement decreases
because of grinding cement with mineral additions.
Following waste materials are used for grinding of
cement: blast furnace slag, fly ash, waste types of
gypstone from desulphurization processes or
chemical productions [1,9].
Savings in the area of fuel emissions of CO2 will
depend on accessibility of alternative fuel and
biomass. Emission of CO2 produced by combustion
of carbonaceous fuel is directly proportional to
consumption of heat. Declared emission at specific
consumption of 3000 MJ/1t of clinker with
combustion of black coal is 0.32 t of CO2. Use of
natural gas reduces emission by ca 25 % (Austrian
report, 1997). In 1995, cement plants of developed
European countries committed themselves to
reduction of emissions by up to 20 %, in particular
by means of introduction of more effective furnace
processes [5].
2.2 CO2 and other gasses
Calcination is the basic process of firing clinker.
This chemical reaction begins with decomposition
of calcium carbonate CaCO3 accompanied by
emission of calcium oxide CaO and emission of
carbon dioxide CO2. The process of clinkering
follows at the temperature around 1400 - 1500°C,
where carbon dioxide reacts with silicon oxide,
aluminum oxide and iron oxide to silicates,
aluminates and ferrites of calcium and form cement
clinker [3,4].
Fig.2 Diagram of CO2 emissions during cement
production [3]
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 Latest Trends in Sustainable and Green Development
Approximately 60 % comes from the process of
calcination and 40 % from the process of
combustion of fuel. There are more harmful
emissions produced during the process of firing
clinker: carbon monoxide CO, nitrogen oxides NOx
- also greenhouse gases, sulphur dioxide and dust.
Proportions of individual gasses produced at
production process of cement are stated in following
Table 1 [5].
Table 1 Threshold values for mandatory reporting
on 19 of the 37 air pollutants covered by the
European Pollutant Emission Register (sector-
specific list for the industrial plants of the cement
industry) [5]
Threshold value
Pollutant
kg/year
Carbon monoxide (CO) 500,000
Carbon dioxide (CO2) 100,000,000
Non-methane volatile
organic compounds 100,000
(NMVOC)
Nitrogen oxides (NOx) 100,000
Sulphur dioxide (SO2) 150,000
Fine dust 50,000
Others 15,000
The limited ability to reduce CO2 emissions in
ordinary Portland cement along with increasing
governmental regulations on emissions necessitates
the development of alternative cement binders and
consequently creation of ‘‘greener” concepts for
building materials.
2.3 Blended cement and cement with
limestone
Manufacturers of cement prepared production of
other types of cement for general purpose in
accordance with valid European standard
EN 197-1 [11], with respect to current
environmentally and energetically demanding
production of Portland cement and with respect to
necessity of reduction of greenhouse gasses [6].
Like in other countries, manufacturers of cement in
Czech Republic also introduce Portland cements
with additional components. In particular, Portland
cement with limestone CEM II/A-LL,
(CEM II/A-L), CEM II/B-LL, (CEM II/B-L) and
blended cements CEM II/A-M and CEM II/B-M.
Blended cements and Portland cements with
limestone considerably widen the range of cement
for manufacture of concrete in accordance with
EN 206-1 [10,12]. Wide range of application of
these cements offers appropriate alternative for
ISBN: 978-1-61804-132-6
selected structures with respect to cost saving and
durability of the structure. The main guidelines of
construction with these cements are following [8]:
• Effective
• Economical
• Environmentally friendly
Blended cements contain more than one additional
component apart from clinker. In Czech conditions,
it is usually slag, limestone and fly ash. Use of more
components makes it possible to make use of their
characteristic properties and enhance end use
property of cement [6,7].
Portland cement with limestone contains clinker
and only one additional component - limestone
(L, LL). Finely ground limestone has positive effect
on workability of fresh concrete, decreases
separation of water and stabilizes coloring of
concrete. On the other hand, final strengths can
decrease. Slag and fly ash decrease initial strengths.
However, they have positive effect on development
of strength and higher final strengths. These
components usually also increase resistance to
aggressive environments. Individual components
can adjust granulometry of cement and thus control
development of hydration heat. Mentioned types of
cement are sufficiently compatible with plasticizers
in common use, like Portland cement [4,6].
3 Experimental part
The experimental part focused on examination of
characteristic properties of concrete. Three mix-
designs were used with three different types of
cement. Common Portland cement was compared to
two types of blended cements.
Following characteristics of fresh and hardened
concrete were observed:
• Consistency (slump test, slump flow)
• Air content in fresh concrete
• Volume weight of fresh concrete
• Compressive strength
• Static elasticity modulus
3.1 Materials
Three mix-designs of aerated concrete with three
different types of cement and identical doses of
components were used. Cements used were
a) CEM I 42,5 R, b) CEM II/A-LL 42,5 R and
c) CEM II/A-M 42,5 R. Aggregate of size fractions
0/4, 8/16 and 11/22 mm. Water, plasticizer and
air-entrainer Stachema.
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 Latest Trends in Sustainable and Green Development

a) CEM I 42,5 R - Common Portland cement 4 Conclusion

b) CEM II/A-LL 42,5 R - Portland cement blended The paper presents current state of cement industry
with limestone and its reaction to the trend of reduction of CO2
c) CEM II/A-M 42,5 R - Portland cement blended emissions. Most European and global cement plants
with 6-20 % slag, fly ash and limestone changed to more economical dry production process
from more costly wet way. Another step of
3.2 Evaluation of tests ecological approach of cement plants is using
Concrete was mixed according to mix-designs. appropriate alternative fuels. Recently, the idea of
Fresh concrete was tested on consistency by Slump Green cement become popular. These cements
test in accordance with EN 12350-2 [14], Slump demand less energy for production and produce less
flow in accordance with EN 12350-5 [15] and air CO2 emissions. These cements consist from clinker
content in fresh concrete in accordance with and usually waste products from other industrial
EN 12350-7 [17]. Testing specimens were made and branches. Fly ash and blast furnace slag are most
then placed in water for the periods of 2, 7, 14, 28 frequently used. Limestone is the most frequently
and 90 days. Basic characteristic property of used replacement from the range of natural
concrete - compressive strength - was determined on resources. Production of such blended cements
cubes with dimensions 150 x 150 x 150 mm. Static (Portland cement and limestone) represents current
elasticity modulus, the elementary property for trend of cement plants and blended cements are
static design of structures, was determined in becoming popular in construction industry. The
accordance with ISO 6784 [13] on testing main reason is properties of concrete made from
specimens with dimensions 400 x 100 x 100 mm. such cements. The properties are the same or even
Following table gives values of characteristic better than those of concrete made from Portland
properties of evaluated concrete. cement, in particular in corrosive environments.
The experimental part focused on assessment of
Table 2 Characteristic properties of evaluated basic characteristics of concrete with blended
concrete cement and cement with limestone in comparison
with common Portland cement. Mix designs were
Characteristic CI C II/A-LL C II/A-M
identical with the only exception - type of cement.
Slump (mm) 220 230 230 Workability of concrete was the same for all types
Slump flow of concrete and the same classing of consistency
(mm) 570 600 610 was reached. As for compressive strength, the
Air content generally known fact of slow development of initial
5,0 4,7 5,0 strength of concrete with blended cement and
(%)
Volume cement with limestone showed. However, even if
weight of fresh 2330 2340 2300 initial strength and development of strength are
concrete lower, concrete can still reach comparable values of
3
(kg/m ) compressive strength at required age of 28 days.
Compressive strength (MPa) Development of static elasticity modulus in the
2 days 43,0 38,0 35,0 period of 7 - 90 days was identical for all types of
7 days 55,3 53,8 48,5 concrete. Nevertheless, in this case, it was cement
14 days 61,0 56,0 52,0 with limestone, which reached better values than
common Portland cement. Blended cement reached
28 days 61,5 60,9 57,2
the lowest values of both compressive strength and
90 days 64,5 66,6 60,3 static elasticity modulus; however, the difference
Static elasticity modulus (MPa) was only minor.
7 days 38500 39000 36000 Concrete as composite material is an important
28 days 39500 42000 38500 part of civil and industrial construction and it is still
the most used composite construction material.
90 days 43000 43000 42000
Therefore it is necessary to support ecological
Note: 1 Labeling of mix designs: thinking and contribute to global energy saving.
C I … CEM I 42,5 R Production of Green cements with more basic
C II/A-LL … CEM II/A-LL 42,5 R components and lower energetic demands is very
C II/A-M … CEM A-M 42,5 R important mainly because it can decrease production
Note: 2 Consistency: Slump test - S5 > 220 mm, of CO2 and its environmental impact. However,
Slump flow - F5 560 to 620 mm ecological approach is not the only argument of

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 Latest Trends in Sustainable and Green Development
Green cements, since they represent a technically
adequate replacement of Portland cement, too.
Acknowledgement:
This paper was supported by the project FAST-S-
12-38 "Complex assessment of selected mechanical
properties of concrete in terms of concrete
microstructure".
References:
[1] Bassioni, G., Global warming and construction
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Rēzeknes Augstskola, Rēzekne, RA
Izdevniecība, Volume I1, 2009, pp. 78-86.
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[3] Hüner, T., Legislative proposals of the
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[5] Guidance document for EPER implementation.
European Commission Directorate - General
for Environment, 2000.
ISBN: 978-1-61804-132-6
[6] Reference Document on Best Available
Techniques in the cement and lime industries,
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http://www.svcement.cz/dokumenty/publikace.
[7] VUMO Prague, Ltd., Union Cement CZ,
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[8] VUMO Prague, Ltd., Union Cement, Cement
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[9] Revised text of lectures on technical and
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[10] VUMO Prague, Ltd., Union Cement CR,
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[11] EN 197-1:2000 Cement - Part 1: Composition,
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[12] EN 206-1 Concrete - Part 1: Specification,
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[13] CSN ISO 6784 Determination of static
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[14] EN 12350-2 Testing fresh concrete – Part 2:
Slump test.
[15] EN 12350-5 Testing fresh concrete – Part 5:
Flow table test.
[16] EN 12350-7 testing fresh concrete – Part 7: Air
content of fresh concrete – Pressure methods.
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