Use of Waste from Granite Gang Saws to Manufacture Ultra-High Performance Concrete Reinforced with Steel Fibers

At a Glance

Metadata	Details
Publication Date	2021-02-17
Journal	Applied Sciences
Authors	Fernando López Gayarre, Jesús Suárez González, Íñigo López Boadella, Carlos López-Colina Pérez, Miguel A. Serrano
Institutions	Universidad de Oviedo
Citations	3
Analysis	Full AI Review Included

Technical Documentation & Analysis: Advanced Material Substitution in High-Performance Composites

Executive Summary

This research paper demonstrates the successful substitution of micronized quartz with ultra-fine granite cutting waste from gang saws (GCW-GS) in Ultra-High Performance Fiber Reinforced Concrete (UHPFRC). The findings validate advanced material substitution strategies, leveraging specific chemical compositions (Fe₂O₃ and CaO) to enhance mechanical performance in complex composites.

Core Achievement: GCW-GS waste is a viable, high-performance substitute for micronized quartz in UHPFRC, yielding superior results compared to previous granite waste studies (GCW-D).
Optimal Performance Point: A 35% substitution ratio maximized mechanical gains, resulting in a 12% increase in flexural strength and a 35% increase in tensile strength over the control mix.
Chemical Mechanism: The presence of Fe₂O₃ (up to 14.6%) and CaO (up to 4.5%) in the GCW-GS promotes favorable pozzolanic reactions and improves particle packing density.
Compressive Strength: Compressive strength was robustly maintained or improved across all substitution ratios, peaking at 134 MPa (14% increase) at 70% substitution.
Material Science Relevance: This study highlights the critical role of ultra-fine particle geometry and chemical composition in optimizing advanced composite matrices.
6CCVD Connection: The granite cutting industry relies on high-performance diamond tooling (PCD/SCD) for processing ultra-hard materials, a core specialization of 6CCVD.

Technical Specifications

The following hard data points were extracted from the UHPFRC testing results, focusing on the optimal 35% substitution ratio and maximum performance metrics.

Parameter	Value	Unit	Context
Optimal Substitution Ratio	35	%	Yielded maximum flexural and tensile strength gains.
Maximum Compressive Strength	134	MPa	Achieved at 70% GCW-GS substitution.
Compressive Strength Increase (Max)	14	%	Relative to control mix (at 70% substitution).
Flexural Strength Increase (Max)	12	%	Relative to control mix (at 35% substitution).
Tensile Strength Increase (Max)	35	%	Relative to control mix (at 35% substitution).
GCW-GS Bulk Density	2856	kg/m³	Higher density than micronized quartz (2609 kg/m³).
GCW-GS Fe₂O₃ Content	14.59	%	Key component driving pozzolanic activity.
GCW-GS CaO Content	4.53	%	Key component driving pozzolanic activity.
Elasticity Modulus Decrease (Max)	8.5	%	Observed at 100% substitution (41 GPa vs. 45 GPa control).

Key Methodologies

The experimental program involved precise control over material composition, mixing, and curing to achieve Ultra-High Performance Fiber Reinforced Concrete (UHPFRC).

Material Selection:
- Cement: CEM I 42.5 R/SR (800 kg/m³).
- Aggregates: Two fractions of silica sand (0/0.5 mm and 0.5/1.6 mm).
- Additions: Densified silica fume (0.15 µm mean particle size) and micronized quartz (40 µm max particle size) or GCW-GS substitute.
- Fibers: Short steel fibers (0.2 mm diameter, 13 mm length) (160 kg/m³).
- Admixture: Polycarboxylate superplasticizer (SP).
Substitution Strategy: Micronized quartz was replaced by GCW-GS at 35%, 70%, and 100% by volume. The SP dosage was increased with higher GCW-GS content (up to 18 kg/m³ at 100% substitution) to compensate for water reaction with CaO.
Mixing Sequence: Sands and quartz/waste were mixed first, followed by silica fume and cement (30 s dry mix). Water was added, followed by superplasticizer and steel fibers after 2 min 30 s. Total mixing time was 25 min.
Curing Protocol (EN 12390-2): Specimens were demolded after 24 h and cured for 28 days in a humid chamber maintained at 20 °C and 95% relative humidity.
Mechanical Testing: Standardized tests were performed for:
- Compressive Strength (10x10x10 cm cubes, EN 12390-3).
- Modulus of Elasticity (15x30 cm cylinders, EN 12390-13).
- Flexural Strength (10x10x40 cm prisms, NF P 18-470).
- Tensile Strength (Indirect analysis from stress-strain curves).

6CCVD Solutions & Capabilities

This research demonstrates the engineering complexity involved in optimizing composites using ultra-fine, high-performance powders derived from hard material processing. 6CCVD specializes in the ultimate ultra-hard material—MPCVD Diamond—providing the foundational materials for extreme wear applications, high-precision tooling, and advanced sensing required in similar industrial and research environments.

Applicable Materials for Advanced Engineering

To replicate or extend research involving extreme material processing or high-performance composites, 6CCVD offers tailored diamond solutions:

Application Focus	Recommended 6CCVD Material	Rationale & Benefit
Extreme Wear Tooling (e.g., Granite Saw Segments)	Polycrystalline Diamond (PCD)	Superior abrasion resistance and thermal stability required for cutting ultra-hard materials like granite. We offer plates up to 125mm.
Chemical/Electrochemical Sensing (Monitoring CaO/Fe₂O₃ effects)	Boron-Doped Diamond (BDD)	BDD films provide unparalleled chemical inertness and a wide electrochemical window, ideal for monitoring complex chemical reactions (like pozzolanic activity) in harsh, high-pH environments.
High-Precision Structural Sensors (Strain/Thermal Monitoring)	Single Crystal Diamond (SCD)	Excellent thermal conductivity and mechanical stiffness (Modulus of Elasticity) for integrating high-stability sensors into structural components or testing rigs.
Ultra-Smooth Surfaces (Friction/Wear Studies)	Optical Grade SCD	Polishing capability to achieve Ra < 1nm for SCD, essential for minimizing friction in high-load mechanical tests or tooling interfaces.

Customization Potential & Engineering Support

6CCVD’s in-house capabilities directly address the need for custom, high-specification materials often required in advanced research and industrial applications like those referenced in this paper (e.g., specialized tooling or sensor integration).

Customization Service	Relevance to Advanced Composites/Tooling	6CCVD Capability
Custom Dimensions	Providing specific geometries for PCD tooling inserts or large-area substrates for composite testing.	Plates/wafers up to 125mm (PCD). Substrates up to 10mm thick.
Precision Polishing	Ensuring minimal friction and maximum durability for diamond cutting edges or sensor surfaces.	Ra < 1nm (SCD) and Ra < 5nm (Inch-size PCD).
Metalization Layers	Creating robust electrical contacts or bonding layers for integrating diamond sensors (e.g., BDD) into concrete or testing apparatus.	Internal capability for Au, Pt, Pd, Ti, W, Cu deposition.
Material Doping	Tailoring electrical properties for specific sensing or electronic applications.	Custom Boron-Doped Diamond (BDD) synthesis.

6CCVD’s in-house PhD team provides expert consultation on material selection, optimizing diamond specifications (SCD, PCD, BDD thickness, doping, and surface finish) for projects requiring extreme performance, such as high-wear tooling or advanced structural monitoring systems.

For custom specifications or material consultation, visit 6ccvd.com or contact our engineering team directly.

View Original Abstract

The purpose of this study is to analyze the feasibility of using the ultra-fine waste coming from the granite cutting waste gang saws (GCW-GS) to manufacture ultra-high performance, steel-fiber reinforced concrete (UHPFRC). These machines cut granite blocks by abrasion using a steel blade and slurry containing fine steel grit. The waste generated by gang saws (GCW-GS) contains up to 15% Fe2O3 and up to 5% CaO. This is the main difference from the waste produced by diamond saws (GCW-D). Although this waste is available in large quantities, there are very few studies focused on recycling it to manufacture any kind of concrete. In this study, the replaced material was the micronized quartz powder of natural origin used in the manufacture of UHPRFC. The properties tested include workability, density, compressive strength, elasticity modulus, flexural strength, and tensile strength. The final conclusion is that this waste can be used to manufacture UHPFRC with a better performance than that from diamond saws given that there is an improvement of their mechanical properties up to a replacement of 35%. Even for higher percentages, the mechanical properties are within values close to those of control concrete with small decreases.

Tech Support

Original Source

DOI: https://doi.org/10.3390/app11041764

References

2017 - Using glass sand as an alternative for quartz sand in UHPC [Crossref]
2017 - Partial substitution of silica fume with fine glass powder in UHPC: Filling the micro gap [Crossref]
2016 - Development of ultra-high-performance concrete using glass powder—Towards ecofriendly concrete [Crossref]
2014 - Utilization of iron ore tailings as fine aggregate in ultra-high performance concrete [Crossref]
2015 - The Influences of Iron Ore Tailings as Fine Aggregate on the Strength of Ultra-High Performance Concrete
2009 - Performance of high strength concrete made with copper slag as a fine aggregate [Crossref]
2015 - Studies on ultra high performance concrete incorporating copper slag as fine aggregate [Crossref]
2018 - Performance of mortar and concrete incorporating granite sludge as cement replacement [Crossref]
2016 - Performance of sustainable concrete containing granite cutting waste [Crossref]