Impact of carbonation and fiber hornification on the performance of fiber-cements

Abstract

The present study evaluates the effect and advantages of the combined use of two treatments on fiber-cement composites: 1) accelerated carbonation on the cement matrix and 2) hornification of commercially used unbleached pine pulp (Pinus radiata D. Don). The premise of the study was to develop a composite with superior physical–mechanical performance, increased durability, all within a sustainability context. Chemical, physical, and morphological characterization of the pulps with and without treatment was conducted. For fiber-cement composites, instrumental techniques such as XRD, TGA, SEM, and physical–mechanical characterization (before/after accelerated aging) were applied. The heat treatment does not deteriorate the pulps and reduces their hygroscopicity. Accelerated carbonation enhanced matrix mechanical properties, increasing modulus of rupture by 51% and specific energy by 154%. The mass fraction of Ca(OH)₂ decreased from 11.1% to 0.3%, while the mass fraction of CaCO₃ increased from 37.0% to 60.2%. After 200 cycles of accelerated aging, composites with accelerated carbonation or treated pulps showed pulp preservation and matrix densification. Composites with combined treatments exhibited the best performance and durability before and after accelerated aging. The potential and feasibility of applying these combined treatments to fiber and matrix are established from technical, economic, and environmental perspectives.

Keywords

Composite properties / Cellulosic fiber reinforcement / Cement-based composites / Durability / Eco-efficient blended cement / Thermal treatment

References

[1] do Amaral, L. M., de Souza Rodrigues, C., & Poggiali, F. S. J. (2021). Hornification on vegetable fibers to improve fiber-cement composites: A critical review. Journal of Building Engineering, 103947.

[2] WeiJ, MeyerC. Degradation rate of natural fiber in cement composites exposed to various accelerated aging environment conditions. Corrosion Science, 2014, 88: 118-132.

[3] SoroushianP, BalachandraA, NassarS, WeerasiriR, DarsanasiriN, AbdolN. Effect of fiber type and content on the performance of extruded wood fiber cement products. Case Studies in Construction Materials, 2022, 16. Article e00968

[4] StapperJL, GauvinF, BrouwersHJH. Influence of short-term degradation on coir in natural fibre-cement composites. Construction and Building Materials, 2021, 306. 124906

[5] ArdanuyM, ClaramuntJ, Toledo FilhoRD. Cellulosic fiber reinforced cement-based composites: A review of recent research. Construction and Building Materials, 2015, 79: 115-128.

[6] LaverdeV, MarinA, BenjumeaJM, OrtizMR. Use of vegetable fibers as reinforcements in cement-matrix composite materials: A review. Construction and Building Materials, 2022, 340. 127729

[7] DrisR, GasperiJ, RocherV, TassinB. Synthetic and non-synthetic anthropogenic fibers in a river under the impact of Paris megacity: Sampling methodological aspects and flux estimations. Science of the Total Environment, 2018, 618: 157-164.

[8] TeixeiraJN, SilvaDW, VilelaAP, Savastano JuniorH, VazL.E.V. deSiqueiraBrandão, MendesRF. Lignocellulosic materials for fiber cement production. Waste and Biomass Valorization, 2020, 11: 2193-2200.

[9] FerreiraSR, LimaPRL, SilvaFA, Toledo FilhoRD. Effect of sisal fiber hornification on the fiber-matrix bonding characteristcs and bending behavior of cement based composites. Key Engineering Materials, 2014, 600: 421-432.

[10] FonsecaCS, SilvaMF, MendesRF, HeinPRG, ZangiacomoAL, SavastanoHJr, TonoliGHD. Jute fibers and micro/nanofibrils as reinforcement in extruded fiber-cement composites. Construction and Building Materials, 2019, 211: 517-527.

[11] SilvaDW, ScatolinoMV, PereiraTGT, VilelaAP, EugenioTMC, MartinsMA, MendesRF, BufalinoL, TonoliGHD, MendesLM. Influence of thermal treatment of eucalyptus fibers on the physical-mechanical properties of extruded fiber-cement composites. Materials Today: Proceedings, 2020, 31: S348-S352

[12] LiQ, IbrahimL, ZhouW, ZhangM, YuanZ. Treatment methods for plant fibers for use as reinforcement in cement-based materials. Cellulose, 2021, 28: 5257-5268.

[13] RameshM, PalanikumarK, ReddyKH. Plant fibre based bio-composites: Sustainable and renewable green materials. Renewable and Sustainable Energy Reviews, 2017, 79: 558-584.

[14] CapraiV, GauvinF, SchollbachK, BrouwersHJH. Influence of the spruce strands hygroscopic behaviour on the performances of wood-cement composites. Construction and Building Materials, 2018, 166: 522-530.

[15] Mejia-BallesterosJE, RodierL, FilomenoR, SavastanoHJr, FiorelliJ, RojasMF. Influence of the fiber treatment and matrix modification on the durability of eucalyptus fiber reinforced composites. Cement and Concrete Composites, 2021, 124. 104280

[16] FerreiraSR, SilvaFDA, LimaPRL, Toledo FilhoRD. Effect of fiber treatments on the sisal fiber properties and fiber-matrix bond in cement based systems. Construction and Building Materials, 2015, 101: 730-740.

[17] Tolêdo FilhoRD, ScrivenerK, EnglandGL, GhavamiK. Durability of alkali-sensitive sisal and coconut fibres in cement mortar composites. Cement and Concrete Composites, 2000, 22: 127-143.

[18] De KlerkMD, KayondoM, MoelichGM, de VilliersWI, CombrinckR, BoshoffWP. Durability of chemically modified sisal fibre in cement-based composites. Construction and Building Materials, 2020, 241. 117835

[19] WeiJ, MeyerC. Degradation mechanisms of natural fiber in the matrix of cement composites. Cement and Concrete Research, 2015, 73: 1-16.

[20] LavoineN, DeslogesI, DufresneA, BrasJ. Microfibrillated cellulose–its barrier properties and applications in cellulosic materials: A review. Carbohydrate Polymers, 2012, 90: 735-764.

[21] MármolG, SavastanoHJr. Study of the degradation of non-conventional MgO-SiO2 cement reinforced with lignocellulosic fibers. Cement and Concrete Composites, 2017, 80: 258-267.

[22] ArdanuyM, ClaramuntJ, García-HortalJA, BarraM. Fiber-matrix interactions in cement mortar composites reinforced with cellulosic fibers. Cellulose, 2011, 18: 281-289.

[23] BarraBN, SantosSF, BergoPVA, AlvesC, GhavamiK, SavastanoH. Residual sisal fibers treated by methane cold plasma discharge for potential application in cement based material. Industrial Crops and Products, 2015, 77: 691-702.

[24] MendesS, HugenLN, Dos SantosRD, Toledo FilhoRD, FerreiraSR. Influence of water amount and immersion time on the sisal fibers hornification process. Journal of Natural Fibers, 2021, 18: 1712-1721.

[25] WeiJ, MeyerC. Improving degradation resistance of sisal fiber in concrete through fiber surface treatment. Applied Surface Science, 2014, 289: 511-523.

[26] FuZ, YaoY. Pyrolysis mechanism of natural fiber in cement-based composites at high temperatures. Construction and Building Materials, 2022, 351. 128986

[27] RojasDFH, Pineda-GómezP, Guapacha-FloresJF. Effect of silica nanoparticles on the mechanical and physical properties of fibercement boards. Journal of Building Engineering, 2020, 31. Article 101332

[28] RodierL, da Costa CorreiaV, Savastano JuniorH. Elaboration of eco-efficient vegetable fibers reinforced cement-based composites using glass powder residue. Cement and Concrete Composites, 2020, 110. 103599

[29] A.N. Junior, S.R. Ferreira, R.D. Toledo Filho, E. de M.R. Fairbairn, J. Dweck. (2019). Effect of early age curing carbonation on the mechanical properties and durability of high initial strength Portland cement and lime-pozolan composites reinforced with long sisal fibres, Composites Part B: Engineering, 163, 351–362.

[30] dos SantosV, TonoliGHD, MarmolG, SavastanoHJr. Fiber-cement composites hydrated with carbonated water: Effect on physical-mechanical properties. Cement and Concrete Research, 2019, 124. 105812

[31] BallesterosJEM, MármolG, FilomenoR, RodierL, SavastanoH, FiorelliJ. Synergic effect of fiber and matrix treatments for vegetable fiber reinforced cement of improved performance. Construction and Building Materials, 2019, 205: 52-60.

[32] Carvalho MachadoPJ, dos R. FerreiraRA, de Castro MottaL. Aparecida. Study of the effect of silica fume and latex dosages in cementitious composites reinforced with cellulose fibers. Journal of Building Engineering, 2020, 31. 101442

[33] MoW, ChenK, YangX, KongF, LiuJ, LiB. Elucidating the hornification mechanism of cellulosic fibers during the process of thermal drying. Carbohydrate Polymers, 2022, 289. 119434

[34] HanW, ZhaoC, ElderT, ChenK, YangR, KimD, PuY, HsiehJ, RagauskasAJ. Study on the modification of bleached eucalyptus kraft pulp using birch xylan. Carbohydrate Polymers, 2012, 88: 719-725.

[35] SalménL. Effect of drying conditions on cellulose micro fi bril aggregation and “ horni fi cation”. Cellulose, 2018, 25: 6333-6344.

[36] HribernikS, Stana KleinschekK, RihmR, GansterJ, FinkHP, Sfiligoj SmoleM. Tuning of cellulose fibres’ structure and surface topography: Influence of swelling and various drying procedures. Carbohydrate Polymers, 2016, 148: 227-235.

[37] ClaramuntJ, ArdanuyM, García-HortalJA, FilhoRDT. The hornification of vegetable fibers to improve the durability of cement mortar composites. Cement and Concrete Composites, 2011, 33: 586-595.

[38] HamzehY, NajafiSMH, HubbeMA, SalehiK, FirouzabadiMRD. Recycling potential of unbleached and bleached chemical pulps from juvenile and mature wood of Populus deltoides. hfsg, 2012.

[39] KottititumB, PhungQT, MaesN, PrakaypanW, SrinophakunT. Early age carbonation of fiber-cement composites under real processing conditions: A parametric investigation. Applied Sciences, 2018, 8. Article 190

[40] SantosSF, SchmidtR, AlmeidaAEFS, TonoliGHD, SavastanoH. Supercritical carbonation treatment on extruded fibre-cement reinforced with vegetable fibres. Cement and Concrete Composites, 2015, 56: 84-94.

[41] HeZ, JiaY, WangS, MahoutianM, ShaoY. Maximizing CO2 sequestration in cement-bonded fiberboards through carbonation curing. Construction and Building Materials, 2019, 213: 51-60.

[42] Liu, Z., & Meng, W. (2021). Fundamental understanding of carbonation curing and durability of carbonation-cured cement-based composites: A review. Journal of CO₂Utilization44, Article 101428.

[43] TonoliGHD, PizzolVD, UrreaG, SantosSF, MendesLM, SantosV, JohnVM, FríasM, SavastanoH. Rationalizing the impact of aging on fiber–matrix interface and stability of cement-based composites submitted to carbonation at early ages. Journal of Materials Science, 2016, 51: 7929-7943.

[44] SoroushianP, WonJ-P, HassanM. Durability characteristics of CO2-cured cellulose fiber reinforced cement composites. Construction and Building Materials, 2012, 34: 44-53.

[45] Lesti, M., Tiemeyer, C., & Plank, J. (2013). CO₂ stability of Portland cement based well cementing systems for use on carbon capture & storage (CCS) wells. Cement and Concrete Research, 45, 45–54. https://doi.org/10.1016/j.cemconres.2012.12.001

[46] PizzolVD, MendesLM, FrezzattiL, SavastanoH, TonoliGHD. Effect of accelerated carbonation on the microstructure and physical properties of hybrid fiber-cement composites. Minerals Engineering, 2014, 59: 101-106.

[47] ASTM. (2011). Standard Specification for Portland Cement (ASTM-C150M).

[48] CelikK, MeralC, Petek GurselA, MehtaPK, HorvathA, MonteiroPJM. Mechanical properties, durability, and life-cycle assessment of self-consolidating concrete mixtures made with blended portland cements containing fly ash and limestone powder. Cement and Concrete Composites, 2015, 56: 59-72.

[49] IkaiS, ReichertJR, RodriguesAV, ZampieriVA. Asbestos-free technology with new high toughness polypropylene (PP) fibers in air-cured Hatschek process. Construction and Building Materials, 2010, 24: 171-180.

[50] BallesterosJEM, dos SantosV, MármolG, FríasM, FiorelliJ. Potential of the hornification treatment on eucalyptus and pine fibers for fiber-cement applications. Cellulose, 2017, 24: 2275-2286.

[51] JaymeG. Mikro-quellungsmessungen an zellstoffen. Wochenblatt für Papierfabrikation, 1944, 6: 187-194

[52] ISO. (2014). Pulps - Determination of water retention value (WRV) (ISO-23714).

[53] ScatolinoMV, SilvaDW, BufalinoL, TonoliGHD, MendesLM. Influence of cellulose viscosity and residual lignin on water absorption of nanofibril films. Procedia Engineering, 2017, 200: 155-161.

[54] Viscosity of Pulp (Capillary Viscometer Method) (T 230 om-04), 2004.

[55] P.J. Van Soest. (2018). Nutritional ecology of the ruminant, Cornell University Press.

[56] SantosSF, RodriguesJdeA, TonoliGHD, AlmeidaAEFdeS, SavastanoH. Effect of colloidal silica on the mechanical properties of fiber–cement reinforced with cellulosic fibers. Journal of Materials Science, 2014, 49: 7497-7506.

[57] SavastanoH, WardenPG, CouttsRSP. Brazilian waste fibres as reinforcement for cement-based composites. Cement and Concrete Composites, 2000, 22: 379-384.

[58] PizzolVD, MendesLM, SavastanoH, FríasM, DavilaFJ, CincottoMA, JohnVM, TonoliGHD. Mineralogical and microstructural changes promoted by accelerated carbonation and ageing cycles of hybrid fiber-cement composites. Construction and Building Materials, 2014, 68: 750-756.

[59] TonoliGHD, FuenteE, MonteC, SavastanoH, LahrFAR, BlancoA. Effect of fibre morphology on flocculation of fibre-cement suspensions. Cement and Concrete Research, 2009, 39: 1017-1022.

[60] EN. (1994). EN 494 Standard. Fibre-Cement Profiled Sheets and Fittings for Roofing—Products Specification and Test Methods.

[61] Rilem. (1984). Internationale des laboratoires d´ essais et des recheches sur les materiaux et les constructions (rilem). rilem 49tfr: testing methods for fibre reinforced cement-based composites, Matér. Constr. 17. 441–456.

[62] ASTM. (2009). Dry and Wet Bulk Density, Water Absorption and Apparent Porosity of Thin Sections of Glass-Fiber Reinforced Concrete (ASTM-C 948–81).

[63] WeiseU. Hornification: Mechanisms and terminology. Paber Ja Puu, 1998, 80: 110-115

[64] Fernandes DinizJMB, GilMH, CastroJAAM. Hornification - Its origin and interpretation in wood pulps. Wood Science and Technology, 2004, 37: 489-494.

[65] KooB, JoJ, ChoS-M. Drying effect on enzymatic hydrolysis of cellulose associated with porosity and crystallinity. Applied Sciences, 2020, 105545.

[66] FuY, WangR, LiD, WangZ, ZhangF, MengQ, QinM. Changes in the microstructure and properties of aspen chemithermomechanical pulp fibres during recycling. Carbohydrate Polymers, 2015, 117: 862-868.

[67] ClaramuntJ, ArdanuyM, García-HortalJA. Effect of drying and rewetting cycles on the structure and physicochemical characteristics of softwood fibres for reinforcement of cementitious composites. Carbohydrate Polymers, 2010, 79: 200-205.

[68] BallesterosJEM, SantosSF, MármolG, SavastanoH, FiorelliJ. Evaluation of cellulosic pulps treated by hornification as reinforcement of cementitious composites. Construction and Building Materials, 2015, 100: 83-90.

[69] FerreiraJC, EvtuguinDV, PratesA. Effect of cellulose structure on reactivity of eucalyptus acid sulphite dissolving pulp. Cellulose, 2020, 27: 4763-4772.

[70] QuintanaE, VallsC, BarnetoAG, VidalT, ArizaJ, RonceroMB. Studying the effects of laccase treatment in a softwood dissolving pulp: Cellulose reactivity and crystallinity. Carbohydrate Polymers, 2015, 119: 53-61.

[71] HowardRC. The effects of recycling on paper quality. Journal of Pulp and Paper Science, 1990, 16: J143-J149

[72] BacarinGB, CabreraFC, da SilvaMR, JobAE. The distribution of lignin and xylan in the inner and surface layers of the fiber from eucalyptus kraft pulp and its effects on oxygen delignification. Materials Research, 2017, 20: 945-950.

[73] FernandoS, GunasekaraC, ShahpasandiA, NguyenK, SofiM, SetungeS, MendisP, RahmanMT. Sustainable cement composite integrating waste cellulose fibre: A comprehensive review. Polymers, 2023, 15. 520

[74] M.-J. Le Guen, R.H. Newman, A. Fernyhough, S.J. Hill, M.P. Staiger. (2016). Correlations between the physiochemical characteristics of plant fibres and their mechanical properties, in: Nat. Fibres Adv. Sci. Technol. Towar. Ind. Appl. From Sci. to Mark., Springer, 35–47.

[75] Urrea-CeferinoGE, PanesarDK, JuniorHS. Adjusting curing parameters for innovative and durable vegetable fibre-cement composites. Cement and Concrete Composites, 2019, 103: 121-133.

[76] Filomeno, R. H., Rodier, L. B., Ballesteros, J. E. M., Rossignolo, J. A., & Savastano, H., Jr. (2020). Optimizing the modified atmosphere parameters in the carbonation process for improved fiber-cement performance. Journal of Building Engineering,32, Article Article 101676.

[77] Alarcon-RuizL, PlatretG, MassieuE, EhrlacherA. The use of thermal analysis in assessing the effect of temperature on a cement paste. Cement and Concrete Research, 2005, 35: 609-613.

[78] Benítez-GuerreroM, López-BeceiroJ, Sánchez-JiménezPE, Pascual-CospJ. Comparison of thermal behavior of natural and hot-washed sisal fibers based on their main components: Cellulose, xylan and lignin. TG-FTIR analysis of volatile products. Thermochimica Acta, 2014, 581: 70-86.

[79] RostamiV, ShaoY, BoydAJ, HeZ. Microstructure of cement paste subject to early carbonation curing. Cement and Concrete Research, 2012, 42: 186-193.

[80] AlmeidaAEFS, TonoliGHD, SantosSF, SavastanoH. Improved durability of vegetable fiber reinforced cement composite subject to accelerated carbonation at early age. Cement and Concrete Composites, 2013, 42: 49-58.

[81] ChenT, GaoX. Effect of carbonation curing regime on strength and microstructure of Portland cement paste. Journal of CO2 Utilization, 2019, 34: 74-86.

[82] RaabeJ, SilvaDW, Del MenezziCHS, TonoliGHD. Impact of nanosilica deposited on cellulose pulp fibers surface on hydration and fiber-cement compressive strength. Construction and Building Materials, 2022, 326. 126847

[83] MortonJH, CookeT, AkersSAS. Performance of slash pine fibers in fiber cement products. Construction and Building Materials, 2010, 24: 165-170.

[84] Urrea-CeferinoGE, RempeN, dos SantosV, Savastano JuniorH. Definition of optimal parameters for supercritical carbonation treatment of vegetable fiber-cement composites at a very early age. Construction and Building Materials, 2017, 152: 424-433.

Funding

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior(001)

RIGHTS & PERMISSIONS

The Author(s)