Sulfur concrete, sometimes named thioconcrete or sulfurcrete, is a composite construction material, composed mainly of sulfur and aggregate (generally a coarse aggregate made of gravel or crushed rocks and a fine aggregate such as sand). Cement and water, important compounds in normal concrete, are not part of sulfur concrete. The concrete is heated above the melting point of elemental sulfur (115.21 °C (239.38 °F)) at ca. 140 °C (284 °F) in a ratio of between 12% and 25% sulfur, the rest being aggregate. Low-volatility (i.e., with a high boiling point) organic admixtures (sulfur modifiers), such as dicyclopentadiene (DCPD), styrene, turpentine, or furfural, are also added to the molten sulfur to inhibit its crystallization and to stabilize its polymeric structure after solidification. In the absence of modifying agents, elemental sulfur crystallizes in its most stable allotropic (polymorphic) crystal phase at room temperature. With the addition of some modifying agents, elemental sulfur forms a copolymer (linear chains with styrene, cross-linking structure with DCPD) and remains plastic. Sulfur concrete then achieves high mechanical strength within ~ 24 hours of cooling. It does not require a prolonged curing period like conventional cement concrete, which after setting (a few hours) must still harden to reach its expected nominal strength at 28 days. The rate of hardening of sulfur concrete depends on its cooling rate and also on the nature and concentration of modifying agents (cross-linking process). Its hardening is governed by the fairly rapid liquid/solid state change and associated phase transition processes (the added modifiers maintaining the plastic state while avoiding its recrystallization). It is a thermoplastic material whose physical state depends on temperature. It can be recycled and reshaped in a reversible way, simply by remelting it at high temperature. A sulfur concrete patent was already registered in 1900 by McKay. Sulfur concrete was studied in the 1920s and 1930s and received renewed interest in the 1970s because of the accumulation of large quantities of sulfur as a by-product of the hydrodesulfurization process of oil and gas production and its low cost.
Characteristics Sulfur concrete has a low porosity and is a poorly permeable material. Its low hydraulic conductivity slows down water ingress in its low porosity matrix and so decreases the transport of harmful chemical species, such as chloride (pitting corrosion), towards the steel reinforcements (physical protection of steel as long as no microcracks develop in the sulfur concrete matrix). It is resistant to some compounds like acids which attack normal concrete. Beside its impermeability, Loov et al. (1974) also consider amongst the beneficial characteristics of sulfur concrete its low thermal and electrical conductivities. Sulfur concrete does not cause adverse reaction with glass (no alkali–silica reaction), does not produce efflorescences, and also presents a smooth surface finish. They also mention amongst its main limitations, its high coefficient of thermal expansion, the possible formation of acid under the action of water and sunlight. It also reacts with copper and produces a smell when melted.
Uses Sulfur concrete was developed and promoted as a building material to get rid of large amounts of stored sulfur produced by hydrodesulfurization of gas and oil (Claus process). As of 2011, sulfur concrete has only been used in small quantities when fast curing or acid resistance is necessary. The material has been suggested by researchers as a potential building material on Mars, where water and limestone are not easily available, but sulfur is.
Advantages and benefits More recently, it has been proposed as a near-carbon-neutral construction material. Its waterless and less energy-intensive production (in comparison with ordinary cement and regular concrete) makes it a potential alternative for high-CO2-emission portland-cement-based materials. Due to improvements in fabrication techniques, it can be produced in high quality and large quantities. Recyclable sulfur concrete sleepers are used in Belgium for the railways infrastructure, and are mass-produced locally. THIOTUBE is the brand name for certified acid-resistant DWF (dry weather flow) discharge pipes used in Belgium.
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