Calcium carbide residue (CCR) is a waste by-product from acetylene gas production. The main component of CCR is Ca(OH)2, which can react with siliceous materials through pozzolanic reactions, resulting in a product similar to those obtained from the cement hydration process. Thus, it is possible to use CCR as a substitute for Portland cement in concrete. In this research, we synthesized CCR and silica fume through a chemical combustion technique to produce a new reactive cementitious powder (RCP). The properties of paste and mortar in fresh and hardened states (setting time, shrinkage, and compressive strength) with 5% cement replacement by RCP were evaluated. The hydration of RCP and OPC (Ordinary Portland Cement) pastes was also examined through SEM (scanning electron microscope). Test results showed that in comparison to control OPC mix, the hydration products for the RCP mix took longer to formulate. The initial and final setting times were prolonged, while the drying shrinkage was significantly reduced. The compressive strength at the age of 45 days for RCP mortar mix was found to be higher than that of OPC mortar and OPC mortar with silica fume mix by 10% and 8%, respectively. Therefore, the synthesized RCP was proved to be a sustainable active cementitious powder for the strength enhanced of building materials, which will result in the diversion of significant quantities of this by-product from landfills.

In this research, we assessed the influence of an ultrafine 2CaO·SiO2 powder on the hydration properties of a reactive powder concrete system. The ultrafine powder was manufactured through chemical combustion method. The morphology of ultrafine powder and the development of hydration products in the cement paste prepared with ultrafine powder were investigated by scanning electron microscopy (SEM), mineralogical composition were determined by X-ray diffraction, while the heat release characteristics up to the age of 3 days were investigated by calorimetry. Moreover, the properties of cementitious system in fresh and hardened state (setting time, drying shrinkage, and compressive strength) with 5% ordinary Portland cement replaced by ultrafine powder were evaluated. From SEM micrographs, the particle size of ultrafine powder was found to be up to several hundred nanometers. The hydration product started formulating at the age of 3 days due to slow reacting nature of belitic 2CaO·SiO2. The initial and final setting times were prolonged and no significant difference in drying shrinkage was observed when 5% ordinary Portland cement was replaced by ultrafine powder. Moreover, in comparison to control reactive powder concrete, the reactive powder concrete containing ultrafine powder showed improvement in compressive strength at and above 7 days of testing. Based on above, it can be concluded that the manufactured ultrafine 2CaO·SiO2 powder has the potential to improve the performance of a reactive powder cementitious system.