UTILISATION OF PHOSPHOGYPSUM IN

CEMENT MORTAR AND CONCRETE

S. S. Bhadauria*, Rajiv Gandhi Proudyogiki Vishwavidyalya, Bhopal (M. P.), India
Rajesh B. Thakare, JSPMs B. N. College of Engineering, Pusad (M. S.), India
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31st Conference on OUR WORLD IN CONCRETE & STRUCTURES: 16 17 August 2006, Singapore

UTILISATION OF PHOSPHOGYPSUM IN
CEMENT MORTAR AND CONCRETE
S. S. Bhadauria*, Rajiv Gandhi Proudyogiki Vishwavidyalya, Bhopal (M. P.), India
Rajesh B. Thakare, JSPMs B. N. College of Engineering, Pusad (M. S.), India

Abstract
Abundant of research investigations have been conducted to utilized the waste or
chemical gypsum, phosphogypsum for various applications. Most of the research
investigations were carried out by purifying phosphogypsum for the impurities
present in it and then its utilization were suggested. In another research approach
phosphogypsum could be utilized without any treatment and therefore it may be
entitled as untreated, impure or raw phosphogypsum. Investigations have been
carried out, in order to study the effect of replacement of cement with raw
phosphogypsum (PG) in cement, cement mortar, and cement concrete mixes.
Different percentages of cement have been replaced with raw phosphogypsum in
cement, cement mortar, cement concrete on equal dry weight basis. The properties
of such cement, cement mortar and concrete mixes produced compared with
conventional mixes. The conventional concrete mixes have been modified to
accommodate raw phosphogypsum as a part of cement to be suitable for the
concrete, for workability and 28 days compressive strength varying from 15 N/ mm2
to 25 N/ mm2.
Keywords: cement, cement mortar, concrete mixes, compressive strength, workability.
1. Introduction
Phosphogypsum (PG) is often used interchangeably in the research literature with the terms
chemical, synthetic, waste or by-product gypsum, which is produced as solid chemical hazardous
waste or by-product in industries, by wet or dry processes (sulphuric acidulation of phosphate rocks).
The disposal of phosphogypsum was very simple matter in the early days of industry, as plants had
very low capacities (often producing only 25 tons per day of P2O5 versus a typical plant today is rated
at one kilo tons per day and about up to five kilo tons per day) and environmental concerns and
regulations were insignificant. Therefore, phosphogypsum is categorised as hazardous waste in
Environmental Protection Agency (EPA) and under category 16 of hazardous waste (Management
and Handling) rules 1989 framed by Government of India [1,2, 3].
In India, Phosphogypsum is currently being disposed into open sandy yards or in ponds close to
the plants in the form of slurry made by pumping phosphogypsum with sufficient quantity of water.
After percolation and drying, the phosphogypsum is stockpiled for future use. Currently, approximately
11 million-ton of phosphogypsum is stockpiled at various industrial sites across the country [4].
The annual production of phosphogypsum from one dozen phosphoric acid and fertilizers plants is of
the order of approximately five million tons [4, 5]. Therefore, it is the second largest pollutant in the

country after fly ash [4]. At present, in India only about 12% of phosphogypsum is being utilised from
the large amount produced [6].
The proper utilisation of phosphogypsum is needed to solve environmental and disposal
problems. In different countries attempts have been made from time to time to find ways and means
of utilising phosphogypsum and therefore disposing significant quantity of waste. Concrete, which is a
very important constituent of modern construction, is already adopted for waste management system,
with exemplary applications like High Volume Fly ash (HVFA) technique. Indeed, concrete in
particular is being used as a construction material of a number of waste disposal units, be they for
operation, processing or storage of wastes.
2. Literature review
Utilisation of phosphogypsum in concrete is not new technique, Gutt first proposed it, he had
presented a practical approach to handle phosphogypsum in concrete [7].
Ouyang, Nanni and Chang studied sulphate attack resistance of Portland cement mixture
containing phosphogypsum and conventional aggregate. A wide range of SO3 and C3A contents were
investigated with respect to linear expansion and compressive strength development for specimen
submerged in fresh and seawater. The cement contents were varied between 10% - 30% by weight,
whereas phosphogypsum varied from 0 50%, lime rock aggregate was used. The results indicated
that, the optimum C3A content, which corresponds to minimum expansion, is about 1.1% for Portland
cement having C3A content less than 7%. And phosphogypsum contents directly proportional to
expansion in cement mixes. Seawater immersion decreases the strength development rate of
cylinders and increases linear expansion of bars [8].
Ghafoori and Chang studied production of compacted concrete using phosphogypsum, in which
they inferred such mixes could achieve excellent compressive strength under compaction [12].
Resembled study reported by Lin and Chang by using 10% cement and 90% phosphogypsum mixture
[9].
Chang investigated the effectiveness of phosphogypsum-based concrete in corrosion protection
of reinforcement. Test results indicated that pH value increased rapidly when phosphogypsum mix
contained small amount of cement. Other effective way of protecting against corrosion was increasing
thickness of cover [10].
Nanni produced bench model phosphogypsum bricks of size 45 X 95 X 203 mm with semi
automatic press having a capacity of 1780 kN. The bricks thus produced were handled immediately
after fabrication. The bricks were found good in appearance and strength [11].
Chang and Mantell published a book on engineering properties and construction applications of
phosphogypsum with and without other materials (fly ash, slags, epoxy, fibres, etc). The authors have
presented the primary available data on tests of engineering properties and have presented the stateof-the-art on construction applications [12].
Chang, Chin and Ho have published state of art report on phosphogypsum for secondary road
construction. It was concluded phosphogypsum when subjected to compaction could be transformed
into a solid of valuable strength. It could be used very effectively as binder to stabilised soil, replace
shell or clay in secondary road and aggregate and water. A base course was built by spreading 5 inch
of loose phosphogypsum on existing soil, over which the concrete was laid. This pavement was
tested for abrasion, durability, shrinkage, compensation, onsite deflection and radiation monitoring.
The project demonstrated that PG based RCC was suitable for construction of parking facilities. PG
without was detrimental to strength contributed to good mix and surface finish because of fine
grinding [13].
Nanni and Chang reported application of phosphogypsum was investigated as an aggregate in
construction of various Roller Compacted Concrete (RCC) slabs. Several phosphogypsum-based
mixtures were prepared in three different mixing procedures and were compacted using suitable
vibrator. A thickness design procedure of this concrete pavement was also suggested. The project
indicated that phosphogypsum based RCC was suitable for pavement construction applications.
Moreover, phosphogypsum was suitable, as it provide set retardation and drying shrinkage
compensation [14].
Ong, Metcalf, Seals and Taha studied unconfined compressive strength of various cementstabilised phosphogypsum (CSPG) and it was shown that the mix behaves like cement-stabilised soil.
The strength and its relation between parameters were studied for different curing conditions. It was
concluded phosphogypsum could be stabilised with cement to produce an adequate material for road
base construction to the requirement of the local codes [15].
Foxworthy, Ott and Seals utilised phosphogypsum based slag aggregate in Portland cement
concrete mixtures. The durability behaviour of such aggregate was explored. The entire preliminary

tests on phosphogypsum were performed. The phosphogypsum slag aggregate based concrete mix
was prepared and tested for compressive strength, flexural and splitting tensile strength. The result
indicated that the slag aggregate performed well as a coarse aggregate in cement concrete and
should perform satisfactorily in highway pavement system [16].
Murthy, et. al. carried out studies on basic properties of fly ash-lime-gypsum (FaL-G) cement
concrete using phosphogypsum. And it was concluded that phosphogypsum is suitable for producing
good quality FaL-G concrete [17].
Roy, Kalvakaalava and Seals were studied micro structural and phase characteristics of
phosphogypsum cement mixtures. The effect of tricalcium aluminate (C3A) content of the stabilising
cement (with two different C3A percentage), curing time (7, 28, 45 and 90 days), proportion of
phosphogypsum (5% to 60%), grain size, impurities in phosphogypsum on microstructure (SEM) and
phase properties of mix was studied. Derivative thermogravitimetric analysis (DTA) was used in this
study for hydrated products of these mixes. The study was concluded the addition of phosphogypsum
to Portland cement produced large amount of ettringite. Phosphogypsum increased the degree of
hydration of cement in the mixtures in the long term. The amount of carbonation in phosphogypsumbased mixture was found relatively low [18].
Gutti,, Roy, Metcalf and Seals studied the effect of admixture content, dry density and curing
condition on linear expansion of cement-stabilised phosphogypsum (CSPG) over a period of ninety
days. The phosphogypsum was stabilized using 8% type I Portland cement, different specimens were
prepared and cured for different curing conditions. For soaked specimen, they found ettringite growth
was widespread and unusually large as compared to the amount of cement [19].
Smadi, Haddad and Akour studied utilisation of phosphogypsum as cement (OPC and PPC)
replacement agents in mortars and found decrease in compressive strength and increase in flexural
strength as compared with conventional mix. The incorporation of phosphogypsum in the cement has
drastically increased its initial strength. This strength development was attributed to formation of
anhydrate at higher temperatures [20].
Katamine investigated the deformation behaviour of asphalt concrete mixtures containing four
phosphate waste fillers (12.7 mm reject, 4.5 reject, lime and phosphogypsum) and compared the
behaviour to a standard mixture containing limestone filler. It was recommended that the slime and
phosphogypsum fillers should not be used in wearing course mixtures. It was further concluded that
the Marshall test method provided misleading conclusion with respect to the effects of water on the
mixture containing slime and phosphogypsum fillers [21].
Kumar investigated the physical and mechanical properties of FALG bricks and hollow blocks by
using different proportions of fly ash, lime and gypsum. The durability of these blocks was also
investigated. It was concluded that these blocks were sufficient strength for their use in load bearing
walls [22].
Phosphogypsum (treated and untreated) has not yet been studied and utilised in concrete in
India. Phosphogypsum obtained from the process plants in India contains greater proportions of
impurities, radioactivity and pH. These parameters may seriously affect strength and durability of
concrete if used in high volume. There is, therefore, a strong need to investigate preliminary
properties of low volume use of unpurified (untreated) phosphogypsum in cement, mortar and
concrete mixes.
In the present investigation, apart from cement and mortar mixes, concrete mix design method
has been tried to produce concrete mixes using phosphogypsum. In case of cement
phosphogypsum mix and mortar all the preliminary properties were studied. Cement concrete mixes
with phosphogypsum as an ingredient have been designed called as rational method for concrete
strength ranging from 15 N/mm2 to 25 N/mm2. Tests have been carried out on phosphogypsum
concrete mixes and the results have been compared with those obtained from conventional concrete.
3. Cement phosphogypsum mixes
In case of cement phosphogypsum mixes, the materials used were phosphogypsum and ordinary
Portland cement.
3.1 Phosphogypsum
Phosphogypsum was obtained from Rashtriya Chemical and Fertilizer (RCF), Chembur plant in
Maharashtra State, India. It was tested according to IS: 12679 - 1989 and found to satisfy the
requirements of IS: 12679 1989 [27]. The chemical composition of phosphogypsum is as shown in
Table 1. The specific gravity obtained was 3.15. The phosphogypsum known to have some of the
chemical impurities like phosphates and World wide for most of the applications as a binder or
cements, etc. Phosphogypsum supposed to be treated for these impurities; therefore phosphogypsum
without treatment referred here as raw or impure phosphogypsum (PG).

Table 1: Chemical composition of phosphogypsum

Chemical constituents
Percentage
CaO
31.2
SiO2
3.92
SO3
42.3
R2O3
3.6
MgO
0.49
Phosphate, Fluoride, etc.
18.49
3.2 Cement
The Ordinary Portland Cement, 53 grade conforming to IS: 12269 - 1987 was used [28]. The
cement was procured from local market and in one lot to maintain uniformity through out the
investigation.
3.3 Water
Ordinary tap water was used for mixing and curing operation.
4. Cement phosphogypsum mix test programme
The Ordinary Portland cement was replaced by phosphogypsum in each mixes 5% 20% (by dry
weight). The cement and phosphogypsum was mixed dried thoroughly and then water was added.
These mixes were tested for normal consistency, setting time, and soundness as per different parts of
IS: 4031 1988 and results were compared with cement mixes without phosphogypsum [34].
5. Cement phosphogypsum mix test results and discussions
5.1 Normal consistency
The normal consistency was conducted as per IS: 4031 (Pt 4) 1988 [29]. The normal
consistency results are tabulated in Table 2. It was observed that phosphogypsum provides
additional stiffness to the paste, and therefore it was required to add water for desired penetration of
Vicats plunger. However, for five percent replacement of raw phosphogypsum the normal consistency
is very close to standard value and for further addition of phosphogypsum the value increased beyond
limit specified in IS: 12269 1987 i.e. 30% as per Indian standards.
Table 2: Normal consistency of cement and cement phosphogypsum mixes
Normal consistency
Percentage replacement of
cement
(%)
0
29
5
30
10
34.2
15
36
20
36.8
25
37.2
50
44
100
52
5.2 Setting time
The setting time was conducted as per IS: 4031 (Pt 5) 1988 [30]. The water content observed
by normal or standard consistency was used for measuring initial setting time. It was observed that
even for five percent replacement of cement with raw or impure phosphogypsum the initial and final
time was increased beyond standard value for ordinary Portland cement as specified in IS: 12269 1987. The initial setting time results are presented in Table 3.
Table 3: Setting time of cement and cement phosphogypsum mixes
Percentage replacement
Initial setting Final setting
of cement
time (minute) time (minute)
0
30
490
5
120
595
10
180
866
15
250
942

5.3 Soundness
The soundness of cement was conducted as per IS: 4031 (Pt 3) 1988 [31]. As quoted earlier,
the raw phosphogypsum is known to have impurities; therefore, it is very important to measure
soundness of paste made with replacing cement. The test results are presented in Table 4. The
results indicated that even 20% replacement of cement does not contribute to unsound paste.
Table 4: Soundness of cement and cement phosphogypsum mixes
Percentage replacement
Soundness
of cement
(mm)
0
1
5
2
10
3
15
5
20
8
6. Cement phosphogypsum mortar mix
In case of mortar, the materials used were phosphogypsum, cement, sand, and ordinary tap
water. The details of properties of materials were discussed in previous section.
6.1 Sand
Local river sand was used as fine aggregate. Fine aggregate conforming to IS: 650 1966 was
used for testing [33].
7. Mortar mix proportions and test programme
The standard mix proportion of 1:3 by weight was considered for the test. The proportions of
phosphogypsum were varied from 5%, 10% and 15% of ordinary Portland cement by dry weight.
Each time twelve numbers of cubes were cast with the water binder ratio 0.40, 0.45, and 0.50. The
test was carried out as per IS: 4031 (Pt 6) 1988 [34].
7.1 Mortar mix test results and discussion
The cement mortar cubes were tested for compressive strength for three days of curing by
varying water cement ratio 0.4, 0.45 and 0.5. The results of mortar cube compressive strength for
three days of curing with variation of phosphogypsum percent and water cement ratio is as shown in
Table 5. It is observed that plain cement mortar cubes are less strength as compared to five percent
phosphogypsum, and maximum strength is obtained for water cement ratio 0.45.
Therefore, it is clear from compressive strength consideration that replacement of five percent of
Ordinary Portland Cement with raw phosphogypsum is advantageous as per strength point of view.
More over, if phosphogypsum percentage increased beyond five percent there is decrease in
compressive strength of mortar mixes. It is observed that, white spots are appeared on the surface of
specimen may be due to effloresces or internal sulphate attack. The effect may also be due to high
content of highly acidic phosphogypsum beyond 5% in mixes.
Table 5: Cube compressive strength of cement mortar and cement phosphogypsum mortar
Three days cube compressive
28 days
Seven days
Percentage
strength in N/ mm2 for
compressive
compressive
Replacement
different water cement ratio
strength in N/ mm2 strength in N/ mm2
of cement
0.40
0.45
0.50
0.45
0.45
0
15.04
17.03
16.48
37.4
53.2
5
20.06
23.07
21.06
40.3
55.5
10
11.03
12.70
10.78
25.67
43.45
15
10.86
15.05
10.53
26.76
40.31
8. Concrete mix proportions
Concrete mixes with phosphogypsum as an ingredient have been designed by Rational method
for strength varying from 15 N /mm2 to 25 N /mm2 [35]. Maximum size of the graded aggregate is
taken as 20 mm and the fineness modulus of the fine aggregate is taken as 2.87 conforming to IS:
383 1970 [36]. The quantities of ingredients required are tabulated as under in Table 6.
The details of materials used in the experimentation are discussed in previous section. Potable
water was used to cast and cure the sample. Three different mixes of cement, fine and coarse
aggregates, namely 1:1.9:3.9, 1:1.8:3.3, and 1:1.7:3.2 by dry weight were used for present

investigations. Cement was replaced by phosphogypsum in different percentages, i. e., 5%, 10%,
15%, and 20%.
9. Experimental investigations of concrete mixes
9.1 Workability
The workability of fresh concrete was assessed by conducting Compaction Factor test as per
guidelines of IS: 1199 1970 [37]. The Compaction Factor of concrete without phosphogypsum was
found to be 0.935 and concrete with five percent phosphogypsum was 0.92. It is observed that the
further replacement of cement with raw phosphogypsum it is very difficult to mix the concrete due to
inadequate water cement ratio. Presence of fine particles of phosphogypsum in concrete causes a
stabilizing effect on the rheology of fresh concrete and reduce tendency of segregation and bleeding,
make concrete somewhat sticky.
9.2 Compressive strength and rate of strength gain
The specimens were cast with concrete mixes mentioned and cured for 28, 35 and 45 days in the
laboratory, (100% RH and 25 20C). On completion of the curing period the specimen were taken out
and tested as per IS: 516 1959 for compressive strength was carried out in order to assess
performance of the concrete [37, 38]. Table 6 presents the influence of curing age on the
compressive strength of phosphogypsum concrete cubes. Each value represents average value of
three tested specimens. Table 6 shows that, there is significant increase in compressive strength of
concrete having five percent phosphogypsum than that of conventional mix i. e. without PG. In
addition, Table 6 show the rate of percentage increases in compressive strength considerably
increases with decrease in aggregate cement ratio.
Table 6: Compressive strength (N/mm2) of concrete mixes
Average Compressive strength (N/mm2) of 1:1.9:3.9 mix designed for 15
N/mm2
Age (Days)
0%
5%
10%
15%
20%
14.6
28
14.2
13.6
10.8
10.1
19.3
35
19.0
17.9
12.1
12.1
24.9
45
24.7
23.5
14.3
10.6
Average Compressive strength (N/mm2) of 1:1.8:3.3 mix designed for 20
N/mm2
Age (Days)
0%
5%
10%
15%
20%
19.0
28
18.1
17.2
14.0
11.9
21.2
35
20.2
19.8
16.4
16.0
26.0
45
25.6
25.1
21.2
17.6
2
Average Compressive strength (N/mm ) of 1:1.7:3.2 mix designed for 25
N/mm2
Age (Days)
0%
5%
10%
15%
20%
26.4
28
24.8
18.7
16.1
13.0
31.2
35
27.8
24.8
20.9
18.8
34.0
45
31.7
25.3
22.0
18.9
The Tables 6 and Tables 7 shows that there is constant increase in compressive strength of
concrete containing five percent of phosphogypsum as compared to conventional concrete. Further
increase in phosphogypsum content causes decrease in compressive strength, but rate is slow as
compared with previous mix.
Table 7: Percentage compressive strength gain by concrete with five percent PG over plain
concrete
Percentage
increase in compressive strength
Aggregate/
Concrete mix
Cement ratio
28 days
35 days
45 days
Average value
1:1.9:3.9
5.9
2.7
1.6
0.8
1.7
1:1.8:3.3
5.1
4.7
4.7
1.5
3.6
1:1.7:3.2
4.8
6.1
10.9
6.8
7.9

10. Economics of phosphogypsum cement concrete

The economy of using phosphogypsum depends entirely on relative cost of phosphogypsum to
cement, transportation charges of phosphogypsum from source to place of applications, purification
process involved, etc. including all these in to account the cost of phosphogypsum in India is only
30% per kilogram of ordinary Portland cement. Experimental investigations have revealed that, for all
the mixes, five of ordinary Portland cement can be replaced with unpurified phosphogypsum, which
accounts for considerable savings, in case of mass concrete and large construction projects.
11. Conclusions
The mixture in which cement replaced with five percent phosphogypsum having almost same
standard or normal consistency than that of plain cement and thus water requirement of the
cement phosphogypsum mix minutely affected. But, further replacements of ordinary Portland
cement with raw PG seriously affect the consistency.
Phosphogypsum in ordinary Portland cement mixes considerably retards setting time but does not
contribute to produce unsound cement paste.
Phosphogypsum can be economically used up to five percent as an ingredient or admixture of
cement-mortar mix, both for stone and brick masonry work.
The degree of workability of concrete mix with five percent phosphogypsum decreases as compared
to conventional concrete, but it improves cohesiveness of the concrete mix and thus reduction in
segregation and bleeding.
The compressive strength of phosphogypsum cement concrete (with five percent PG) is improved
indicates that phosphogypsum has immense potential to be utilised in concrete applications,
especially mass concrete work.
Acknowledgments
The author would like to express their deep sense of gratitude to Florida Institute of Phosphate
Research, Florida, and Ms. Karen Steward for their generous debt of literatures supplied to author.
The authors are thankful to Science and Engineering Research Council (SERC), Department of
Science and Technology, Government of India, for research grant number 92865.
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