Mineral Resources for Construction Materials Lecture PDF

LECTURE 2: MINERAL RESOURCES FOR CONSTRUCTION MATERIALS Cristina Ruiz Agudo OBJECTIVES OF THE LECTURE Understand the basic definitions and classifications of minerals and rocks Explore the geological processes that produce mineral resources Learn about the distribution of mineral r...

LECTURE 2: MINERAL RESOURCES FOR CONSTRUCTION MATERIALS Cristina Ruiz Agudo OBJECTIVES OF THE LECTURE Understand the basic definitions and classifications of minerals and rocks Explore the geological processes that produce mineral resources Learn about the distribution of mineral resources in the Earth's crust Examine the properties and applications of minerals in construction Study specific types of mineral resources used in construction (e.g., limestone, marble, clay, gypsum, sand) Understand extraction and processing methods for mineral resources and the environmental impact Explore sustainability and resource management in the context of mineral resources OUTLINE INTRODUCTION  BASIC DEFINITIONS o Mineral o Natural solid with defined chemical composition and crystalline structure o Mostly inorganic, formed from geological processes o Can be pure elements or compounds, not mixtures NaCl o Examples: NaCl, CaCO3 o Mineraloids o Natural mineral-like substances lacking constant chemical Table salt (NaCl) composition or crystal structure o Examples: obsidian, opal, pearl o Rock definition o Consists of one or more minerals or mineraloids o Examples: limestone (contains calcite (CaCO3), quartz (SiO2), and clays)  Pyrite (F2S) MINERAL CLASSIFICATION o Metallic minerals o Ferrous (contain iron) o Have magnetic properties o Essential for the metallurgical industry Calcite (CaCO3) o Non-ferrous (no iron) o More expensive but offer desirable properties (e.g., lightweight aluminum, conductive copper) o Non-metallic minerals o E.g., limestone, gypsum, mica, sand, gravel, clay, marble o Used in cement, ceramics, glass, and lime production  GEOLOGICAL PROCESSES PRODUCING MINERAL RESOURCES  THE ROCK CYCLE o It is a dynamic process that recycles Earth’s materials in different forms, from molten magma deep below the surface to solid rock formations and sediments. o Three type of rocks: o Igneous o Sedimentary o Metamorphic rocks Physical Geology 2nd Edition  IGNEOUS ROCKS o Formed from solidified magma or lava (e.g., granite, basalt) o Classified by origin and composition Basalt o Origin: o Intrusive (slow-cooling, coarse crystals) o Extrusive (fast-cooling, small crystals) o Composition: SiO2 % o Felsic (high) Iceland o Intermediate o Mafic o Ultramafic (low)  SEDIMENTARY ROCKS o Created from the accumulation and lithification of sediment (e.g., limestone, sandstone) or by precipitation from solution (evaporites, gypsum) Limestone o Formed through deposition and compression of minerals, rock fragments, and organic matter. Antequera (Spain) By Fernando Domínguez Cerejido – CC BY-SA 4.0 Agia Pavlos, Greece https://www.geologyin.com/  METAMORPHIC ROCKS o Derived from pre-existing rocks called protolith or parent rock (sedimentary, igneous, or metamorphic) o Transformed due to pressure and heat (e.g., marble, slate) Marble o Complex range of rock types with different physical characteristics o Metamorphic change: was it due to increased temperature, pressure, or both, or were chemically reactive fluids involved? Carrara (Italy)  DISTRIBUTION OF MINERAL RESOURCES IN THE EARTH EARTH'S CRUST Nine elements make up over 99.5% of the crust (e.g., oxygen, silicon, aluminum) COMPOSITION Minor and trace elements Account for less than 0.5% of crust Need enrichment to form exploitable deposits Often combined with oxygen, sulfur, or carbon Formation of mineral deposits Require specific natural processes for sufficient enrichment Operate on geological time scales (non-renewable on human timescales) o Thin outer shell (10-100 km thick) o Contains most exploitable mineral resources o Represents only 0.4% of Earth's mass https://studygeographia.blogspot.com/ MINERAL RESOURCES CONSUMPTION  o Increasing global demand o Population growth: faster than any time in history o Economic development in emerging countries o New technologies and applications o Consumption trends o Mine production of main metals increased by orders of magnitude since 1900 o Current technologies utilize almost the entire periodic table o Challenges o Depletion of easily accessible resources INCREASING GLOBAL o Need for deeper mining and processing of lower-grade ores DEMAND o Increased environmental impact and health risks o Higher extraction and processing costs PROPERTIES AND APPLICATIONS OF MINERALS FOR CONSTRUCTION PROPERTIES OF MINERALS FOR CONSTRUCTION o PHYSICAL PROPERTIES o CHEMICAL PROPERTIES o Strength o Chemical stability o Compressive, tensile strength, shear o Resistance to decomposition or alteration over time o Durability o Important for long-term durability of structures o Weather resistance (sun, air, rain) o Wear resistance (uses) o Corrosion resistance o Particularly important for metals used in o Density construction (e.g., steel reinforcement) o Hardness o Affects longevity of structures, especially in o Thermal properties coastal environments o Thermal conductivity o Fire resistance o Thermal expansion o Ability to withstand high temperatures without losing structural integrity o Porosity and permeability o Critical for safety in building design  SPECIFIC APPLICATIONS OF MINERAL RESOURCES IN CONSTRUCTION UHPC bridge o Structural Materials o Binding Materials o Decorative Materials o Specialty Applications https://www.constructionplusasia.com/  o CONCRETE o Composed of cement, aggregates, and water o High compressive strength, versatility in form o Used in foundations, walls, bridges, and roads o STEEL o High tensile strength, ductility o Used in reinforced concrete, structural frames, and bridges o AGGREGATES o Sand, gravel, and crushed stone o Essential in concrete and as base materials for roads o BRICKS o Produced by firing clays, shale, and sand STRUCTURAL o Strength and Durability MATERIALS o Uses in structural and non-structural applications o EARTH-CONSTRUCTION MATERIALS o Thermoregulating properties in indoor environments o Now regaining value due to their sustainability  o CONCRETE Lect 3 & 4 & 5 o Composed of cement, aggregates, and water o High compressive strength, versatility in form Lect 2 o Used in foundations, walls, bridges, and roads o STEEL o High tensile strength, ductility o Used in reinforced concrete, structural frames, and bridges o AGGREGATES o Sand, gravel, and crushed stone o Essential in concrete and as base materials for roads o BRICKS o Produced by firing clays, shale, and sand STRUCTURAL o Strength and Durability MATERIALS o Uses in structural and non-structural applications Lect 7 o EARTH-CONSTRUCTION MATERIALS o Thermoregulating properties in indoor environments o Now regaining value due to their sustainability  Lect 2 CONCRETE „In 2021, the cement industry was estimated to be directly responsible for Concrete is the second most consumed material worldwide (after emitting almost 7% of total water)! anthropogenic carbon Fundamental for housing and infrastructure of our modern society dioxide emissions by the high strength material International Energy Agency durability (IEA) “ abundancy of raw materials International Energy Agency (IEA). Cement – Analysis - 2022. https://www.iea.org/reports/cement  Lect 2 CONCRETE „In 2021, the cement industry was estimated to be directly responsible for emitting almost 7% of total anthropogenic carbon dioxide emissions by the International Energy Agency (IEA) “ International Energy Agency (IEA). Cement – Analysis - 2022. https://www.iea.org/reports/cement  Definition: Granular, inert material used in construction AGGREGATES Main types: Crushed stone (e.g., limestone, granite), sand and gravel Key applications: Concrete and mortar production Road and pavement construction (component in asphalt) Essential for infrastructure (highways, railways, buildings) Usage statistics: 30,000 tons per 1 km of highway https://multico.com.ph/ 90% of paved roads contain aggregates 2 tons per cubic meter of concrete Fine Aggregate (Sand): 0.063 mm - 4 mm Composition considerations: Limestone: ~50-75% of crushed stone Coarse Aggregate (Gravel): 4 mm - 63 mm Sand composition varies (often silica-based) Crushed Stone: 4 mm - 63 mm Environmental concerns: Sand crisis STEEL Structural steel: beams, columns, and girders form the skeleton of many buildings Reinforcement: Steel rebar is used to reinforce concrete, increasing its tensile strength. Temporary structures: Scaffolding and formwork often use steel components https://www.build-review.com/ Bridges: Steel is a primary material in bridge construction due to its strength and durability. Roofing: industrial and commercial buildings. Stairs and elevators Doors and windows Own picture Own picture  Lect 7 Definition: According to ASTM C1232 standard, a brick is a BRICKS solid or hollow masonry unit of clay or shale, usually formed into a rectangular prism, then burned or fired in a kiln. Composition: clays and sand Density: 1.300 kg/m³ - 2.200 kg/m³ Properties: (a) highly durable, (b) offer long-term performance, (c) low maintenance, (d) high-thermal mass, (e) reusable and recyclable, and (f) generate healthy and comfortable https://gruposteel.es/ environments. Key applications (Essential for housing) Load-bearing walls in buildings Non-load-bearing partition walls Historical building renovation, External façades https://www.leroymerlin.es/ https://www.leroymerlin.es/  Lect 7 Global prevalence: EARTH-CONSTRUCTION Nearly 50% of the world's population lives in earth-based MATERIALS dwellings Common in less developed countries Increasing in countries like US, Brazil, and Australia due to sustainability focus Historical context and renewed interest: One of the oldest building materials Tripadvisor Regaining popularity due to sustainability benefits Compressed Earth Blocks (CEBs): Lower carbon footprint than conventional materials Recyclable and biodegradable Potential to combine traditional techniques with modern sustainability needs https://manali.mx/  o CEMENT o Primary binding agent in concrete o Various types for different applications (e.g., Portland cement, quick-setting cement) o LIME o Used in mortars and plasters o Provides flexibility and breathability in traditional construction o GYPSUM PLASTER o Gypsum-based material used for interior wall finishes o Provides smooth surfaces and fire resistance o BITUMEN BINDING MATERIALS o Used as a binder in asphalt for road construction o Also used in waterproofing applications  o CEMENT Lect 3, 4 & 5 o Primary binding agent in concrete o Various types for different applications (e.g., Portland cement, quick-setting cement) o LIME Lect 3 o Used in mortars and plasters o Provides flexibility and breathability in traditional construction o GYPSUM PLASTER Lect 6 o Gypsum-based material used for interior wall finishes o Provides smooth surfaces and fire resistance o BITUMEN Lect 8 BINDING MATERIALS o Used as a binder in asphalt for road construction o Also used in waterproofing applications Florence o MARBLE o Aesthetic appeal, takes polish well o Used for flooring, countertops, and decorative elements https://www.cupastone.com/ o GRANITE o Durability, variety of colors and patterns o Used for countertops, cladding, and monumental structures o TILES Own picture https://www.leroymerlin.es/ o Ceramic, porcelain, and natural stone tiles o Used for flooring, wall cladding, and roofing DECORATIVE MATERIALS TYPES OF MINERAL RESOURCES USED IN CONSTRUCTION LIMESTONE AND MARBLE Limestone: Sedimentary rock primarily composed of calcium carbonate (CaCO3) in the form of mineral calcite or aragonite. Marble: Metamorphosed limestone with recrystallized calcite. Own picture https://www.artisticstonedesign.com/ 450-700°C 3-10 kilobars (300-1000 MPa) Limestone comprises about 15% of the Earth's sedimentary crust. Calcite in limestone is divided into low- magnesium and high-magnesium calcite, with the dividing line at 4% magnesium.  LIMESTONE VS MARBLE PROPERTIES Property Limestone Marble Mainly composed of calcite, often with fossil Metamorphosed limestone, primarily Composition inclusions calcite Density 2100-2700 kg/m3 2600-2800 kg/m3 Texture Granular with possible fossils and layers Uniform, crystalline texture without layers Hardness Softer (3 on Mohs scale) Harder (3-4 on Mohs scale) Color and Appearance Natural, earthy tones with impurities Range of colors with distinctive veins Weathering More susceptible to weathering and erosion More resistant to weathering Cost Cheap Expensive Typical Uses Cement production, building stone, Sculpture, decorative building material LIMESTONE VS MARBLE MICROSTRUCTURE Oolitic limestone Marmo di Carrara x 25 https://www.florence-rockinart.it/ https://www.florence-rockinart.it/ LIMESTONE VS MARBLE NOTABLE USES Limestone Marble Cheops pyramid  Lect 3 LIME-BASED MORTARS  Lect 3, 7 CLAYS Clay rocks are cohesive unconsolidated sedimentary rocks where size fraction lower than 0.002 mm is dominant Composition Primarily phyllosilicate minerals (e.g., kaolinite, illite, montmorillonite, chlorite) May contain fine-grained quartz, mica, feldspar, and iron oxides and can include biogenic matter Formation: from the weathering of silicate minerals Plasticity: Allows clay to be shaped and molded when mixed with water Uses: bricks, ceramic tiles, earth construction materials (e.g., Compressed Earth Blocks - CEBs) CLAYS USES Earth compressed blocks https://www.designboom.com/design/earth-block-eco-friendly-legos/ https://www.youtube.com/watch?v=2avRCMeSW3Q  Lect 6 GYPSUM (CALCIUM SULFATE DIHYDRATE) Gypsum is the most common sulfate mineral Chemical formula: CaSO4 2H2O White translucent crystalline mineral though impurities can give the mineral a gray, brown, or Iran Naica (Mexico) https://gypsang.com/ pink coloration Alexander Van Driessche Perfect exfoliation Density of about 2300 kg/m3 H2O Hardness: below 2 in Mohs Formation: natural and synthetic (byproduct of H2O industrial processes) Uses in construction: drywall and plaster  Lect 6 GYPSUM-ANHYDRITE CYCLE GYPSUM Calcium sulfate dihydrate (CaSO4 2H2O) 100-130 C ANHYDRITE II BASSANITE (CaSO4) Calcium sulfate hemihydrate Orthorhombic (CaSO4 ½H2O) Low solubility 200-1000 C 130-200 C ANHYDRITE I (CaSO4) Hexagonal  Lect 6 GYPSUM NOTABLE USES Giza pyramids (mortar) Alhambra plasterworks Cheops pyramid Granada (Spain) Minoan civilization (drywalls) Granada (Spain) Heraklion (Crete) Heraklion (Crete) Granada (Spain)  SAND Queensland (Australia) Valencia (Spain) Sand refers to a size: 4 mm - 0.063 mm Results from prolonged weathering, yielding finer grains Two main types of composition: SiO2 in the form of quartz CaCO3 Alessio Sbarbaro Own work, CC BY-SA 2.5 Other types: volcanic (basaltic) sand, olivine sand, gypsum sand Hawaii (US) Hardness: Quartz sand (6-7), Carbonate sand (3) Density: Quartz sand (1.7-2 g/cm3), Carbonate sand (1.7-2 g/cm3) Main uses in construction Glass production Wikipedia Diego Delso, CC BY-SA 3.0 Concrete aggregate (50 billion tons/year) SAND Sand refers to a size: 4 mm - 0.063 mm Results from prolonged weathering, yielding finer grains Two main types of composition: SiO2 in the form of quartz CaCO3 Other types: volcanic (basaltic) sand, olivine sand, gypsum sand http://dx.doi.org/10.1016/j.gsf.2019.11.006 Hardness: Quartz sand (6-7), Carbonate sand (3) Density: Quartz sand (1.7-2 g/cm3), Carbonate sand (1.7-2 g/cm3) Main uses in construction Glass production Concrete aggregate (50 billion tons/year) Volcanic sand https://scienceviews.com/ SAND DEPOSITS Beach Sand Created by wave action, weathering, and river deposition Shoreface, delta, estuary, rivers Marine/Ocean Sand Originates from sediments transported into the ocean and erosion of ocean rocks Thicker layers closer to land Mining can harm ecosystems and fisheries Desert Sand Eolian sand Generally unsuitable for construction due to rounded grain shape (poor cement binding), uniform particle size distribution, high dust content, high porosity  https://www.youtube.com/watch?v=0eVT7iB2BDA SAND A CRITICAL RESOURCE Non-renewable over human timescales High demand for concrete-suitable sand Annual usage: 50 billion tons of beach and fossil sand in construction Concrete production is the main global demand driver Average house requires 200 tonnes of sand One mile of highway needs 15,000 tons Global Sand Extraction Issues Chinese Poyang Lake: Dredging for cement production Dubai: Depleted sea floor around Saudi Arabia, importing from Australia Environmental impacts: Damage to marine ecosystems Increased flooding and erosion risks for coastal communities Emerging illicit sand trade due to lack of global regulation SAND A CRITICAL RESOURCE Non-renewable over human timescales High demand for concrete-suitable sand Annual usage: 50 billion tons of beach and fossil sand in construction Concrete production is the main global demand driver Average house requires 200 tonnes of sand One mile of highway needs 15,000 tons Poyang Lake (China) Global Sand Extraction Issues Chinese Poyang Lake: Dredging for cement production Dubai: Depleted sea floor around Saudi Arabia, importing from Australia Environmental impacts: Damage to marine ecosystems Increased flooding and erosion risks for coastal communities Emerging illicit sand trade due to lack of global regulation www.caixinglobal.com  SLATE Microcrystalline metamorphic rock derived from shale (mudstone = clays & slits) Low-grade metamorphic : 200-320°C 3-12 kilometers = 1-4 kilobars (100-400 MPa) https://www.forbes.com Composed mostly of silicates (80%) and quartz Muscovite Phyllosilicate minerals: muscovite and illite Can be split into thin but tough sheets due to its cleavage Uses: Roofing material (primary use), flooring tiles https://www.forbes.com EXTRACTION AND PROCESSING  EXTRACTION METHODS Carrara Marble Extraction o Surface mining o Open-pit mining o Strip mining o Underground Mining UHPC o Higher-grade metallic ores bridge o Placer mining o Valuable minerals from sediments The location and shape of the deposit, strength of the rock, ore grade, mining costs, and current market price of the commodity are some of the determining factors for selecting the mining method. Reiner Flassig (Own work)  PROCESSING o Steps taken to refine raw materials into usable products (e.g., crushing, grinding, screening, separation, washing). o Highly dependent on the use of the materials o Normally, the mineral resources used in the construction industry do not require much processing (e.g., sand, aggregates) www.jycrusher.com ENVIRONMENTAL IMPACT OF MINING Environmental Impacts: Erosion, biodiversity loss, water and soil contamination Health risks for local populations Regulations: Environmental assessments and management plans require Limestone mine (India) JK cements Varying enforcement, especially in developing countries Industry self-regulation and financial sector oversight Waste Management: Large amounts of toxic tailings produced Stored in ponds; failures can cause disasters Waste classification and management crucial in planning Rio Tinto (Spain) SUSTAINABILITY AND RESOURCE MANAGEMENT  RESOURCE MANAGEMENT Recycled aggregates from concrete o Resource depletion concerns o Minerals are non-renewable sources at our time-scales o Recycling and reusing construction materials like concrete, steel, glass, gypsum boards, asphalt… o Recycle aggregates from concrete o Carbonated cement paste o Alternative and synthetic materials https://reagg.com/ o Examples of engineered alternatives like synthetic aggregates, fiber-reinforced concrete, and bio-based materials. TAKE HOME MESSAGES SUMMARY Mineral resources are crucial for construction and infrastructure Understanding mineral properties is critical to their effective use Global demand for construction minerals is increasing rapidly Sustainable management of mineral resources is essential Recycling and alternative materials can help address resource depletion Balancing economic needs with environmental concerns is critical THANK YOU CRISTINA RUIZ AGUDO LIMESTONE AND MARBLE Limestone forms when calcium carbonate precipitates out of water Can occur through both biological and nonbiological processes Biological limestone forms through the accumulation of marine organisms (e.g., coral, shellfish) over millions of years  o REQUIRE SPECIFIC NATURAL PROCESSES FOR SUFFICIENT ENRICHMENT FORMATION OF o OPERATE ON GEOLOGICAL TIME MINERAL DEPOSITS SCALES (NON-RENEWABLE ON HUMAN TIMESCALES)