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Autoclaved aerated concrete (AAC) is a building material that combines heat insulation
properties with sufficient mechanical strength for masonry construction. Compared to
ordinary concrete, the matrix is highly porous (>50%) and hardened by a hydrothermal curing
process at 150°C - 200°C. During this process, quartz sand and portlandite react to form first
calcium silicate hydrates (C-(A)-S-H) with Ca/Si ratios <1.3 and then tobermorite. Especially
tobermorite, which has a much larger crystallite size than C-(A)-S-H, provides improved
mechanical strength. This reaction sequence is influenced by many parameters and
additives of which calcium sulfate is probably the most important. Despite several attempts to
investigate these hydrothermal reactions, the actual reaction mechanism involved when
adding sulfate ions is not fully understood. It has been suggested that the addition of ca.
1.5 wt% significantly improves the mechanical properties due to the enhanced formation and
arrangement of tobermorite in the porous matrix. Since the sulfate content in AAC waste is
exceeding regulatory threshold for low-quality reuse in some countries, the aim of this study
was to investigate in detail the reaction mechanisms involving sulfate addition. Such
knowledge may open up the possibility to improve AAC production and to avoid the need for
sulfate addition. To achieve this goal, this research work focused on investigating the
hydrothermal curing process to determine the sequence of hydrothermal reactions and the
spatial distribution of the phases formed. For this purpose, a new setup for in situ X-ray
diffraction was specifically designed to study hydrothermal reactions and to conduct time
intensive experiments on a normal laboratory diffractometer. In order to quantitatively
evaluate the in situ measurements by Rietveld analysis using TOPAS, it was also necessary
to develop atomistic structure models for C-(A)-S-H phases. This was made possible by
adopting a supercell approach that was previously used to describe turbostratically stacked
clay minerals. The structure models, derived from tobermorite, are placed in an otherwise
empty supercell to simulate the C-(A)-S-H nanostructure. Adopting these methodological
advances, it was possible to obtain absolute phase quantities from in situ data and to track
the reaction kinetics of the hydrothermal curing process. These results were then combined
with ex situ X-ray diffraction and scanning electron microscopy. Confirming previous studies,
the major effect of sulfate ions was the formation and decomposition of hydroxylellestadite. It
was further revealed that C-(A)-S-H formation was delayed during hydroxylellestadite
formation, which is supposed to support the silicate ion diffusion and hence the tobermorite
formation at a stage critical for improved hardening of AAC. This can be linked to the
formation of lower amounts of capillary pores in the range of 1-5 µm, as observed by
scanning electron microscopy, and therefore a lower concentration of inherent defects that
resulted in the improved mechanical properties. This research work highlights how important the spatial distribution of crystallites is for the properties of a building material and how this
distribution can be influenced by small alterations in reaction chemistry.