Durability of Limestone-Filler Based Concrete in Acidic Environment

Abstract

Concrete structures exposed to acidic environments are highly susceptible to deterioration due to chemical attack, resulting in strength reduction, increased permeability, and reduced service life. The present study investigates the influence of limestone powder as a partial replacement for cement on the durability and mechanical performance of concrete subjected to acidic conditions. Limestone powder was incorporated at replacement levels of 0%, 5%, 10%, and 15% by weight of cement. Concrete specimens including cubes and cylinders were cast and tested for compressive strength and split tensile strength at 28 and 56 days. Durability performance was evaluated by immersing specimens in diluted hydrochloric acid solution and monitoring mass loss and strength reduction. Results indicate that partial replacement of cement with limestone powder improves particle packing, reduces permeability, and enhances resistance against acid attack up to an optimum level. Among all mixes, the 5% replacement level demonstrated superior performance in terms of strength and durability. The study highlights the potential use of limestone powder as a sustainable and economical supplementary material for durable concrete production.

Introduction

Concrete is the most widely used construction material due to its strength, durability, versatility, and cost-effectiveness. However, concrete structures exposed to aggressive environments such as industrial areas, sewage systems, and marine regions are susceptible to acid attack, which causes deterioration through the reaction of acids with cement hydration products. This results in leaching, increased porosity, and reduced structural integrity.

To enhance concrete durability and sustainability, limestone powder has been investigated as a partial cement replacement. Limestone powder improves particle packing, refines pore structure, reduces voids, enhances the interfacial transition zone, lowers costs, and provides environmental benefits. The study aims to evaluate the mechanical and durability performance of limestone-filler-based concrete exposed to 1% hydrochloric acid (HCl), determine the effect of varying limestone replacement levels on mass loss and acid resistance, analyze microstructural characteristics using SEM, and identify the optimum limestone filler content for improved long-term durability.

The literature review indicates that limestone-based and blended cementitious systems generally improve durability, reduce permeability, and enhance resistance to aggressive environments such as sulphate and acid attacks. Studies have shown that limestone filler can improve early-age strength, reduce water penetration, and contribute to sustainability, although excessive limestone content may reduce compressive strength and resistance to carbonation and chloride penetration.

The materials used in the study include:

• OPC 43 Grade Cement conforming to IS 8112.
• M-Sand as fine aggregate conforming to IS 383:2016.
• 20 mm crushed angular coarse aggregates conforming to IS 383:2016.
• Limestone powder (particle size < 75 μm) as a filler material.
• FOSROC Conplast SP-430 superplasticizer to improve workability.

The study seeks to establish the optimum limestone powder replacement level that enhances concrete performance and durability under acidic exposure conditions.

Conclusion

The experimental results demonstrated that acidic exposure affected all concrete specimens by causing gradual deterioration of the cementitious matrix. The interaction between hydrochloric acid and cement hydration products led to leaching, mass loss and minor reductions in mechanical properties over time. The incorporation of limestone filler improved the overall performance of concrete by refining the pore structure and enhancing the compactness of the matrix. The filler effect reduced void spaces within the concrete and restricted the penetration of aggressive acidic ions. As a result, limestone-filler-based concrete exhibited improved resistance to acid attack compared to conventional concrete. From the study, the limestone powder significantly influenced the strength characteristics of concrete exposed to acidic conditions. The highest compressive strength was achieved at 15% limestone powder replacement, recording 37.63 MPa at 28 days and 37.50 MPa at 56 days, outperforming the control mix. In terms of split tensile strength, the 5% replacement level showed the best performance with 3.80 MPa at 56 days, indicating enhanced crack resistance and improved bonding within the concrete matrix under acidic exposure. The mass loss results showed that limestone powder improved the durability of concrete exposed to a 1% HCl solution. In cube specimens, the 10% replacement mix exhibited the lowest mass loss (4% at 56 days), while the 5% replacement mix showed the highest mass loss (7% at 56 days). In cylinder specimens, the 5% replacement mix performed best with only 2% mass loss at 56 days, whereas the 15% replacement mix recorded the highest value (6% at 56 days). Overall, limestone powder replacement enhanced both strength and durability, with 10% replacement levels providing the most favorable overall performance under acidic exposure conditions. The SEM investigation provided microstructural evidence supporting the mechanical and durability test results. The micrographs revealed dense hydration products, well-developed C-S-H gel, reduced pore connectivity, and satisfactory bonding within the matrix. The overall microstructure remained compact and stable, indicating good durability characteristics. Based on the combined evaluation of compressive strength, split tensile strength, mass-loss behavior under acidic exposure, and SEM microstructural analysis, the 05% to 10% limestone powder replacement level is considered the optimum mix. It provides the best balance between mechanical performance and durability, exhibiting superior resistance to acid-induced deterioration while maintaining adequate strength characteristics for structural applications.

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Copyright

Copyright © 2026 Manish B, Prof. Rajkumar Tadkal, Prof. Shivanand V C. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.