Enhancing the Strength and Durability of Cement Mortar: Synergetic Effects of Shell Powder, Calcium Formate and Basalt Fibers

This study focuses on the core issue of sustainably utilizing shells to enhance the performance of cement mortar. The influence of shell powder on the slump flow, setting time, mechanical strengths, drying shrinkage rate and carbonation depth of cement mortar is investigated. The flexural and compressive strengths of cement mortar incorporating calcium formate after 12 h, 3-day and 28-day curing periods are examined. The effect of basalt fibers on the attenuation of cement mortar’s mechanical properties (flexural and compressive strengths) after NaCl freeze–thaw cycles is also studied. Scanning electron microscopy-energy dispersive spectroscopy (SEM-EDS) is employed to elucidate the underlying mechanisms. Results show that the slump flow, setting time and mechanical strengths have cubic function relationships with the shell powder’s mass ratio, while the drying shrinkage rate and carbonation depth follow quadratic function changes. Cement mortar with 15% shell powder by mass of the total binder materials demonstrates the highest slump flow and mechanical strengths. At this shell powder mass ratio, cement mortar shows the lowest drying shrinkage rate and carbonation depth. Calcium formate positively influences the 12-h mechanical strengths. After 3 days of curing, the mechanical strengths of cement mortar with 0.3% calcium formate are the highest. The calcium carbonate powder reduces the drying shrinkage rate of mortar and increases the content of Ca and C elements. The mass ratio of calcium formate exhibits a negative correlation with the cement mortar’s mechanical strengths after being cured for 28 days. The addition of basalt fibers enhances resistance to chloride salt freeze–thaw and dry-wet alternations erosion performance. These findings will provide a sustainable and effective strategy for utilizing agricultural by-products in concrete structures.