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Cement accelerator

A cement accelerator, also known as an accelerating admixture, is a chemical additive incorporated into concrete, mortar, or cement mixtures to expedite the hydration of hydraulic cement, thereby shortening the initial and final setting times and promoting faster early-age strength development.^[1] These admixtures are particularly valuable in scenarios requiring rapid construction progress, such as cold weather concreting or projects with tight schedules, where they help minimize the time needed for form removal, finishing, and protection against early freezing.^[2] Cement accelerators are classified under standards like ASTM C494 as Type C (set-accelerating without water reduction) or Type E (set-accelerating with water reduction).^[3] The most common and effective type is calcium chloride (CaCl₂), which is typically added at dosages up to 2% by mass of cement and accelerates hydration by increasing the dissolution rate of cement compounds, though its use is restricted in reinforced or prestressed concrete due to corrosion risks to embedded steel.^[1] Non-chloride alternatives, including calcium formate, sodium thiocyanate, nitrates, nitrites, and triethanolamine, provide similar acceleration without the corrosion concerns and are preferred for durable structures exposed to chlorides or sulfates.^[2] Chemically, these admixtures influence the nucleation and growth of hydration products like calcium silicate hydrate, enhancing the rate of heat evolution and strength gain, particularly at temperatures below 10°C (50°F).^[3] In practice, cement accelerators enable earlier load-bearing capacity, reduce bleeding, and shorten curing periods, facilitating applications in pavement repairs, precast elements, and emergency infrastructure work.^[1] However, overuse can lead to increased drying shrinkage, potential cracking, or later-age strength reductions, necessitating precise dosage based on mix design, ambient conditions, and compatibility testing.^[2] They are not antifreeze agents and must be combined with proper thermal protection in subfreezing environments to prevent damage from ice formation.^[3]

Overview

Definition

A cement accelerator is a chemical admixture added to concrete, mortar, rendering, or screeds to speed up the hydration reaction of cement, thereby reducing initial and final setting times while enhancing early-age strength development.^[4] These admixtures are typically dosed at 1-3% by weight of cement and are available in liquid or powder forms; they target the chemical reactions involving key Portland cement components, such as tricalcium aluminate (C3A) and tricalcium silicate (C3S), to shorten the dormant period of hydration.^[4] In contrast to retarders, which extend setting times to improve workability in hot conditions, or plasticizers, which enhance concrete flowability by reducing water demand without altering set time, cement accelerators specifically hasten the onset of hardening and early strength gain.^[4]

Purpose and benefits

Cement accelerators are primarily used to expedite the setting and early strength development of concrete, enabling faster formwork removal and shorter overall construction timelines. This is particularly valuable in scenarios where rapid progress is required, such as in precast concrete production or emergency repairs, allowing structures to bear loads sooner without extended waiting periods.^[5]^[6] Key benefits include significant increases in early compressive strength, often up to 50% higher at 1-3 days compared to plain concrete, which supports quicker structural integrity and reduces the risk of damage during early handling. Accelerators also shorten the initial setting time by 20-50%, enhancing productivity in applications like shotcrete where immediate adhesion and buildup are essential. In cold weather concreting below 5°C, these admixtures counteract slowed hydration by reducing set times from hours to minutes, ensuring normal solidification and hardening without long-term durability loss when properly dosed.^[5]^[7]^[8] Both chloride-based and non-chloride accelerators provide these advantages, with the choice depending on corrosion risks in reinforced concrete; overall, they improve construction efficiency by minimizing labor and equipment downtime while maintaining final performance standards.^[5]

History

Early development

The development of cement accelerators emerged in the context of rapid industrialization and the expanding use of Portland cement, which was patented in 1824 by Joseph Aspdin as a durable binding material resembling natural Portland stone.^[9] By the mid-19th century, Portland cement production surged to meet demands for infrastructure projects such as bridges, sewers, and urban housing, particularly from the 1850s onward when concrete applications proliferated in Europe and North America.^[9] This growth highlighted the need for faster-setting materials to accelerate construction timelines, prompting early experiments with soluble salts to modify cement hydration rates, including influences on gypsum's role in controlling initial set times.^[10] Calcium chloride was introduced as the first widely adopted set accelerator in 1873, specifically to expedite the hardening of concrete in demanding construction environments.^[11] Its addition, typically at 1-2% by weight of cement, promoted quicker strength gain by enhancing early hydration reactions, allowing for reduced curing periods and improved workability in challenging conditions. The first patent for its use in concrete followed in 1885, solidifying its practical application.^[11] By the early 20th century, calcium chloride had become a standard additive for winter concreting, enabling pours in temperatures below freezing by generating heat through accelerated hydration and mitigating freeze-thaw risks during initial setting.^[11] By the mid-20th century, as reinforced concrete became widespread, concerns over corrosion risks to embedded steel from calcium chloride emerged, leading to initial research in the late 1950s and restrictions by the 1970s, though its use continued for rapid construction benefits until then.^[12]

Modern advancements

Following World War II, the widespread adoption of chemical admixtures, including set accelerators, accelerated in the 1950s as concrete played a central role in global reconstruction efforts, enabling faster construction timelines and improved material performance in infrastructure projects.^[13] By the 1960s, concerns over corrosion in reinforced concrete prompted the introduction of non-chloride accelerators, such as calcium nitrite, which served as both setting accelerators and anodic corrosion inhibitors, marking a shift away from traditional calcium chloride options.^[14] In the 1970s, the American Society for Testing and Materials (ASTM) refined standards for chemical admixtures, building on the initial 1962 issuance of ASTM C494 to ensure consistent performance and safety in concrete applications.^[15] During the 1980s and 1990s, research advanced alkali-free liquid accelerators, particularly those based on triethanolamine combined with aluminum compounds, which enhanced early strength development in sprayed concrete while minimizing alkali-aggregate reactions and dust rebound.^[16] From the 2000s to the 2020s, emphasis has shifted toward sustainable, low-alkali options like aluminum sulfate-based accelerators, which promote rapid hydration without introducing chlorides or excess alkalis, supporting eco-friendly practices in modern construction. This evolution was driven by environmental regulations and durability challenges posed by chloride-induced corrosion, leading to a significant industry transition where non-chloride accelerators became predominant by the early 2000s to enhance long-term concrete integrity.^[14] A 2007 SINTEF report underscored their efficacy in challenging Nordic climates, noting that thiocyanate-based variants could achieve up to 74% of reference strength at -5°C, aiding cold-weather applications like precast elements.^[14] As of 2025, the focus continues on eco-friendly accelerators, with the global market for concrete accelerators projected to grow at a CAGR of 7.8% through 2034, driven by sustainable formulations and new production facilities.^[17]

Types

Chloride-based accelerators

Chloride-based accelerators are chemical admixtures primarily consisting of soluble chloride salts that expedite the hydration of Portland cement in concrete mixtures. The most widely used is calcium chloride (CaCl₂), typically added in flake, pellet, or solution form at a dosage of 1-2% by weight of cement. Other chloride salts such as sodium chloride (NaCl) and magnesium chloride (MgCl₂) can promote acceleration but are less effective and less commonly used than CaCl₂ due to inferior performance and similar corrosion risks.^[18] These accelerators exhibit high efficacy in reducing initial and final setting times, often shortening the process by 1-3 hours depending on dosage and ambient conditions, while also boosting early compressive strength by 30-100% within 72 hours. They are notably cost-effective compared to alternative admixtures, making them suitable for applications requiring rapid strength development. However, the introduction of chloride ions poses significant risks, particularly accelerating corrosion of embedded steel reinforcement in reinforced concrete by penetrating protective oxide layers and promoting electrochemical reactions.^[18]^[19] Usage of chloride-based accelerators is generally restricted to non-reinforced concrete or structures with low corrosion risk to mitigate these issues. Historically dominant in concrete production through the mid-20th century, their application faced stringent limitations starting in the 1970s due to observed corrosion failures, with standards capping dosages at 0.5-1% by cement weight in many cases to prevent exacerbation of alkali-aggregate reaction (AAR), which causes expansive gel formation and cracking. They are less preferred today in favor of non-chloride alternatives for broader safety.^[18]^[20]^[21]

Non-chloride accelerators

Non-chloride accelerators represent a class of admixtures designed to hasten the setting and early strength development of cementitious materials without introducing chloride ions, thereby addressing corrosion risks associated with traditional accelerators. These compounds are particularly valued in applications involving steel reinforcement, where chloride-induced degradation can compromise structural integrity. Common organic examples include triethanolamine (TEA), which enhances early hydration rates; sodium thiocyanate, which promotes rapid initial setting at low temperatures; calcium formate; and nitrates or nitrites such as calcium nitrate and calcium nitrite. Inorganic variants, such as aluminum sulfate and sodium aluminate, function by accelerating the formation of ettringite and other hydration products, with dosages varying by compound—typically 0.02–0.05% for TEA, 0.5–2% for calcium formate, and 2–8% for aluminum sulfate in shotcrete applications.^[22]^[6]^[23]^[24]^[25] The primary properties of non-chloride accelerators include a significantly reduced risk of corrosion to embedded steel, making them suitable for reinforced concrete structures. Unlike chloride-based options, they do not promote pitting or rust formation in the presence of moisture. Certain formulations, particularly those based on aluminum sulfate, enable flash setting, which is essential for shotcrete applications in tunneling and mining, allowing for quick adhesion and layer buildup. However, overdosing can lead to potential losses in later-age strength, as excessive acceleration may disrupt balanced hydration and result in a more porous microstructure.^[26]^[27]^[28]^[29] Advancements in non-chloride accelerators have focused on alkali-free liquid formulations, emerging prominently since the 1990s, which minimize efflorescence by limiting soluble alkali release during hydration. These liquids, often combining aluminum compounds with organic stabilizers, offer improved stability and reduced rebound in sprayed applications. Additionally, powder forms such as calcium sulfoaluminate have been developed for dry mixes, providing consistent acceleration in precast and repair concretes while enhancing early compressive strengths without compromising long-term durability.^[30]^[31]^[32]

Chemical Mechanisms

Hydration processes

The hydration of Portland cement is a complex exothermic process involving the reaction of its primary clinker phases—tricalcium silicate (C₃S), dicalcium silicate (C₂S), tricalcium aluminate (C₃A), and tetracalcium aluminoferrite (C₄AF)—with water to form a hardened paste that provides structural integrity. C₃S, comprising 50–70% of ordinary Portland cement, hydrates rapidly to produce calcium silicate hydrate (C-S-H) gel, the primary binding phase responsible for early strength development, along with calcium hydroxide (portlandite). C₂S, making up 15–30%, hydrates more slowly, contributing to long-term strength through similar C-S-H formation but with less portlandite. C₃A (5–10%) reacts quickly to initiate setting by forming ettringite, while C₄AF (5–15%) plays a minor role in hydration, producing similar aluminate phases and contributing to the cement's color and sulfate resistance. The water-cement ratio significantly influences the hydration rate and extent, with lower ratios (e.g., 0.3–0.4) promoting denser microstructures and higher strength by limiting porosity, whereas higher ratios enhance workability but slow overall progress and reduce durability.^[33] Hydration proceeds through distinct stages that determine the paste's workability and strength gain. The initial dormant (or induction) period lasts 1–4 hours, during which dissolution of ions from the cement surface occurs slowly, maintaining fluidity for placement. This is followed by the acceleration stage, marked by rapid heat evolution from C₃S hydration, leading to initial setting and the onset of stiffening around 3–12 hours post-mixing. The deceleration phase then ensues, where reaction rates slow due to product layer formation, transitioning to diffusion-controlled processes that support early strength development. Finally, the full hardening stage involves prolonged, gradual reactions over days to years, achieving 60–65% completion by 28 days and yielding ultimate compressive strengths.^[33] Gypsum, added at 3–5% as calcium sulfate dihydrate during cement grinding, plays a crucial role in controlling the rapid hydration of C₃A to prevent flash set, a premature stiffening that would render the paste unworkable. It reacts with C₃A in the presence of water to form ettringite (calcium sulfoaluminate hydrate), which coats the particles and delays further aluminate reactions until sulfate depletion, after which monosulfate forms. This regulation ensures a balanced induction period. Cement accelerators often target this phase by enhancing ettringite formation to expedite setting without disrupting the overall process.^[33]^[34]

Acceleration theories

Cement accelerators enhance the hydration rate through several primary theories, including nucleation acceleration, where they act as seeds to promote crystal growth of hydration products such as calcium silicate hydrate (C-S-H) and ettringite.^[35] Dissolution enhancement occurs as accelerators increase the solubility of key ions, like Ca²⁺, thereby elevating their concentration in the pore solution and driving faster precipitation.^[36] Specific mechanisms vary by accelerator type; chloride-based ones, such as calcium chloride, accelerate tricalcium aluminate (C₃A) hydration by providing chloride ions that form soluble chloroaluminate complexes, reducing protective layers on C₃A grains and promoting rapid ettringite formation, while calcium ions increase supersaturation for faster C-S-H precipitation.^[37] Non-chloride accelerators like triethanolamine (TEA) promote C₃S nucleation via adsorption onto particle surfaces at low dosages, creating additional sites for C-S-H growth while potentially complexing with aluminates to influence early setting.^[38] The rate of hydration can be modeled as proportional to the product of ion concentrations, expressed as:

\text{Rate} \approx k [\ce{Ca^{2+}}]^m [\ce{OH-}]^n

where accelerators increase the rate constant k or exponents m and n through enhanced solubility and pH effects.^[39] Crystallization kinetics during acceleration are often described by the Avrami equation:

X(t) = 1 - \exp(-k t^n)

with n typically ranging from 3 to 4 for cement systems, reflecting three-dimensional growth; accelerators lower the induction time and elevate k by facilitating nucleation.^[40] Recent research as of 2025 has explored physical acceleration methods, such as adding nano-scale nucleation seeds like colloidal nano-silica or synthetic C-S-H particles, which promote heterogeneous nucleation and growth of hydration products, accelerating early-age strength gain while being compatible with reinforced concrete.^[41] Experimental evidence from isothermal calorimetry demonstrates that accelerators shorten the dormant period by 20-50% and intensify the acceleration peak, indicating faster onset of main hydration.^[42] Scanning electron microscopy (SEM) images further reveal denser early microstructures with finer, more interconnected C-S-H networks in accelerated pastes compared to plain cement, supporting nucleation and dissolution enhancements.^[43]

Applications

Construction practices

Cement accelerators are commonly used in cold weather concreting when air temperatures fall below 4°C (40°F) for more than three consecutive days, helping to minimize damage from freezing of the mix and promote timely hydration to achieve required strengths.^[44] According to guidelines such as ACI 306, this approach ensures protection against damage in such conditions by accelerating the setting process without excessive heat generation.^[45] They are also applied in high-volume concrete pours for infrastructure like bridges and dams, where faster curing cycles support sequential placement and reduce overall project duration.^[46] In practice, accelerators are integrated into the mix either at the batch plant for consistent dosing or at the site for on-demand adjustments, ensuring compatibility with other admixtures like superplasticizers that maintain workability.^[47] Liquid forms meeting ASTM C494 Type C or E specifications are typically added at the plant to avoid interactions and achieve uniform acceleration.^[48] For example, in highway repair projects, they enable an initial set in 4 to 6 hours, allowing rapid reopening of lanes and minimizing traffic disruptions.^[49] Case studies from the 2010s highlight their role in urban tunneling across Europe, such as the Northern Line Extension in London, where accelerators in sprayed concrete facilitated quick stabilization of excavations, reducing downtime in densely populated areas.^[50] These applications align with standards like ACI 306, which emphasize controlled acceleration to balance speed and durability in cold or time-sensitive environments.^[44]

Specialized uses

Cement accelerators play a crucial role in precast concrete production by accelerating hydration to achieve sufficient early strength, enabling demolding times as short as 4 to 8 hours after casting. This rapid strength development allows for multiple mold turnovers per day, significantly boosting factory productivity; for instance, the use of C-S-H seed accelerators can facilitate up to four mold cycles within 24 hours.^[51] In shotcrete applications, particularly for mining and underground construction, non-chloride accelerators such as alkali-free formulations promote flash-set properties, supporting rapid tunnel lining where immediate structural support is essential to ensure worker safety and operational continuity.^[52]^[53] In repair and restoration projects, accelerators enable quick-setting formulations critical for minimizing downtime in infrastructure. For emergency airport runway repairs, fast-setting cements incorporating accelerators can attain compressive strengths exceeding 3,500 psi within three hours, allowing traffic resumption often within one day to avoid prolonged flight disruptions.^[54] Similarly, in dam grouting, accelerators are added to cement-based mixtures to expedite set times and achieve high early strength, effectively sealing cracks and controlling water flow in rehabilitation efforts.^[55] Beyond construction, cement accelerators find applications in diverse industries requiring rapid sealing and bonding. In oil well cementing, additives like calcium chloride accelerate slurry setting to form hydraulic seals quickly, preventing fluid migration between zones and ensuring well integrity during drilling operations.^[56] For 3D-printed concrete, controlled accelerator dosages enhance interlayer adhesion by optimizing the balance between initial fluidity and rapid stiffening, which is vital for maintaining structural integrity across successive layers without slumping.^[57] Historically, analogous acceleration effects appear in Roman-era pozzolanic concretes, where hot mixing of quicklime with volcanic ash promoted rapid initial reactions, contributing to the material's fast setting and long-term durability in marine structures.^[58]

Effects and Considerations

Advantages and limitations

Cement accelerators offer notable advantages in enhancing concrete performance, particularly in scenarios requiring rapid strength development. They promote significant early compressive strength gains, enabling concrete to achieve quicker load-bearing capacity and formwork removal.^[25] This acceleration reduces overall labor costs by shortening construction timelines and allows for more efficient project scheduling.^[59] Furthermore, accelerators improve concrete's resilience in adverse conditions, such as low temperatures, by expediting hydration processes that would otherwise be slowed.^[60] Despite these benefits, cement accelerators have limitations that can impact long-term concrete durability. Early strength enhancement often comes at the expense of ultimate strength, with potential reductions due to altered hydration dynamics.^[4] Overdosing accelerators can exacerbate drying shrinkage, increasing the likelihood of cracking in the hardened concrete.^[61] Chloride-based variants heighten the risk of corrosion in reinforced structures, as noted in discussions of their chemical interactions.^[62] Non-chloride accelerators mitigate this issue but incur higher costs, making them less economical for large-scale applications.^[63] Environmental and safety considerations add further complexity to accelerator use. Certain organic accelerators can affect air quality in enclosed mixing environments. In response to sustainability demands, research since the 2010s has increasingly focused on bio-based alternatives to reduce reliance on synthetic chemicals and lower the carbon footprint of concrete production; the bio-based concrete admixtures market, valued at approximately US$15.8 billion in 2021, is projected to reach US$24.09 billion by 2030.^[64]

Dosage guidelines

The dosage of cement accelerators is typically expressed as a percentage by weight of the cementitious material and generally ranges from 0.5% to 2% for most applications, with trial mixes recommended to optimize performance and ensure compliance with standards such as ASTM C494 Type C, which specifies requirements for set-accelerating admixtures.^[25]^[65] Several factors influence the appropriate dosage, including ambient temperature, where higher dosages—often approaching the upper limit of 2%—are required in cold conditions below 10°C to counteract slowed hydration rates and achieve desired set times.^[22]^[66] The type of cement also plays a role, as those with higher tricalcium aluminate (C3A) content respond more rapidly to accelerators, potentially requiring lower dosages compared to low-C3A cements.^[67] Additionally, compatibility with other admixtures must be verified through testing, as interactions can alter effectiveness and necessitate dosage adjustments. Dosages should not exceed 2% by weight of cement to prevent flash set, a rapid and uncontrolled hardening that compromises workability.^[65]^[66] Relevant standards provide further guidance on limits and testing. In Europe, EN 934-2 specifies that admixtures for concrete, including accelerators, must have a chloride content not exceeding 0.1% by mass when used in reinforced or prestressed concrete to minimize corrosion risks.^[68] Set time is evaluated using the Vicat needle apparatus per ASTM C191, measuring initial and final setting times to confirm the accelerator's efficacy at the selected dosage. Overdosing beyond recommended levels can lead to adverse effects, including flash set and reduced long-term compressive strength depending on the admixture type and conditions.^[4]

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Fast-Setting Cement Speeds Runway Repairs
Apr 22, 2024 · Pavement engineers replace asphalt with concrete that reached 3500 psi compressive strength in three hours.
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[PDF] Embankment Dams - Bureau of Reclamation
Accelerators are used to speed the set time and achieve high early strength. The use of accelerators in cement grout is common when flowing water is a problem.
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The Effect of Accelerator Dosage on Fresh Concrete Properties and ...
Jan 14, 2020 · This paper presents for Shotcrete 3D Printing (SC3DP) technology the effect of a range of accelerator dosages (0%, 2%, 4%, 6%) on fresh concrete ...
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Riddle solved: Why was Roman concrete so durable? - MIT News
Jan 6, 2023 · Researchers have assumed that the key to the ancient concrete's durability was based on one ingredient: pozzolanic material such as volcanic ash.
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What is Accelerator in Concrete? - WanHong - WHHPMC
Typical dosage rates range from 1-2% of cement weight for calcium chloride, 1-3% for non-chloride accelerators, 3-8% for shotcrete accelerators, and ...
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Accelerating Admixtures Enhance Concrete Durability | Key Benefits
Faster strength development · Improved Resistance to Early Water Infiltration · Improved Resistance to Chemical Attacks: · Enhanced Performance in Cold Weather.
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[PDF] Understanding and Controlling Shrinkage and Cracking in Shotcrete
Research and practical experience have shown that most accelerators will increase the shrinkage of concretes and shotcretes, particularly at early ages. This, ...
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Disadvantages of Using a Calcium Chloride Concrete Accelerator |
Feb 15, 2022 · Using a calcium chloride concrete accelerator significantly increases the risk of efflorescence, discoloration and corrosion in the concrete.Missing: based properties usage AAR
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When to use NCA and Calcium Chloride as Accelerators in Ready ...
Oct 2, 2023 · Accelerators are additives used in concrete mixes to reduce the setting time and speed up the rate of early strength gain. They are particularly ...
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US4897120A - Accelerator for portland cement derived from fertilizer
... concrete, breaks down and forms urea, which further breaks down to release ammonia in the fresh concrete. U.S. Pat. No. 4,064,191 discloses an organic ...
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(PDF) Bio-Based Cement Concrete Admixtures for Green Recovery ...
Aug 6, 2024 · The study assesses the relevance of bio-based admixtures in achieving green recovery in concrete and cement mortar.
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Material Matters: Accelerators - National Precast Concrete Association
Nov 17, 2015 · Accelerators are added to concrete to increase the rate of early strength gain and to reduce initial and final set times.Missing: definition | Show results with:definition
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Concrete Acceleration - Peters Chemical Company
Calcium chloride (CaCl2), has the ability to accelerate cement hydration and reduce set time by as much as two thirds. Research has shown that a 2% addition ...Missing: 1900 | Show results with:1900
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Cement Hydration Kinetics - National Precast Concrete Association
Mar 14, 2016 · Cements with low C3A contents, low C3S contents and higher C2S contents offer lower heat of hydration. Cements with high to very high C3S ...
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[PDF] BRMCA Information Sheet
Sep 27, 2019 · Admixtures conforming to BS EN 934-17 have a chloride content ≤ 0.10% or a maximum value declared by the manufacturer.
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Effect of high dosage lignosulphonate and naphthalene sulphonate ...
Sep 1, 2016 · Overdose usage of LS and NS has negative effect on mortar. •. SEM analysis proved porous structure of overdosed LS and NS mixtures. •.