Workability and strength of coarse high calcium fly ash geopolymer

In this paper, the basic properties viz., workability and strength of geopolymer mortar made from coarse lignite high calcium fly ash were investigated. The geopolymer was activated with sodium hydroxide (NaOH), sodium silicate and heat. The results revealed that the workable flow of geopolymer mortar was in the range of 110 ± 5%–135 ± 5% and was dependent on the ratio by mass of sodium silicate to NaOH and the concentration of NaOH. The obtained compressive strength was in the range of 10–65 MPa. The optimum sodium silicate to NaOH ratio to produce high strength geopolymer was 0.67–1.0. The concentration variation of NaOH between 10 M and 20 M was found to have a small effect on the strength. The geopolymer samples with high strength were obtained with the following practices: the delay time after moulding and before subjecting the sample to heat was 1 h and the optimum curing temperature in the oven was 75 °C with the curing duration of not less than two days.     

Lightweight geopolymer concrete containing aggregate from recycle lightweight block

In this research, the properties of lightweight geopolymer concrete containing aggregate from recycle lightweight block were studied. The recycle block was crushed and classified as fine, medium and coarse aggregates. The compressive strength and density with various liquid alkaline/ash ratios, sodium silicate/NaOH ratios, NaOH concentrations, aggregate/ash ratios and curing temperatures were tested. In addition, porosity, water absorption, and modulus of elasticity were determined. Results showed that the lightweight geopolymer blocks with satisfactory strength and density could be made. The 28-day compressive strength of 1.0–16.0 MPa, density of 860–1400 kg/m³, water absorption of 10–31% and porosity of 12–34%, and modulus of elasticity of 2.9–9.9 GPa were obtained. It can be used as lightweight geopolymer concrete for wall and partition.     

Properties of metakaolin based geopolymer incorporating calcium carbonate

An alkaline solution, thermally activated kaolinite clay and a mineral additive (calcium carbonate) were mixed with the aim to elaborate a geopolymer material with physical and mechanical properties comparable to those of classical construction materials.The starting reagents were characterized by quantitative chemical analyses (XRF), mineralogical analyses (XRD), thermal gravimetric analyses (TGA), and grain size distribution measurements. The setting of the mixture (polymerization) was implemented by measuring the evolution of the viscosity as a function of time at different temperatures.The geopolymers were synthesized at a temperature of 40 °C. The investigation of the mechanical behavior reveals that these materials display acceptable characteristics: the flexural and compression strength are around 4.6 and 26 MPa respectively, for an added calcium carbonate over dry matter ration up to 12% by weight.The promising results exposed in this paper show that the geopolymer formulations can be adapted for applications in construction and civil engineering structures as an alternative to conventional materials.     

Compressive strength and chloride resistance of self-compacting concrete containing high level fly ash and silica fume

The influence of high-calcium fly ash and silica fume as a binary and ternary blended cement on compressive strength and chloride resistance of self-compacting concrete (SCC) were investigated in this study. High-calcium fly ash (40–70%) and silica fume (0–10%) were used to replace part of cement at 50, 60 and 70 wt.%. Compressive strength, density, volume of permeable pore space (voids) and water absorption of SCC were investigated. The total charge passed in coulombs was assessed in order to determine chloride resistance of SCC. The results show that binary blended cement with high level fly ash generally reduced the compressive strength of SCC at all test ages (3, 7, 28 and 90 days). However, ternary blended cement with fly ash and silica fume gained higher compressive strength after 7 days when compared to binary blended fly ash cement at the same replacement level. The compressive strength more than 60 MPa (high strength concrete) can be obtained when using high-calcium fly ash and silica fume as ternary blended cement. Fly ash decreased the charge passed of SCC and tends to decrease with increasing fly ash content, although the volume of permeable pore space (voids) and water absorption of SCC were increased. In addition when compared to binary blended cement at the same replacement level, the charge passed of SCC that containing ternary blended cement was lower than binary blended cement with fly ash only. This indicated that fly ash and silica fume can improve chloride resistance of SCC at high volume content of Portland cement replacement.     

Mechanical performance of low cement reactive powder concrete (LCRPC)

The possibility of producing a reactive powder concrete (RPC) with low cement content was aimed in the scope of this study. Cement was replaced with class-C fly ash (FA) up to 60% for this purpose. Three different curing conditions (standard water curing, autoclave curing and steam curing) were applied to specimens. Two series of RPC composites were prepared with bauxite and granite aggregates. Mechanical properties such as compressive strength, splitting tensile strength, flexural strength and fracture energy of composites were investigated. Test results showed that, compressive strength of 200 MPa can be reached with low cement by using high-volume fly ash. Thermally treated specimens showed compressive strength beyond 250 MPa and high volume fly ash RPC have superior performance. Furthermore, compressive strength values reached up to 400 MPa with external pressure application during setting and hardening stages.     

Mechanical performance of low cement reactive powder concrete (LCRPC)

The possibility of producing a reactive powder concrete (RPC) with low cement content was aimed in the scope of this study. Cement was replaced with class-C fly ash (FA) up to 60% for this purpose. Three different curing conditions (standard water curing, autoclave curing and steam curing) were applied to specimens. Two series of RPC composites were prepared with bauxite and granite aggregates. Mechanical properties such as compressive strength, splitting tensile strength, flexural strength and fracture energy of composites were investigated. Test results showed that, compressive strength of 200 MPa can be reached with low cement by using high-volume fly ash. Thermally treated specimens showed compressive strength beyond 250 MPa and high volume fly ash RPC have superior performance. Furthermore, compressive strength values reached up to 400 MPa with external pressure application during setting and hardening stages.     

Fabrication and mechanical properties of β-TCP pieces by gel-casting method

In the present work, dense β-TCP ceramics were fabricated by gel-casting method. The effects of the solids loading on the rheological behavior of β-TCP slurries were investigated. When the concentration of the slurries was increased from 40 to 60 vol.%, the compressive strength of green pieces was raised from 12.4 ± 1.1 to 41.2 ± 2.3 MPa, and flexural strength from 9.4 ± 0.4 to 16.3 ± 0.9 MPa. The density of the final specimens was 97.4% of the theoretical density after pressureless sintering at 1100 °C. The compressive strength, flexural strength, elasticity modulus and the fracture toughness of the sintered pieces were 291 ± 15 MPa, 93.0 ± 8.7 Mpa, 72.4 ± 7.5 GPa and 0.92 ±0.04 Mpa·m^0.5 respectively. SEM images show a compact and uniform microstructure; XRD and FTIR determined the phase and the radical before and after sintering.     

A study on the effects of high temperature on mechanical properties of fiber reinforced cementitious composites

The flexural strength and ductility properties of cementitious composites (mortar) under high temperature may be significantly improved by incorporating different types of fibers. In this study, four different types of fibers are added to cement mortars with the aim to investigate their mechanical contributions to mortars under high temperature, comparatively. Polypropylene (PP), carbon (CF), glass (GF) and polyvinyl alcohol (PVA) fibers are chosen for research. These fibers are added into mortars in five different ratios (0.0%, 0.5%, 1.0%, 1.50% and 2.0%) by volume. The mortars are subjected to the following temperatures: 21 °C (normal conditions), 100 °C (oven dry), 450 °C and 650 °C. The mechanical properties investigated are flexural strength, deflection and compressive strength of the cement mortars. In addition, thin sections of mortars are investigated to obtain changes in mortar because of high temperature. It is concluded that all fiber types contribute to the flexural strengths of mortars under high temperature. However, this contribution decreases with an increase in temperature. The samples with PVA show the best flexural performance (75–150%) under high temperature. CF which does not melt under high temperature also gives high flexural strength (11–85%). The compressive strengths of the mortars reduce under high temperature or with fiber addition. The highest increase in flexural strength and the lowest decrease in compressive strength is at 0.5–1.5% for CF if all temperature conditions are taken into consideration. The optimum fiber addition ratios of the samples containing PP and GF are 0.5% by volume. And for PVA, it is between 0.5% and 1.5% by volume.     

Influence of size and distribution of W phase on strength and ductility of high strength Mg-5.1Zn-3.2Y-0.4Zr-0.4Ca alloy processed by indirect extrusion

A high strength Mg-5.1Zn-3.2Y-0.4Zr-0.4Ca(wt%) alloy containing W phase(Mg_3Y_2Zn_3) prepared by permanent mold direct-chill casting is indirectly extruded at 350?C and 400?C, respectively. The extruded alloys show bimodal grain structure consisting of fine dynamic recrystallized(DRXed) grains and unrecrystallized coarse regions containing fine W phase and β2' precipitates. The fragmented W phase particles induced by extrusion stimulate nucleation of DRXed grains, leading to the formation of fine DRXed grains, which are mainly distributed near the W particle bands along the extrusion direction. The alloy extruded at 350?C exhibits yield strength of 373 MPa, ultimate tensile strength of 403 MPa and elongation to failure of 5.1%. While the alloy extruded at 400?C shows lower yield strength of 332 MPa,ultimate tensile strength of 352 MPa and higher elongation to failure of 12%. The mechanical properties of the as-extruded alloys vary with the distribution and size of W phase. A higher fraction of DRXed grains is obtained due to the homogeneous distribution of micron-scale broken W phase particles in the alloy extruded at 400?C, which can lead to higher ductility. In addition, the nano-scale dynamic W phase precipitates distributed in the un DRXed regions are refined at lower extrusion temperature. The smaller size of nano-scale W phase precipitates leads to a higher fraction of un DRXed regions which contributes to higher strength of the alloy extruded at 350?C.     

Preparation of novel ceramics with high CaO content from steel slag

Steel slag, an industrial waste discharged from steelmaking process, cannot be extensively used in traditional aluminosilicate based ceramics manufacturing for its high content of calcium oxide. In order to efficiently utilize such solid waste, a method of preparing ceramics with high CaO content was put forward. In this paper, steel slag in combination with quartz, talcum, clay and feldspar was converted to a novel ceramic by traditional ceramic process. The sintering mechanism, microstructure and performances were studied by scanning electron microscope (SEM), X-ray diffraction (XRD) techniques, combined experimenting of linear shrinkage, water absorption and flexural strength. The results revealed that all crystal phases in the novel ceramic were pyroxene group minerals, including diopsite ferrian, augite and diopsite. Almost all raw materials including quartz joined the reaction and transformed into pyroxene or glass phase in the sintering process, and different kinds of clays and feldspars had no impact on the final crystal phases. Flexural strength of the ceramic containing 40 wt.% steel slag in raw materials can reach 143 MPa at sintering temperature of 1210 °C and its corresponding water absorption, weight loss, linear shrinkage were 0.02%, 8.8%, 6.0% respectively. Pyroxene group minerals in ceramics would contribute to the excellent physical and mechanical properties.     

Alkali-activated aluminosilicate composite with heat-resistant lightweight aggregates exposed to high temperatures: Mechanical and water transport properties

A lightweight composite material with alkali-activated aluminosilicate binder is investigated. The intended use of this material is the high-temperature applications, such as the fire-protecting layers for Portland-cement based structures. Therefore, a heat-resistant mixture of expanded vermiculite and electrical porcelain is used as aggregates. Basic physical characteristics, mechanical properties and water- and water vapor transport properties are studied as functions of previous heat treatment up to 1200 °C. Experimental results show that the studied material has very good high-temperature properties which are quite superior to Portland-cement concrete. The open porosity increases only up to 7% between room temperature and 1000 °C. The material keeps 35% of its original compressive strength and 66% of its flexural strength even in the worst case of 800 °C pre-heating. After pre-heating to 1200 °C the compressive strength is found 30% higher and flexural strength three-and-half times higher than in the reference state. Liquid moisture diffusivity is after the heat treatment up to three orders of magnitude higher than in reference room-temperature conditions. The water vapor transport parameters allow fast removal of water vapor and other gaseous compounds over the whole studied heat-treatment range.     

Synthesis of hydroxysodalite zeolite by alkali-activation of basalt powder rich in calc-plagioclase

Hydroxysodalite (H-SOD) microcrystalline particles were synthesized from basalt powder rich in calcic-plagioclase (anorthite) by alkali activation at 80 °C/24 h. Sodium hydroxide (NaOH) solution was used as alkaline activator. The reactivity of the natural solid precursor basalt was studied using differential scanning calorimetry (DSC), and a maximum reaction enthalpy of (?ΔH) of 170 J/g was obtained. The chemical, mineralogical, and textural properties were obtained by using X-ray powder diffractometry (XRD), Fourier transform infrared spectroscopy (FTIR), scanning electron microscopy (SEM), thermogravimetric analysis (TGA), and N₂-adsorption-desorption measurements. The synthesized material has a specific BET surface area of 20.5 m² g^?1 approximately 200 times higher than raw basalt material (0.1 m² g^?1). The compressive strength of basalt based H-SOD/sand composite samples cured at 80 °C for 24 h upon using different amounts of the activator (NaOH) was evaluated under dry and saturated conditions. The dry samples with NaOH/basalt mass ratio of 0.12 have reached a compressive strength of 57 MPa. Wet samples, on the other hand, showed a compressive strength of 25 MPa after seven days of soaking in water and four episodes of wetting and drying. The present work illustrates that crystalline H-SOD could be synthesized from cheap basalt powder precursor.     

Compressive strength of high strength class C fly ash-based geopolymers with reactive granulated blast furnace slag aggregates designed by Taguchi method

Compressive strength of geopolymeric specimens produced by class C fly ash and granulated blast furnace slag aggregates has been studied. Four different independent factors comprising of aggregate content, sodium hydroxide concentration, curing time and curing temperature were considered as the variables. To attain the maximum possible accurate responses by means of the smallest amount of examinations, Taguchi design of experiment method was followed. By taking into account three levels for each factor, 9 series of experiments were conducted on the specimens at 2 and 7 days of water curing regime. For both considered regimes, a specimen with 30 weight percent of aggregate and sodium hydroxide concentration of 12 M cured at 90 °C for 16 h had the highest compressive strength. On account of reactivity between aggregates and the fly ash, the compressive strength was reached to 69.3 ± 5.3 MPa and 76.2 ± 3.6 MPa at 2 and 7 days of water curing, respectively. Fracture surface of specimens with the highest and the lowest strengths as well as effect of each considered factor on the compressive strength of the specimens were studied.     

Mechanical properties of reactive powder concrete containing high volumes of ground granulated blast furnace slag

The mechanical properties (flexural strength, compressive strength, toughness and fracture energy) of steel microfiber reinforced reactive powder concrete (RPC) were investigated under different curing conditions (standard, autoclave and steam curing). Portland cement was replaced with ground granulated blast furnace slag (GGBFS) at 20%, 40% and 60%. Sintered bauxite, granite and quartz were used as aggregates in different series. The compressive strength of high volume GGBFS RPC was over 250 MPa after autoclaving. When an external pressure was applied during setting and hardening stages, compressive strength reached up to 400 MPa. The amount of silica fume can be decreased with increasing amount of GGBFS. SEM micrographs revealed the tobermorite after autoclave curing.     

Investigation of Ti coatings on cubic boron nitride (cBN) grits by discharge treatment in spark plasma sintering system

The Ti coatings on cubic boron nitride (cBN) grits were prepared by discharge treatment on a mixture of Ti powders and cBN grits in spark plasma sintering system. The uniform and full coatings with a thickness of ～1.2 μm were prepared at 850 °C for 60 min, which were constituted with TiB₂, TiN, and Ti phases. The compressive fracture strength and toughness impact of the Ti-coated cBN grits were 11.6% and 7.4% higher than the cases of the pristine ones, respectively. With the aid of Ti coatings, the interface bonding strength between cBN grits and Fe-based matrix was improved by 335 MPa in the Fe-based matrix/cBN composites.     

Effects of NaOH concentrations on physical and electrical properties of high calcium fly ash geopolymer paste

The effects of sodium hydroxide (NaOH) concentration on setting time, compressive strength and electrical properties at the frequencies of 100 Hz–10 MHz of high calcium fly ash geopolymer pastes were investigated. Five NaOH concentrations (8, 10, 12, 15 and 18 molar) were studied. The liquid to ash ratio of 0.4, sodium silicate to sodium hydroxide ratio of 0.67 and low temperature curing at 40 °C were selected in making geopolymer pastes. The results showed that NaOH concentration had significant influence on the physical and electrical properties of geopolymer paste. The pastes with high NaOH concentrations showed increased setting time and compressive strength due to a high degree of geopolymerization as a result of the increased leaching of silica and alumina from fly ash. The dielectric constant and conductivity increased with NaOH concentration while tan δ decreased due to an increase in geopolymerization. At the frequency of 10³ Hz, the dielectric constants of all pastes were approximately 10⁴ S/cm and decreased with increased frequency. The relaxation peaks of tan δ reduced with an increase in NaOH concentration and ranged between 2.5 and 4.5. The AC conductivity behavior followed the universal power law and the values were in the range of 3.7 × 10⁻³–1.5 × 10⁻² at 10⁵–10⁶ Hz.     

High strength geopolymer binder based on waste-glass powder

This paper presents a study on the synthesis of geopolymers based on alkaline activation of waste-glass powder using aqueous solutions of sodium hydroxide and sodium silicate with different Na₂O contents as alkali activators. Three types of calcium aluminate cements were also incorporated into the dry binder at levels up to 24% by weight in order to modify the chemical composition of the geopolymer source materials. The prepared mortars were tested for workability, setting time, compressive strength, free-alkali content and tendency towards efflorescence formation. FTIR and SEM analyses were also performed to characterize the morphology and structure of the produced geopolymer. The optimized geopolymer mortar exhibited a remarkable maximum compressive strength of 87 MPa. The results showed that inclusion of calcium aluminate cements in the silica-rich waste-glass powder leads to release high amounts of reactive alumina into aluminosilicate gels, improving the geopolymerization reactions and resulting in the formation of a more cross-linked network that exhibits higher compressive strength. High alumina cement Secar 71 showed the greatest effect in strength enhancement due to the higher amount of reactive alumina releasing into the reaction medium. The findings demonstrate a new potential of value-added reuse application for waste-glass powder by adding a suitable amount of materials that are rich in reactive alumina.     

Physical and mechanical characterization of Fiber-Reinforced Aerated Concrete (FRAC)

Fiber-Reinforced Aerated Concrete (FRAC) is a novel lightweight aerated concrete that includes internal reinforcement with short polymeric fibers. The autoclaving process is eliminated from the production of FRAC and curing is performed at room temperature. Several instrumented experiments were performed to characterize FRAC blocks for their physical and mechanical properties. This work includes the study of pore-structure at micro-scale and macro-scale; the variations of density and compressive strength within a block; compressive, flexural and tensile properties; impact resistance; and thermal conductivity. Furthermore, the effect of fiber content on the mechanical characteristics of FRAC was studied at three volume fractions and compared to plain Autoclaved Aerated Concrete (AAC). The instrumented experimental results for the highest fiber content FRAC indicated compressive strength of approximately 3 MPa, flexural strength of 0.56 MPa, flexural toughness of more than 25 N m, and thermal conductivity of 0.15 W/K m.     

Development of high mechanical properties and moderate thermal conductivity cast Mg alloy with multiple RE via heat treatment

A new cast Mg–2 Gd–2 Nd–2 Y–1 Ho–1 Er–0.5 Zn–0.4 Zr(wt%) alloy was prepared by direct-chill semicontinuous casting technology. The microstructure, mechanical properties and thermal conductivity of the alloy in as-cast, solid-solution treated and especially peak-aged conditions were investigated. The as-cast alloy mainly consists of β-Mg matrix,(Mg, Zn)_3 RE phase and basal plane stacking faults. After proper solid-solution treatment, the microstructure becomes almost Mg-based single phase solid solution except just very few RE-riched particles. The as-cast and solid-solution treated alloys exhibit moderate tensile properties and thermal conductivity. It is noteworthy that the Mg alloy with 8 wt% multiple RE exhibits remarkable age-hardening response( HV = 35.7), which demonstrates that the multiple RE(RE = Gd, Nd, Y, Ho, Er) alloying instead of single Gd can effectively improve the age-hardening response.The peak-aged alloy has a relatively good combination of high strength/hardness(UTS(ultimate tensile strength) 300 MPa; TYS(tensile yield strength) 210 MPa; 115.3 HV), proper ductility(ε≈ 6%) and moderate thermal conductivity(52.5 W/(m K)). The relative mechanisms mainly involving aging precipitation of β￠ and β' phases were discussed. The results provide a basis for development of high performance cast Mg alloys.     

Study on vacuum brazing of high purity alumina for application in proton synchrotron

The paper describes an experimental study to evaluate two different vacuum brazing processes to obtain high purity alumina (99.7%) joints suitable for application in rapid cycle proton synchrotron. Two different brazing routes, adopted for making alumina–alumina brazed joints, included (i) multi-step Mo–Mn metallization, followed by brazing with BVAg-8 alloy and (ii) advanced single-step active brazing with CuSil-ABA® alloy. Both the brazing routes yielded helium leak tight and ultra-high vacuum (pressure < 10⁻⁹ mbar) compatible joints. Active-brazed specimens exhibited tensile and mean flexural strengths of 62 and 110 MPa, respectively. Metallized-brazed specimens, although associated with relatively lower tensile strength (35 MPa) than the targeted value (>50 MPa), displayed higher mean flexural strength of 149 MPa. The results of the study demonstrated that active brazing is a simple and cost effective alternative to conventional multi-step metallization route for producing quality joints of high purity alumina for application in rapid cycle proton synchrotron machine.