Effect of grog addition on the properties and microstructure of a red ceramic body for brick production

In the present paper crushed fired brick waste, known as grog, was used in mixtures with clayey body to make typical red ceramics for bricks. The effect of the grog addition up to 20 wt% on the extrusion stage as well as on properties and microstructure of bricks fired at 700 °C was evaluated. The results indicate that the extrusion of the unfired clayey body was not impaired by the grog addition. Additions above 5 wt% decreased the mechanical strength of both the dry body and the fired ceramic pieces. This is associated with the increase in porosity during the firing stage due to the grog behavior.     

Techno-economical evaluation of a rice husk ash (RHA) based sand–cement block for reducing solar conduction heat gain to a building

This paper reports on the performance of a rice husk ash (RHA) based sand–cement block. Its performance is compared with that of a standard commercial clay brick. The RHA-cement block reduces solar heat gain in buildings and the comparisons include an evaluation of room temperature, solar conduction heat transfer and economics. An appraisal of the two was conducted using two small rooms (floor area of 5.75 m²). One of the rooms was constructed using the RHA based sand–cement block wall; the other, which served as the reference, used a commercial clay brick wall. Experiments were performed throughout a period of one summer month (March) in Thailand. The results showed that the RHA based sand–cement block reduced solar heat transfer by 46 W. An economic analysis indicates that the payback period of the RHA block in tandem with a 1 ton, split-type air conditioner depends on the indoor set-point temperature. The payback period is 4.08 years when the indoor set-point temperature of 26 °C is taken.     

Calcium and sulphur distribution in fired clay brick in the presence of a black reduction core using micro X-ray fluorescence mapping

A new finding of the observation of an elemental gradient or zoning of calcium and sulphur in fired brick bodies is described, that does not appear to have been reported in the literature before. Many raw clays used in brickmaking and pottery contain sulphur and calcium evenly distributed in low amounts in the unfired clay body. However, when the clay body is fired in the kiln at 1050 °C, the elements sulphur and calcium appear to combine to a compound, most probably calcium sulphate. The formation of calcium sulphate, visualised using energy dispersive imaging micro X-ray fluorescence (μ-XRF), only occurs around a so-called reduction core, also known as ‘black core’, caused by reduced magnetite Fe₃O₄ in the centre of the brick body. The presence of a black reduction core appears to cause the formation of a calcium sulphate layer around the black reduction core. This research contributes to the understanding of phenomena like salt formation, efflorescence and durability in solid clay brick bodies. Large sums are spent on building conservation by national economies and improvement of bricks is of key interest to them.     

Lime based steam autoclaved fly ash bricks

About 10 million tonnes of fly ash are produced yearly as waste from coal fired thermal power plants in Turkey. Only a small portion of this waste is utilized as a raw material in the production of cement and concrete. In this study, Seyitömer power plant fly ash was investigated in the production of light weight bricks. Fly ash, sand and hydrated lime mixtures were steam autoclaved under different test conditions to produce brick samples. An optimum raw material composition was found to be a mixture of 68% fly ash, 20% sand and 12% hydrated lime. The optimum brick forming pressure was 20 MPa. The optimum autoclaving time and autoclaving pressure were found 6 h and 1.5 MPa, respectively. The compressive strength, unit volume weight, water absorption and thermal conductivity of the fly ash–sand–lime bricks obtained under optimum test conditions are 10.25 MPa, 1.14 g/cm³, 40.5% and 0.34 W  m⁻¹ K⁻¹ respectively. The results of this study suggested that it was possible to produce good quality light weight bricks from the fly ash of Seyitömer power plant.     

Comparison of fibrous insulations – Cellulose and stone wool in terms of moisture properties resulting from condensation and ice formation

Cellulose fibres are often used as thermal insulation in buildings. The organic nature of cellulose fibres, however, makes the insulation sensitive to high moisture content. This study investigates the moisture performance of cellulose insulation when exposed to a subzero environment. The paper is focused on the condensation and freezing in the material and includes comparison with the authors previous studies on stone-wool insulation. While the used stone-wool samples were water-repellent due to resin binders, cellulose is a typical representative for hydrophilic thermal insulation to which any contact with water condensate can be crucial.Test specimens of loose-fill cellulose were placed in a special laboratory device providing high moisture load. During a period of 100 h the specimens were subjected to a continuous load of moisture at atmospheric conditions on one side while the other side of the specimen faced a surrounding temperature of 0, −10 and −20 °C and the laboratory tests were repeated three times for each set of the specific thermal conditions (T_i = +20 °C, T_e = 0, −10 and −20 °C). The results indicate that there are minor changes in the water vapour permeability of the specimens. The experimental data from the investigation is compared with a mathematical model that simulates moisture diffusivity of cellulose together with accumulation due to sorption and freezing, using the actual climatic data.     

Utilization of copper tailing for autoclaved sand–lime brick

The influences of the batch ingredients and the autoclaving processes on the properties of autoclaved sand–lime brick from low SiO₂ content copper tailing were studied. The results show that the copper tailing with low content of SiO₂ can be used to produce autoclaved sand–lime bricks meeting GB11945-1999 for Mu 15 sand–lime brick, if only the proportion of the copper tailing in the brick batch does not exceed 50% (% by mass) and appropriate proportions of river sand and sand powder are added to compensate for the low SiO₂ content. XRD and SEM analyses show that the main hydrothermal reaction products in the brick are 0.9 nm, 1.1 nm and 1.4 nm tobermorite phases, and the andradite in the copper tailing nearly does not take part in the autoclaving reaction.     

Use of natural and thermally activated porphyrite in cement production

The aim of the present study was to investigate the use of porphyrite in the production of Portland cement. Natural and thermally activated porphyrites were used as a clay raw material and an activator, respectively, at 0, 10, 20, 30, 40 and 50 wt% in order to assess their effects on the cement properties. According to the test results, the compressive strength of the specimens decreased with increasing natural porphyrite content in various curing periods. However, the compressive strength of cement produced with 10 wt% porphyrite (activator) activated at 650 °C for 30 min showed a higher value (56 MPa in TPC-6) than cement without activator (51 MPa in RPC-2). Due to thermal activation, porphyrite activator containing a glass phase possesses an enhanced reactivity during clinker hydration that intensifies the synthesis of hydrosilicates and improves compressive strength accordingly. The X-ray diffraction analysis confirmed an intensive formation of Portland cement minerals such as C₃S, β-C₂S, C₃A and C₄AF. The addition of thermally activated porphyrite has also led to an improvement of the rheological behavior, stability to expansion, increase in setting time and decrease in specific surface area of cement. As prepared cement composites and concretes with improved properties meet the requirements of State Standards 310-86 and 10181-81 for Portland cement and concrete, respectively. The findings in this report indicate that porphyrite can be utilized both as a raw material and an activator in the production of cement.     

Autoclaved brick from low-silicon tailings

The load-bearing brick is made from low-silicon tailings by pressing and autoclaving process, in the presence of alkali-activated slag/fly ash cementing material (AAFSC). Tailings accounts for 83% of the total mass of the brick. The compressive strength of the brick is up to 16.1 MPa, bending strength 3.8 MPa, and with low drying shrinkage and good freeze–thaw resistance. Some factors influencing the mechanical strength of the brick including forming pressure, forming water content and curing regime, are investigated. The hydration products, freeze–thaw durability and anti-carbonation characteristics of the products are discussed.     

Hybrid effect of carbon nanotube and nano-clay on physico-mechanical properties of cement mortar

In this work, several nanomaterials have been used in cementitious matrices: multi wall carbon nanotubes (MWCNTs) and nano-clays. The physico-mechanical behavior of these nanomaterials and ordinary Portland cement (OPC) was studied. The nano-clay used in this investigation was nano-kaolin. The metakaolin was prepared by thermal activation of nano-kaolin clay at 750 °C for 2 h. The organic ammonium chloride was used to aid in the exfoliation of the clay platelets. The blended cement used in this investigation consists of ordinary Portland cement, carbon nanotubes and exfoliated nano metakaolin. The OPC was substituted by 6 wt.% of cement by nano metakaolin (NMK) and the carbon nanotube was added by ratios of 0.005, 0.02, 0.05 and 0.1 wt.% of cement. The blended cement: sand ratio used in this investigation was 1:2 wt.%. The blended cement mortar was prepared using water/binder ratio of 0.5 wt.% of cement. The fresh mortar pastes were first cured at 100% relative humidity for 24 h and then cured in water for 28 days. Compressive strength, phase composition and microstructure of blended cement were investigated. The results showed that, the replacement of OPC by 6 wt.% NMK increases the compressive strength of blended mortar by 18% compared to control mix and the combination of 6 wt.% NMK and 0.02 wt.% CNTs increased the compressive strength by 29% than control.     

Durability of masonry systems: A laboratory study

We deal with the textural aspects, porometry and hydric behaviour of combinations of building materials and their durability under attack by salt crystallisation and freezing. We selected 4 types of lime mortar (pure lime mortar, lime mortar + air-entraining agent, lime mortar + pozzolana and lime mortar + air-entraining agent + pozzolana) which were used in combination with either brick or calcarenite stone. Lime mortars were chosen because they are compatible with traditional building materials, including the bricks and calcarenites that were widely used in the historical buildings that make up our architectural heritage. There are more similarities between the pore size ranges in calcarenites and mortars than there are between those in bricks and mortars. In all cases, a fine layer of calcite microcrystals develops at the contact surface between the mortar and the stone or brick. This is produced by the transformation of the portlandite, which concentrates in this area due to capillary moisture migration. This surface may on the one hand represent an obstacle to the flow of water between the different parts of the system formed by these materials, but on the other it may also favour greater adherence between the components, especially in the calcarenite + mortar combination, which proved to be the most resistant to deterioration in the freeze–thaw tests.     

Effects of calcination temperature of kaolinite clays on the properties of geopolymer cements

The aim of this work is to determine the most convenient calcination temperature of kaolinite clays in view of producing geopolymer cements. In this light, the clay fractions of three kaolin minerals were used. The clay fractions were characterized (chemical and thermal analyses and X-ray diffraction) and then calcined in the temperature range of 450 and 800 °C. The obtained amorphous materials were dissolved in a strongly alkaline solution in order to produce geopolymer cements whose pastes were characterized by determining their setting time, linear shrinkage and compressive strength. Hardened geopolymer cement paste samples were also submitted to X-ray diffraction, Fourier transform infrared spectroscopy and scanning electron microscopy analyses. The setting time of geopolymer cement pastes produced from the clay fractions calcined at 450 °C was very long (test samples could be handled easily only after 21 days at the ambient atmosphere of the laboratory). For the clay fractions calcined between 500 and 700 °C, the setting time of geopolymer cement pastes reduced with increasing temperature and varied between 130 and 40 min. Above 700 °C, the setting time began to increase. The linear shrinkage of the hardened geopolymer cement paste samples aged between 21 and 28 days attained its lowest value around 700 °C. Above 700 °C, the linear shrinkage began to increase. The compressive strength of the hardened geopolymer cement paste samples was between 11.9 and 36.4 MPa: it increased with samples from the clay fractions calcined between 500 and 700 °C but dropped above 700 °C.It can be concluded that the most convenient temperature for the calcination of kaolinite clays in view of producing geopolymer cements is around 700 °C.     

Physical and mechanical properties of durable sisal fiber–cement composites

Sisal fiber–cement composites reinforced with long unidirectional aligned fibers were developed and their physical–mechanical behavior was characterized in the present study. Flat and corrugated sheets were cast by a manual lay-out of the fibers in a self-compacted cement matrix and compressed with a pressure of 3 MPa. Direct tensile and bending tests were performed to determine the first crack, post-peak strength and toughness of the composites. Drying shrinkage, capillary water absorption and water tightness tests were performed to characterize the physical properties of the composites. To ensure the composite durability, the ordinary Portland cement matrix was modified by adding metakaolin and calcined waste crushed clay brick to consume the calcium hydroxide generated during Portland cement hydration. The durability of the newly developed composite was determined through accelerated aging conditions using the hot-water immersion test. The developed material presented a multiple cracking behavior under bending, even when subjected to 6 months of hot-water immersion under 60 °C. Scanning Electron Microscopy was used to investigate the micro-structure of the composites before and after aging.     

Preparation of load-bearing building materials from autoclaved phosphogypsum

Previous studies have been carried out on calcined phosphogypsum (PG) for making the building materials. The present study was focused on autoclaved PG and its use in making load-bearing wall bricks. Autoclaved PG was prepared from original waste PG with steam pre-treatment. The crystalline phase, morphology, and thermal characteristics of original waste PG and autoclaved PG were investigated by XRD, SEM, and SDT. Then bricks of the size of Chinese standard brick were prepared from different types of PG in the PG-fly ash–lime–sand system. Results showed that the compressive strength of bricks from autoclaved PG by lower-pressure steam of 0.12 MPa, 120 °C for 16 h was much higher. The flexural strength and compressive strength of the bricks could reach 4.0 MPa and 15.0 MPa, respectively. The durability of the bricks was investigated by 15 freezing–thawing cycles at temperatures from ?20 °C to 20 °C, and the weight loss was only 0.029% after all of cycles. Hemihydrates (CaSO₄ · 0.5H₂O) were dehydrated products from dihydrates in original PG with lower-pressure steam treatment, and hemihydrates were susceptible to absorbing the humidity and were transformed into densified re-crystallization gypsum (CaSO₄ · 2H₂O) that contributed to the final strength of bricks. Microstructural characteristics of bricks were investigated by XRD and SEM. Tobermorite was the significant hydrated product, which contributed to the strength of bricks. The use of autoclaved PG for making load-bearing wall bricks was recommended instead of conventional burnt clay bricks.     

Preparation of eco-friendly construction bricks from hematite tailings

With the objective of reducing the negative impacts on environment and utilizing the secondary resource of tailings, the possibility of making construction bricks by using the hematite tailings from western Hubei province of China was investigated. Besides hematite tailings, the additives of clay and fly ash were added to the raw materials to improve the brick quality. Through the process of mixing, forming, drying and firing, the bricks were produced. The optimum conditions were found to be that the hematite tailings content were as high as 84%, forming water content and forming pressure were respectively in the range of 12.5–15% and 20–25 MPa, and the suitable firing temperature was ranged from 980 to 1030 °C for 2 h. Under these conditions, the mechanical strength and water absorption of the reddish fired specimens were 20.03–22.92 MPa and 16.54–17.93%, respectively, and the other physical properties and durability were well conformed to Chinese Fired Common Bricks Standard (GB/T5101-2003). The phases and morphologies of the green tailings and fired specimen were characterized by XRD and SEM. The results showed that the main mineral phases of the product were hematite, quartz, anorthite and tridymite, which were principally responsible for the mechanical strength of bricks.     

Nanostructured zonolite–cementitious surface compounds for thermal insulation

This paper investigates the effect of zonolite loadings on the thermal resistivity and indirect tensile strength of nanostructured cementitious compounds. The main objective of this research is to develop a structural lightweight compound that can be used on building skins and cores for pre fabricated structural insulated panels (SIPs). The application of this compound is intended to improve the thermal resistivity of the building envelope with suitable mechanical performances. The zonolite dosage was added to the cement-nano clay blend at different dosages up to 40% by weight. The nano clay reinforcement used is montmorillonite clay (Hydrated sodium calcium aluminum silicate). The mixes were prepared using water of consistence. The wet compounds were molded in PVC cylindrical molds, having 50 mm inside diameter and 27 mm height, and left for 24 h, then demolded and cured in humid air (20 ± 1 °C&100% RH) for 28 days. The samples were then dried at 105 ± 5 °C for 24 h before testing using a forced convection oven. The thermal resistivity and indirect tensile strength of the different compounds were evaluated. Results demonstrate that the thermal resistivity at 40% zonolite loading enhanced by about 2.9 folds compared to the control samples. An increase of more than 30% in the indirect tensile strength was also achieved when a 0.5% by weight of polycarboxylate superplasticizer was used.     

Formulation of blended cement: Effect of process variables on clay pozzolanic activity

Chemical, physical and mineralogical properties of crude and calcined local kaolinitic clay were studied in detail in order to use it as an artificial pozzolan. The aim of this study was to investigate and optimize the properties of mortars in which calcined clay is employed as a pozzolan.A three variable (calcination time: X1, calcination temperature: X2 and % of calcined clay in the blended cement: X3) rotatable orthogonal composite design was set up. It was concluded that the compressive strengths were governed by the calcination temperature and the percentage of the calcined clay in the blended cement. It was proven that the strengths could be improved by increasing simultaneously the percentage of incorporation and the calcination temperature of the clay. It was also demonstrated that at temperatures lower than 700 °C, the increase of the calcination time, improved the compressive strength, while above 700 °C, the opposite effect was observed. Finally, a blended cement composition has been formulated and optimized using the desirability functions. The optimized blended cement contains 25% of calcined clay, heated for 3 h at a temperature of 750 °C.     

Stiffness and strength parameters for hardening soil model of soft and stiff Bangkok clays

A comprehensive set of experimental data on Bangkok subsoils from oedometer and triaxial tests are analysed in this paper in order to determine the stiffness and strength parameters for Hardening Soil Model. The parameters determined are the Mohr–Coulomb effective stress strength parameters together with the stiffness parameters; tangent stiffness for primary oedometer loading, secant stiffness in undrained and drained triaxial tests, unloading/reloading stiffness and the power for stress level dependency of stiffness. The oedometer data are obtained from three different Bangkok soil layers: soft clay at 6–8 m depths; medium clay at 12–14 m depths; and stiff clay at 15.5–18 m depths. The triaxial tests data are carried out for soft and stiff clays at depths of 5.5–6 m and of 16–18 m under both undrained and drained conditions, respectively. Finally, two sets of parameters for soft and stiff Bangkok clays are numerically calibrated against undrained and drained triaxial results using PLAXIS finite element software.     

Gas temperatures in heavy goods vehicle fires in tunnels

Large-scale fire tests were carried out with heavy goods vehicle (HGV) cargos in the Runehamar tunnel in Norway. The tunnel is a decommissioned, two-way-asphalted road tunnel that is 1600 m long, 6 m high and 9 m wide, with a slope varying between 0.5% uphill and 1% downhill. In total four tests were performed with fire in an HGV set-up and a longitudinal ventilation flow of approximately 3 m/s. In three tests, mixtures of different cellulose and plastic materials were used; in the fourth test a commodity consisting of furniture and fixtures was used. In all tests the mass ratio was approximately 82% cellulose and 18% plastic. A polyester tarpaulin covered the cargo.One purpose of the large-scale tests was to obtain new relevant gas temperature-time data from large-scale HGV fires in tunnels. There is presently a lack of such information for road tunnels. The maximum heat release rates produced by the four different fire loads varied between 66 and 202 MW resulting in maximum gas temperatures at the ceiling ranging between 1281 and 1365 °C. A comparison with literature values shows that the gas temperatures obtained here are uniformly higher than those obtained in other similar large-scale test series conducted using solid materials. A mathematical correlation of a temperature–time curve is given and this is the best representation of the measured temperature and a combination of frequently used temperature curves for tunnels (the HC curve and the RWS curve).     

Oil shale amended raw clay: Firing transformations and ceramic properties

Effects of oil shale additions (up to 20 wt.%) on the firing transformations and ceramic properties (water absorption, firing shrinkage and bending strength) of an illitic-chloritic non-calcareous raw clay were investigated in the range 700–1075 °C. For the first study, X-ray diffraction, thermal analyses, scanning electron microscopy and energy dispersive X-ray spectrometry were used. The results show that oil shale additions lead to the development of anorthite and diopside, and the vanishing of magnesian phases (Mg-spinel and olivine), particular for quantitative additions, as well as to a drastic decrease of the glassy phase. Anorthite developed from lime, supplied from calcite, and clay minerals breakdowns. The contribution of free silica to the latter reaction is plausible, especially at higher firing temperatures. For the development of diopside, higher calcium activities were needed. In such condition, Mg-phases vanished. As compared with the calcite effect, the organic matter associated with shale did not have an appreciable impact on the neoformation process. On the other hand, it is found that the measured ceramic properties experienced a marked change as a function of moderate oil shale additions (<12 wt.%) because of the glassy phase effect. In contrast, they remained practically unchanged for higher contents (>12 wt.%) because of calcium silicates formation.     

Experimental and finite element analysis on the steel fiber-reinforced concrete (SFRC) beams ultimate behavior

Steel fiber-added reinforced concrete (SFRC) applications have become widespread in areas such as higher upper layers, tunnel shells, concrete sewer pipes, and slabs of large industrial buildings. Usage of SFRC in load-carrying members of buildings having conventional reinforced concrete (RC) frames is also gaining popularity recently because of its positive contribution to both energy absorption capacity and concrete strength.This paper presents experimental and finite element analysis of three SFRC beams. For this purpose, three SFRC beams with 250 × 350 × 2000 mm dimensions are produced using a concrete class of C20 with 30 kg/m³ dosage of steel fibers and steel class S420 with shear stirrups. SFRC beams are subjected to bending by a four-point loading setup in certified beam-loading frame, exactly after having been moist-cured for 28 days. The tests are with control of loads. The beams are loaded until they are broken and the loadings are stopped when the tensile steel bars are broken into two pieces. Applied loads and mid-section deflections are carefully recorded at every 5 kN load increment from the beginning till the ultimate failure.One of the SFRC beams modeled by using nonlinear material properties adopted from experimental study is analyzed till the ultimate failure cracks by ANSYS. Eight-noded solid brick elements are used to model the concrete. Internal reinforcement is modeled by using 3D spar elements. A quarter of the full beam is taken into account in the modeling process.The results obtained from the finite element and experimental analyses are compared to each other. It is seen from the results that the finite element failure behavior indicates a good agreement with the experimental failure behavior.