Foaming and Physico-Mechanical Properties of Geopolymer Pastes Manufactured from Post-Metallurgical Recycled Slag.

This paper presents a research program aimed towards developing a method of producing lightweight, porous geopolymer composites for the construction industry based on industrial wastes. A direct method involving the addition of chemicals is currently most commonly used to produce the porous mineral structure of a geopolymer matrix. This relies on a reaction in a highly alkaline environment of the geopolymer to produce a gas (usually hydrogen or oxygen) that forms vesicles and creates a network of pores. This paper demonstrates the feasibility of producing a slag-based geopolymer paste foamed with aluminum powder, taking into account different parameters of fresh paste production: the mixing duration, its speed and the timing of foaming agent addition. The foaming process of the fresh paste in terms of the volumetric changes and temperature development of the fresh paste during the curing of the material are observed. After hardening, the physical properties (density and porosity) as well as the mechanical parameters (compressive strength and work of damage) are determined for the nine manufactured foamed pastes. Image analysis software was used to assess the porosity distribution of the material across the cross-section of the samples. The results enabled the design of the mixing procedure to be adopted during the manufacture of such composites.

Mechanical Properties and Water Permeability of Textile-Reinforced Reactive Powder Concrete with Lightweight Aggregate.

This paper focuses on the development of thin-walled panels with specific properties for applications such as water-tight structures. The authors propose the use of textile-reinforced concrete (TRC) as a composite material and highlight its advantages, which include high tensile strength, improved crack resistance, and design flexibility. The study presents a novel approach which combines TRC with reactive powder concrete (RPC) as a matrix and a lightweight aggregate. RPC, known for its brittle behaviour, is reinforced with glass fibres and a textile fabric to increase its flexural strength. The research includes a comprehensive analysis of the physical and mechanical properties of both the unreinforced RPC matrix and the TRC composite. In particular, the lightweight aggregate RPC matrix has a porosity of 41%, and its mechanical properties, such as flexural and compressive strength, are discussed. The TRC composites, produced in thicknesses ranging from 1 mm to 4 mm, are subjected to flexural tests to evaluate their behaviour under load. The thicker elements show typical damage phases, while the thinner elements show greater flexibility and elasticity. SEM observations confirm good adhesion between the glass fibres and the RPC matrix. Water permeability tests show that the TRC composite, despite its highly porous structure, achieves a water permeability two orders of magnitude higher than that of a reference material, highlighting the roles of both the porous aggregate and the matrix hydration. The paper concludes with a proof of concept-a canoe called the PKanoe, which is constructed from the developed TRC composite. The design of the canoe is supported by numerical analysis to ensure its optimal shape and structural integrity under load. The research contributes to the exploration of innovative materials for sustainable civil engineering applications and addresses both structural and environmental considerations.

Feasibility Review of Aerated Materials Application in 3D Concrete Printing.

Recent years have witnessed a growing global interest in 3D concrete printing technology due to its economic and scientific advantages. The application of foamed concrete, renowned for its exceptional thermal and acoustic insulation properties, not only holds economic attractiveness but also aligns seamlessly with the principles of sustainable development. This study explores various solutions related to 3D printing technology in construction, discussing the design, production, and properties of foamed concrete mixtures. The integration of 3D printing and the potential for automating the entire process offers opportunities to boost productivity and reduce construction costs. Furthermore, the utilization of foamed concrete with its commendable insulation properties will enable a reduction in the usage of materials other than concrete (e.g., mineral wool, facade mesh, and polystyrene), significantly facilitating the recycling process during building demolition. This, in turn, will lead to the preservation of nonrenewable natural resources and a decrease in CO2 emissions. Despite the promising results, there have been limited studies focusing on 3D printing with foamed materials, whereas a survey of the existing body of literature indicates a notable absence of endeavors pertaining to the utilization of aerated concrete within the realm of 3D printing, especially geopolymer composites (GP) and hybrid geopolymer composites (HGP). The outcomes delineated in the ensuing discourse are demonstrative for conventionally used materials rather than the additive manufacturing variant. Hence, this work aims to systematically review existing practices and techniques related to producing foamed concrete with 3D printing technology. This analysis also contributes to the establishment of a foundational framework and furnishes a preliminary basis upon which future endeavors aimed at the 3D printing of aerated concrete can be embarked. The findings from the literature analysis justify the desirability of continuing research on this topic, particularly when considering the potential for large-scale industrial implementation. This article provides a comprehensive state of the knowledge on the development of 3D printing techniques for foamed concrete mixtures. By consolidating and analyzing findings from different studies, this article offers insights into the advancements, challenges, and potential applications of foamed concrete in additive manufacturing processes. This, in turn, contributes to the overall understanding and advancement of 3D printing technologies using foamed concrete as a versatile and sustainable construction material. The encouraging results obtained from the analysis further underscore the need for the continued exploration of 3D printing, especially with an eye towards its industrial-scale implementation.

The Effect of Preconditioning Temperature on Gas Permeability of Alkali-Activated Concretes.

Alkali-activated materials (AAM) are binders that are considered an eco-friendly alternative to conventional binders based on Portland cement. The utilization of industrial wastes such as fly ash (FA) and ground granulated blast furnace slag (GGBFS) instead of cement enables a reduction of the CO2 emissions caused by clinker production. Although researchers are highly interested in the use of alkali-activated concrete (AAC) in construction, its application remains very restricted. As many standards for hydraulic concrete's gas permeability evaluation require a specific drying temperature, we would like to emphasize the sensitivity of AAM to such preconditioning. Therefore, this paper presents the impact of different drying temperatures on gas permeability and pore structure for AAC5, AAC20, and AAC35, which contain alkali-activated (AA) binders made from blends of FA and GGBFS in slag proportions of 5%, 20%, and 35% by the mass of FA, respectively. The preconditioning of samples was performed at 20, 40, 80, and 105 °C, up to the obtainment of constant mass, and then gas permeability was evaluated, as well as porosity and pore size distribution (mercury intrusion porosity (MIP) for 20 and 105 °C). The experimental results demonstrate up to a three-percentage-point rise in the total porosity of low-slag concrete after 105 °C in comparison to 20 °C, as well as a significant increase in gas permeability, reaching up to 30-fold amplification, contingent upon the matrix composition. Notably, the alteration in pore size distribution, influenced by the preconditioning temperature, exhibits a substantial impact. The results highlight an important sensitivity of permeability to thermal preconditioning.

Mechanical Strength and Chloride Ions' Penetration of Alkali-Activated Concretes (AAC) with Blended Precursor.

The purpose of this study was to investigate the properties of hardened alkali-activated concrete, which is considered an eco-friendly alternative to Portland cement concrete. In this paper, the precursors for alkali-activated concrete preparations are blends of fly ash and ground-granulated blast-furnace slag in three slag proportions: 5%, 20%, and 35%, expressed as a percentage of fly ash mass. Thus, three concretes were designed and cast, denominated as AAC5, AAC20, and AAC35. Their physical and mechanical characteristics were investigated at 28 and 180 days, as well as their properties of chloride ion transport. The modified NT BUILD 492 migration test was applied to determine the chloride ions' penetration of the alkali-activated concretes. Improvement of mechanical strength and resistance to chloride aggression was observed with ground-granulated blast-furnace slag content increase in the compositions of the tested concretes. Mercury intrusion porosimetry tests provided insight into the open pore structures of concretes. A significant decrease in the total pore volume of the concrete and a change in the nature of the pore diameter distribution due to the addition of ground granulated blast furnace slag were demonstrated.

Interlayer Bond Strength Testing in 3D-Printed Mineral Materials for Construction Applications.

There are no standards for testing the properties of 3D-printed materials; hence, the need to develop guidelines for implementing this type of experiment is necessary. The work concerns the development of a research methodology for interlayer bond strength evaluation in 3D-printed mineral materials. In additive manufactured construction elements, the bond strength is a significant factor as it determines the load-bearing capacity of the entire structural element. After we completed a literature review, the following three test methods were selected for consideration: direct tensile, splitting, and shear tests. The paper compares the testing procedure, results, and sample failure modes. The splitting test was found to be the most effective for assessing layer adhesion, by giving the lowest scatter of results while being an easy test to carry out.

Optimizing the L/S Ratio in Geopolymers for the Production of Large-Size Elements with 3D Printing Technology.

Geopolymer concretes can be a viable alternative to conventional Portland cement-based materials. In their design, it is important to maintain an appropriate liquid-to-solid ratio (L/S), which affects several properties, such as the compressive strength, water absorption, and frost resistance. The objective of this paper is to analyze the influence of the fly-ash and metakaolin precursor types for three different L/S ratios: 0.30, 0.35, and 0.45. The results of the physical and mechanical properties, including the apparent density and compressive strength, as well the durability parameters, including frost resistance and water penetration depth, are presented in this paper. It was found that as the L/S ratio decreased, the average compressive strength increased for all materials. After freeze-thaw cycles, decreases in the compressive strength properties were observed for all types of materials-metakaolin- and fly ash-based-irrespective of the L/S ratio. Moreover, the frost resistance of geopolymers increased with the increase in the L/S ratio. The printability of the mixes was also verified in order to confirm the application of the developed materials to additive manufacturing processes.

Utilization of Crushed Pavement Blocks in Concrete: Assessment of Functional Properties and Environmental Impacts.

Production of concrete is connected to extensive energy demands, greenhouse gases production or primary sources depletion. Reflecting current economical, social, or environmental trends, there is strong pressure on mitigation these requirements and impacts. The exploitation of secondary- or waste materials in production processes has therefore a great potential which is not related solely to binders but also to fillers. In this light, this paper aims at thorough investigations of concrete mixtures with crushed concrete pavements as partial or full replacement of natural coarse aggregates. The research combines experimental techniques to quantify the influence of the substitution on basic physical, mechanical, and heat/moisture transport/storage parameters. The experimental data obtained are further exploited as input data for computational prediction of coupled heat and moisture transport to assess the influence of the aggregates substitution on hygrothermal performance of the built-in concretes. In the last step, the environmental impacts are assessed. Since the changes in the hygrothermal performance were found to be insignificant (i), the compressive strength were improved by up to 25% (ii) and most of the environmental impact indicators were decreased (iii) at the same time, the findings of the research presented predeterminate such a reuse strategy to wider application and use.

Chloride Ions' Penetration of Fly Ash and Ground Granulated Blast Furnace Slags-Based Alkali-Activated Mortars.

Due to the need to reduce the CO2 emissions of mineral binders, researchers are considering the use of alkali-activated materials (AAMs) as an alternative to cementitious binders. The properties of AAMs can be more advantageous than those presented by cementitious binders, and thus they can replace Portland cement binders in some applications. Mechanical tests of AAMs are being conducted on an ongoing basis; however, durability issues related to reinforcing steel in conditions in which steel members interact with chloride ions remain unsolved. In this paper, the precursors for AAM preparations are blends of fly ash (FA) and ground granulated blast-furnace slag (GGBFS) in four slag proportions: 0%, 10%, 30% and 50% expressed as a percent of FA mass. Four alkali-activated mortars were prepared, denominated as AAM 0, AAM 10, AAM 30 and AAM 50, respectively. Their basic physical and mechanical characteristics were investigated, as were their gas transport properties. The nitrogen Cembureau method was applied to determine the permeability of the mortar. The transport properties of the chloride ions were determined using the modified NT BUILD 492 migration test. The comparison of results obtained demonstrated a positive effect of GGBFS addition in terms of an increase in bulk density, permeability, porosity and, at the same time, a reduction in chloride ion penetration. The water absorption tests also provided insight into the open pore structures of mortars. The measurements revealed a strong dependence between fluid transport through the mortars and the water absorption and initial water content of materials.

Development and Characterization of Lightweight Geopolymer Composite Reinforced with Hybrid Carbon and Steel Fibers.

The aim of this paper is to analyze the influence of hybrid fiber reinforcement on the properties of a lightweight fly ash-based geopolymer. The matrix includes the ratio of fly ash and microspheres at 1:1. Carbon and steel fibers have been chosen due to their high mechanical properties as reinforcement. Short steel fibers (SFs) and/or carbon fibers (CFs) were used as reinforcement in the following proportions: 2.0% wt. CFs, 1.5% wt. CFs and 0.5% wt. SFs, 1.0% wt. CFs and 1.0% wt. SFs, 0.5% wt. CFs and 1.5% wt. SFs and 2.0% wt. SFs. Hybrid reinforcement of geopolymer composites was used to obtain optimal strength properties, i.e., compressive strength due to steel fiber and bending strength due to carbon fibers. Additionally, reference samples consisting of the geopolymer matrix material itself. After the production of geopolymer composites, their density was examined, and the structure (using scanning electron microscopy) and mechanical properties (i.e., bending and compressive strength) in relation to the type and amount of reinforcement. In addition, to determine the thermal insulation properties of the geopolymer matrix, its thermal conductivity coefficient was determined. The results show that the addition of fiber improved compressive and bending strength. The best compressive strength is obtained for a steel fiber-reinforced composite (2.0% wt.). The best bending strength is obtained for the hybrid reinforced composite: 1.5% wt. CFs and 0.5% wt. SFs. The geopolymer composite is characterized by low thermal conductivity (0.18-0.22 W/m ∙ K) at low density (0.89-0.93 g/cm3).

Strength and Microstructure Characteristics of Blended Fly Ash and Ground Granulated Blast Furnace Slag Geopolymer Mortars with Na and K Silicate Solution.

Mineral geopolymer binders can be an attractive and more sustainable alternative to traditional Portland cement materials for special applications. In geopolymer technology the precursor is a source of silicon and aluminium oxides, the second component is an alkaline solution. In the synthesis of geopolymer binders the most commonly used alkaline solution is a mixture of sodium or potassium water glass with sodium or potassium hydroxide or silicate solution with a low molar ratio, which is more convenient and much safer in use. In this paper, we present the influence of sodium or potassium silicate solution on the physical and mechanical properties of fly ash and ground granulated blast furnace slag-based geopolymer mortars. Mercury intrusion porosimetry and microstructural observation allowed for comparing the structure of materials with a different type of alkaline solution. The evolution of compressive and flexural tensile strength with time determined for composites using 10%, 30% and 50% slag contents (referring to fly ash mass) was analysed. The tests were performed after 3, 7, 14 and 28 days. It was observed that, as the amount of slag used increases in the precursor, the strength of the material grows. Mortars with the sodium alkaline solution were characterised by a higher strength at a young age. However, the values of strength 28 days were higher for geopolymers with potassium alkaline solution reaching 75 MPa in compression. Geopolymer mortar microstructure observation indicates a high matrix heterogeneity with numerous microcracks. Matrix defects may be caused by the rapid kinetics of the material binding reaction or shrinkage associated with the drying of the material.

Feasibility Study of Digital Image Correlation in Determining Strains in Concrete Exposed to Fire.

Concrete is prone to spalling when exposed to fire. During fire tests, the strains of concrete elements are hard to identify, both from the fire-exposed face and the non-exposed face. This paper presents a field experiment which employed the original CivEng digital image correlation (DIC) method developed at the Cracow University of Technology to measure the strain fields of elements exposed to heating by a pin-point gas burner. The paper presents experimental proof that it is possible to analyze the deformation of both unheated and fire-exposed sides of heated concrete by the DIC method. The strain fields, crack patterns and modes of crack development are presented. The study shows the encouraging results of employing the DIC method to test concrete behavior under fire attack.

Role of Polypropylene Fibres in Concrete Spalling Risk Mitigation in Fire and Test Methods of Fibres Effectiveness Evaluation.

The explosive behaviour of concrete in fire is observed in rapidly heated concrete. The main factors controlling the occurrence of spalling are related to the material's low porosity and high density as well as the limited ability to transport gases and liquids. Thus, for high-strength, ultrahigh-strength, and reactive powder concrete, the risk of spalling is much higher than for normal-strength concrete. The paper presents the discussion on the leading hypothesis concerning the occurrence of concrete spalling. Moreover, the methods for spalling prevention, such as polypropylene fibre application, which has been found to be an effective technological solution for preventing the occurrence of spalling, are presented. Various tests and testing protocols are used to screen concrete mixes propensity toward spalling and to evaluate the polypropylene fibres' effectiveness in spalling risk mitigation. The most effective testing methods were selected and their advantages were presented in the paper. The review was based mainly on the authors' experiences regarding high performance concrete, reactive powder concrete testing, and observations on the effect of polypropylene fibres on material behaviour at high temperature.

Effect of Cement Type on the Mechanical Behavior and Permeability of Concrete Subjected to High Temperatures.

The paper presents experimental investigations concerning the influence of the cement type (CEMI 42.5 R Portland cement and CEMIII/A 42.5 N slag cement-with 53% granulated blast furnace slag) on the mechanical and transport properties of heated concretes. The evolution of properties due to high temperature exposure occurring during a fire was investigated. High temperature exposure produces changes in the transport and mechanical properties of concrete, but the effect of cement type has not been widely studied in the literature. In this paper, concretes were made with two cement types: CEMI and CEMIII, using basalt (B) and riverbed aggregates (RB). The compressive and tensile strength, as well as the static modulus of elasticity and Cembureau permeability, were tested after high temperature exposure to 200, 400, 600, 800, and 1000 °C. The evaluation of damage to the concrete and crack development due to high temperature effects was performed on the basis of the change in the static modulus of elasticity. The test results clearly demonstrated that permeability increases with damage, and it follows an exponential type formula for both types of cement.