Search Results (450)

The combined application of fibers and lightweight aggregates (LWAs) represents an effective approach to achieving high-strength, lightweight concrete. To enhance the predictability of the mechanical properties of fiber-reinforced lightweight aggregate concrete (LWAC), this study conducts an in-depth investigation into its hydration characteristics. In this study, high-strength LWAC was developed by incorporating low water absorption LWAs, various volume fractions of basalt fiber (BF) (0.1%, 0.2%, and 0.3%), and a ternary cementitious system consisting of 70% cement, 20% fly ash, and 10% silica fume. The hydration-related properties were evaluated through isothermal calorimetry test and high-temperature calcination test. The results indicate that incorporating 0.1–0.3% fibers into the cementitious system delays the early hydration process, with a reduced peak heat release rate and a delayed peak heat release time compared to the control group. However, fitting the cumulative heat release over a 72-h period using the Knudsen equation suggests that BF has a minor impact on the final degree of hydration, with the difference in maximum heat release not exceeding 3%. Additionally, the calculation model for the final degree of hydration in the ternary binding system was also revised based on the maximum heat release at different water-to-binder ratios. The results for chemically bound water content show that compared with the pre-wetted LWA group, under identical net water content conditions, the non-pre-wetted LWA group exhibits a significant reduction at three days, with a decrease of 28.8%; while under identical total water content conditions it shows maximum reduction at ninety days with a decrease of 5%. This indicates that pre-wetted LWAs help maintain an effective water-to-binder ratio and facilitate continuous advancement in long-term hydration reactions. Based on these results, influence coefficients related to LWAs for both final degree of hydration and hydration rate were integrated into calculation models for degrees of hydration. Ultimately, this study verified reliability of strength prediction models based on degrees of hydration. Full article

This study presents a progressive strength prediction model for cement paste based on the hypothesis that compressive strength is governed by the microstructural compactness of hydration products. A three-stage modeling framework was developed: (1) a semi-empirical model for pure cement paste incorporating water-to-cement ratio and paste density; (2) a density-corrected effective water–cement ratio ${\left(w/c\right)}_{eff}$ that accounts for the physical effects of mineral additives including fly ash, slag, and limestone powder; and (3) a hydration-informed strength model incorporating curing age and temperature through an equivalent hydration degree $\alpha \left(t_e\right)$. Experimental validation using over 60 cement paste mixes demonstrated high predictive accuracy, with coefficients of determination up to 0.97. The proposed model unifies the influence of binder composition, packing density, and curing conditions into a physically interpretable and practically applicable formulation. It enables early-age strength prediction of blended cementitious systems using only routine mix and density parameters, supporting performance-based mix design and optimization. The methodology provides a robust foundation for extending compactness-based modeling to more complex cementitious materials and structural applications. Full article

In this study, alkali-activated coal gangue-slag material (AACGS) was prepared using coal gangue and slag as precursors, and its feasibility as conductive mortar substrate material was preliminarily investigated. Firstly, this study employed Response Surface Methodology (RSM) to develop statistical models correlating the alkali equivalent, water-to-binder ratio, and slag content with the compressive strength, flexural strength, and resistivity of AACGS, aiming to identify the optimal mix proportions. Secondly, based on the optimal ratio identified above and using carbon fibers (CF) as the conductive phase, an alkali-activated conductive mortar (CF-AACGS) was prepared, and its compressive strength, flexural strength, and resistivity were tested. Lastly, XRD and SEM-EDS were conducted to characterize the mineral composition and microstructure of CF-AACGS. The results indicate that when the alkali equivalent, water-to-binder ratio, and slag content are 13.34%, 0.54, and 57.52%, respectively, the AACGS achieves compressive strength, flexural strength, and resistivity of 72.5 MPa, 7.0 MPa, and 62.41 Ω·m at 28 days. Under the action of the alkali activator, coal gangue and slag undergo hydration reactions, forming a denser N, C-(A)-S-H gel. This effectively improves the interface transition zone between the CF and AACGS, endowing the CF-AACGS with superior mechanical properties. Furthermore, the AACGS matrix enhances the conductive contact point density by optimizing CF dispersion, which significantly reduces the resistivity of the CF-AACGS. Full article

Alkali-activated building materials have attracted the interest of many researchers due to their low cost and eco-efficiency. Different binders with different chemical compositions can be used for their production, so the reaction mechanism can become complex and the results of studies can vary widely. In this work, several alkali-activated mortars based on marginal by-products as binders, such as high calcium fly ash and ladle furnace slag, are investigated. Their mechanical (flexural and compressive strength, ultrasonic pulse velocity, and modulus of elasticity) and physical (porosity, absorption, specific gravity, and pH) properties were determined. After evaluating the mechanical performance of the mortars, the optimum mixture containing fly ash, which reached 15 MPa under compression at 90 days, was selected for the production of precast compressed slabs. Steel or glass fibers were also incorporated to improve their ductility. To reduce the density of the slabs, 60% of the siliceous sand aggregate was also replaced with recycled polyethylene terephthalate (PET) plastic aggregate. The homogeneity, density, porosity, and capillary absorption of the slabs were measured, as well as their flexural strength and fracture energy. The results showed that alkali activation can be used to improve the mechanical properties of weak secondary binders such as ladle furnace slag and hydrated fly ash. The incorporation of recycled PET aggregates produced slabs that could be classified as lightweight, with similar porosity and capillary absorption values, and over 65% achieved strength compared to the normal weight slabs. Full article

Three-dimensional (3D) concrete printing (3DCP) has gained significant attention over the last decade due to its many claimed benefits. The absence of effective real-time quality control mechanisms, however, can lead to inconsistencies in extrusion, compromising the integrity of 3D-printed structures. Although the importance of quality control in 3DCP is broadly acknowledged, research lacks systematic methods. This research investigates the feasibility of using ultrasonic pulse velocity (UPV) as a practical, in situ, real-time monitoring tool for 3DCP. Two different groups of binders were investigated: limestone calcined clay (LC³) and zeolite-based mixes in binary and ternary blends. Filaments of 200 mm were extruded every 5 min, and UPV, pocket hand vane, flow table, and viscometer tests were performed to measure pulse velocity, shear strength, relative deformation, yield stress, and plastic viscosity, respectively, in the fresh state. Once the filaments presented printing defects (e.g., filament tearing, filament width reduction), the tests were concluded, and the open time was recorded. Isothermal calorimetry tests were conducted to obtain the initial heat release and reactivity of the supplementary cementitious materials (SCMs). Results showed a strong correlation (R² = 0.93) between UPV and initial heat release, indicating that early hydration (ettringite formation) influenced UPV and determined printability across different mixes. No correlation was observed between the other tests and hydration kinetics. UPV demonstrated potential as a real-time monitoring tool, provided the mix-specific pulse velocity is established beforehand. Further research is needed to evaluate UPV performance during active printing when there is an active flow through the printer. Full article

Additive manufacturing (AM) has brought significant breakthroughs to the construction sector, such as the ability to fabricate complex geometries, enhance efficiency, and reduce both material usage and construction waste. However, several challenges must still be addressed to fully transition from conventional construction practices to innovative and sustainable green alternatives. This study investigates the use of non-cementitious traditional mixtures for green construction applications through 3D printing using Liquid Deposition Modeling (LDM) technology. To explore the development of mixtures with enhanced physical and mechanical properties, natural pine and cypress wood shavings were added in varying proportions (1%, 3%, and 5%) as sustainable additives. The aim of this study is twofold: first, to demonstrate the printability of these eco-friendly mortars that can be used for conservation purposes and overcome the challenges of incorporating bio-products in 3D printing; and second, to develop sustainable composites that align with the objectives of the European Green Deal, offering low-emission construction solutions. The proposed mortars use hydrated lime and natural pozzolan as binders, river sand as an aggregate, and a polycarboxylate superplasticizer. While most studies with bio-products focus on traditional methods, this research provides proof of concept for their use in 3D printing. The study results indicate that, at low percentages, both additives had minimal effect on the physical and mechanical properties of the tested mortars, whereas higher percentages led to progressively more significant deterioration. Additionally, compared to molded specimens, the 3D-printed mortars exhibited slightly reduced mechanical strength and increased porosity, attributable to insufficient compaction during the printing process. Full article

This study presents a detailed and comprehensive investigation into the macro-scale performance, strength gain mechanisms, environment and economic performance of graphene oxide (GO)-enhanced low-emission concrete. A comprehensive experimental program evaluated fresh and hardened properties, including slump retention, bleeding, air content, compressive, flexural, and tensile strength, drying shrinkage, and elastic modulus. Scanning Electron Microscopy (SEM), energy-dispersive spectroscopy (EDS), Thermogravimetric analysis (TGA) and proton nuclear magnetic resonance (¹H-NMR) was employed to examine microstructural evolution and early age water retention, confirming GO’s role in accelerating cement hydration and promoting C-S-H formation. Optimal performance was achieved at 0.05% GO (by binder weight), resulting in a 25% increase in 28-day compressive strength without compromising workability. This outcome is attributed to a tailored, non-invasive mixing strategy, wherein GO was pre-dispersed during synthesis and subsequently blended without the use of invasive mixing methods such as high shear mixing or ultrasonication. Fourier-transform infrared (FTIR) spectroscopy further validated the chemical compatibility of GO and PCE and confirmed the compatibility and efficiency of the admixture. Sustainability metrics, including embodied carbon and strength-normalized cost indices (USD/MPa), indicated that, although GO increased material cost, the overall cost-performance ratio remained competitive at breakeven GO prices. Enhanced efficiency also led to lower net embodied CO₂ emissions. By integrating mechanical, microstructural, and environmental analyses, this study demonstrates GO’s multifunctional benefits and provides a robust basis for its industrial implementation in sustainable infrastructure. Full article

This study presents a performance-based concrete mix design methodology rooted in the paste–aggregate binary framework, aiming to reduce binder content while ensuring optimal workability and strength. We found that inter-particle spacing (SPT) and paste rheology jointly govern fresh concrete behavior, with slump increasing nonlinearly with SPT and a critical transition zone around 20–35 µm; paste yield stress controls slump, while plastic viscosity governs segregation resistance. A two-level strength model was developed to predict concrete strength from paste properties based on compactness and hydration (R² = 0.90). Fixing SPT at 25 µm was identified as optimal for achieving balanced flowability with minimal paste volume. This approach effectively decouples aggregate packing optimization from paste calibration, offering a physically interpretable and practical framework for designing sustainable, low-carbon, and low-shrinkage concrete. Full article

The construction industry is the main consumer of mineral resources. At the same time, the Portland cement (PC) industry occupies a leading position, using expensive, high-quality raw materials. This is due to the high rate of construction in different areas (industrial, civil, road construction, etc.). The widespread application of PC is due primarily to the strength and durability of composite materials based on it. Taking into account their specific purpose, PC-based composites are usually optimized to achieve specified characteristics and rational use of raw materials. To reduce PC consumption and justify the possibility of its use in complex binders, this manuscript analyzes the composition of a functional polymer–mineral additive; the nature and mechanisms of its interaction with PC depend on the method of introducing the additive (dry mixing/joint grinding of the clinker–gypsum mixture with the additive at the stage of binder preparation). Based on the data of XRD, IR, and SEM analysis, as well as taking into account patent information, the composition of the additive was clarified. The combined application of the above methods allowed us to establish the uniformity of the additive distribution in the binder depending on the introduction method and to evaluate the effect of each additive component and its mutual impact on the processes occurring during cement hydration. As a result, it was established that the most effective introduction method is combined grinding. A phenomenological model of the structure formation of additives containing cement paste is proposed. The binder production by the combined grinding method promotes the intensification of the processes occurring during hydration, as evidenced by the data of qualitative and quantitative XRD, IR, and DTA analysis, differential scanning calorimetry (DSC), and TGA analysis. Full article

Cement–based mortars are essential in both modern construction and heritage conservation, where balancing mechanical strength with material compatibility is crucial. Mortars containing ––binders with low hydraulic activity, such as CEM II/B–L, often exhibit increased porosity and diminished strength, limiting their suitability for structurally demanding applications. This study investigates the potential of multiwalled carbon nanotubes (MWCNTs) to enhance the mechanical and microstructural properties of mortars formulated with both CEM II/B–L and CEM I binders. The influence of CNT incorporation was systematically assessed through compressive and flexural strength tests, vacuum saturation tests, mercury intrusion porosimetry (MIP), scanning electron microscopy (SEM), and differential thermal analysis (DTA). The results demonstrate significant mechanical improvements attributable to nanoscale mechanisms including crack bridging, pore–filling, and stress redistribution. Microstructural characterization revealed a refined pore network, increased densification of the matrix, and morphological modifications of hydration products. These findings underscore the effectiveness of CNT reinforcement in cementitious matrices and highlight the critical role of binder composition in influencing these effects. This work advances the development of high–performance mortar systems, optimized for enhanced structural integrity and long–term durability. Full article

This study investigates the long-term durability and crystallization-induced degradation mechanisms of alkali-activated slag (AAS) mortars with varying water-to-binder ratios (w/b, 0.4, 0.45, 0.5) under semi-immersion in 5 wt.% sodium sulfate solution. Through 360 d of exposure, the evolution of physical–mechanical properties (mass change, open porosity, compressive/flexural strength) and ion migration patterns (SO₄²⁻, Na⁺, Ca²⁺) were analyzed to unravel the interplay between pore structure, ion transport, and crystallization-induced deterioration. Results demonstrated that higher w/b ratios exacerbated surface crystallization and spalling due to accelerated ion transport and pore coarsening. Early-stage strength gains (up to 25.15% at 120–180 d) stemmed from pore refinement via sulfate deposition and continued slag hydration. However, prolonged exposure triggered microstructural degradation, with open porosity increasing by 58.9% and strength declining by 30.6% at 360 d for a w/b of 0.5 compared to a w/b of 0.4. This was driven by crystallization pressure and the decalcification of hydration products. Ion migration analysis revealed SO₄²⁻ enrichment in evaporation area and outward Na⁺ diffusion, establishing supersaturation gradients that aligned with crystallization damage progression. These findings provide critical insights for optimizing AAS mortar formulations to mitigate sulfate crystallization risks in semi-immersed environments. Full article

The rheological behavior of cementitious paste plays a pivotal role in determining the workability, pumpability, and uniformity of fresh concrete. Classical rheological models often struggle to capture the complex flocculation and hydration effects inherent in cement-based systems, and they typically depend on parameters that are difficult to measure directly, limiting their practical utility. This study presents a novel composition-based constitutive model that introduces a virtual maximum packing fraction (${\varphi }_{max}$) to account for interparticle flocculation and entrapped water effects. By establishing quantitative relationships between powder characteristics—such as particle size and specific surface area—and rheological parameters, the model enables physically interpretable and measurable predictions of yield stress and plastic viscosity. Our validation against 65 paste formulations with varying water-to-binder ratios, mineral admixture types and dosages, and superplasticizer contents demonstrates strong predictive accuracy (R² > 0.98 for plain pastes and >0.85 for blended systems). The influence of superplasticizers is effectively captured through modifications to ${\varphi }_{max}$, allowing the model to remain both robust and parameter efficient. This framework supports forward prediction of paste rheology from raw material properties, offering a valuable tool for intelligent mix design in high-performance concrete applications such as self-consolidating and 3D-printed concrete. Full article

This study explores the synergistic potential of ladle slag (LS) and sunflower shell fly ash (SSFA) in alkali-activated binder systems, focusing on their chemical and mineralogical characteristics and the influence of SSFA addition on the mechanical performance of LS-based pastes. X-ray fluorescence and XRD analysis revealed that LS is rich in CaO and latent hydraulic phases such as γ-belite and mayenite, while SSFA is dominated by K₂O, SO₃, and KCl/K₂SO₄ phases, reflecting its biomass origin. Infrared spectroscopy and thermal analysis confirmed the presence of carbonate, hydroxide, and hydrate phases, with SSFA exhibiting more complex thermal behavior due to volatile-rich composition. When used alone, LS produced weak binders; however, a 10 wt% SSFA addition tripled compressive strength to nearly 30 MPa, indicating a significant activation effect. Further increases in SSFA content led to strength reduction, likely due to increased porosity and excess salts. Microstructural analysis showed that SSFA promotes the formation of AFm phases such as Friedel’s salt and hydrocalumite, altering hydration pathways and enhancing early strength through chemical activation and carbonation processes. The findings highlight the potential of combining LS and SSFA as a sustainable binder system, offering a waste-derived alternative for low-carbon construction materials. Full article

This study systematically investigates the influence of mix proportion on and the early-age properties and CO₂ uptake of CO₂-mixed cement paste, focusing on variations in the water-to-binder (w/b) ratio, slag content, and air-entraining agent (AEA) dosage. Mineralogical characteristics were analyzed using X-ray diffraction (XRD) and thermogravimetric analysis (TGA), while pore structures were assessed via nitrogen adsorption. CO₂ uptake was quantified immediately after mixing. Results indicate that a low w/b ratio limits CO₂ dissolution and transport, favors hydration over carbonation, and leads to a coarser pore structure. At moderate w/b ratios, excess free water facilitates concurrent carbonation and hydration; however, thinner water films ultimately hinder CaCO₃ precipitation and C-S-H nucleation. Slag contents up to 30% slightly suppress early carbonation and hydration, while higher dosages significantly delay both reactions and increase capillary porosity. An increasing AEA dosage stabilizes CO₂ bubbles, suppressing immediate CO₂ dissolution and reducing the early formation of carbonation and hydration products; excessive AEAs promotes bubble coalescence and results in an interconnected pore network. An optimized mix design, moderate water content, slag below 30%, and limited AEA dosage enhance the synergy between carbonation and hydration, improving early pore refinement and reaction kinetics. Full article

Stratlingite is known as one of the hydration products of aluminum-rich cements. Its microstructure and, consequently, mechanical properties, depend on the Al/Si ratio and hydration conditions. The layered structure of stratlingite is characterized as defected, with vacancies in the aluminosilicate layer. This study uses density functional theory calculations on different stratlingite models to show how chemical composition, water content, and structural defects affect its mechanical properties. The developed models represent structures with full occupancy, with little or no content of structural water, and with vacancies in the aluminosilicate layer. It was shown that the full occupancy models have the highest toughness and are strongly anisotropic. The calculated bulk modulus (B_H) of the models with full occupancy was about 40 GPa, being in the typical range for calcium aluminosilicate minerals. The water loss led to an increase in B_H by approximately 40% compared to the models with full occupancy. In contrast, the models with vacancies exhibited a decrease in B_H of about 30%. In models with the high silicon content (Al/Si ratio of 1/4), B_H, Young’s (E_H), and shear (G_H) moduli decreased in a range 15%–30% compared to the models with an Al/Si ratio of 2/3 of Al/Si. Finally, according to Pugh’s ratio (B_H/G_H), which serves as a criterion for brittle–ductile transition (1.8), the models with full occupancy exhibit a brittle behavior, whereas the defected structures are closer to ductile. This could explain the elastic behavior of stratlingite binder in concretes. Generally, the calculations showed that all investigated parameters (chemical composition, water content, and structural defects) have a significant impact on the mechanical properties of stratlingite minerals. Full article