Search Results (16)

To address the limitations of traditional hardened concrete road surfaces in coal mine tunnels, which are prone to damage and entail high maintenance costs, this study proposes using modular concrete blocks composed of fly ash and coal gangue as an alternative to conventional materials. These blocks offer advantages including ease of construction and rapid, straightforward maintenance, while also facilitating the reuse of substantial quantities of solid waste, thereby mitigating resource wastage and environmental pollution. Initially, the mineral composition of the raw materials was analyzed, confirming that although the physical and chemical properties of Liangshui Well coal gangue are slightly inferior to those of natural crushed stone, they still meet the criteria for use as concrete aggregate. For concrete blocks incorporating 20% fly ash, the steam curing process was optimized with a recommended static curing period of 16–24 h, a temperature ramp-up rate of 20 °C/h, and a constant temperature of 50 °C maintained for 24 h to ensure optimal performance. Orthogonal experimental analysis revealed that fly ash content exerted the greatest influence on the compressive strength of concrete, followed by the additional water content, whereas the aggregate particle size had a comparatively minor effect. The optimal mix proportion was identified as 20% fly ash content, a maximum aggregate size of 20 mm, and an additional water content of 70%. Performance testing indicated that the fabricated blocks exhibited a compressive strength of 32.1 MPa and a tensile strength of 2.93 MPa, with strong resistance to hydrolysis and sulfate attack, rendering them suitable for deployment in weakly alkaline underground environments. Considering the site-specific conditions of the Liangshuijing coal mine, ANSYS 2020 was employed to simulate and analyze the mechanical behavior of the blocks under varying loads, thicknesses, and dynamic conditions. The findings suggest that hexagonal coal gangue blocks with a side length of 20 cm and a thickness of 16 cm meet the structural requirements of most underground mine tunnels, offering a reference model for cost-effective paving and efficient roadway maintenance in coal mines. Full article

Significant construction and demolition waste (CDW) is produced by many useless concrete buildings, bridges, airports, highways, railways, industrial mining, etc. The rising need for new construction has increased the use of natural materials, impacting the ecosystem and incurring high costs from mining natural aggregates (NA) and processing CDW. The concept and implementation of recycled aggregate concrete (RAC) offer a sustainable solution for the concrete industry. Crushed concrete, made from recycled concrete, can be used instead of natural aggregates in structural concrete. This sustainable byproduct, recycled concrete aggregate (RCA), has the potential to replace natural aggregate. This paper examines the benefits of RAC from economic, social, environmental, and technological perspectives and discusses the replacement ratio (RR)—the weight percentage of natural aggregate replaced by recycled aggregate—which is crucial to RAC performance. A collection of used data on mechanical properties and economic performance, national specifications, standards, and guidelines is reviewed to determine the optimal replacement ratio for RCA, which was found to be 20%. Finally, we discuss the challenges and future of using RAC in structural concrete. Full article

The quartz sand filter medium used in micro-irrigation media filters has the disadvantages of short filtration cycle, surface filtration, and mining pollution. Selecting resources as new filter media is essential to improve the performance of the media filter and boost sustainable development. In this study, the traditional quartz sand filter medium and two new filter media were selected, and their corresponding filtration performances were comparatively studied. The influence of the type, particle size, and height of the filter medium on filtration performance was evaluated. The sediment content and distribution based on the size of particles in quartz sand, crushed glass, and glass bead filter layers was measured and analyzed. The hydraulic performance of different filter columns was analyzed. The results showed that for a given particle size, quartz sand exhibits the best sediment retention ability. This promoted the aggregation of small sediment particles into larger ones, whereas the crushed glass and bead glass filter layers promoted the splitting of large sediment particles into smaller ones, which enabled the reduction of blockage during the micro-irrigation process. The filtration rate of the quartz sand filter column exhibited the least fluctuation relative to crushed glass and glass bead filter media, and the pressure in each column exhibited a linear incremental change. In summary, glass microbeads are not suitable as filter material, crushed glass is suitable for general micro-irrigation systems, and quartz sand is suitable for micro-irrigation systems with elaborate filtration requirements. The findings of this study can provide theoretical guidance for the selection of the micro-irrigation filter material. Full article

The mineral raw materials industry is crucial for European industry, with the European Economic and Social Committee estimating that 70% of the industry relies directly or indirectly on its supply. In the context of a decarbonized and digitalized economy, the new European industrial model requires carbon-neutral raw materials and production processes. The crucial role of aggregates mining, as the primary construction material, emerges as a key supplier in this paradigm. Aggregates are the main component of the built environment and are a social and economic engine in most countries. Quarries of this type include a wide range of sizes and exploitation methods and use characteristic mining and processing equipment. Quarries are commonly close to their processing plants, which transform natural rock into crushed and ground materials with different grain sizes depending on the future uses. The quarry itself and the presence of certain equipment and facilities help distinguish it from mining sites that exploit other materials. Effective management of aggregates quarries is important in promoting circular economy practices, ensuring efficient management, reuse, and recycling of diverse wastes, including the recovery of high-value components and the production of recycled aggregates, and addressing construction and demolition waste (DCW) management. As aggregates become a progressively scarcer resource due to the increasing demand from developing countries, it is essential to provide reliable and comprehensive information on their potential to the public, policymakers, and other stakeholders to promote their use. This study focuses on employing artificial intelligence and computer vision analysis to automatically identify aggregates quarries from satellite images within continental Spain. A model has been trained to detect aggregates quarries from satellite images by computer vision. The model permits the detection of mining exploitation and the objects located at the interior, which permits determination of the type of mine and the activity status of it. The findings highlight the ability of artificial vision to discern quarries and distinguish whether the observed feature is an aggregates quarry. Additionally, the technology allows for the determination of the quarry’s operational status, distinguishing between active and abandoned quarries. The ability to detect the locations of quarries and assess their activity statuses is of significant value for resource exploration initiatives and location-allocation assessments. It can be a valuable tool for authorities involved in land planning, activities monitoring, and early detection of potential illegal mining activities. This analytical approach demonstrates substantial potential for various stakeholders, including mining companies, mining authorities, policymakers, and land use planners in both the private and public sectors. Full article

Iron ore tailings from iron ore mines pose environmental challenges. However, their reuse could provide significant environmental benefits. This study focused on producing clean concrete using iron ore tailings as crushed stone aggregate (IOTA) and calcium carbonate whiskers (CWs) as reinforcement. Five mixture groups were prepared: normal concrete (NAC) with natural crushed stone aggregate (NA), iron ore tailings concrete (TAC) with IOTA, and CW (10%, 20%, and 30%)-reinforced TAC (TAC-CW). Mechanical properties like the compressive strength (f_cu) and splitting tensile strength (f_st), as well as sulfate freeze–thaw (F-T) cycle resistance, were thoroughly investigated. Additionally, pore structure and microstructure were characterized using nuclear magnetic resonance (NMR) and scanning electron microscopy (SEM) techniques. The results showed that IOTA’s complete replacement of NA decreased concrete mechanical properties and frost resistance, but incorporating CWs effectively compensated for these losses. Specifically, the f_cu and f_st of TAC-CW20 with 20% CWs increased by 23.26% and 49.6% compared to TAC and were higher than those of NAC. With increasing F-T cycles, concrete internal pore structure significantly deteriorated, and corrosive products increased significantly, which was further confirmed by SEM. TAC-CW20 significantly optimized pore structure. Overall, the successful application of iron ore tailings as eco-friendly materials enhanced concrete performance and reduced the environmental impact of construction activities. Full article

In the course of mining and processing of almost all petrographic varieties of rock raw materials for the production of building and materials, aggregates for road and railway construction, waste is generated. These are usually fine-grained fractions of these rocks that are difficult to manage and are deposited at dumps. The article presents and describes the results of the physical, chemical, and mineralogical properties of fine-grained waste from the production of amphibolite aggregate from Pilawa Gorna in Lower Silesia (S-W Poland). Such studies have not been carried out on this waste before. The tested waste is a very fine-grained dusty material (<0.100 mm) originating from the dedusting of the crushing and classification operations during the production of aggregates. Preliminary studies of the separation of the tested material using collector-less flotation and gravity separation are also presented. Detailed chemical analysis shows that most of the elements in the studied rock dust occur in abundance close to the average in the Earth’s crust. The collector-free flotation of the investigated sample allows effective separation of graphite and the part of sulfide minerals Cu, Ni, and Mo. The presented results may be the basis for further research and development of the concept of their economic use. Full article

This paper presents an attempt to obtain technically valuable lightweight aggregate produced from a mixture of fluidized bed fly ash and post-mining residues. The motivation to take up this study is a problem with the reasonable utilization of huge amounts of ashes produced by power plants in Poland. The ashes still produced and those stored in heaps amount to a tonnage of millions, and new ways to utilize them are desired. A real lack of mineral aggregates (non-renewable resources) demands the search for alternative materials. Using the industrial ashes as aggregates is a possible solution to the two above-mentioned problems. The aim of the study was to produce the lightweight aggregate components and to assess them in terms of their physical and mechanical properties. The components were prepared by mixing, granulation, and sintering at the temperature of over 1170 °C. Evaluation of physical parameters was based on parameters such as bulk density and water absorption. The study of mechanical properties was carried out on the basis of aggregates’ resistance to crushing. The obtained results revealed that using a mixture of the combustion and post-mining residues in the production of a lightweight aggregate is beneficial and results in the formation of a porous and durable structure. The measured resistance to the crushing of the produced aggregates varied from 5.9 MPa to 7.5 MPa. They also showed a high freeze-thaw resistance and good resistance to aggressive environments (bases, acids, salt). The registered properties indicate that the aggregates meet the basic requirements for materials used in construction and road-building. This study has a scientific and didactic value in that it describes the step-by-step process of planning and implementing the production of synthetic mineral aggregates. Full article

The aim of this article is to present possibilities of producing aggregates with an increased content of regular particles in some well-known examples, as well as to present previously unused methods of aggregate production. Traditional aggregate production systems require the use of three or four grinding stages (depending on the particle size of the feed), but fine fractions contain approximately 10% irregular grains on average. The conducted research has shown that in innovative patented technological systems, it is possible to obtain regular aggregates with a share of irregular grains below 3%. The separated irregular aggregates can be crushed again or used for other purposes. The advantages of such inventions include less grinding stages, reduced dust, and lower energy consumption. Regular aggregates also have benefits compared to typical ones. The analyzed aggregate products from various mines showed that regular aggregates have better properties, for example, higher resistance to grinding and abrasion. This article also describes the advantages of using such aggregates for concrete or other applications. Full article

Crushing is one of the most energy-consuming technological processes. The purpose of grinding is to achieve the desired grain size of mineral raw materials. The process of grinding consists of many factors, for example, the size and form of crushed grains, as well as their mutual arrangement inside the crushing machine chamber, the technological parameters of the crusher, the material properties, and the speed of the moving grains. One of the key parameters of the aggregate is its resistance to grinding. Resistance to grinding is related to the strength of the products made from aggregates subjected to grinding, which affects the overall quality of these products. Therefore, the aim of this study is to analyze the impact of the crushing of natural aggregate on the LA crumbling strength index. Two types of aggregates were analyzed—natural gravel and natural pebbles crushed in a crusher. Aggregates were acquired from two mines belonging to the plant Kruszgeo S.A. in Rzeszów, i.e., ZEK (Zakład Eksploatacji Kruszywa) Ostrów and ZEK Strzegocice II. The aggregate crushing process was carried out for 4–8 mm and 10–14 mm fractions using cone crushers of the 1044 type. Aggregate crushing was carried out in a Los Angeles drum, in accordance with the requirements of EN 1097-2:2020. The analysis showed that for grits of the 10–14 mm fraction, the lower values of the LA indices were obtained, which allows for obtaining a bigger index of crushing strength than in the case of crushing using the 4–8 mm fraction. This analysis showed how important the process of grinding aggregates is and, thus, the appropriate selection of fractions for the grit crushing process for the aggregate strength on grinding. Subjecting the aggregate to the grinding process results in an improvement in the crushing strength indicator, thus obtaining better strength parameters of the products manufactured from the aggregates subjected to the process of crushing (for example, concrete). The originality of the study is an analysis of key Polish aggregates and the crushing strength index. Full article

At present, there is a shortage of high-quality feedstock to produce widely used building materials—concretes. Depletion of natural resources and growing restrictions on their extraction, in connection with environmental protection, necessitate the search for an equivalent replacement for conventional raw materials. Magnesium–silicate rocks are a waste of the mining industry. We researched the possibility of using these rocks as coarse and fine aggregates in heavy concrete production. Following the requirements of the national standards, we studied the physical and mechanical characteristics of the obtained material. It was found that the strength of concrete, made of magnesium–silicate rock coarse aggregate, at the age of 28 days of hardening is within 28 MPa, while the strength of the control sample is 27.3 MPa. Replacing quartz sand with dunite sand also leads to an increase in concrete strength (~4%). Complete replacement of aggregates facilitates an increase in strength by 15–20% than the control sample. At the same time, the density of the obtained materials becomes higher. Concretes have a dense structure that affects their quality. Concrete water absorption is within 6%. The fluxing coefficient is 0.85–0.87. The application of magnesium–silicate rocks in concrete production enables the complete replacement of conventional aggregates with mining waste without reducing the quality of the obtained materials. Furthermore, the issues of environmental protection in mineral deposit development are being addressed. Full article

The presented research aims to clarify the specific effect of the individual components of concrete with Portland cement CEM I 42.5 R on the volume changes of concrete. The effect of the filler component was evaluated from the point of view of the composition and type of aggregate (crushed versus mined) and from the point of view of the mineralogical composition of the aggregate. Concrete formulas with a maximum aggregate grain size of 16 and 22 mm were assessed. The effect of the binder component on the shrinkage of the concrete was monitored on the concrete mixtures produced using the same aggregate and maintaining the same strength class of concrete, C 45/55. The effect of the addition of finely ground limestone, finely ground granulated blast furnace slag and coal high-temperature fly ash was monitored. It was found that the maximum aggregate grain and the type of grading curve do not have a significant effect on the volume changes of concrete. Concretes with mined aggregates showed lower shrinkage than concretes with crushed aggregates. The most significant is the effect of the type of aggregate on the volume changes in the first 24 h. Mineral additives have a positive effect on the elimination of the volume changes of concrete, while the addition of high-temperature fly ash proved to be the most suitable. Full article

Virtually every concrete structure comes into contact with abrasive effects of flowing media or solids, which have a direct impact on the durability of concrete. An abrasive effect is most pronounced in transport or water management structures, and these structures are often designed for a significantly longer service life (usually 100 years). This research evaluates the influence of the filler component in terms of the type of aggregate and its mineralogical composition on concrete abrasion resistance. As part of the impact of the binder component, several concrete mixtures were produced using the same aggregate and maintaining the same strength class with the addition of different types of active and inert mineral additives. In other parts of the research, the effect of adding fiber reinforcement on the abrasion resistance of concrete was verified. Mutual connections and correlations in different age groups (7, 28 and 90 days) were sought for all obtained results. The abrasion resistance of the composite was monitored by using standard procedures, especially using a Böhm device. It was found that for good abrasion resistance of concrete, it is not necessary to produce concretes with high strength classes using often expensive mineral additives (microsilica) and quality aggregates, but the maturation time of the composite and its microstructure plays an important role. Full article

Sand has been considered to be something of an immeasurable quantity. There are many indications that this view is no longer valid and that the limiting of natural aggregates usage is doubly justified. Firstly, the extraction of natural aggregates is expensive and has a huge impact on the environment. The main issues in sand and gravel mining are the large areas that are affected, ground water level changes, illegal mining, unsuitability of desert and marine sand, and costs of transport. Secondly, metallurgical waste can be used as a substitute for natural aggregates. This is doubly beneficial—the waste is recycled and the use of natural aggregates is reduced. Waste is stored in landfills that take up large areas and there is also the possibility of ground and groundwater pollution by hazardous compounds. The research presented in this article focuses on the technological conditions of using metallurgical waste in its original form and as a component of recycled concrete aggregate (RCA). The use of metallurgical sludge waste or crushed or round RCA to produce concrete deteriorates the consistency and does not significantly affect the air content and density of the concrete mix. RCA lowers the density of hardened concrete. Metallurgical sludge waste or RCA usage adversely affect the absorbability and permeability of concrete. Concrete containing metallurgical sludge waste is of higher compressive strength after 7 and 28 days, with up to 60% of waste as a sand replacement. RCA concrete achieved higher compressive strength also. Full article

The Lower Silesia area in SW Poland is characterized by a geological structure that is conducive to mining activity. The exploitation of rock raw materials plays an important role in this sector of the economy. By the end of 2017, there were in total approximately 400 current concessions for the exploitation of rock raw materials in the analysed area (Polish Geological Institute, MIDAS database—Management and Protection System of Polish Mineral Resources). The conducted mining activity results in waste, which in the greatest amount occurs in the process of obtaining crushed road and construction aggregates, natural aggregates, carbonate raw materials for the cement and lime industry, as well as stone elements for construction and road engineering. At the end of 2016, the mining plants accumulated 26,569,600 Mg of waste. As part of the European Regions Toward Circular Economy (CircE) project, research was conducted on the volume and composition of the mining waste of rock raw materials in the years 2010–2016 within Lower Silesia. This research used the methods of statistical, descriptive and spatial analysis to identify mining plants with the highest potential for using their wastes. In the course of this study, 6 mining plants with the highest potential of using their waste for industrial production purposes were selected. In order to objectively select these plants, the methodology of qualitative multi-criteria analysis was developed, and 7 criteria were selected for assessing the economic potential of using waste from the mining of rock raw materials. An additional result of this research is a database and graphical presentation of changes in the spatial distribution of generated waste in the Lower Silesia region in the years ranging from 2010 to 2016. Full article

In the rapidly developing modern society, many raw materials, such as crushed limestone and river sand, which are limited, are consumed by the concrete industry. Naturally, the usage of waste materials in concrete have become an interesting research area in recent years, which is used to reduce the negative influence of concrete on the environment. Hence, this paper presents the development of a sustainable lightweight wet-mix shotcrete by replacing natural coarse gravel with a kind of byproduct, nut shell (walnut). Fibers made from dumped polyethylene terephthalate (PET) bottles were mixed in the composite to improve the properties of the lightweight wet-mix shotcrete. The initial evaluation of the fresh concrete mixed with different volume fraction of walnut shell was carried out in terms of its performance capacities of mechanical properties (i.e., tensile and compressive strength), pumpability and shootability (i.e., slump, pressure drop per meter and rebound rate) and the results were compared with plain concrete. With increase of walnut shell, compressive and splitting tensile strength of casting concrete decreased, while slump and pressure drop reduced slightly. Additionally, appropriate dosage of walnut shell can improve the shootability of fresh concrete with low rebound rate and larger build-up thickness. In the second series tests, polypropylene (PP) fiber and multi-dimension fiber were also mixed in composite for comparative analysis. After mixing fibers, the splitting tensile strength had obtained marked improvement with slight reduction of compressive strength, along with acceptable fluctuation in terms of pumpability and shootability. Furthermore, relation of density and compressive strength, relation of rebound and density, build-up thickness and relation of compressive and splitting tensile strength were discussed. This study found wet-mix shotcrete incorporating PET fiber with walnut shell of about 35% coarse aggregate replacement could be used for roadway support as lightweight shotcrete per requirements of mine support. Full article