Search Results (13)

The presented research is focused on the development and testing of the magnesium potassium phosphate cement-based materials (MKPC-based). Firstly, the fresh state properties of the pastes consisting of dead burned magnesia powder, potassium dihydrogen phosphate, setting retarder borax applied in the range of 0–10 wt.%, and batch water were investigated. The aim of testing was to characterize the hydration process in dependence on the borax content. The properties of raw MgO powder were described by chemical composition and particle size distribution. The properties tested in fresh state included shear stress (viscosity), Young’s modulus of elasticity, and temperature; their time dependence was observed. The measurements started immediately after the mixing process. At the age of 14 days, basic structural and mechanical properties of the hardened pastes were obtained. The mixture with 5 wt.% of borax proved to be the most advantageous in terms of setting time, sample integrity, and mechanical strength; therefore, it was chosen as the binder for the following part of the study—MKPC-based mortar development. In the next step, the MKPC paste containing 5 wt.% of borax was supplemented by silica sand aggregate, and the resulting material was marked as a reference. Subsequently, three other mixtures were derived by replacing 100% of quartz sand by lightweight aggregate; namely by expanded glass aggregate, waste rubber from tires, and combination of both in ratio 1:1. The aggregates were characterized by chemical composition (except for the rubber granulate), and loose and compacted powder density. For the resulting hardened composites, basic structural, hygric, strength, and thermal parameters were investigated. The use of lightweight aggregates brought in a considerable decrease in heat transport parameters and low water permeability while maintaining sufficient strength. The favorable obtained material properties are underscored by the fact that magnesia-phosphate is considered to be a low-carbon binder. The combination of magnesia-phosphate binder and recycled aggregate provides a satisfying, environmentally friendly, and thermally efficient alternative to traditional Portland cement-based materials. Full article

The article is devoted to the development of resource-saving technology of porous granular materials for energy-efficient construction. The relevance of the work for international research is to emphasize expanding the raw material base of porous lightweight concrete aggregates at the expense of technogenic and substandard materials. The work aims to study the processes of porization of glass crystalline granules from polymineral raw materials mixtures. The novelty of the work lies in the establishment of regularities of thermal foaming of glass crystalline granules when using waste of magnetic separation of skarn-magnetite (WMS) ores and lignite clay. Studies of liquid glass mixtures with various mineral fillers revealed the possibility of the formation of a porous structure with the participation of opoka, WMS and lignite clay. This is due to the presence in the materials of substances that exhibit thermal activity with the release of a gas phase. The foaming efficiency of the investigated materials increases when combined with glass breakage. The addition of WMS and lignite clay to the glass mixture increases the pore size in comparison with foam glass. The influence of the composition of raw mixtures on the molding and stability of granules is determined. The addition of sodium carbonate helps to strengthen the raw granules and reduce the softening temperature of the mass. The composition of the molding mixture of glass breakage, liquid glass and a multicomponent additive is developed, which provides an improvement in the molding properties of the glass mass, foaming of granules at a temperature of 750 °C. Foam glass crystalline granules have polymodal porosity, characterized by a density of 330–350 kg/m³, a compressive strength of 3.2–3.7 MPa, and a thermal conductivity of 0.057–0.061 W/(m·°C). Accordingly, the developed granules have a high potential use in structural and heat-insulating concretes. Full article

Predicting the properties of concrete before its design and application process allows for refining and optimizing its composition. However, the properties of lightweight concrete are much harder to predict than those of normal weight concrete, especially if the forecast concerns the insulating properties of concrete with artificial lightweight aggregate (LWA). It is possible to use porous aggregates and precisely modify the composition of lightweight concrete (LWC) with specific insulating properties. In this case, it is advisable to determine the parameters of the components and perform preliminary laboratory tests, and then use theoretical methods (e.g., artificial neural networks (ANNs) to predict not only the mechanical properties of lightweight concrete, but also its thermal insulation properties. Fifteen types of lightweight concrete, differing in light filler, were tested. Lightweight aggregates with different grain diameters and lightweight aggregate grains with different porosity were used. For the tests, expanded glass was applied as a filler with very good thermal insulation properties and granulated sintered fly ash, characterized by a relatively low density and high crushing strength in the group of LWAs. The aim of the work is to demonstrate the usefulness of an ANN for the determination of the relationship between the selection of the type and quantity of LWA and porosity, density, compressive strength, and thermal conductivity (TC) of the LWC. Full article

Geopolymer concrete (GC) is a substantial sort that is created by utilizing metakaolin, ground granulated blast furnace slag (GGBS), silica fumes, fly ash, and other cementitious materials as binding ingredients. The current study concentrated on the structural behavior of the ferrocement geopolymer HSC-columns subjected to axial loading and produced using rice straw ash (RSA). The major goal of this research was to use the unique features of the ferrocement idea to manufacture members that function as columns bearing members. As they are more cost-effective and lower in weight, these designed elements can replace traditional RC members. The study also intended to reduce the cost of producing new parts by utilizing low-cost materials such as light weight expanded and welded wire meshes, polyethylene mesh (Tensar), and fiber glass mesh. For this purpose, an experimental plan was conducted and a finite element prototype with ANSYS2019-R1 was implemented. Nine geopolymer ferrocement columns of dimensions of 150 mm × 150 mm × 1600 mm with different volume-fraction and layers as well as a number of metallic and nonmetallic meshes were examined under axial compression loading until failure. The performance of the geopolymer columns was examined with consideration to the mid-span deflection, ultimate failure load, first crack load with various phases of loading, the cracking patterns, energy absorption and ductility index. Expanded or welded ferrocement geopolymer columns showed greater ultimate failure loads than the control column. Additionally, using expanded or welded columns had a considerable effect on ultimate failure loads, where the welded wire mesh exhibited almost 28.10% compared with the expanded wire mesh. Columns reinforced with one-layer of nonmetallic Tensar-mesh obtained a higher ultimate failure load than all tested columns without concrete cover spalling. The analytical and experimental results were in good agreement. The results displayed an accepted performance of the ferrocement geopolymer HSC-columns. Full article

The subject matter of the work presented here is the development and evaluation of novel lightweight mortars that meet the functional and technical criteria imposed on repair mortars. In a broad experimental campaign, lime, natural hydraulic lime, and lime–cement mortars were designed and tested. Lightweight aggregate, expanded perlite, granules from expanded glass and zeolite were used as full replacements for quartz sand. The hardened mortars were tested at the ages of 28 days and 90 days. The conducted tests and analyses were focused on the assessment of structural, mechanical, hygric and thermal parameters. The salt crystallization resistance and effect of salt presence on the hygroscopicity of the investigated mortars were also investigated. The use of lightweight aggregates in the composition of mortars resulted in their high porosity, low density, satisfactory mechanical parameters, improved water vapor transmission capability and water absorption. The mortars with expanded perlite and glass granulate were ranked among thermal insulation mortars of classes T1 and T2, respectively. The use of lightweight aggregates enabled the development of mortars with great durability in terms of salt action, which was almost independent of binder type. The ability to accommodate water vapor was increased by the effect, i.e., the use of lightweight aggregates and the presence of salt in mortars increased porous space. Taking into account the compatibility, functional, and technical criteria, lime- and natural hydraulic lime-based lightweight mortarswere classified as repair mortars, providing improved thermal performance. The lime–cement lightweight plasters can be recommended only for repair of building structures where cement and lime–cement materials were original applied. Full article

This study addresses the application of polyvinyl alcohol (PVA) fibers to improve the performance of lightweight cement composites with pozzolans. Blended cement mixes based on expanded glass granules were modified with PVA fibers (Type A: Ø40 µm, L = 8 mm and Type B: Ø200 µm, L = 12 mm). The following research methods were used to analyse the effect of the fibers on the structure of cement matrix and physical-mechanical properties of lightweight composite: SEM, XRD, DTG, calorimetry tests, and standard test methods of physical and mechanical properties. Results from the tests showed that a denser layer of hydrates was formed around the PVA fiber and the amounts of portlandite, CSH, and CASH formed in the specimens with PVA were found to be higher. PVA fibers of Type A accelerated hydration of the cement paste, slightly increased the compressive strength of the lightweight composite, but had no significant effect on the values of density, ultrasonic pulse velocity and flexural strength. The shrinkage of cement composite was significantly reduced using both types of PVA fiber and both types of PVA fibers increased the fracture energy of lightweight cement composite with expanded granules. Full article

This study focuses on the development of an alkali-activated lightweight foamed material (AA-LFM) with enhanced density. Several mixes of tungsten waste mud (TWM), grounded waste glass (WG), and metakaolin (MK) were produced. Al powder as a foaming agent was added, varying from 0.009 w.% to 0.05 w.% of precursor weight. Expanded granulated cork (EGC) particles were incorporated (10% to 40% of the total volume of precursors). The physical and mechanical properties of the foamed materials obtained, the effects of the amount of the foaming agent and the percentage of cork particles added varying from 10 vol.% to 40% are presented and discussed. Highly porous structures were obtained, Pore size and cork particles distribution are critical parameters in determining the density and strength of the foams. The compressive strength results with different densities of AA-LFM obtained by modifying the foaming agent and cork particles are also presented and discussed. Mechanical properties of the cured structure are adequate for lightweight prefabricated building elements and components. Full article

In this paper, light burned magnesia dispersed in the magnesium chloride solution was used for the manufacturing of magnesium oxychloride cement-based composites which were lightened by granulated scrap tires and expanded glass. In a reference composite, silica sand was used only as filler. In the lightened materials, granulated shredded tires were used as 100%, 90%, 80%, and 70% silica sand volumetric replacement. The rest was compensated by the addition of expanded glass granules. The filling materials were characterized by particle size distribution, specific density, dry powder density, and thermal properties that were analyzed for both loose and compacted aggregates. For the hardened air-cured samples, macrostructural parameters, mechanical properties, and hygric and thermal parameters were investigated. Specific attention was paid to the penetration of water and water-damage, which were considered as crucial durability parameters. Therefore, the compressive strength of samples retained after immersion for 24 h in water was tested and the water resistance coefficient was assessed. The use of processed waste rubber and expanded glass granulate enabled the development of lightweight materials with sufficient mechanical strength and stiffness, low permeability for water, enhanced thermal insulation properties, and durability in contact with water. These properties make the produced composites an interesting alternative to Portland cement-based materials. Moreover, the use of low-carbon binder and waste tires can be considered as an eco-efficient added value of these products which could improve the environmental impact of the construction industry. Full article

High requirements for the properties of construction materials and activities directed at environment protection are reasons to look for new solutions in concrete technology. This research was directed at solutions affecting the reduction of energy consumption and CO₂ emissions. The use of lightweight concretes (LWCs) allows one to meet both conditions at the same time. The purpose of the research presented in this paper was to investigate the abilities of using lightweight aggregates (LWAs) of the following types: 2 and 4 mm granulated expanded glass aggregate (GEGA) as ingredients with excellent insulating properties and 8 mm granulated fly ash aggregate (GAA) as an ingredient with a relatively high resistance to crushing. The influence of the percentage participation of each aggregate in all LWCs was variable and amounted to 0%, 25%, 50%, 75%, and 100%. A series of 15 LWC mixes were prepared for various LWA participations and for a constant water–cement ratio (w/c = 0.5). Concrete tests were carried out for the following criteria: density, porosity, compressive strength, and the modulus of elasticity. In order to fully analyze fracture processes in LWCs with the participation of GEGA and GAA and to assess the correctness of the results obtained during the experiments, numerical models that corresponded to both geometrical and load diagrams of elements under research were created. The numerical analyses of the LWCs were conducted by means of the conventional finite element method (FEM). Full article

Global economic growth causes an increase in natural resources exploitation, particularly in construction branch. The growing use of electricity contributes to climate change. Therefore, it is necessary to search the solutions, which will allow for reducing natural resources exploitation. One of the many opportunities to do that is the application of the recycled materials. The authors of the given article have analyzed three variants of construction solutions. One of them was the production of the walls of a building from reinforced concrete prefabricates with styrofoam insulation layer. The second variant for analysis were prefabricated walls from lightweight concrete, made of sintered clay aggregate with a foam core. The third proposed variant was a system of multi-layered walls, which was made of lightweight concrete with granulated expanded glass aggregate (GEGA). The main objective of the research was to assess the use of lightweight GEGA prefabricates, focusing on economic and technological aspects of the solution. The authors have analyzed the entire construction costs; ceilings and stairs were assumed as reinforced concrete elements. In calculations, the weight of the elements was taken into account, as well as transportation and mounting costs. On the basis of this cost analysis, it was concluded that the use of prefabricated element, made of lightweight concrete with GEGA, could be a replacement for the solutions, widely applied until these days. The analysis has also shown that the use of prefabricates with GEGA is sensible from the economic viewpoint, as it allows for saving construction time. Moreover, the solutions, proposed here, allow for saving natural resources and assuming a more environmentally friendly and caring attitude. Full article

The purpose of the research was to assess the possibility of using granulated expanded glass aggregate (GEGA) with cement grout as a replacement of a sub-grade and frost-protection layer, made of natural fine aggregates (NATU), stabilized with a hydraulic binder. Instead of traditional parts of the road construction, such as the sub-grade and frost-protection layer with the application of fine aggregate, stabilized with cement, the authors propose only one layer, made of lightweight water-permeable material, containing GEGA with a grain size from 8 to 11.2 mm. In the article the authors present the physical properties of the materials, applied for the road layers, the properties of the fine aggregate, stabilized with cement, and those of the cement composite with GEGA as an alternative solution. The laboratory test results of fine aggregates, stabilized with cement and of cement composites with GEGA, are presented. Porosity, volume density, compressive strength, and frost resistance are being researched. The results of those tests are meant to play an essential role in designing the thickness of road layers. Different types of pavement structure (asphalt and concrete) and different values of road load are being considered in the given work. The paper is concluded with considerations on an innovative solution, involving the use of ecological materials. Full article

Lightweight concrete (LWC) is a group of cement composites of the defined physical, mechanical, and chemical performance. The methods of designing the composition of LWC with the assumed density and compressive strength are used most commonly. The purpose of using LWC is the reduction of the structure’s weight, as well as the reduction of thermal conductivity index. The highest possible strength, durability and low thermal conductivity of construction materials are important factors and reasons for this field’s development, which lies largely in modification of materials’ composition. Higher requirements for construction materials are related to activities aiming at environment protection. The purpose of the restrictions is the reduction of energy consumption and, as a result, the reduction of CO₂ emission. To limit the scope of time-consuming and often high-cost laboratory works necessary to calibrate models used in the test methods, it is possible to apply Artificial Neural Networks (ANN) to predict any of the concrete properties. The aim of this study is to demonstrate the applicability of this tool for solving the problems, related to establishing the relation between the choice of type and quantity of lightweight aggregates and the porosity, bulk density and compressive strength of LWC. For the tests porous lightweight Granulated Expanded Glass Aggregate (GEGA) and Granulated Ash Aggregate (GAA) have been used. Full article

Lightweight aggregate concrete is a material with very low density and good thermal insulation, and several types of lightweight aggregates have been used for lightweight concrete. Since the characteristics of lightweight aggregates strongly affect the properties of lightweight concrete, a proper consideration for the use of lightweight aggregate is very important for development of lightweight materials. In particular, the sizes and spatial distributions of lightweight aggregates can influence the material responses of lightweight concrete, such as compressive strength and thermal conductivity. In this study, different types of gradings of lightweight aggregates are adopted to investigate the effect of gradings on the material properties. Liaver ${}^{\circledR }$ , an expanded glass granulate, is used as a lightweight aggregate for the specimens. Virtual models of the lightweight specimens with different gradings are numerically generated, and both mechanical and thermal properties are evaluated using experimental and numerical approaches for more detailed investigation. The obtained results can be utilized to suggest an optimal grading that satisfies both the mechanical and thermal properties of lightweight concrete specimen. Full article