Search Results (165)

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

The alkali–silica reaction (ASR) is an important mechanism of concrete deterioration, whereby reactive silica in aggregate interacts with cement alkalis to form expanding gel, which compromises the structural integrity of the concrete. Although the Republic of Korea has historically been classified as a low-risk region for ASR due to its geological stability, documented examples of concrete damage since the late 1990s have necessitated a rigorous reassessment of local aggregates. This study evaluated the ASR potential of 84 aggregate samples sourced from diverse Korean geological regions using standardized protocols, including ASTM C 1260 for mortar bar expansion and ASTM C 289 for chemical reactivity, supplemented by soundness, acid drainage, and weathering index analyses. The results indicate expansion within the range of 0.1–0.2%, classified as potentially deleterious, for some rock types. In addition to ASR reactivity, isolated high anomalies (e.g., high soundness, acid producing, and weathering) suggest the existence of other durability risks. Consequently, while Korean aggregates predominantly have a low ASR reactivity, the adoption of various validated ASR tests as a routine test and the integration of supplementary cementitious materials are recommended to ensure long-term concrete durability, highlighting the need for sustained monitoring and further investigation into mitigation strategies. Full article

The development of sustainable cementitious materials is crucial to reduce the environmental footprint of the construction industry. Alkali-activated materials (AAMs) have emerged as promising environmentally friendly alternatives; however, their compatibility with natural stone in heritage structures remains poorly understood, especially regarding salt migration and related damage to stones. This study presents a novel methodology for assessing salt movement in solid materials between two types of stones—Boñar and Silos—and two types of binders: blended Portland cement (BPC) and an AAM. The samples underwent capillarity and immersion tests to evaluate water absorption, salt transport, and efflorescence behavior. The capillarity of the Silos stone was 0.148 kg·m⁻²·t^−0.5, whereas this was 0.0166 kg·m⁻²·t^−0.5 for the Boñar stone, a ninefold difference. Conductivity mapping and XRD analysis revealed that AAM-based mortars exhibit a significantly higher release of salts, primarily sodium sulfate, which may pose a risk to adjacent porous stones. In contrast, BPC showed lower salt mobility and different salt compositions. These findings highlight the importance of evaluating the compatibility between alternative binders and heritage stones. The use of AAMs may pose significant risks due to their tendency to release soluble salts. Although, in the current experiments, no pore damage or mechanical degradation was observed, additional studies are required to confirm this. A thorough understanding of salt transport mechanisms is therefore essential to ensure that sustainable restoration materials do not inadvertently accelerate the deterioration of structures, a process more problematic when the deterioration affects heritage monuments. Full article

Significant progress has been made in the low-temperature toughness and crack resistance of polypropylene fiber-reinforced composites. However, there is still a gap in the research on damage evolution under freeze–thaw cycles and complex stress ratios. To solve the problem of durability degradation of traditional rubble masonry in cold regions, this paper focuses on the study of polypropylene fiber-mortar-masonry blocks with different fiber contents. Using acoustic emission and digital image technology, the paper conducts a series of tests on the scaled-down polypropylene fiber-mortar-masonry structure, including uniaxial compressive tests, three-point bending tests, freeze–thaw cycle tests, and tests with different stress ratios. Based on the Kupfer criterion, a biaxial failure criterion for polypropylene fiber mortar-masonry stone (PPF-MMS) was established under different freeze–thaw cycles. A freeze–thaw damage evolution model was also developed under different stress ratios. The failure mechanism of PPF-MMS structures was analyzed using normalized average deviation (NAD), RA-AF, and other parameters. The results show that when the dosage of PPF is 0.9–1.1 kg/m³, it is the optimal content. The vertical stress shows a trend of increasing first and then decreasing with the increase in the stress ratio, and when α = 0.5, the degree of strength increase reaches the maximum. However, the freeze–thaw cycle has an adverse effect on the internal structure of the specimens. Under the same number of freeze–thaw cycles, the strength of the specimens without fiber addition decreases more rapidly than that with fiber addition. The NAD evolution rate exhibits significant fluctuations during the middle loading period and near the damage failure, which can be considered precursors to specimen cracking and failure. RA-AF results showed that the specimens mainly exhibited tensile failure, but the occurrence of tensile failure gradually decreased as the stress ratio increased. Full article

Historical masonry structures deteriorate over time, requiring restoration and strengthening. Hydraulic lime-based mortars (HLMs), due to their compatibility with historical materials, are commonly used for this purpose. This study examines the fire resistance of masonry walls constructed with HLMs. Masonry prisms with clay bricks were prepared using HLMs in accordance with material testing standards. Specimens were subjected to high temperatures ranging from 200 °C to 800 °C, followed by flexural–compression tests for mortar and compression tests for masonry prisms. A total of 20 masonry prism specimens, 15 brick specimens, and 15 mortar specimens were tested, including reference specimens at room temperature. Experimental results indicate that masonry prisms, clay bricks, and HLMs progressively lose their mechanical properties as temperature increases. The elastic modulus of masonry prisms was evaluated according to relevant standards, and Finite Element Analysis (FEA) was conducted to validate temperature-dependent material properties. The stress–strain response of M15 HLM masonry prisms was determined, addressing the absence of such data in EN 1996-1-2. Additionally, compression test results were compared with digital image correlation (DIC) analyses to enhance measurement accuracy. This study provides critical insights into the thermal performance of masonry walls with HLMs, contributing to the development of fire-resistant restoration materials. 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 service status of rail, fasteners and track slabs is the key determinant of whether the ballastless track is ready for traffic after a fire. The track slab rail support bolt anchoring performance and the shoulder service performance damaged by fire were tested. Experiments of ballastless track slab concrete burned at different high temperatures were carried out to compare macro- and microstructural properties of the concrete under high-temperature burning to study the microstructure of hydration products after high-temperature burning and reveal the damage mechanism of the track slab concrete after a fire. The results show that the fire damage to the rail and fastener is mainly deformations, fractures and strength reduction. The degree of the fire damage of the mortar layer and base slab is much lower than that of the track slab. The main fire damage to the concrete is track and base slab cracks, spalling and gaps. The degree of the fire damage to the mortar layer and base slab is much lower than that of the track slab. The fire damage of the track slab concrete is mainly bursts, and the concrete cracks, spalling and deterioration occur layer by layer from the outside to inside. The shoulder injury is the most serious, the shear resistance is greatly reduced, the rail support is protected by the rail and fastener, the impact of the fire damage is small and the bolt anchoring performance was not decreased. The position of the track slab’s inside damage corresponds to the surface damage position. The steel bar inside the track slab is in good condition, and there is no obvious damage. The bulk expansion of the ballastless track concrete was caused by the expansion of aggregates under fire. When the expansion of aggregates is constrained by the shrinkage of hydration products, greater internal stress is generated, which is the main reason for the cracking or bursting of the ballastless track slab concrete under high temperatures. Full article

Asphalt concrete has a unique low-temperature fracture mechanism due to the complex interaction between macro- and micro-cracks. This study investigated the toughening effect of micro-cracks on the crack propagation behavior of asphalt concrete at low temperatures. The Taylor model was applied to establish a modulus damage model of asphalt concrete. In combination with the discrete element method (DEM), a 2D microstructure damage model of asphalt concrete with heterogeneity (aggregate, mortar, and voids) and multi-level (aggregate gradation) characteristics was constructed. A virtual semi-circular bending (SCB) test was performed to reveal the toughening effect of the micro-cracks in terms of macroscopic and microscopic parameters, such as the modulus damage variable, dynamic parameters associated with the main crack propagation, and stress field distribution, laying a foundation for predicting the propagation behavior and path of macroscopic cracks in asphalt concrete. The results showed that (1) the proposed modulus damage model based on the Taylor model produced results that were in good agreement with the numerical simulation (virtual SCB test) results. With an increase in the micro-crack density, the influence of the main cracks on the modulus damage of asphalt concrete gradually reduced, indicating that the micro-cracks exhibited a toughening effect on the main crack propagation; (2) At the meso-scale, the toughening effect of the micro-cracks extended the duration of the crack propagation stage and macro-crack formation stage; that is, the toughening effect of the micro-cracks had a shielding effect on the main crack propagation; (3) The toughening effect could inhibit the shear stress field, contributing to preventing the deterioration in the modulus of asphalt concrete. Full article

Asphalt pavements are subjected to both repeated vehicle loads and erosive deterioration from complicated environments in service. Salt erosion exerts a serious negative impact on the service performance of asphalt pavements in salt-rich areas such as seasonal frozen areas with snow melting and deicing, coastal areas, and saline soils areas. In recent years, the performance evolution of asphalt materials under salt erosion environments has been widely investigated. However, there is a lack of a systematic summary of salt erosion damage for asphalt materials from a multi-scale perspective. The objective in this paper is to review the performance evolution and the damage mechanism of asphalt mixtures and binders under salt erosion environments from a multi-scale perspective. The salt erosion damage and damage mechanism of asphalt mixtures is discussed. The influence of salt categories and erosion modes on the asphalt binder is classified. The salt erosion resistance of different asphalt binders is determined. In addition, the application of microscopic test methods to investigate the salt damage mechanism of asphalt binders is generalized. This review finds that the pavement performance of asphalt mixtures decreased significantly after salt erosion. A good explanation for the salt erosion mechanism of asphalt mixtures can be provided from the perspective of pores, interface adhesion, and asphalt mortar. Salt categories and erosion modes exerted great influences on the rheological performance of asphalt binders. The performance of different asphalt binders showed a remarkable diversity under salt erosion environments. In addition, the evolution of the chemical composition and microscopic morphology of asphalt binders under salt erosion environments can be well characterized by Fourier Infrared Spectroscopy (FTIR), Gel Permeation Chromatography (GPC), and microscopic tests. Finally, the major focus of future research and the challenges that may be encountered are discussed. From this literature review, pore expansion mechanisms differ fundamentally between conventional and salt storage asphalt mixtures. Sulfate ions exhibit stronger erosive effects than chlorides due to their chemical reactivity with asphalt components. Molecular-scale analyses confirm that salt solutions accelerate asphalt aging through light-component depletion and heavy-component accumulation. These collective findings from prior studies establish critical theoretical foundations for designing durable pavements in saline environments. Full article

Recent studies have shown the viability of low-grade calcined clays as a partial substitute for cement in construction applications. However, there is limited information about the performance of low-grade calcined clay in withstanding chloride-rich environments. This paper investigates the durability performance of mortar prepared by partially substituting cement with low-grade calcined clay. Naturally occurring clay having a kaolinite content of 17% was calcined at 900 °C, blended and used to prepare composite cement samples containing up to 40% by weight low-grade calcined clay. Durability studies were conducted using the rapid chloride penetration test (RCPT), freeze and thaw, sorptivity, permeable porosity, ultrasonic pulse velocity (UPV), and autogenous shrinkage. The incorporation of calcined clay resulted in significant improvements in durability properties, including reductions in sorptivity, permeable porosity, and chloride ion penetration. Additionally, enhanced freeze–thaw resistance was observed, indicating the ability of calcined clays to mitigate deterioration under harsh environmental conditions. These improvements in durability translate to extended service life and reduced maintenance requirements for concrete structures. Full article

With increasing service life, concrete durability gradually deteriorates, requiring urgent repair and reinforcement. Conventional cement-based repair materials exhibit disadvantages such as high brittleness, low tensile strength, poor adhesion, and insufficient durability, making them inadequate for high-quality structural repairs. Based on the molecular structure–activity relationship, this study developed a novel waterborne epoxy–cement-based composite repair material using self-synthesized waterborne epoxy resin (WEP). The mechanism by which WEP improves the performance of cement-based materials was elucidated. The results indicate that WEP significantly influenced the early formation of silicate crystals. Furthermore, the addition of WEP enhanced material flexibility and adhesion, achieving flexural strength of 12.9 MPa and direct tensile bond strength of 2.13 MPa at 28 days, representing increases of approximately 30% and 58%, respectively, compared to the control group. Stress–strain curve analysis revealed that the ultimate strain of WEP-modified cement mortar reached 0.024%. SEM analysis revealed that cured WEP formed a dense cross-linked network with cement hydration products. This microstructural modification refined the pore structure, effectively addressing the material’s brittleness, ductility, and durability limitations. Full article

Radiation-shielding concrete, widely used in protective structures because of its effective shielding properties, employs magnetite aggregates to achieve higher compressive strength than conventional concrete. However, prolonged exposure to high temperatures leads to mechanical degradation. This study investigates the thermal evolution of magnetite concrete under microwave heating across varying temperatures (38–800 °C). A microwave oven was utilized for heating, and COMSOL Multiphysics was employed to establish an electromagnetic-thermal-mechanical coupled model, analyzing surface characteristics, temperature distribution, stress-strain behavior, and residual compressive strength. Results indicate that internal temperatures exceed surface temperatures during microwave heating, with a maximum temperature difference surpassing 150 °C at 800 °C. Compressive stresses predominantly arise in the mortar, while tensile stresses concentrate in aggregates and the interface transition zone, causing stress concentration. Mortar exhibits greater deformation than aggregates as temperatures increase. Simulated and experimental residual compressive strengths show strong agreement, with a maximum deviation of 7.58%. The most rapid mechanical deterioration occurs at 450–600 °C, marked by a residual compressive strength decline of 0.07 MPa/°C and the formation of penetrating cracks. Full article

The evaluation of water absorption in concrete is regarded as an important indicator for assessing the causes of its deterioration and durability. Traditionally adopted methods for durability assessment in concrete materials, however, lack in providing real-time monitoring of the absorption process and information about the material deformability at surfaces (volumetric changes) caused by swelling in cement hydrates (i.e., C-S-H). In this study, a one-dimensional water absorption test was performed on small-size mortar specimens of three different strengths, and their top (flattened) surface was continuously monitored for volume changes by utilizing surface strain gauges along with the DICM. After the water absorption test, the same specimens were tested to determine mechanical properties such as compressive strength and Young’s modulus. Moreover, the water absorption characteristics, like depth/rate, were evaluated in DICM by tracing changes in waterfront positions with the progression of strains during the water absorption process in mortars. Additionally, the surface strain gauges confirmed the accuracy of strains evaluated by the DICM. The absorption characteristics obtained from observations in the DICM were correlated with the mechanical properties and expansion strain of the test specimens. The results indicated that the durability properties were not only related to the water absorption rate but also to the mechanical properties and volume changes due to saturation. Full article

The service of reinforced concrete structures (RCSs) in harsh coastal environments is often threatened by chloride corrosion. The penetration of chloride ions through concrete pores into the steel/concrete interface will cause the depassivation and corrosion of steel rebars, which will lead to the deterioration and failure of RCSs durability. It is important to repair and protect the corrosion damage of existing concrete structures and ensure their high durability, and the high performance of repairing and protecting materials is crucial. In this paper, a novel cement-based protective coating material with low porosity, high impermeability and chloride-corrosion resistance was designed and prepared by introducing polypropylene fiber and high-performance cement into commercial cement-based protective materials through the double modification strategy of fiber-toughening and substrate-enhancing, in order to provide a reliable corrosion protection solution for the high durability and long life of RCSs under chloride erosion environment. Based on this, the microstructure and pore structure of the double-modified coating material was systematically analyzed by SEM, XRD, X-CT and other characterization methods. The impermeability and chloride corrosion resistance of this material were scientifically evaluated, and the protection mechanism was systematically discussed. The results show that the impermeability of the double-modified coating material is about 2.8 times higher than that of the untreated mortar. At the same time, the corrosion current density was significantly reduced to 8.60 × 10⁻⁷ A·cm⁻², which was about 86% lower than that of the untreated sample (6.11 × 10⁻⁶ A·cm⁻²). The new cement-based coating material optimized by double-modification effectively inhibits the formation and propagation of microcracks in the protective coating through the bridging effect of fibers. At the same time, the regulation of cement hydration products and the densification of pore structure are realized by adjusting the composition of cement matrix. Based on the above two aspects of microstructure improvement, the chloride-corrosion protection performance of the novel cement-based protective coating material has been greatly improved. Full article

Exposure to elevated temperatures leads to the deterioration of the mechanical properties of cementitious materials. However, the inclusion of fibers can mitigate, to some extent, the negative effects of high temperatures on these materials. Specifically, polypropylene (PP) fibers, a synthetic fiber type, have been demonstrated to improve the performance of cement-based composites. Therefore, it is essential to investigate the impact of temperature on the behavior of fiber-reinforced mortar for its broader application in construction. This study explores the effects of varying PP fiber contents (0%, 0.2%, 0.4%, 0.6%, 0.8%, and 1%) and different temperature exposures (25 °C, 200 °C, 400 °C, 600 °C, 800 °C, and 1000 °C) on the performance of cement mortar. The experimental results show that elevated temperatures significantly degrade both the mechanical and thermal properties of fiber-reinforced mortar. As the temperature and fiber content increase, both the quality and thermal conductivity of the mortar decrease. Between 25 °C and 200 °C, the incorporation of PP fibers (ranging from 0% to 0.2%) significantly enhances the compressive and flexural strengths of the mortar. However, this improvement becomes less pronounced as the fiber content exceeds 0.2%. At temperatures above 200 °C, further increases in temperature, coupled with higher fiber contents, consistently lead to a reduction in the compressive and flexural strengths. Based on the principles of continuous damage mechanics (which describes the degradation and fracture of materials under loading) and the dual-parameter Weibull distribution theory, a constitutive model is proposed to describe the damage behavior of high-temperature PP-fiber-reinforced mortar under uniaxial compressive stress. Full article