Search Results (87)

Concrete is the most used construction material, but its long-term performance depends on durability. Although fly ash has been used as a supplementary cementitious material, the effects of its mechanical activation on the concrete durability require further investigation. This study evaluated the influence of replacing 30% of cement with natural Class F fly ash (NFA) and ground fly ash (GFA) in concrete with a water-to-binder ratio (w/b) of 0.62, using a mixture without fly ash (WFA) as reference. Mechanical activation was performed by milling the fly ash, followed by characterization through particle size analysis and X-ray diffraction. Concrete durability was assessed using electrical resistivity, ultrasonic pulse velocity (UPV), water absorption, porosity, rapid chloride permeability (RCPT), carbonation resistance, and compressive strength tests. Mechanical milling reduced and transformed the ash morphology from spherical to amorphous, while quartz and mullite remained the main crystalline phases. Compared with CNFA, CGFA exhibited up to 101% higher electrical resistivity, 39.6% greater resistance to chloride penetration, 10.8% improved carbonation resistance, 0.4% lower water absorption, and a 5.38% reduction in porosity, although compressive strength decreased by more than 20%. These results demonstrate that mechanically activated fly ash is a viable alternative for enhancing the concrete durability performance exposed to aggressive environments. Full article

Compared with inland areas, coastal fair-faced concrete (CFFC) in coastal environments is subject to more severe environmental erosion during its service life. An inappropriate mix design can lead to the failure of concrete structures. It is therefore necessary to develop appropriate mix designs and conduct research into their performance. The orthogonal method was combined to study the influence laws of four factors, namely water-cement ratio (W/B), cement content (W_C), fly ash content (W_FA), and microbead content (W_BM), on the slump (Sp), mechanical properties (f_c^7d, f_c^28d), and apparent porosity properties (SM) of CFFC. After verification, the durability of CFFC with the optimal ratio was further examined. The results show that the order of influence of each factor on Sp, f_c^7d, f_c^28d, and SM is: W/B > W_C > W_BM > W_FA, W_FA > W/B > W_C > W_BM, W/B > W_C > W_FA > W_BM, W_C > W/B > W_FA > W_BM, respectively. The SF and flowability of CFFC with the optimal ratio are 198 mm and 579 mm, respectively; the corresponding f_c^7d and f_c^28d are 45.06 MPa and 64.03 MPa, respectively; and the maximum pore diameter, surface pore area ratio, and standard deviation of the pore distribution of the optimal CFFC are 2.14 mm, 0.31%, and 1.52 mm, respectively. The 84 d rapid chloride penetration coefficient, 28 d maximum carbonation depth, and 28 d shrinkage of the optimal CFFC are 2.1 × 10⁻¹² m²/s, 5.6 mm, and 405 µε, respectively. When prepared using the optimal mix proportions, CFFC can meet the requirements for high-performance fair-faced concrete projects in coastal areas, thereby providing valuable guidance for the practical applications of CFFC in coastal engineering. Full article

This study develops a rapid-hardening and high-fluidity ultra-high-performance cement (UHPC)-based grout by incorporating calcium sulfoaluminate (CSA) cement as an early strength component, along with steel and wollastonite fibers as hybrid reinforcements. The UHPC grout proportions containing different contents of CSA cement and wollastonite fibers were designed to investigate fluidity, mechanical properties, hydration kinetics, microstructure and chloride resistance. The results showed that both CSA cement and wollastonite fibers significantly enhanced the compressive and flexural strength of UHPC grout. The incorporation of CSA cement led to rapid compressive strengths of 23 MPa at 6 h and 75.9 MPa at 1 day, marking a significant enhancement compared to the reference group and indicating excellent early-age performance. CSA cement accelerated the hydration process of the UHPC grout and promoted formation of more ettringite. Wollastonite fibers and U-type expansive agent (UEA) further improved the mechanical performance through bridging and physical filling effects. Moreover, CSA cement and wollastonite fibers effectively optimized expansion behavior and refined pore structure of the UHPC grout, and improved its chloride penetration resistance. Although both components influenced the fluidity of the grout, the UHPC grout still maintained high fluidity, offering a promising outlook for its potential use in demanding engineering applications. Full article

Ordinary Portland cement (OPC) production contributes approximately 7–8% of global anthropogenic CO₂ emissions, driving urgent demand for clinker-efficient binders utilizing industrial by-products. Flue gas desulfurization (FGD) gypsum and ground granulated blast-furnace slag (GGBFS) represent underutilized industrial by-products with documented potential as supplementary cementitious materials. This study investigates the mechanical, durability and microstructural performance of OPC–GGBFS–FGD gypsum ternary concrete mixtures incorporating untreated flue gas desulfurization (FGD) gypsum at 0–20% of total binder mass and ground granulated blast-furnace slag (GGBFS) at 25–50% of total binder mass in M30 structural concrete (w/b = 0.45). Compressive, split tensile and flexural strengths were evaluated at 7–90 days alongside rapid chloride penetration (RCPT), water absorption, strength efficiency index (SEI) and SEM–EDX analyses. Binary GGBFS replacement progressively enhanced long-term compressive strength, with T35F0 attaining 55.6 N/mm² at 90 days (+33.7% relative to the OPC control). Moderate FGD gypsum contents (5–10%) further enhanced overall performance. Among all mixtures, T50F10 exhibited the best overall performance on the mechanical and durability indicators evaluated, achieving 54.2 N/mm² compressive strength at 90 days together with a rapid chloride permeability value of 410 C, corresponding to ‘Very Low’ chloride ion penetrability. Beyond 10% FGD gypsum, progressive multi-parameter deterioration was observed, and mixtures containing 20% FGD gypsum failed to meet the M30 design requirement at 28 days. SEM–EDX confirmed that optimum sulfate activation produced a dense C–(A)–S–H-rich matrix, while excess sulfate caused matrix disruption. The findings establish 10% FGD gypsum by total binder mass as the optimum sulfate activation threshold for the investigated GGBFS and FGD gypsum sources at w/b = 0.45, and demonstrate the potential of untreated industrial FGD gypsum to produce durable, low-clinker structural concrete. Full article

This study investigates the combined use of fly ash (FA) and plastic waste (PW) as partial replacements for cement and coarse aggregates in the production of paver blocks. Experimental mixes were developed with a substitution level of FA (10% to 30%) and PW (3% to 15%). The performance of the modified concrete block was evaluated in terms of compressive strength (CS), flexural strength (FS), ultrasonic pulse velocity (UPV), water absorption (WA), Cantabro abrasion resistance (CAR), and rapid chloride permeability test (RCPT). Experimental results revealed that the optimal mixture, containing 25% FA and 12% PW (M4), exhibited superior performance. Compared with the control mix, the 56-day compressive and flexural strengths increased by 14.1% and 15.3%, respectively. The UPV value increased to 5.1 km/s, indicating improved concrete quality and matrix densification. Durability performance was significantly enhanced, with water absorption reduced by 25.4%, Cantabro abrasion mass loss decreased by 23.7%, and chloride ion penetrability reduced by 50.0% at 56 days. Statistical analysis using two-way ANOVA confirmed that FA and PW contents significantly influenced paver block performance (p < 0.05). The economic assessment further demonstrated cost savings of up to 3.0% compared with conventional concrete paver blocks. The study demonstrates that FA and PW can be effectively valorized in paver block production, offering both economic and environmental benefits. This green approach supports sustainable construction practices and promotes efficient waste management. Full article

The use of iron tailing powder (ITP) and granulated blast-furnace slag (GBFS) offers a feasible route for preparing low-cement mortar while recycling industrial by-products. In this study, seven cement mortar mixtures were designed to investigate the influence of the ITP–GBFS ratio on mechanical properties, microstructure, hydration products, and chloride ion penetration resistance. The mixtures included plain cement mortar (A0), mortar with 50% ITP (A1), mortar with 50% GBFS (A2), and four composite mixtures (A3–A6) in which ITP and GBFS jointly replaced 50% of cement at different ratios. The results showed that the mixture containing 20% ITP and 30% GBFS (A4) exhibited the best overall performance among the composite mixtures. At 28 d, A4 reached a compressive strength of 51.3 MPa and a flexural strength of 11.0 MPa, exceeding those of the plain cement control. SEM and XRD analyses suggested that the optimized ITP–GBFS combination promoted the formation of poorly crystalline hydration products, such as C–S–H/C–A–S–H gels, and refined the pore structure, resulting in a denser hardened matrix. The rapid chloride migration test showed that the chloride migration coefficient of A4 was 15.47 × 10⁻¹² m²/s, only slightly higher than that of A0, indicating that the optimized composite binder maintained chloride penetration resistance close to that of plain cement mortar while replacing 50% of cement. The results indicate that a properly proportioned ITP–GBFS binder can maintain acceptable strength and chloride resistance while reducing cement consumption. Full article

To balance ultra-early strength development and workable time in cement-based grouting materials for rapid repair applications, an ultra-early high-strength grout system was developed by regulating the dosage of an accelerating agent (CF), retarder content, and water-to-binder ratio (w/b). The effects of these parameters on setting behavior, workability, mechanical properties, volumetric stability, and durability were systematically investigated. X-ray diffraction (XRD) and scanning electron microscopy coupled with energy-dispersive spectroscopy (SEM/EDS) were further conducted to qualitatively evaluate the hydration characteristics and microstructural evolution of the optimized system. The results showed that CF accelerated early hydration and promoted the rapid formation of ettringite (AFt), which contributed to the development of ultra-early strength. The incorporation of a retarder effectively prolonged the workable time and improved slurry workability. Increasing the w/b ratio enhanced flowability and toughness, although excessive w/b reduced compressive strength. The optimal mixture contained 30% CF, 0.02% retarder, and a w/b ratio of 0.19. Under this condition, the grout exhibited a flowability of 312 mm and compressive strengths of 81.4 MPa at 1 h and 121.3 MPa at 28 d. In addition, low air shrinkage (0.027% at 28 d) and excellent chloride penetration resistance (12 C at 28 d) were achieved. Microstructural observations suggested that the dense structure formed by AFt and C–S–H gel contributed to the improved macroscopic performance. This study provides an engineering-oriented reference for the mix design and performance optimization of ultra-early high-strength cement-based grouting materials for rapid repair applications. Full article

The corrosion behavior and time-dependent mechanism of 22MnB5 steel featuring a thinned Al-Si coating (60 g/m²) were systematically investigated in a chloride ion wet–dry cyclic environment, motivated by the demand for thinning and toughening development of aluminum-silicon coatings. A periodic immersion accelerated corrosion test using 3.5% NaCl solution was conducted, together with macro/microscopic morphology observation (SEM/EDS), phase analysis (XRD, FTIR), and electrochemical measurements (polarization curves, EIS). The Al-Si coated steel was studied over corrosion periods of 1, 8, 10, and 20 days to elucidate its corrosion behavior, interfacial evolution, and failure mechanism. The results indicated that the corrosion process exhibited a three-stage evolution: stable protection, rapid failure, and dynamic equilibrium. At the initial stage (1 day), a dense Al₂O₃ passive film formed on the coating surface, providing excellent substrate protection, with a corrosion current density of only 1.77 µA/cm² and a maximum charge-transfer resistance (R₂) of 652 Ω·cm². In the middle stage (8 days), Cl⁻ permeated through the cracked film, triggering selective dissolution of Al, while Si was enriched in situ to form a porous residual layer; the corrosion current density (I_corr) sharply increased to 13.25 µA/cm², and R₂ dropped to its minimum of 156.6 Ω·cm². Corrosion products at this stage were mainly Al₂O₃ and SiO₂, accompanied by small amounts of iron oxyhydroxides and hydroxides, and local coating failure began to appear. During the later stage (10–20 days), the corrosion products evolved into γ-FeOOH, α-FeOOH, and Fe₂O₃, which, together with an amorphous SiO₂ gel network enriched at the interface, formed a dual-layer composite rust layer. R2 consequently recovered from 156.6 Ω·cm² at 8 days to 424 Ω·cm² at 20 days, indicating a reduced corrosion rate and entry into a stable inhibition stage. The critical failure mechanism is that Cl⁻ preferentially penetrates the surface of the Al₂O₃ passive film, disrupting the metastable state of the coating and thereby creating pathways for corrosive media intrusion. The findings of this study can provide technical support for the safe application of such as-received coatings in non-load-bearing components with heat and corrosion resistance requirements. Full article

Concrete remains one of the most extensively utilized construction materials for buildings, bridges, and infrastructure. High-volume fly ash (HVFA) concrete has emerged as a sustainable choice to conventional mixtures, primarily due to its reduced cement demand and enhanced durability. Nevertheless, systematic investigations on the fineness fly ash contributions both for strength growth and durability performance of normal-strength HVFA concrete remain limited. The present study examines the effect of fly ash particle size, employed as a partial cement replacement, on the compressive strength and durability of normal-strength HVFA concrete. In this work, 50% of the cement by weight was substituted with fly ash of two fineness levels: passing sieve No. 200 and sieve No. 400. Twelve specimens were prepared for each mix variation, comprising compressive strength specimens (Ø15 cm × 30 cm) tested at 14, 28, and 56 days, as well as durability specimens assessed using the Rapid Chloride Penetration Test (RCPT) at 56 days. The results demonstrate that finer fly ash markedly improves compressive strength, with the highest value of 36.33 MPa recorded at 56 days for HVFA concrete comprising fly ash passing sieve No. 400. Regarding durability, increased fineness substantially reduced chloride ion ingress, as indicated by a decline in charge passed from 1845 coulombs in normal concrete to 987 coulombs in HVFA concrete with fly ash passing sieve No. 400, corresponding to a classification of very low chloride penetrability. These findings highlight the critical contribution of the fineness of fly ash in optimizing both mechanical performance and durability characteristics of HVFA concrete. Full article

In the rapid chloride migration (RCM) test, the chloride concentration at the chromogenic boundary often differs from the standard value of 0.07 mol/L, leading to an overestimated migration coefficient, especially when the penetration depth is shallow. This study investigates the effect of penetration depth on the measured migration coefficient and proposes a practical correction method. RCM tests were carried out on four concrete mixtures with fly ash and slag under various voltages, two curing ages, and multiple test durations. The results show that the migration coefficient decreases as the penetration depth increases. A simple empirical correction model is introduced, using a chromogenic error ε obtained by fitting the experimental data. After correction, most of the modified migration coefficients fall within ±20% of the true values. The proposed model provides a useful engineering tool for rapid estimation of chloride migration coefficients in field laboratories where direct chloride concentration measurement is not available. Full article

The inherent drying shrinkage of geopolymers restricts their widespread application in concrete crack repair, particularly for medium-to-wide cracks that demand stringent workability and penetrability. This study systematically investigates the effects of three single-component expansive agents (MgO, CaO, and CSA) on the fresh properties, mechanical performance, and microstructural evolution of a slag-fly ash-based geopolymer. The optimal modified formulation was subsequently evaluated for remediating preinduced concrete cracks (2.0, 2.5 and 3.0 mm apertures) and benchmarked against ordinary Portland cement and epoxy resin. The results indicate that while CaO and CSA severely compromise paste fluidity and induce rapid setting, MgO modification provides an exceptional operational window. An 8 wt.% MgO dosage (MG8) induces only a marginal 3.73% reduction in paste fluidity and maintains stable initial and final setting times, thereby preserving excellent workability retention and enabling precise construction scheduling. Microstructural analyses (XRD, SEM, and MIP) reveal that the precipitation of micro expansive Mg(OH)₂ effectively suppresses the 28-day drying shrinkage to 0.23%, while facilitating the attainment of a robust compressive strength of 44.1 MPa and preserving a highly favorable strength development trajectory. In the structural repair phase, the MG8 demonstrated outstanding compressive strength recovery, peaking at 28.80 MPa for 2.0 mm cracks, which significantly outperformed both the cement and epoxy resin repaired groups. Conversely, the epoxy resin repaired specimens exhibited superior splitting tensile strength due to the inherent elongation properties of the flexible macromolecular polymer. Comprehensive durability assessments revealed that the MG8 repair system exhibits exceptional resistance against freeze–thaw cycles and sulfate/chloride attacks, ensuring long-term structural integrity that significantly outperforms conventional materials. Overall, this work presents a viable and durable geopolymer-based alternative to traditional materials, aiming to ensure timely and reliable remediation concrete cracks that do not cause structural damage. Full article

Rapid urban expansion and industrial development have significantly increased waste generation while simultaneously intensifying the demand for construction materials. This dual pressure has accelerated the depletion of natural resources and raised serious environmental concerns. To address these challenges, considerable research efforts have focused on developing sustainable cementitious materials with reduced environmental impact and improved durability performance. One promising approach involves partially substituting Portland cement (PC) with supplementary cementitious materials (SCMs), which can enhance material performance while reducing environmental footprint and production costs. Recently, recycled powder (RP) derived from construction and demolition waste (CDW) has attracted growing attention as a sustainable alternative binder component. This review provides a comprehensive evaluation of the durability performance of Portland cement mortars incorporating RP obtained from concrete waste. Key durability indicators, including water absorption, capillary transport, chloride penetration resistance, freeze–thaw behavior, carbonation resistance, sulfate attack resistance, and drying shrinkage, are critically examined under various activation methods. In addition, the environmental and economic implications associated with RP utilization, including cost efficiency and CO₂ emission reduction potential, are analyzed. The findings provide a structured understanding of RP activation strategies and their effectiveness in improving the durability and sustainability of cement-based materials. Full article

The limitations of conventional cement mortar as a widely used construction material include low tensile capacity, high permeability, and susceptibility to chemical degradation. The increasing demand for durable and sustainable construction materials has led to increased attention in modifying cementitious materials through nanotechnology. This study investigates the influence of nano-silica (NS) and nano-alumina (NA) on the physical, strength-related, and durability characteristics of cement mortar to determine the optimum nanomaterial type and dosage for performance enhancement. Six mortar mixes, in addition to a reference mix, were designed and prepared by adding 1%, 1.5%, and 2% of the cement weight with NS and NA separately, and were evaluated for flowability, setting time, density, porosity, sorptivity, compressive and flexural strength, rapid chloride penetration, acid resistance, and energy-dispersive X-ray spectroscopy analysis. Both NS and NA slightly reduced flowability but enhanced strength and durability. Incorporation of 1.5% NS yielded the highest 28-day compressive strength (95 MPa), around 12% higher than the control mix, whereas 1% NA resulted in the greatest early-age strength gain. Both nanomaterials enhanced matrix densification, leading to reductions in porosity (up to 22%) and chloride permeability (up to 44%) for NS. In summary, these findings demonstrate that NS outperforms NA in terms of reactivity and durability. Optimal dosages were identified as 1.5% for NS and 1% for NA, providing the best balance of workability, mechanical enhancement, and durability improvements. These results highlight the effectiveness of nanomaterial incorporation as a promising approach to developing high-performance, durable cement mortars suitable for advanced infrastructure applications. Full article

In this study, the effects of nanofibrillated cellulose (NFC) on the performance of cementitious composites have been explored. The composite mixtures contained cement that was replaced by 40% slag to prepare a high-performance composite, along with fine aggregate and NFC. The air content reduced drastically in the presence of NFC; hence, air entraining admixture (AEA) was added to maintain the criteria of CSA A23.1. In total, eight mixtures were tested with varying dosages of NFC of 0.25%, 0.5%, and 0.75%, where four mixtures contained AEA. Different properties such as fresh (slump flow, air content), mechanical (compressive strength, tensile strength, flexural strength), and durability (rapid chloride penetration, rapid chloride migration, bulk resistivity, resistance against freeze–thaw) have been investigated to evaluate the effectiveness of NFC with high-volume slag after 7 and 28 days. The microstructure of the composites and the distribution of the nanofibers within the paste are also studied by using SEM images. The results revealed that NFC improved the specimen’s splitting strength, flexural strength, and durability. Splitting tensile strength increased by up to 50% at 0.75% NFC, while flexural strength improved by 162% at 0.5% dosage. A negative impact on the compressive, flexural, and durability properties was observed for the 0.75% dosage of NFC due to fiber agglomeration, whereas the 0.5% dosage exhibited the best overall performance. The optimum NFC dosage is found to be 0.25–0.5% which yields a high-strength and durable composite. This research will provide an understanding of the effect of air concentration and NFC on cementitious composites. Full article

Cementitious composites are heterogeneous porous materials whose pore structure plays a critical role in resistance to chloride-ion penetration. A waterborne nano-silicate-based densifier (CF-S5) was used to examine its influence on the pore structure and resistance to the chloride ion penetration of mortar. We investigated the resistance to the chloride ion penetration of mortar with added CF-S5 admixture through the Rapid Chloride Permeability Test (RCPT). We investigated the pore structure characteristics of mortar by mercury intrusion porosimetry (MIP) coupled with fractal theory and investigated the degree of hydration of the cement paste by thermogravimetric analysis (TG). Ultimately, the degree of correlation between multifractal parameters and the chloride ion migration coefficient of mortar was examined using gray relational analysis (GRA). Results indicate that the CF-S5 admixture reduces mortar porosity and the content of harmful pores while increasing pore tortuosity, thus improving the resistance to the chloride ion penetration of mortar. Multifractal analysis indicated that the CF-S5 admixture decreased the connectivity and increased the complexity of the mortar pore structure. The CF-S5 admixture did not reduce the hydration degree of cement paste at 28 d. Additionally, the multifractal parameters show a high gray relational degree with the chloride migration coefficient; therefore, they may serve as potential indicators to reflect the resistance to the chloride ion penetration of mortar. Full article