Search Results (96)

The sustainable valorization of electrolytic manganese residue (EMR) and fly ash (FA) presents critical environmental challenges. This study systematically investigates the performance optimization of EMR-FA ceramic composites through the coordinated regulation of raw material ratios, sintering temperatures, and additive effects. While the composite with 85 g FA exhibits the highest mechanical strength, lowest porosity, and minimal water absorption, the formulation consisting of 45 wt% EMR, 40 wt% FA, and 15 wt% kaolin is identified as a balanced composition that achieves an effective compromise between mechanical performance and solid waste utilization efficiency. Sintering temperature studies revealed temperature-dependent property enhancement, with controlled sintering at 1150 °C preventing the over-firing phenomena observed at 1200 °C while promoting phase evolution. XRD-SEM analyses confirmed accelerated anorthite formation and the morphological transformations of FA spherical particles under thermal activation. Additive engineering demonstrated that 8 wt% CaO addition enhanced structural densification through hydrogrossular crystallization, whereas Na₂SiO₃ induced sodium-rich calcium silicate phases that suppressed anorthite development. Contrastingly, ZrO₂ facilitated zircon nucleation, while TiO₂ enabled progressive performance enhancement through amorphous phase modification. This work establishes fundamental phase–structure–property relationships and provides actionable engineering parameters for sustainable ceramic production from industrial solid wastes. Full article

This research evaluates the mechanical properties, environmental impacts, and cost-effectiveness of Hub Coal fly ash (FA)-based geopolymer concrete (FAGPC) as a sustainable alternative to ordinary Portland cement (OPC) concrete. This local FA has not been investigated previously. A total of 24 FAGPC mixes were tested under both ambient and heat curing conditions, varying the molarities of sodium hydroxide (NaOH) solution (10-M, 12-M 14-M and 16-M), sodium silicate to sodium hydroxide (Na₂SiO₃/NaOH) ratios (1.5, 2.0, and 2.5), and alkaline activator solution to fly ash (AAS/FA) ratios (0.5 and 0.6). The test results demonstrated that increasing NaOH molarity enhances the compressive strength (CS.) by 145% under ambient curing, with a peak CS. of 32.8 MPa at 16-M NaOH, and similarly, flexural strength (FS.) increases by 90% with a maximum FS. of 6.5 MPa at 14-M NaOH. Conversely, increasing the Na₂SiO₃/NaOH ratio to 2.5 reduced the CS. and FS. of ambient-cured specimens by 12.5% and 10.5%, respectively. Microstructural analysis revealed that higher NaOH molarity produced a denser, more homogeneous matrix, supported by increased Si–O–Al bond formation observed through energy-dispersive X-ray spectrometry. Environmentally, FAGPC demonstrated a 35–40% reduction in embodied CO₂ emissions compared to OPC, although the production costs of FAGPC were 30–35% higher, largely due to the expense of alkaline activators. These findings highlight the potential of FAGPC as a low-carbon alternative to OPC concrete, balancing enhanced mechanical performance with sustainability. New, green, and cheap activation solutions are sought for a new generation of more sustainable and affordable FAGPC. Full article

This study focuses on the development of high-performance composite cementitious materials for offshore engineering applications, addressing the critical challenges of durability, environmental degradation, and carbon emissions. By incorporating polycarboxylate superplasticizers (PCE) and combining fly ash (FA), ground granulated blast furnace slag (GGBS), and silica fume (SF) in various proportions, composite mortars were designed and evaluated. A series of laboratory tests were conducted to assess workability, mechanical properties, volume stability, and durability under simulated marine conditions. The results demonstrate that the optimized composite exhibits superior performance in terms of strength development, shrinkage control, and resistance to chloride penetration and freeze–thaw cycles. Microstructural analysis further reveals that the enhanced performance is attributed to the formation of additional calcium silicate hydrate (C–S–H) gel and a denser internal matrix resulting from secondary hydration. These findings suggest that the proposed material holds significant potential for enhancing the long-term durability and sustainability of marine infrastructure. Full article

The utilization of steel slag (SS), fly ash (FA), and ground granulated blast furnace slag (GGBFS) as soil additives in construction represents a critical approach to achieving resource recycling of these industrial by-products. This study aims to activate the SS-FA-GGBFS composite with a NaOH solution and Na₂CO₃ and employ the activated solid waste blend as an admixture for lateritic clay modification. By varying the concentration of the NaOH solution and the dosage of Na₂CO₃ relative to the SS-FA-GGBFS composite, the effects of these parameters on the activation efficiency of the composite as a lateritic clay additive were investigated. Results indicate that the NaOH solution activates the SS-FA-GGBFS composite more effectively than Na₂CO₃. The NaOH solution significantly promotes the depolymerization of aluminosilicates in the solid waste materials and the generation of Calcium-Silicate-Hydrate and Calcium-Aluminate-Hydrate gels. In contrast, Na₂CO₃ relies on its carbonate ions to react with calcium ions in the materials, forming calcium carbonate precipitates. As a rigid cementing phase, calcium carbonate exhibits a weaker cementing effect on soil compared to Calcium-Silicate-Hydrate and Calcium-Aluminate-Hydrate gels. However, excessive NaOH leads to inefficient dissolution of the solid waste and induces a transformation of hydration products in the modified lateritic clay from Calcium-Silicate-Hydrate and Calcium-Aluminate-Hydrate to Sodium-Silicate-Hydrate and Sodium-Aluminate-Hydrate, which negatively impacts the strength and microstructural compactness of the alkali-activated solid waste composite-modified lateritic clay. Full article

The aim of this work is to investigate the effect of curing temperature and time on the development of compressive strength in geopolymer mortars produced using ground granulated blast-furnace slag (GGBFS) and fly ash (FA). Considering curing circumstances, both the activation energy and the reference temperature could be used properly to build a reliable anticipated model for predicting the compressive strength of geopolymer-based products (mortar and concrete) using maturity-based techniques. In this study, the compressive strength development of geopolymer mortar made from (FA) and (GGBFS) under varying curing conditions. The mortar was prepared using an alkali solution of sodium hydroxide (NaOH) and sodium silicate (Na₂SiO₃) in a 1:1 ratio, with NaOH molarity of 12. Specimens were cast following ASTM C109 standards, with a binder/sand ratio of 1:2.75, and compacted for full densification. FA-based mortar was cured at 40 °C, 80 °C, and 120 °C, while GGBFS-based mortar was cured at 5 °C, 15 °C, and 40 °C for durations of 0.5 to 32 days. Compressive strength was evaluated at each curing period, and data were analyzed using ASTM C1074 procedures alongside a computational model to determine the best-fit datum temperature and activation energy. The Nurse-Saul maturity method and Arrhenius equation were applied to estimate the equivalent age and maturity index of each mix. A predictive model was developed for geopolymer concrete prepared at an alkali-to-binder ratio of 0.45 and NaOH molarity of 12. The final equation demonstrated high accuracy, offering a reliable tool for predicting geopolymer strength under diverse curing conditions and providing valuable insights for optimizing geopolymer concrete formulations. Full article

Alkali-activated binders (AAB) are a suitable and sustainable alternative to ordinary Portland cement (OPC), with reductions in natural resource usage and environmental emissions in regions where the necessary industrial residues are available. Despite its potential, the lack of mix design methods still limits its applications. This paper proposes a systematic parametric validation for AAB mix design applied to pastes and concretes, valorizing steel slag as precursors. The composed binders are based on coal fly ash (FA) and Basic Oxygen Furnace (BOF) steel slag. These precursors were activated with sodium silicate (Na₂SiO₃) and sodium hydroxide (NaOH) alkaline solutions. A parametric investigation was performed on the mix design parameters, sweeping the (i) alkali content from 6% to 10%, (ii) silica modulus (SiO₂/Na₂O) from 0.75 to 1.75, and (iii) ash-to-slag ratios in the proportions of 75:25 and 50:50, using parametric intervals retrieved from the literature. These variations were analyzed using response surface methodology (RSM) to develop a mechanical model of the compressive strength of the hardened paste. Flowability, yield stress, and setting time were evaluated. Statistical analyses, ANOVA and the Duncan test, validated the model and identified interactions between variables. The concrete formulation design was based on aggregates packing analysis with different paste contents (from 32% up to 38.4%), aiming at self-compacting concrete (SCC) with slump flow class 1 (SF1). The influence of the curing condition was evaluated, varying with ambient and thermal conditions, at 25 °C and 65 °C, respectively, for the initial 24 h. The results showed that lower silica modulus (0.75) achieved the highest compressive strength at 80.1 MPa (28 d) for pastes compressive strength, densifying the composite matrix. The concrete application of the binder achieved SF1 fluidity, with 575 mm spread, 64.1 MPa of compressive strength, and 26.2 GPa of Young’s modulus in thermal cure conditions. These findings demonstrate the potential for developing sustainable high-performance materials based on parametric design of AAB formulations and mix design. Full article

Solid waste-based cementitious materials (SWBC) are composed of steel slag (SS), granulated blast furnace slag (GBFS), fly ash (FA), desulfurization gypsum (DG), and Portland cement (PC). Currently, SWBC holds great potential as a sustainable building material; however, its low early compressive strength and volume expansion limit its range of application. Therefore, the main objective of this study is to enhance the mechanical properties and dimensional stability of SWBC by adding nano-SiO₂, while also improving its resistance to chloride ions, thereby promoting its use in the field of sustainable building materials. A comprehensive experimental approach integrating mechanical performance testing, shrinkage analysis, and chloride diffusion coefficient evaluation was established, with the testing methods of thermogravimetric analysis-differential scanning calorimetry (TG-DSC), X-ray diffraction (XRD), and scanning electron microscopy (SEM). The study found that adding nano-SiO₂ enhanced the nucleation of calcium silicate hydrates (C-S-H) gel in hydrated SWBC, leading to improved compressive strength and reduced chloride permeability when SiO₂ addition was 0.5%. When the hydration period extends to 28 days, the modified SWBC achieves a compressive strength of 56 MPa. However, excessive nano-SiO₂ (≥1%) inhibited the long-term hydration of SWBC but had no significant effect on the final compressive strength. Full article

The incorporation of industrial by-products such as fly ash (FA) into cementitious materials plays a vital role in promoting environmental sustainability during cement production. This study evaluates the feasibility of using siliceous fuel fly ash, sourced from thermal power stations in the Rhenish region of Germany, as a partial cement replacement in mortar formulations. Mortar specimens with FA replacement levels ranging from 5 wt% to 30 wt% were prepared and tested. Data were collected through standardized laboratory testing of mechanical properties (compressive and flexural strength), physical characteristics (porosity, sorptivity) and microstructural analysis via SEM and XRD. The results showed that increasing FA content generally led to reductions in strength and increases in porosity and sorptivity, due to the mineralogical composition and higher water demand linked to the porous FA structure. However, when FA was used at levels not exceeding 10 wt%, the physical and mechanical properties remained within acceptable limits for construction applications. Additionally, the use of plasticizing admixtures proved effective in mitigating workability and strength issues by reducing the water-to-binder ratio. These findings highlight that, despite certain limitations, siliceous FA can be safely and effectively used in low percentages, contributing to sustainable mortar production and reducing reliance on Portland cement. In addition, the use of fly ash contributes to reduced CO₂ emissions and lower production costs, promoting sustainable and cost-efficient construction solutions. Full article

Considering the urgent need for sustainable construction materials, this study investigates the mechanical and microstructural responses of novel hybrid geopolymer concrete blends incorporating Fly Ash (FA), Ground Granulated Blast Furnace Slag (GGBS), Cement (C) and Precipitated Silica (PS) as partial replacements for traditional cementitious materials. The motive lies in reducing CO₂ emissions associated with Ordinary Portland Cement (OPC). The main aim of the study was to optimise the proportions of industrial wastes for enhanced performance and sustainability. The geopolymer mixes were activated using a 10 M sodium hydroxide (NaOH)—Sodium Silicate (Na₂SiO₃) solution and cast into cubes (100 mm), cylinders (100 mm × 200 mm) and prism specimens for compressive, split tensile and flexural strength testing, respectively. Six combinations of mixes were studied: FA/C (50:50), GGBS/C (50:50), FA/C/PS (50:40:10), FA/GGBS/PS (50:40:10), GGBS/C (50:50) and GGBS/FA/PS (50:40:10). The results indicated that the blend with 50% FA, 40% GGBS and 10% PS exhibited higher strength. Mixes with GGBS and PS presented a l0 lower slump due to rapid setting and higher water demand, while GGBS-FA-cement mixes indicated better workability. GGBS/C exhibited a 24.6% rise in compressive strength for 7 days, whereas FA/C presented a 31.3% rise at 90 days. GGBS/FA mix indicated a 35.5% strength drop from 28 days to 90 days. SEM and EDS analyses showed that FA-rich mixes had porous microstructures, while GGBS-based mixes formed denser matrices with increased calcium content. Full article

The usage of geopolymer-based materials (GPBMs) in concrete structures has been broadly promoted by the current construction sector. GPBMs have an outstanding influence on enhancing concrete mechanical properties. Geopolymers (GPs) also have a potential impact on reducing the carbon dioxide emissions emitted by the current cement production procedure. Therefore, this paper aims to evaluate the impact of some variables that affect green and mechanical properties of fly ash-based geopolymer concretes (FA–GPCs), i.e., different silica fume (SF) contents, alkaline activator solution (AAS) percentages, sodium silicate-to-sodium hydroxide (SS/SH) ratios, sodium hydroxide (NaOH) molarity, and additional water. A slump test was used to evaluate the concrete workability to assess the green properties of the designed fly ash-geopolymer concrete mixes (FA–GPCMs). The 14- and 28-day compressive strengths were used to evaluate the concrete’s mechanical properties. Results indicate that the workability of prepared FA–GPCMs reduced with improving SF content (5% to 30%), SS/SH ratio (1% to 3%), and NaOH molarity (10 M to 16 M), while reducing alkaline activator percentages to 35% resulted in a decrease in the FA–GPCMs’ workability. Also, increasing SF replacement percentages from 5% to 15% in FA–GPCMs resulted in significant 14- and 28-day FA–GP compressive strength enhancements compared to FA–GPCM produced with 0% SF, while SF contents of 20%, 25%, and 30% led to a decline in the 14- and 28-day FA–GPC compressive strength compared to that of G1–SF15%. Full article

This study evaluates the influence of multiwall carbon nanotubes (MWCNTs), reduced graphene oxide (rGO), and magnesium oxide (MgO) on the thermal conductivity of alkali-activated engineered composites (AAECs). Thirty-two ambient-cured AAECs consisting of two types of powdered-form reagents/activators (type 1—calcium hydroxide: sodium meta silicate = 1:2.5; type 2—calcium hydroxide: sodium sulfate 2.5:1), two dosages of MgO (0 and 0.5%) of MgO, three percentages (0, 0.3%, and 0.6%) of MWCNTs/rGO, and binary (45% ground granulated blast furnace slag ‘GGBFS’ and 55% Class C fly ash ‘FA-C’) and ternary combinations (40% GGBFS, 25% FA-C and 35% class F fly ash ‘FA-F’) of industrial-waste-based source materials, silica sand, and polyvinyl alcohol (PVA) fiber were developed using the ‘one-part dry mix’ technique. Problems associated with the dispersion and agglomeration of nanomaterials during production were avoided through the use of defined ultra-sonication with a high-shear mixing protocol. The impact of the combination of source materials, activators, and MgO/MWCNT/rGO dosages and their combinations on the thermal properties of AAECs is evaluated and discussed based on temperature–time history and thermal conductivity/diffusivity properties along with micro-structural characteristics. It was found that the change in temperature of the AAECs decreased during testing with the addition of MWCNTs/rGO/MgO. The thermal conductivity and diffusivity of AAECs increased with the increase in MWCNT/rGO/MgO contents due to the formation of additional crystalline reaction products, improved matrix connectivity, and high conductivity of nanomaterials. MWCNT AAECs showed the highest thermal conductivity of 0.91–1.26 W/mK with 49% enhancement compared to control AAECs followed by rGO AAECs. The study confirmed the viability of producing MgO/MWCNT/rGO-incorporated AAECs with enhanced thermal properties. Full article

A major challenge in modern infrastructure is the excessive reliance on traditional Portland cement, which contributes significantly to environmental degradation and durability issues. This study addresses the need for sustainable and durable construction materials by investigating geopolymer concrete as an eco-friendly alternative, optimizing its mechanical and microstructural properties to enhance long-term performance in infrastructure applications. The performance of sustainable geopolymer concrete made with silica fume (SF) and fly ash (FA) and utilizing different alkaline activators (AAs) was examined in this study. The alkaline activators included sodium hydroxide (SH), potassium hydroxide (PH), and sodium silicate (SS) solutions. A total of twelve geopolymer concrete mixes were prepared and evaluated. The study considered several variables, including SF content (ranging from 10% to 100%), type of AA (SH+SS or PH+SS), AA concentration, and the AA to cementitious materials (AA/C) ratio. Workability, compressive strength, bending strength, tensile strength, and water absorption were among the mechanical characteristics of the concrete that were assessed, both in fresh and hardened states of the proposed concrete. The geopolymer concrete microstructure was also examined by performing X-ray diffraction (XRD), energy dispersive X-ray (EDX), and scanning electron microscopy (SEM) investigations on a few chosen mixes. The findings showed that when SF content was 10%, 20%, 30%, and 100% as a replacement of FA, the concrete slump rose by 10%, 15%, 15%, and 120%, respectively. However, the compressive strength was increased only with up to 20% SF. Geopolymer concrete with PH as the alkaline activator exhibited up to 13% lower compressive strength compared to SH. The geopolymer concrete microstructure was influenced by the presence of SF, leading to the formation of ettringite. Some FA particles that remained unreacted or were only partially reacted, along with voids, were observed. The findings from this study contribute to the development of sustainable geopolymer concrete, offering a promising solution for green structural applications. Full article

To achieve environmental and economic goals in ground improvement, a one-part geopolymer (OPG), synthesized from binary precursors (fly ash [FA] and granulated blast furnace slag [GGBFS]) and a solid activator (solid sodium silicate [NS]), was used to replace ordinary Portland cement (OPC) for stabilizing high-water-content soft clay. The effects of different initial water content (50%, 80%, 100%, and 120%) and various OPG binder content (10%, 20%, 30%, and 40%) on the strength development of the OPG-stabilized soft clay were investigated through unconfined compressive strength (UCS) and unconsolidated undrained (UU) triaxial tests. Additionally, the microstructure evolution and the distribution of pores in the OPG-stabilized soft clay were examined by the utilization of mercury intrusion porosimetry (MIP) and scanning electron microscopy-energy-dispersive spectroscopy (SEM-EDS) techniques, respectively. The life cycle assessment (LCA) methodology was then used to analyze the environmental and economic advantages of employing an OPG binder for soil stabilization. It was revealed that the optimal content of OPG binder was contingent upon the water content of soft clay, with variations in requirements for strength development. Specifically, for soft clay not demanding early strength, a maximum binder content of 20% is proposed. Conversely, for soft clay that necessitated rapid strength gain, the OPG binder content escalated with increasing water content of the soft clay, in which soft clays with different water contents had corresponding required amounts of OPG binder. For soil with water content ranging from 50% to 80%, the recommended OPG binder content is 20%. While for soil with 100% and 120% water content, the designed OPG binder content is suggested to be 30% and 40%, respectively. The environmental assessment demonstrated that the utilization of OPG as a binder for the stabilization of soft clay reduces costs and carbon emissions in comparison to OPC. The present study provides substantial theoretical validation for the utilization of OPG as a novel binder to stabilize soft clay with elevated water content, which holds promise as an eco-friendly and cost-effective solution in ground improvement. Full article

There is a growing demand for sustainable solutions in civil engineering concerning the carbon footprint of cementitious composites. Alkali-Activated Binders (AAB) are materials with great potential to replace ordinary Portland cement (OPC), with similar strength levels and lower environmental impact. Despite their improved environmental performance, their durability remains a gap in the literature, influenced by aspects of mechanical behavior, physical properties, and microstructure. This paper aims to assess the impact of steel slag aggregates and curing temperature of a proposed AAB based concrete formulation by characterizing fresh state, mechanical behavior, and microstructure. The proposed AAB is composed of fly ash (FA) and basic oxygen furnace (BOF) steel slag (SS) as precursors, sodium silicate and sodium hydroxide solution as activators, in total replacement of OPC, using baosteel slag short flow (BSSF) SS as aggregate in comparison with natural aggregate. The concrete formulation was designed to achieve a high-performance concrete (HPC) and a self-compacting concrete (SCC) behavior. Mechanical characterization encompassed hardened (compressive strength and Young’s modulus), fresh state (J-ring, slump flow, and T50), and durability tests (scanning electronic microscopy, water penetration under pressure, and chloride ion penetration). The compressive strength (64.1 ± 3.6 MPa) achieves the requirements of HPC, while the fresh state results fulfill the SCC requirements as well, with a spread diameter from 550 mm to 650 mm (SF-1 class). However, the flow time ranges from 3.5 s to 13.8 s. There was evidence of high chloride penetrability, affected by the lower electrical resistance inherent to the material. Otherwise, there was a low water penetration under pressure (3.5 cm), which indicates a well-consolidated microstructure with low connected porosity. Therefore, the durability assessment demonstrated a divergence in the results. These results indicate that the current durability tests of cementitious materials are not feasible for AAB, requiring adapted procedures for AAB composite characterization. Full article

Fly ash (FA) is the main solid waste emitted from coal-fired power plants. Due to its high yield, low utilization rate, and occupation of a large amount of land, it exerts enormous pressure on the Earth’s environment. With the deepening of the concept of sustainable development, exploring the reuse of industrial waste such as FA has become a key strategy. If FA can be combined with commonly used jewelry in people’s lives, it will be of great significance to promote the high-net-worth utilization of FA. Therefore, this study synthesized a fly-ash-based composite material with color-changing function and combined it with necklaces as the main material. In the first stage, after blending fly ash and slag, an alkaline activator with a total mass of 10% was added. When the proportion of fly ash was 60%, the compressive strength of the prepared fly-ash-based composite material reached 10.1 MPa. This was attributed to the reaction between sodium silicate in the alkaline activator and free CaO, MgO, and other substances in the fly ash to form hydrated silicate colloids, which solidify the fly ash and transform it into a complex three-dimensional network skeleton. In the second stage, a UV resistant coating with thermochromic function was obtained by blending acrylic resin, TiO₂, and a thermosensitive color-changing agent. It was applied to the surface of fly-ash-based composite materials, and the results showed that as the content of the color-changing agent increased, the number of pores on the surface of the coating gradually decreased. When the content of color-changing agent was 10%, the prepared 10%FAB not only had good surface color but also had good thermal stability, UV absorption ability, superhydrophobicity, and mechanical properties. Therefore, 10%FAB was selected as the basic material for jewelry design. In the third stage, the traditional Chinese technique of “gold inlaid with jade” was utilized to develop jewelry applications for the FA composites. As such, 10%FAB was processed into necklaces, which not only had modern design aesthetics but also had good color-changing effects above 30 °C. And after a long period of UV aging experiments, the necklace did not show any wrinkles, bubbles, or other phenomena. Due to the excitation of TiO₂ hole–electron pairs, the necklace’s UV absorption ability was further improved. This study demonstrates the potential application of industrial waste in decorative products, expands the high-end utilization of fly ash as a low-cost material, and provides new ideas for building a low-carbon lifestyle. Full article