Search Results (106)

Rapid pavement repair demands materials that combine accelerated strength gains, dimensional stability, long-term durability, and sustainability. However, finding materials or formulations that offer these balances remains a critical challenge. This study systematically evaluates two polymer-modified belitic calcium sulfoaluminate (CSA) concretes—CSAP (powdered polymer) and CSA-LLP (liquid polymer admixture)—against a traditional Type III Portland cement (OPC) control under both laboratory and realistic outdoor conditions. Laboratory specimens were tested for fresh properties, early-age and later-age compressive, flexural, and splitting tensile strengths, as well as drying shrinkage according to ASTM standards. Outdoor 5 × 4 × 12-inch slabs mimicking typical jointed plain concrete panels (JPCPs), instrumented with vibrating wire strain gauges and thermocouples, recorded the strain and temperature at 5 min intervals over 16 weeks, with 24 h wet-burlap curing to replicate field practices. Laboratory findings show that CSA mixes exceeded 3200 psi of compressive strength at 4 h, but cold outdoor casting (~48 °F) delayed the early-age strength development. The CSA-LLP exhibited the lowest drying shrinkage (0.036% at 16 weeks), and outdoor CSA slabs captured the initial ettringite-driven expansion, resulting in a net expansion (+200 µε) rather than contraction. Approximately 80% of the total strain evolved within the first 48 h, driven by autogenous and plastic effects. CSA mixes generated lower peak internal temperatures and reduced thermal strain amplitudes compared to the OPC, improving dimensional stability and mitigating restraint-induced cracking. These results underscore the necessity of field validation for shrinkage compensation mechanisms and highlight the critical roles of the polymer type and curing protocol in optimizing CSA-based repairs for durable, low-carbon pavement rehabilitation. Full article

In this research project a large linear electromagnetic actuator (LLEA) was designed and manufactured. The electromagnetic performance was published in previous works, but in this paper we focus on the technological challenges related to the manufacturing in particular. This LLEA was based on the magnet-free switched-reluctance principle, having six effective energised stator “teeth” and four passive mover parts (4:6 ratio). Various aspects and challenges encountered during the manufacturing, transport, and assembly are discussed. Thermal expansion of steel contributed to the decision of the modular design, with each module having 1.3 m in length, with a 2 mm longitudinal dilatation gap. The initial prototype was tested with a 10.6 m length, with plans to extend the test track to 60 m, which was fully achievable due to the modular design and required 29 tons of electrical steel to be built. The stator laminations were cut by a bespoke progressive tool with stamping, and other parts by a CO₂ laser. Mounting was based on welding (back of the stator) and clamping plates (through insulated bolts). The linear longitudinal force was on the order of 8 kN, with the main air gap of 7.5–10 mm on either side of the mover. The lateral forces could exceed 40 kN and were supported by appropriate construction steel members bolted to the concrete floor. The overall mechanical tolerances after installation remained below 0.5 mm. The technology used for constructing this prototype demonstrated the cost-effective way for a semi-industrial manufacturing scale. Full article

Non-uniform temperature fields are developed during the welding of studs in steel–concrete composite bridges. Due to uneven thermal expansion and reversible solid-state phase transformations between ferrite/martensite and austenite structures within the materials, residual stresses are induced, which ultimately degrades the mechanical performance of the structure. For a better understanding of the influence on steel–concrete composite bridges’ structural behavior by residual stress, accurate simulation of the spatio-temporal temperature distribution during stud welding under practical engineering conditions is critical. This study introduces a precise simulation method for temperature evolution during stud welding, in which the Gaussian heat source model was applied. The simulated results were validated by real welding temperature fields measured by the infrared thermography technique. The maximum error between the measured and simulated peak temperatures was 5%, demonstrating good agreement between the measured and simulated temperature distributions. Sensitivity analyses on input current and plate thickness were conducted. The results showed a positive correlation between peak temperature and input current. With lower input current, flatter temperature gradients were observed in both the transverse and thickness directions of the steel plate. Additionally, plate thickness exhibited minimal influence on radial peak temperature, with a maximum observed difference of 130 °C. However, its effect on peak temperature in the thickness direction was significant, yielding a maximum difference of approximately 1000 °C. The thermal influence of group studs was also investigated in this study. The results demonstrated that welding a new stud adjacent to existing ones introduced only minor disturbances to the established temperature field. The maximum peak temperature difference before and after welding was approximately 100 °C. Full article

The construction of concrete pavements has increased due to their better durability, lifespan, and lower maintenance costs. However, this has resulted in the increased consumption of Portland cement, which is one of the major contributors to carbon emissions. Consequently, the research on alternative binders such as geopolymer concrete has increased in recent times. There are several research studies that investigate the feasibility of geopolymer concrete as a construction material, with limited studies exploring its application in concrete pavements. Therefore, this review study explores the material properties of geopolymer concrete pertinent to the performance of concrete pavements. It also discusses the potential of various industrial and agricultural waste as precursor material in geopolymer concrete. The findings of this paper show that most of the studies used fly ash and ground granulated blast furnace slag (GGBFS) as precursor material in geopolymer pavement-quality concrete, and there is a vast scope in the exploration of other industrial and agricultural waste as precursor material. The mechanical and durability properties of geopolymer pavement-quality concrete are superior to conventional pavement concrete. It is also observed that the drying shrinkage and coefficient of thermal expansion of geopolymer pavement-quality concrete are lower than those of conventional pavement concrete, and this will positively benefit the long-term performance of concrete pavements. The results of fatigue analysis and mechanical load test on the geopolymer pavement-quality concrete indicate its improved performance when compared to the conventional pavement concrete. Full article

Cement is widely used as the primary binder in concrete; however, growing environmental concerns and the rapid expansion of the construction industry have highlighted the need for more sustainable alternatives. Geopolymers have emerged as promising eco-friendly binders due to their lower carbon footprint and potential to utilize industrial byproducts. Geopolymer mortar, like other cementitious substances, exhibits brittleness and tensile weakness. Basalt fibers serve as fracture-bridging reinforcements, enhancing flexural and tensile strength by redistributing loads and postponing crack growth. Basalt fibers enhance the energy absorption capacity of the mortar, rendering it less susceptible to abrupt collapse. Basalt fibers have thermal stability up to about 800–1000 °C, rendering them appropriate for geopolymer mortars designed for fire-resistant or high-temperature applications. They assist in preserving structural integrity during heat exposure. Fibers mitigate early-age microcracks resulting from shrinkage, drying, or heat gradients. This results in a more compact and resilient microstructure. Using basalt fibers improves surface abrasion and impact resistance, which is advantageous for industrial flooring or infrastructure applications. Basalt fibers originate from natural volcanic rock, are non-toxic, and possess a minimal ecological imprint, consistent with the sustainability objectives of geopolymer applications. This study investigates the mechanical and thermal performance of a geopolymer mortar composed of metakaolin and red mud as binders, with basalt powder and limestone powder replacing traditional sand. The primary objective was to evaluate the effect of basalt fiber incorporation at varying contents (0.4%, 0.8%, and 1.2% by weight) on the durability and strength of the mortar. Eight different mortar mixes were activated using sodium hydroxide (NaOH) and sodium silicate (Na₂SiO₃) solutions. Mechanical properties, including compressive strength, flexural strength, and ultrasonic pulse velocity (UPV), were tested 7 and 28 days before and after exposure to elevated temperatures (200, 400, 600, and 800 °C). The results indicated that basalt fiber significantly enhanced the performance of the geopolymer mortar, particularly at a content of 1.2%. Specimens with 1.2% fiber showed up to 20% improvement in compressive strength and 40% in flexural strength after thermal exposure, attributed to the fiber’s role in microcrack bridging and structural densification. Subsequent research should concentrate on refining fiber type, dose, and dispersion techniques to improve mechanical performance and durability. Examinations of microstructural behavior, long-term durability under environmental settings, and performance following high-temperature exposure are crucial. Furthermore, investigations into hybrid fiber systems, extensive structural applications, and life-cycle evaluations will inform the practical and sustainable implementation in the buildings. Full article

Lightweight artificial aggregates (LWAs) are widely used in civil construction, but their conventional production depends on pure clays, a finite natural resource that negatively impacts the environment. This study aims to contribute to minimizing this issue by exploring the use of sustainable ternary mixtures of kaolinitic clay (KC), chamotte residues (CHT), and eucalyptus firewood ash (EFA), promoting a more environmentally friendly approach to the manufacture of LWAs. Thus, the aim was to develop and optimize LWAs using different replacements of industrial waste. Furthermore, the Taguchi method is employed to identify the optimal manufacturing parameters, such as waste content, sintering temperature, and heating time. The research involved the production of 32 distinct mixtures with different proportions of KC, CHT, and EFA, processed through grinding and sintering at temperatures ranging from 1075 °C to 1180 °C. The samples were evaluated for density, water absorption, mechanical strength, and expansion index. Statistical analysis was conducted using ANOVA to validate the most significant factors. The results revealed that mixtures with 80% of waste presented an aggregate expansion index of up to 60%, a minimum bulk density of 1.20 g/cm³ (which aligns with requirements for structural applications but exceeds the maximum bulk density for some lightweight aggregates), and crushing strength higher than 5 MPa, satisfying the normative criteria for commercial LWAs. In addition, 63 industrial applications were identified for the developed materials, ranging from structural lightweight concretes to thermal and acoustic insulation with varied microstructures. Therefore, the partial replacement of clay by CHT and EFA waste represents a promising alternative for producing sustainable LWAs, helping to reduce environmental impacts while providing quality materials for various applications in the most diverse industrial sectors. Full article

Enhancing the utilization rate of waste glass in concrete is crucial for achieving solid waste reduction and low carbon emissions in the construction industry. This study employs the method of simultaneously replacing fine aggregate and cementitious materials in concrete with glass sand and glass powder to prepare composite waste glass concrete (CGC). The compressive strength, alkali–silicate expansion, and thermal properties of CGC were investigated experimentally. The experimental results show that the pozzolanic activity of fine glass powder in CGC can effectively mitigate the ASR reaction, enhance glass utilization, and allow the glass content to reach up to 17.79% of the total concrete mass. The thermal conductivity of the compounded waste glass concrete decreased linearly with increasing temperature, and the specific heat capacity showed three distinct peaks in the range of 180–800 °C, which were caused by chemical dehydration, quartz phase transition, and CaCO₃ decarbonization, respectively. Furthermore, to examine the impact of replacement mode on the high-temperature resistance of waste glass concrete, the residual strength, physical properties, and microstructure of the concrete were evaluated. It was found that the residual strength ratio of CGC (0.73) exhibited a distinct advantage at 600 °C. At this time, the melting effect of glass can reduce the pore size of concrete and transform large pores into capillary pores. However, as the temperature rises to 800 °C, the melting effect of glass no longer alleviates the high-temperature damage to concrete, and the degree of decomposition of hydration products determines the concrete strength. Full article

To address the demands of the low-carbon era, this study proposed a solution by using eggshell powder (ESP), fly ash, and ground granulated blast furnace slag together with alkaline solution in the preparation of lightweight geopolymer foam concrete (LWGFC). The aim of this study is to investigate the influence of replacing precursor materials with 5–20% ESP on the expansion behavior, physical, mechanical characteristics, and thermal conductivity of LWGFC. Additionally, the study examines the effect of varying the silicate modulus (SiO₂/Na₂O ratios of 1.0, 1.25, and 1.5) on the properties of LWGFC. Incorporating ESP from 5% to 20% with a constant SiO₂/Na₂O ratio reduced the initial setting time, while a high SiO₂/Na₂O ratio controlled the setting time and expansion volume. The high SiO₂/Na₂O ratio decreased the porosity and enhanced the compressive strength of the LWGFC but increased the thermal conductivity. The inclusion of more than 10% ESP content negatively affected compressive strength; however, a high SiO₂/Na₂O ratio can mitigate this detrimental effect. The thermal conductivity of optimal-content ESP mixtures with a SiO₂/Na₂O ratio of 1.0 was about 0.84 W/m·K, which is 2.1% lower than mixtures with a ratio of 1.25 and 18.6% lower than those with a ratio of 1.5. High-content ESP mixtures had a density of 1707 kg/m³, 0.97 W/m·K, and a compressive strength of 18.9 MPa at a low SiO₂/Na₂O ratio. Finally, the inclusion of ESP in the LWGFC, along with the use of an appropriate silicate modulus, resulted in improved strength development while decreasing porosity. Full article

This research aims to address the environmental and economic challenges associated with conventional concrete by partially replacing cement—the most polluting, expensive, and energy-intensive ingredient—with industrial paint sludge ash (PSA), a highly contaminated industrial waste that is typically landfilled. Mortar mixtures were prepared with PSA replacement levels ranging from 0% to 20% in 5% increments while maintaining a constant water-to-binder ratio of 0.48. This study comprehensively evaluated the fresh, mechanical, durability, and microstructural properties of the PSA-modified mortar to assess its potential as an ecofriendly construction material. Results showed that as PSA content increased, the fresh properties, such as workability/slump flow and setting time, decreased, while the water demand for attaining normal consistency increased. Soundness tests indicated expansion up to 15% PSA replacement, beyond which expansion became more pronounced. Compressive strength improved significantly with PSA replacements of 5% to 15% compared to the control sample, with a slight decline at 15% relative to 5% and 10%. This trend was consistent with bulk density and ultrasonic pulse velocity measurements. Furthermore, the incorporation of PSA enhanced key durability properties, including water absorption, sulfate resistance, and porosity reduction, up to 15% PSA replacement. Microstructural analysis using SEM, XRD, TGA/DTA, and FTIR confirmed that PSA inclusion led to increased mortar densification, with the 10% PSA mix exhibiting thermal stability and minimal mass loss at elevated temperatures. FTIR spectra further indicated improved composition with higher PSA content. Overall, PSA proved to be a viable partial cement replacement, offering enhanced mortar properties without compromising performance. Its use contributes to sustainability by reducing reliance on cement, lowering construction costs, and eliminating the environmental and logistical burdens of paint sludge disposal. Full article

Temperature variations have a significant impact on the performance and durability of rigid (concrete) pavement. As concrete is subjected to daily and seasonal temperature changes, it experiences thermal expansion and contraction. These movements, if not properly managed, can lead to cracking, joint deterioration, and loss of structural integrity. The pavement system is adversely affected by intense heat and significant flooding. This study aims to analyze the impact of several parameters on the performance of rigid pavement under typical, thermal, and flooding situations. This study investigates the properties of concrete and the dimensional design of rigid pavement with FEACONS IV software to assess their impact on the performance of concrete pavement during thermal and flooding conditions. The main conclusions of this study derived from the FEACONS IV analysis are as follows. Rigid pavement can enhance load-carrying capacity due to a lower elastic modulus, adequate flexural strength, and aggregates with a lower coefficient of thermal expansion. Increased thickness of concrete slabs and shorter slab lengths assist in minimizing load- and temperature-induced stresses. The increase in the subgrade modulus reaction value during flooding conditions improves pavement strength. However, in higher thermal conditions, a higher subgrade reaction modulus can increase the stress induced by temperature and load. Rigid pavement using porous limestone aggregate exhibits a reduced elastic modulus and coefficient of thermal expansion, suggesting higher resilience compared to rigid pavement composed of river gravel or granite. The findings suggest that higher thermal conditions will cause pavement damage. Agencies need to account for higher temperatures while designing and maintaining pavement. Flooding saturates the concrete pavement and subgrade layer, adversely affecting its performance over time. Full article

Gradient damage processes in cementitious materials are generally produced by chemical and/or physical processes that travel from outside to inside. Depending on the type of damage, it can cause different effects such as decreased porosity, cracking, or steel corrosion in the case of carbonation, or increased porosity, micro-cracks, expansion, and spalling (also present in thermal damage) in the case of external attack by sulphates or acid attack. Therefore, estimating the boundaries of this damage is an essential task for concrete quality assessment. The first objective of this work was to use neural networks (NNs) for ultrasound tomographic reconstruction of concrete samples in order to estimate the advance front in gradient damage. Unlike the usual X-ray tomography, ultrasound tomography is affected by diffraction, among other factors. NNs can learn to compensate for these effects; however, they require a large amount of training data to achieve accurate results. In the case of cement-based materials, obtaining and measuring a real training database could be complicated, expensive, and time-consuming. For this purpose, a training process using simulated measurements was carried out. The second objective of this work was to demonstrate the feasibility of training neural networks through simulations, which reduces costs. Finally, the trained neural network for tomographic reconstruction was evaluated using real cylindrical concrete specimens. Each specimen consisted of an outer cylinder, representing externally exposed cement, and an inner cylinder, simulating the unaffected core. The Structural Similarity Index (SSIM) was used as a metric to assess the reconstruction accuracy, achieving values of 0.95 for simulated signals and up to 0.82 for real signals. Full article

As part of this study, mechanical property tests were carried out at different stages with different curing temperatures to elucidate the effect of temperature on the mechanical properties of concrete. The curing temperatures were laboratory curing temperature (standard curing at 20 °C) and variable temperature curing (simulated site ambient temperature curing) according to the actual temperature of previous construction sites. The compressive strength, split tensile strength, axial tensile strength, and modulus of elasticity values were tested, and the growth rates were calculated. According to previous experiments, the maturity indexes under two kinds of maintenance conditions were calculated based on the N-S maturity formula, F-P equivalent age calculation formula, and D-L equivalent age calculation formula proposed by the maturity theory. Moreover, logarithmic function, exponential function, and hyperbolic function fitting were carried out using the fitting software to study the developmental relationship between strength and maturity. The physical phase analysis of low-heat cement was performed using XRD and simultaneous thermal analysis, and pore structure analysis was conducted using the mercuric pressure method (MIP). We also conducted an SEM analysis of hydration products and the micromorphology of low-heat cement with 25% fly ash. Energetic spectroscopy analyzed the elemental content. In this study, it was found that temperature has a significant effect on the mechanical properties of concrete, with temperature having the greatest effect on splitting tensile strength. The strength of low-heat silicate cement concrete increases with maturity. The highest correlation coefficient was based on the hyperbolic function fit in the F-P equivalent age. The improved development of concrete strength in the later stages of the two curing conditions in this test indicates that low-heat cement is suitable for use in hydraulic tunnels. The low-heat cement generates a large number of C-S-H gels via C₂S in the late stage, filling the internal pores, strengthening the concrete densification to make the structure more stable, guaranteeing the late development of concrete strength, and imparting a micro-expansive effect, which is effective for long-term crack resistance in hydraulic lining structures. Full article

Concrete’s coefficient of thermal expansion (CTE) is a critical property affecting the durability and performance of rigid pavements. This review paper examines the significance of CTE in pavement design and the factors influencing it, including the type of aggregate, cement composition, age, relative humidity, and curing conditions. Thermal stress due to temperature changes and moisture variation can lead to cracking, spalling, and warping in concrete pavements, impacting their performance. The paper also discusses experimental methods for measuring CTE, alongside recent advances like mechanistic–empirical pavement design and prediction models. Integrating CTE considerations into pavement design enhances the predictive accuracy of pavement performance, particularly in addressing issues like joint movement and cracking. By comprehensive literature review and synthesizing current research, the paper emphasizes the importance of integrating CTE considerations into pavement design for improved durability and performance predictions. The paper emphasizes the importance of integrating CTE considerations into pavement design for improved durability and performance predictions. Full article

Alkali-activated materials (AAMs) are promoted as a sustainable alternative to ordinary Portland cement (OPC). They not only have excellent resistance to high temperatures and chemical corrosion, but they can also help to reduce greenhouse gas emissions and reduce energy consumption. Despite their superior resistance to high temperatures compared to conventional cement-based concretes, studies have indicated that AAMs still face challenges related to performance degradation under elevated temperatures. This paper systematically reviews and summarizes the thermal properties (i.e., thermal expansion, thermal stability, and thermal conductivity), mechanical performance, and deterioration mechanisms of various alkali-activated composite systems. The findings reveal significant variability in resistance to high temperatures among different AAM systems, originating from the diversity of precursor materials used. Generally, the strength deterioration of various AAMs below 400 °C is minimal or even slightly increased, while between 600 °C and 800 °C, the strength degradation is significantly accelerated. Upon reaching 800 °C, the rate of the strength deterioration of AAMs tends to stabilize, with some alkali-activated composites even exhibiting signs of strength recovery. After exposure to high temperatures of 800 °C, the retentions of the compressive strength and flexural strength of alkali-activated composites are in the ranges of about 20–60% and 20–40%, respectively. The degradation mechanisms at elevated temperatures primarily include crystalline-phase transformation, microstructural changes, and thermal incompatibility arising from the differing coefficients of thermal expansion between the matrix and the aggregates. Finally, this paper discusses effective strategies to enhance the resistance of AAMs to high temperatures and highlights both the opportunities and challenges for future research in this field. Full article

Cracks and other defects in concrete will affect its durability, thermal insulation effect, and energy consumption. ASR is one of the common causes of concrete cracks. In this study, mortar specimens modified with fly ash were prepared using the mortar bar rapid method, and the inhibition effect of ASR in two alkali environments and the building energy efficiency characteristics were comparatively analyzed. SEM, EDS, and XRD were used to analyze the microstructure, elemental distribution, and products in the specimens’ interfacial transition zone comparatively. The results show that a replacement amount of 20–30% fly ash can restrain ASR expansion and maintain high mechanical strength. In both alkaline environments, K and Al are enriched in the interface transition zone and combine with SiO₂ and Al₂O₃ to form a stable framework aluminosilicate mineral. In addition to the inhibition effect of fly ash on ASR, the external wall heat dissipation flux decreased from 132.6 W/m² to 117.6 W/m², a decrease of 11.3%, and the overall envelope heat dissipation flux decreased by 9.2%, significantly reducing building energy consumption. This study provides a new perspective for the development of building energy-saving materials and helps green buildings and sustainable development. Full article