Search Results (68)

Opal glass, known for its mechanical strength, hygiene, and aesthetic appeal, contains fluorides that hinder recycling and often lead to landfilling. This study investigates the use of discarded opal glass for the production of sustainable alkali-activated materials (AAMs), contributing to waste valorization and reduced raw material consumption. By optimizing the activation process, dense products with high compressive strength, comparable to conventional concretes, were obtained using low-molarity alkaline solutions and low-temperature curing (60 °C). In addition, lightweight porous structures with porosity exceeding 80% were successfully produced through direct foaming and salt templating. The developed materials exhibited good chemical stability under aggressive conditions. Preliminary biological tests indicated antimicrobial activity and low toxicity, supporting their potential use in applications where hygiene and durability are important. The results highlight the versatility of mild alkali activation for transforming waste opal glass into dense and porous materials with tunable properties. Full article

Promoting construction waste utilization, this study explores using 30% mass fraction recycled micro powder (brick/concrete/hybrid) to replace cement in A03 foam concrete, as well as microbial foaming agents for insulation boards. The results show that hybrid micro powder foam concrete achieved higher compressive strength (0.7 MPa, 0.65 MPa) than pure brick (0.54 MPa) and concrete powder (0.61 MPa). For 30% hybrid micro powder insulation boards (brick:concrete ratios 2:8–8:2), when the ratio is 4:6, their performance meets JC/T 2200-2013 standards. At this point, the compressive strength is 0.43 MPa, the drying shrinkage is 0.29 mm, and the thermal conductivity 0.062 is W/(m·K). As the proportion of recycled brick powder increases, the material properties first improve and then decline, indicating that the proportion of recycled brick powder has a significant impact on the material’s overall performance; within an appropriate range, optimal performance can be achieved. Full article

Gravelly soil is widely used in western China but suffers from poor gradation, low water stability, and weak freeze–thaw resistance. Traditional cementitious stabilizers involve high energy and carbon emissions. To address these issues, a novel, eco-friendly gravelly soil stabilizer was prepared from waste foamed concrete (WFC) via crushing, ball milling, and high-temperature calcination. This study systematically evaluated stabilization performance and mechanisms. Results indicate that the WFC stabilizer significantly enhances soil properties. At the optimal 30% dosage, the 28-day unconfined compressive strength (UCS) reached 6.5 MPa (a 333% increase), and water stability was significantly improved. Under freeze–thaw conditions, the 30% dosage yielded a mere 2% mass loss after five cycles, with the UCS reaching 9.56 MPa (a 437% increase). Microstructural analyses (XRD, SEM) revealed that hydration generates calcium silicate hydrate (C-S-H) gel and katoite (Ca₃Al₂(SiO₄)_3−x(OH)_4x). These products effectively fill soil pores and the spaces of the particles, optimizing the microstructure. This study provides a sustainable pathway for WFC recycling and offers a relatively lower energy consumption, low-carbon and high-performance stabilizer for reinforcing gravelly soil subgrades in cold regions. Full article

This study evaluates the performance of foamed geopolymer concrete (FGC) incorporating rigid polyurethane (PU) waste as a partial sand replacement and aluminum powder (AP, 1%) as a foaming agent. The mixtures were based on metakaolin, fly ash, and silica fume. Fresh and hardened properties were assessed, including workability, setting time, density, compressive strength, flexural strength, splitting tensile strength, elastic modulus, water absorption, porosity, gas permeability, and chloride ion penetration. Microstructural characteristics were examined using scanning electron microscopy (SEM). The results show that moderate PU incorporation significantly enhances mechanical performance. The optimal mixture (PU30) achieved a compressive strength of 47.25 MPa at 180 days, representing a 15.6% increase compared to the control. Flexural and splitting tensile strengths improved by 19.9% and 16.7%, respectively, while the elastic modulus increased by 33.8% to 0.95 GPa. These improvements are attributed to enhanced particle packing and more efficient stress transfer within the matrix. In contrast, higher PU contents (>30%) reduced mechanical performance due to increased total porosity and weakened interfacial bonding. Durability-related properties indicated that mixtures PU20–PU30 exhibited reduced permeability and optimized pore structure, characterized by lower pore connectivity. SEM observations confirmed a denser matrix with uniformly distributed pores at optimal PU levels. Additionally, the integration of Random Forest regression with GLCM-based texture analysis demonstrated strong capability in predicting mechanical properties from SEM images. Overall, the combined use of PU waste and AP enables the production of lightweight, structurally efficient, and sustainable FGC with improved mechanical and durability performance. Full article

The urgent global need for sustainable infrastructure drives the demand for high-value buildings and waste removal. This paper studies the feasibility of using recycled foam concrete aggregate (FCA) as a substitute for natural coarse aggregate (NCA) in concrete and studies its impact on rheology, mechanical degradation, shear resistance, and the full-range replacement ratio (0–100). The experimental results show that the monotonic change in the workability of fresh concrete determines the lubrication threshold at 60% replacement, which is driven by the volume proportion effect. Beyond this value, capillary suction dominates, and the viscosity rises rapidly. From a mechanical perspective, the porous structure of FCA is conducive to “internal curing” so that moisture is released from the drying interface, but it also becomes a source of defects that change the fault topology. Specifically, the critical transition of the shear failure mode shifts from the debonding of the interface to the crushing of the cross-particle aggregate. At this time, the shear capacity decreases substantially, experiencing a reduction of 71.8% when completely replaced. There is a strong correlation between ultrasonic pulse velocity (UPV), rebound number, and compressive strength, and a multivariate nonlinear regression model (R² > 0.85) with non-destructive strength prediction is ultimately obtained. Based on the balance between mechanical capacity and resource cyclability, an optimal alternative zone of 20% to 40% is proposed. This work not only provides a mechanism for multi-scale coupling between pore structure and structural properties but also provides a data-driven method for the safety assessment of lightweight recycled aggregate concrete (RAC). Full article

Foam concrete and fiber-reinforced foam concrete are promising building materials for sustainable and energy-efficient construction. Improving the environmental performance of cellular composites through the use of industrial waste and additives based on them is highly relevant. This study intends to create a novel complex nanomodifying additive (CNA) from industrial waste and nanomaterials, alongside new eco-friendly foam concrete (FC) and fiber-reinforced foam concrete (FFC) mixes incorporating CNA and polypropylene fiber (PF). Experimental studies yielded the optimal CNA formulation and described a method for its preparation. The test results indicate that FC’s properties are enhanced by CNA. The properties were best in the FC that was modified with 10% CNA. The FC control composition was surpassed by a 25.5% increase in compressive strength and a 23.1% increase in flexural strength, with a 9.5% reduction in thermal conductivity. Dispersed PF reinforcement also positively impacts the properties of FFCs with CNA, and the combined modification of 10% CNA and 1.2% PF provides maximum increases in compressive and flexural strength, amounting to 43.1% and 102.2%, respectively, and a 16.9% reduction in thermal conductivity. A microstructural analysis of the cellular composites confirms the feasibility of the tested formulation solutions. The FFCs, when modified by CNA and PF, display a homogeneous cellular structure, and the interpore zones contain multiple clusters of calcium silicate hydrate. Using CNA in the production of FC and FFCs will reduce cement consumption and improve their environmental friendliness. Full article

Currently, foam concrete is a prevalent energy-efficient building material, which is applicable for multiple purposes in a wide variety of buildings and structures. Improving the environmental performance of foam concrete and reducing its production costs through the use of industrial waste is a relevant and promising area. The goal of this study is to create innovative foam concrete (FC) mixtures using industrial waste, focusing on their environmentally friendly and energy-efficient properties for structural and thermal insulation purposes. The production of FC involved industrial waste products like fly ash (FA) and microsilica (MS). Nanosilica (NS) was used as an additional modifying additive. The study experimentally investigated the impact of the proposed formulation and process solutions on FC’s density, compressive strength (CS), and thermal conductivity (TC). The most effective FC modification parameters were identified for FA, MS, and NS. The best combination of 15% FA, 6% MS, and 0.4% NS produces environmentally friendly FC with improved properties: a density of 1142 kg/m³ and a TC of 0.268 W/m×°C, which are 3.8% and 15.2% lower than the control composition, respectively, and a CS of 15.1 MPa, which is 46.6% higher than the control value. Scanning Electron Microscopy (SEM) analysis validates that incorporating pozzolanic additives FA, MS, and NS into the FC composition fosters the development of more robust interpore partitions. This is due to the generation of a significant quantity of supplementary calcium hydrosilicates and a more homogenous pore structure. The structural quality factor of FC with 15% FA, 6% MS, and 0.4% NS increases to 52.4%. The structural and thermal insulation of FCs developed in this study are environmentally friendly building materials with reduced environmental impact and improved performance properties. Full article

Large-scale mining of graphite, a crucial strategic mineral, generates substantial amounts of graphite tailings (GT). The stockpiling of this solid waste occupies vast land resources and poses persistent environmental risks due to potential heavy metal leaching. Repurposing GT into construction materials presents a promising solution, with its use as a partial replacement for fine aggregates in cementitious composites being one of the most effective methods. This review systematically consolidates current research on graphite tailings cement mortar (GTCM) and graphite tailings concrete (GTC). Due to its physicochemical properties comparable to natural sand, GT is suitable for producing building materials. Studies consistently demonstrate that a substitution level of 10% to 20% optimizes overall performance. This optimal range enhances particle packing, promotes cement hydration via pozzolanic activity, and refines the microstructure, leading to improved workability, superior mechanical strength, and enhanced durability, including resistance to permeability, freeze–thaw cycles, and chemical attacks. Moreover, the inherent carbon content imparts electrical conductivity to GTC, enabling functional applications like de-icing and structural health monitoring. The successful utilization of GT also extends to lightweight foamed and autoclaved aerated concrete. However, research on the structural behavior of GTC components remains limited. Preliminary findings on beams and columns are encouraging, but comprehensive studies on their seismic performance and design methodologies are urgently needed to facilitate the widespread engineering application of this sustainable material and mitigate the environmental impact of tailings accumulation. Full article

Foam concrete is well-appreciated for its thermal and acoustic benefits and is prepared by introducing foam into cement slurry/mortar. The current research examines the feasibility of Quarry Micro Fines (QMF), a waste generated from the quarries during sand manufacturing, as a substitute for fine aggregate in the preparation of foam concrete. During the preparation of concrete, a portion of cement is replaced with sugarcane bagasse ash (SCBA), while polypropylene (PP) fibers are added to improve the shrinkage resistance and tensile strength of the resulting concrete. A three-factor, three-level Box–Behnken Design (BBD) in Response Surface Methodology (RSM) was used to optimize the compressive strength of foam concrete, considering QMF (0%, 50%, 100%) by weight of fine aggregate, SCBA (0%, 10%, 20%) by weight of cement, and PP fiber (0.2%, 0.4%, 0.6%) by volume of foam concrete as variables. The three mixtures, including control (FC), mix with 50% QMF, 10% SCBA, and 0.4% PP fiber (F50S10F0.4), and mix with 100% QMF, 10% SCBA, and 0.4% PP fiber (F100S10F0.4), were chosen for a more in-depth investigation based on the test results. While Q50S10F0.4 achieved the highest compressive strength (6.18 MPa), Q100S10F0.4 showed the best overall performance, with low water absorption of 14.10%, porosity of 20.17%, UPV 2388 m/s, and RCPT values of 1407.96 Coulombs. The modified mixtures exhibited enhanced bonding and pore enhancement as demonstrated by scanning electron microscopy and mercury intrusion porosimetry analyses. The study highlights the effective use of QMF, SCBA, and PP fibers in producing high-performance, sustainable foam concrete. Full article

The recycling of ultralight foam concrete (ULFC), both with and without phase-change material (PCM), involves crushing it and using the resulting recycled foam concrete powder (RFCP) as a partial substitute for cement or sand in cement composites. These recycling paths remain insufficiently explored in the literature regarding practical feasibility. Since both RFCP and PCM reduce the flowability of fresh mortars, incorporating RFCP with PCM is, in practice, only feasible with the addition of a superplasticizer (SP). The primary objectives of this study were to determine: (1) the effect of RFCP with PCM, when used to replace cement or sand, on mortar properties, and (2) its influence on the performance of the superplasticizer (SP), to assess the feasibility of using RFCP with PCM in cement composites. The addition of RFCP, both without PCM (RFCP_0) and with PCM (RFCP_PCM), deteriorates the properties of fresh and hardened mortars compared to reference mortars. The negative impact of RFCP is less pronounced when it replaces sand rather than cement. Compared to RFCP_0 mortars, RFCP_PCM mortars exhibit reduced flowability. PCM delays setting and reduces heat evolution during the first 48 h of hardening. PCM does not significantly affect strength or water absorption but increases shrinkage and lowers thermal conductivity. While RFCP_PCM does not impair SP efficiency, PCM causes SP to significantly retard setting and hardening. Full article

The construction industry relies on building materials that provide not only high physical and mechanical performance but also adequate thermal and durability properties. However, several factors still limit the quality and service life of concrete products. The development of the construction industry provides new opportunities for designing efficient construction facilities. To obtain enhanced design capabilities, it is very important to relieve the load on the structure, this can be achieved by reducing the mass of materials without losing strength. This study investigates the enhancement of foam concrete through the combined incorporation of mineral fibers recycled from basalt insulation waste and complex polymer modifiers. The aim was to improve the material’s mechanical performance, durability, and pore structure stability while promoting the sustainable use of industrial by-products. The experimental program included tests on density, compressive strength, water absorption, and thermal conductivity for mixtures of different densities (400–1100 kg/m³). The results demonstrated that the inclusion of mineral fibers and polymer modifiers significantly enhanced structural uniformity and pore wall integrity. Compressive strength increased by up to 35%, water absorption decreased by 25%, and thermal conductivity was reduced by 18% compared with the control mixture. Full article

The preparation of construction waste into eco-friendly recycled powder (RP), partially replacing cement to produce foam concrete with thermal insulation properties, provides a new approach for the resource utilization of RP. In this study, different components of construction waste were used to prepare recycled paste powder (RPP), recycled brick powder (RBP), and recycled concrete powder (RCP). The effects of RP on the microstructural and macroscopic properties of foam concrete were investigated at replacement rates ranging from 0% to 30%. The research results indicate that the microstructure of all three types of RP exhibits irregular shapes, and their chemical compositions show significant differences. Partial replacement of cement with these RP leads to the deterioration of the matrix microstructure, which negatively affects the workability and mechanical properties of the foam concrete. However, the addition of RP effectively mitigates the drying shrinkage of the foam concrete, with RBP showing particularly outstanding performance in this regard. Specifically, the maximum drying shrinkage rate of F-30RBP is 9.33% and 11.31% lower than that of F-30RPP and F-30RCP, respectively. Furthermore, the incorporation of RP has a minimal effect on the thermal conductivity of the foam concrete, indicating that RP is well-suited for use in foam concrete. Full article

The basis of the construction industry is building materials with high-quality indicators in terms of physical, mechanical, and thermophysical characteristics, however, there are a number of issues affecting the quality of manufactured products. The development of the construction industry provides new opportunities for designing efficient construction facilities. To obtain enhanced design capabilities, it is very important to relieve the load on the structure, and this can be achieved by reducing the mass of materials without losing strength. This study investigates the enhancement of foam concrete through the combined incorporation of mineral fibers recycled from basalt insulation waste and complex polymer modifiers. The aim was to improve the material’s mechanical performance, durability, and pore structure stability while promoting sustainable use of industrial by-products. The experimental program included tests on density, compressive strength, water absorption, and thermal conductivity for mixtures of different densities (400–1100 kg/m³). Results demonstrated that the inclusion of mineral fibers and polymer modifiers significantly enhanced structural uniformity and pore wall integrity. Compressive strength increased by up to 35%, water absorption decreased by 25%, and thermal conductivity was reduced by 18% compared with the control mixture. Full article

Wet–dry cycles are a key factor aggravating the durability degradation of foam concrete. To address this issue, this study prepared bentonite slurry–steel slag foam concrete (with steel slag and cement as main raw materials, and bentonite slurry as admixture) using the physical foaming method. Based on 7-day unconfined compressive strength tests with different mix proportions, the optimal mix proportion was determined as follows: mass ratio of bentonite to water 1:15, steel slag content 10%, and mass fraction of bentonite slurry 5%. Based on this optimal mix proportion, dry–wet cycle tests were carried out in both water and salt solution environments to systematically analyze the improvement effect of steel slag and bentonite slurry on the durability of foam concrete. The results show the following: steel slag can act as fine aggregate to play a skeleton role; after fully mixing with cement paste, it wraps the outer wall of foam, which not only reduces foam breakage but also inhibits the formation of large pores inside the specimen; bentonite slurry can densify the interface transition zone, improve the toughness of foam concrete, and inhibit the initiation and propagation of matrix cracks during the dry–wet cycle process; the composite addition of the two can significantly enhance the water erosion resistance and salt solution erosion resistance of foam concrete. The dry–wet cycle in the salt solution environment causes more severe erosion damage to foam concrete. The main reason is that, after chloride ions invade the cement matrix, they erode hydration products and generate expansive substances, thereby aggravating the matrix damage. Scanning Electron Microscopy (SEM) analysis shows that, whether in water environment or salt solution environment, the fractal dimension of foam concrete decreased slightly with an increasing number of wet–dry cycle times. Based on fractal theory, this study established a compressive strength–porosity prediction model and a dense concrete compressive strength–dry–wet cycle times prediction model, and both models were validated against experimental data from other researchers. The research results can provide technical support for the development of durable foam concrete in harsh environments and the high-value utilization of steel slag solid waste, and are applicable to civil engineering lightweight porous material application scenarios requiring resistance to dry–wet cycle erosion, such as wall bodies and subgrade filling. Full article

Foamed concrete has been widely applied in construction engineering; however, the performance requirements vary across different structural components. Its production typically involves a substantial consumption of cement, which imposes both environmental and economic burdens. Therefore, this study examined foamed concrete with dry apparent densities of 500–1000 kg/m³, in which cement was partially replaced (0–30%) by recycled powder from construction and demolition waste. Macroscopic performance was evaluated through drying shrinkage, compressive strength, softening coefficient, carbonation coefficient, and thermal conductivity, while microstructural analysis was conducted to clarify the underlying mechanisms. The results indicate that the internal composition of the recycled powder primarily consists of SiO₂, CaCO₃, and C-S-H gel. When recycled powder is used to replace cement, the microstructure of the resulting paste gradually deteriorates compared to that of the control group without recycled powder, and a significant amount of inert SiO₂ is introduced. As the replacement ratio of recycled powder increases, the compressive strength of foamed concrete across various density grades exhibits a gradual decline. Notably, when the replacement ratio reaches 30%, the reduction in mechanical performance becomes more substantial. However, the incorporation of recycled powder can effectively mitigate the drying shrinkage of foamed concrete. Moreover, the incorporation of recycled powder exerts minimal influence on the thermal conductivity and porosity of foamed concrete, demonstrating its favorable compatibility and potential for application in foamed concrete systems. Full article