Strength and Durability Characteristics of Cement Composites with Recycled Water and Blast Furnace Slag Aggregate

Recently, interest in sustainable development has been increased. In this regard, efforts have been made to prevent environmental pollution, and research on the recycling of construction industry byproducts has been actively conducted in the construction industry. In South Korea, about 20 million tons of waste wash water from the ready-mixed concrete production process are generated, and some of them are recycled using recycling facilities in a ready-mixed concrete plant, but a significant portion of them is discharged or landfilled without permission, causing environmental problems. To increase the recycling rate of steel slag and reduce environmental pollution in the construction industry, we simultaneously applied blast furnace slag fine aggregate (BSFA) and recycled water (RW) to cement mortar. In this study, to examine the feasibility of RW and BSFA, we evaluated the fluidity, compressive strength, tensile strength, drying shrinkage, carbonation depth, and chloride penetration resistance of cement mortar using RW and BSFA. From the test results, the 28-day compressive strengths of all samples using RW and BSFA were higher than that of the control sample. In the case of samples using RW, as the BSFA replacement ratio was increased, the carbonation depth of the samples decreased. Therefore, when RW and BSFA are used properly, the mechanical properties of cement mortar, carbonation resistance, and chloride ion penetration resistance are expected to be effectively improved.     

Experiment on the Properties of Soda Residue-Activated Ground Granulated Blast Furnace Slag Mortars with Different Activators

Soda residue (SR), a solid waste generated in the production of Na₂CO₃ during the ammonia soda process, with a high pH value of 12, can be used as an activator of alkali-activated ground granulated blast furnace slag (GGBFS) cementitious materials. Three groups of experiments on SR-activated GGBFS mortars were designed in this paper to assess the role of the dominant parameters on fluidity and compressive strength of mortars. The results indicate that for fluidity and mechanical properties, the optimal scheme of SR-activated GGBFS mortars is 16:84–24:76 S/G, 0.01 NaOH/b, 0.05 CaO/b, and 0.50 w/b, with fluidity and compressive strength (28 d) of the mortars being 181–195 mm and 32.3–35.4 MPa, respectively. Between 2.5–10% CaCl₂ addition to CaO (5%)-SR (24%)-activated GGBFS mortar is beneficial to the improvement of the compressive strength of C2, whereas the addition of CaSO₄ is harmful. The main hydration products of mortars are ettringite, Friedel’s slat, and CSH gels. The results provide a theoretical basis and data support for the utilization of SR.     

The Influence of Cement Type on the Properties of Plastering Mortars Modified with Cellulose Ether Admixture

In this article, the effect of cement type on selected properties of plastering mortars containing a cellulose ether admixture was studied. In the research, commercial CEM I Portland cement, CEM II and CEM III, differing in the type and amount of mineral additives, and cement class, were used as binders. Tests of consistency, bulk density, water retention value (WRV), mechanical properties and calorimetric tests were performed. It was proved that the type of cement had no effect on water retention, which is regulated by the cellulose ether. All mortars modified with the admixture were characterized by WRV of about 99%. High water retention is closely related to the action of the cellulose ether admixture. As a result of the research, the possibility of using cement with additives as components of plasters was confirmed. However, attention should be paid to the consistency, mechanical properties of the tested mortars and changes in the pastes during the hydration process. Different effects of additives resulted from increasing or decreasing the consistency of mortars; the flow was in the range from 155 mm to 169 mm. Considering the compressive strength, all plasters can be classified as category III or IV, because the mortars attained the strength required by the standard, of at least 3.5 MPa. The processes of hydration of pastes were carried out with different intensity. In conclusion, the obtained results indicate the possibility of using CEM II and CEM III cements to produce plastering mortars, without changing the effect of water retention.     

Strength,Carbonation Resistance,and Chloride-Ion Penetrability of Cement Mortars Containing Catechol-Functionalized Chitosan Polymer

There have been numerous recent studies on improving the mechanical properties and durability of cement composites by mixing them with functional polymers. However, research into applying modified biopolymer such as catechol-functionalized chitosan to cement mortar or concrete is rare to the best of our knowledge. In this study, catechol-functionalized chitosan (Cat-Chit), a well-known bioinspired polymer that imitates the basic structures and functions of living organisms and biological materials in nature, was synthesized and combined with cement mortar in various proportions. The compressive strength, tensile strength, drying shrinkage, accelerated carbonation depth, and chloride-ion penetrability of these mixes were then evaluated. In the ultraviolet–visible spectra, a maximum absorption peak appeared at 280 nm, corresponding to catechol conjugation. The sample containing 7.5% Cat-Chit polymer in water (CPW) exhibited the highest compressive strength, and its 28-day compressive strength was ~20.2% higher than that of a control sample with no added polymer. The tensile strength of the samples containing 5% or more CPW was ~2.3–11.5% higher than that of the control sample. Additionally, all the Cat-Chit polymer mixtures exhibited lower carbonation depths than compared to the control sample. The total charge passing through the samples decreased as the amount of CPW increased. Thus, incorporating this polymer effectively improved the mechanical properties, carbonation resistance, and chloride-ion penetration resistance of cement mortar.     

Effects of Blast Furnace Slag Powder and Limestone Powder on the Mechanical Properties and Durability of Shotcrete Using Monocalcium Aluminate Setting Accelerator

In this study, the effect of fine blast furnace slag powder (SP) and limestone powder (LSP) as a mineral admixture in shotcrete using monocalcium aluminate (CA) as a quick-setting accelerator was evaluated. The shotcrete was prepared with up to 25 wt.% substitutions of mineral admixture, i.e., (SP and LSP), and then the CA accelerator was incorporated by 5 wt.% of binders. To examine the optimal mixing ratio for mineral admixture in shotcrete, penetration resistance, compressive strength, XRD analysis, and MIP analysis were performed on the mortar. On the other hand, compressive strength test, chloride diffusion coefficient, and freeze–thaw resistance were conducted on concrete to evaluate the field applicability of shotcrete. The study revealed the addition of LSP improved setting time and early compressive strength while the addition of SP increased long-term compressive strength. With the addition of both SP and LSP, the early and long-term strength was increased due to the influence of the properties of each admixture. Furthermore, the addition of SP and LSP improves the resistance of shotcrete to chloride ions and freeze–thaw.     

Effect of Amorphous Metallic Fibers on Strength and Drying Shrinkage of Mortars with Steel Slag Aggregate

Recently, with increasingly stringent environmental regulations and the depletion of natural aggregate resources, high-quality aggregates have become scarce. Therefore, significant efforts have been devoted by the construction industry to improve the quality of concrete and achieve sustainable development by utilizing industrial by-products and developing alternative aggregates. In this study, we use amorphous metallic fibers (AMFs) to enhance the performance of mortar with steel slag aggregate. Testing revealed that the 28-day compressive strength of the sample with steel slag aggregate and AMFs was in the range of 48.7–50.8 MPa, which was equivalent to or higher than that of the control sample (48.7 MPa). The AMFs had a remarkable effect on improving the tensile strength of the mortar regardless of the use of natural aggregates. With AMFs, the drying shrinkage reduction rate of the sample with 100% steel slag aggregate was relatively higher than that of the sample with 50% natural fine aggregate. Furthermore, the difference in the drying shrinkage with respect to the amount of AMFs was insignificant. The findings can contribute to sustainable development in the construction industry.     

Study on Strength,Water Stability,Shrinkage, and Microstructure of CFB Slag Modified Cement Stabilized Clay

Circulating fluidized bed slag (CFBS) is an industrial waste produced by coal combustion in power plants. To explore the application of CFB slag in cement-stabilized bases, this paper studies the influence of different dosage of CFBS on the mechanics, water stability, and shrinkage of cement-stabilized soil using laboratory experiments. The hydration activity and interface morphology of CFBS in cement-stabilized clay were observed using XRD and SEM. The improvement mechanism of CFBS on the performance of cement-stabilized clay was revealed. The results indicated that, compared with cement-stabilized clay, cement–CFBS-stabilized clay exhibited better mechanical and water stability, and significantly inhibited the shrinkage deformation of cement-stabilized clay. When the addition of CFBS was 70%, cement–CFBS-stabilized clay had the best mechanics and durability. Microscopic tests show that CFBS contains more active silicon aluminum oxide, which is easily dissolved and the hydration of which produces more gel products, so the mixture structure is denser, the strength is improved, and water does not easily evaporate; it has the characteristics of micro expansion which compensates for dry shrinkage deformation.     

Effect of Flue Gas Desulfurization Gypsum on the Properties of Calcium Sulfoaluminate Cement Blended with Ground Granulated Blast Furnace Slag

This work aims to investigate the effect of additional flue gas desulfurization gypsum (FGDG) on the properties of calcium sulfoaluminate cement (CSAC) blended with ground granulated blast furnace slag (GGBFS). The hydration rate, setting time, mechanical strength, pore structure and hydration products of the CSAC-GGBFS mixture containing FGDG were investigated systematically. The results show that the addition of FGDG promotes the hydration of the CSAC-GGBFS mixture and improves its mechanical strength; however, the FGDG content should not exceed 6%.     

Effect of the Acidity Coefficient on the Properties of Molten Modified Blast Furnace Slag and Those of the Produced Slag Fibers

The online preparation of fibers using molten modified blast furnace slag can not only achieve the high-value-added utilization of the slag but can also make use of the sensible heat of the slag. In this paper, blast furnace slag was modified using iron tailings, and was then used to prepare slag fiber online; the effects of the acidity coefficient on the properties of the molten modified blast furnace slag and modified blast furnace slag fiber were investigated. With an increase in the acidity coefficient from 1.2 to 1.6, the temperature range of the slag melt, with viscosity in the 1–3 Pa·s range, increased from 101.2 °C to 119.9 °C. The melting temperature increased from 1326.2 °C to 1388.7 °C, and the suitable fiber-forming temperature range increased from 70.7 °C to 82.9 °C. With the increasing acidity coefficient, the crystallization temperature of the molten modified slag decreased markedly. When the acidity coefficient was greater than 1.4, the slag system was still in a disordered glassy phase at 1100 °C. The hardening speed gradually reduced with the increasing acidity coefficient when the modified slag was cooled at the critical cooling rate, resulting in a gradual increase in fiber formability. The fibers prepared from the modified slag at different acidity coefficients had smooth surfaces, and were arranged in a crossed manner at the macroscopic level. Their color was white, and small quantities of slag balls were doped inside the fibers. With an increase in the acidity coefficient from 1.2 to 1.6, the average fiber diameter increased from 4.2 μm to 8.2 μm, and their slag ball content increased from 0.73% to 4.49%. Overall, the acidity coefficient of modified blast furnace slag should be less than 1.5 in actual production.     

The Influence of CaO and MgO on the Mechanical Properties of Alkali-Activated Blast Furnace Slag Powder

CaO and MgO are both reported as effective activators for blast furnace slag. However, the synergistic effect of these two components on the mechanical properties of alkali-activated blast furnace slag remains unclear. In this study, the flexural and compressive strengths of alkali-activated blast furnace slag powder with MgO and CaO range from 0% to 30% by the mass ratio of alkali-activated blast furnace slag powder are investigated. Moreover, the dry shrinkage rate of alkali-activated blast furnace slag powder is measured. One percent refractory fibers by volume of binder materials are added in the alkali-activated blast furnace slag. Some refractory fibers are treated with water flushing, meanwhile, some refractory fibers are directly used without any treatment. Finally, the scanning electron microscope, the thermogravimetric analysis curves and the XRD diffraction spectrums are obtained to reflect the inner mechanism of the alkali-activated blast furnace slag powder’s mechanical properties. The water-binder ratios of the alkali-activated blast furnace slag powder are 0.35 and 0.42. The curing ages are 3 d, 7 d and 28 d. The measuring temperature for the specimens ranges from 20 °C to 800 °C. Results show that the flexural and compressive strengths increase with the increased curing age, the decreased water-binder ratio and the addition of refractory fibers. The water-treated refractory fibers can improve the mechanical strengths. The mechanical strengths increase in the form of a quadratic function with the mass ratio of MgO and CaO, when the curing age is 3 d, the increasing effect is the most obvious. A higher water-binder ratio leads to an increasing the drying shrinkage rate. The activated blast furnace slag powder with CaO shows a higher drying shrinkage rate. The mechanical strengths decrease with the increasing testing temperature.     

Effect of the Partial Replacement of Cement with Waste Granite Powder on the Properties of Fresh and Hardened Mortars for Masonry Applications

Granite is a well-known building and decorative material, and, therefore, the amount of produced waste in the form of granite powder is a problem. Granite powder affects the health of people living near landfills. Dust particles floating in the air, which are blown by gusts of wind, can lead to lung silicosis and eye infections, and can also affect the immune system. To find an application for this kind of waste material, it was decided to study the effect of partially replacing cement with waste granite powder on the properties of fresh and hardened mortars intended for masonry applications. The authors planned to replace 5%, 10%, and 15% of cement with waste material. Series of mortar with the addition of granite powder achieved 50% to 70% of the compressive strength of the reference series, and 60% to 76% of the bending strength of the reference series. The partial replacement of cement with the granite powder significantly increased the water sorption coefficient. The consistency of the fresh mortar, and its density and water absorption also increased when compared to the reference series. Therefore, Granite powder can be used as a partial replacement of cement in masonry mortars.     

Effect of Early Curing Temperature on the Tunnel Fire Resistance of Self-Compacting Concrete Coated with Aerogel Cement Paste

In this paper, the effect of early curing temperature on the tunnel fire resistance of self-compacting concrete (SCC) coated with aerogel cement paste (ACP) was studied. The physical properties in terms of the compressive strength, flexural strength, and thermal conductivity of ACP were tested under different early curing temperatures. The tunnel fire resistance of ACP and SCC coated with ACP was determined, and the microstructure of ACP and SCC after a tunnel fire were characterized by scanning electron microscopy. The results show that the strength of ACP initially increased (by 10–40 °C) and then later decreased (by 40–60 °C) with the increase in early curing temperature. ACP under 40 °C early curing exhibited the minimum number of cracks and mass loss after the tunnel fire. Too high or too low early curing temperature reduced the thermal conductivity of ACP but accelerated the formation and expansion of microcracks during the tunnel fire. The residual compressive strength of SCC coated with ACP under 40 °C early curing after the tunnel fire was the highest, demonstrating the best tunnel fire resistance.     

Effects of Alternate Wet and Dry Conditions on the Mechanical and Physical Performance of Limestone Calcined Clay Cement Mortars Immersed in Sodium Sulfate Media

Sulfate attack in concrete structures significantly reduces their durability. This article reports the experimental findings on the effects of sodium sulfate on limestone calcined clay cement (LC³) in an alternate wet and dry media. The samples underwent wet–dry conditions of 28 cycles. Two types of LC³ were studied, one made from clay (LC³-CL) and the other made from fired rejected clay bricks (LC³-FR). The composition of each LC³ blend by weight was 50% clinker, 30% calcined clay, 15% limestone, and 5% gypsum. The reference compressive strength was evaluated at 2, 7, and 28 days of age. Then, ordinary Portland cement (OPC) and LC³-CL blends were subjected to alternate wet–dry cycle tests, immersion in a 5% sodium sulfate solution, or in water. For all exposed samples, sorptivity tests and compressive strength were done. The results showed that LC³ blends met the requirements for KS-EAS 18-1:2017 standard, which specifies the composition and conformity criteria for common cements in Kenya. The LC³ blend also had a lower rate of initial absorption compared to OPC. Additionally, LC³ blend also showed good resistance to sodium sulfate when exposed to alternating wetting and drying environment. OPC showed higher compressive strength than LC³ blends for testing ages of 2, 7, and 28 days. However, the LC³ samples utilized in the sodium sulfate attack experiment, which were later tested after 84 days, exhibited higher compressive strengths than OPC tested after the same period.     

Recycling Blast Furnace Ferronickel Slag as a Replacement for Paste in Mortar: Formation of Carboaluminate,Reduction of White Portland Cement,and Increase in Strength

Blast furnace ferronickel slag (BFFS) is generated in the production of ferronickel alloys and is used as cement replacement in concrete or mortar. The effectivity in reducing cement consumption and improving performance are limited. By referring to the paste replacement method, this work used BFFS to replace an equal volume of the white Portland cement paste to obtain greater performance enhancement. BFFS was used with five levels of replacement (0%, 5%, 10%, 15%, 20%) and four water-to-cement ratios (0.40, 0.45, 0.50, 0.55) were designed. Fluidity, mechanical strength, hydration products, and pore structure of every mixture were measured. The results showed that the workability of the mortars decreased due to the reduced volume of water, but the 28-day compressive strength of the mortars increased, and the cement content of the mortars was also reduced by 33 wt %. The X-ray diffraction (XRD) patterns revealed that there existed a carboaluminate phase, and the presence of the ettringite was stabilized, indicating that the accumulating amount of the hydration products of the mortar increased. Furthermore, the BFFS could consume the portlandite and free water to form a higher amount of chemically bound water due to its pozzolanic activity. A high degree of hydration and a large volume of the hydration products refined the porosity of the hardened mortars, which explained the enhancement of the strength of the mortars. Compared to the cement replacement method, the paste replacement method was more effective in preparing eco-friendly mortar or concrete by recycling BFFS for reducing the cement content of the mortar while improving its strength.     

The Effect of Acidity Coefficient on the Crystallization Properties and Viscosity of Modified Blast Furnace Slag for Mineral Wool Production

The crystallization and viscosity of modified blast furnace slag are key factors in fiber forming conditions. In this paper, the crystallization behavior of modified blast furnace slag under continuous cooling conditions was studied by differential scanning calorimetry, and its crystallization kinetics with different acidity coefficients were established. On this basis, the evolution law of the crystallization phase and the influence of crystallization on the viscosity of modified blast furnace slag with different acidity coefficients were analyzed. The results indicated that the crystallization phases of slag with acidity coefficients of 1.05 and 1.20 were, respectively, Melilite and Anorthite. During the cooling process at the acidity coefficient of 1.05, the critical rates of precipitation of Melilite and Anorthite were 50 °C/s and 20 °C/s, respectively, while they were 20 °C/s and 15 °C/s, respectively, at the acidity coefficient of 1.20. With the increase of the acidity coefficient, the crystal growth mode of slag changed from two-dimensional and three-dimensional mixed crystallization to surface nucleation and one-dimensional crystallization. The crystallization activation energy of slag with acidity coefficients of 1.05 and 1.20 were 698.14 kJ/mol and 1292.50 kJ/mol, respectively. In addition, the change trend of viscosity was related to crystal size and content.     

Study on Mechanical and Frost Resistance Properties of Slag and Macadam Stabilized with Cement and Fly Ash

China is a large country in terms of coal production and consumption. The fly ash and slag produced by thermal power plants pose a great threat to the environment. To reduce the adverse effects of fly ash and slag on the environment, a mixture of slag and macadam stabilized with cement and fly ash was prepared as pavement base material. Compaction tests, unconfined compressive strength tests, splitting strength tests, frost resistance tests, and ultrasonic tests were performed on the mixture. The results show that with an increase in slag replacement rate, the unconfined compressive strength and splitting strength decreased. However, the adverse influence of the slag replacement rate on unconfined compressive strength and splitting strength of specimens gradually weakened with increasing curing time. The frost resistance of the mixture first increased and then decreased with an increase in the slag replacement rate. When cement content was 5% and the slag replacement rate was 50%, the frost resistance of the mixture was the best. Regression analysis of the ultrasonic test showed that the ultrasonic test can effectively characterize the strength of the mixture and the internal damage degree under freeze–thaw cycles. In conclusion, the slag replacement rate of the mixture is recommended to be ~50%, which has preferable mechanical and frost resistance performance.     

Use of Cement Kiln Dust,Blast Furnace Slag and Marble Sludge in the Manufacture of Sustainable Artificial Aggregates by Means of Cold Bonding Pelletization

In this work, three different samples of solid industrial wastes cement kiln dust (CKD), granulated blast furnace slag and marble sludge were employed in a cold bonding pelletization process for the sustainable production of artificial aggregates. The activating action of CKD components on the hydraulic behavior of the slag was explored by evaluating the neo-formed phases present in several hydrated pastes. Particularly, the influence of free CaO and sulfates amount in the two CKD samples on slag reactivity was evaluated. Cold bonded artificial aggregates were characterized by determining physical and mechanical properties of two selected size fractions of the granules for each studied mixture. Eighteen types of granules were employed in C28/35 concrete manufacture where coarser natural aggregate were substituted with the artificial ones. Finally, lightweight concretes were obtained, proving the suitability of the cold bonding pelletization process in artificial aggregate sustainable production.     

The Performance of Concrete Made with Secondary Products—Recycled Coarse Aggregates,Recycled Cement Mortar,and Fly Ash–Slag Mix

The properties of cement concrete using waste materials—namely, recycled cement mortar, fly ash–slag, and recycled concrete aggregate—are presented. A treatment process for waste materials is proposed. Two research experiments were conducted. In the first, concretes were made with fly ash–slag mix (FAS) and recycled cement mortar (RCM) as additions. The most favorable content of the concrete additive in the form of RCM and FAS was determined experimentally, and their influence on the physical and mechanical properties of concrete was established. For this purpose, 10 test series were carried out according to the experimental plan. In the second study, concretes containing FAS–RCM and recycled concrete aggregate (RCA) as a 30% replacement of natural aggregate (NA) were prepared. The compressive strength, frost resistance, water absorption, volume density, thermal conductivity, and microstructure were researched. The test results show that the addition of FAS–RCM and RCA can produce composites with better physical and mechanical properties compared with concrete made only of natural raw materials and cement. The detailed results show that FAS–RCM can be a valuable substitute for cement and RCA as a replacement for natural aggregates. Compared with traditional cement concretes, concretes made of FAS, RCM, and RCA are characterized by a higher compressive strength: 7% higher in the case of 30% replacement of NA by RCA with the additional use of the innovative FAS–RCM additive as 30% of the cement mass.     

Influence of Pozzolan,Slag and Recycled Aggregates on the Mechanical and Durability Properties of Low Cement Concrete

The sustainability of the construction sector demands the reduction of CO₂ emissions. The optimization of the amount of cement in concrete can be achieved either by partially replacing it by additions or by reducing the binder content. The present work aims at optimizing the properties of concrete used in the production of reinforced concrete poles for electrical distribution lines, combining the maximization of compactness with the partial replacement of cement by fly ash, natural pozzolans, and electric furnace slags. Natural aggregates were also partially replaced by recycled ones in mixtures with fly ash. Two types of concrete were studied: a fresh molded one with a dry consistency and a formwork molded one with a plastic consistency. The following properties were characterized: mechanical properties (flexural, tensile splitting, and compressive strengths, as well as Young’s modulus) and durability properties (capillary water absorption, water penetration depth under pressure, resistance to carbonation, chloride migration, and concrete surface resistivity). The service life of structures was estimated, taking the deterioration of reinforcement induced by concrete carbonation or chloride attack into account. Results revealed that mixtures with fly ash exhibit higher mechanical performance and mixtures with fly ash or pozzolans reveal much higher durability results than the full Portland cement-based mixtures.     

The Influence of Hydrated Lime and Cellulose Ether Admixture on Water Retention,Rheology and Application Properties of Cement Plastering Mortars

In this article, the effect of hydrated lime and cellulose ether on the water retention, rheology, and application properties of plasters was studied. For mortars, the consistency, bulk density, and water retention were tested. Rheological measurements of pastes included yield stress and plastic viscosity. In addition to standard tests of mortars and examining the rheological properties of the pastes, a proprietary method for testing the application properties was proposed. The obtained research results made it possible to evaluate the performance of the tested plasters. An attempt was also made to correlate the rheological properties of pastes (plastic viscosity) to the water retention value. The influence of hydrated lime and cellulose ether on selected properties of pastes and plasters was also presented using the statistical Box–Behnken method. The subjective rating of an expert plasterer confirmed the necessity of the modification of plastering mortars with hydrated lime and cellulose ether. As shown, modification of cement plastering mortar with hydrated lime and cellulose ether at the same time allows obtaining a material with favorable technical and technological properties, especially mortars applied by machine.