Fly Ash with Ammonia: Properties and Emission of Ammonia from Cement Composites

The article presents the results of tests performed on fly ash with a high content of ammonium (up to 400 ppm) from the NOx reduction process. The main properties of fly ash were tested according to EN 450-1 and the results were compared with fly ash without ammonium. The comparison showed that fly ash with high concentration of ammonium suits the requirements of the European standard. Although the requirements do not limit the ammonium content, using such material as an additive for cement composites causes the emission of gaseous ammonium during mixing and from the final product. For this reason, the emission of ammonium from mortars containing fly ash were tested. The results have shown that using high ammonium fly ash might pollute indoor air and affect the health of users.     

Durability of Cement and Ash Mortars with Fluidized and Siliceous Fly Ashes Exposed to HCl Acid Environment over a Period of 2 Years

The paper presents results of research on the impact of fly ash from fluidized bed combustion (FBC) of lignite, used in quantities of 30 and 45% by mass, and the mixture of FBC and silicious fly ash in amount of 45% by mass, on properties of cement–ash mortars. Mortars were exposed to aggressive environment of 1, 3, and 5% HCl solutions for 2 years. Mortars containing 45% FBC exposed to 1% HCl solution (pH = 2) showed the highest durability from among other mortars. The growth of their strength observed after 90 days of testing in 1% HCl environment, as well as the lowest drop of strength after 730 days of exposure to this environment, resulted from the reduced amount of large pores from 20 to 200 nm in mortars containing fly ash, with simultaneous growth of smaller pores of <20 nm during testing. A beneficial effect has been demonstrated of FBC addition to cement on properties of cement–ash mortars exposed to the aggressive impact of the HCl. Mortars with FBC fly-ash content increased to 45% by mass showed higher strength values, smaller differences in linear and mass changes, and increased durability in an aggressive environment observed during 730 days of testing.     

Hybrid Materials Based on Fly Ash,Metakaolin, and Cement for 3D Printing

Nowadays, one very dynamic development of 3D printing technology is required in the construction industry. However, the full implementation of this technology requires the optimization of the entire process, starting from the design of printing ideas, and ending with the development and implementation of new materials. The article presents, for the first time, the development of hybrid materials based on a geopolymer or ordinary Portland cement matrix that can be used for various 3D concrete-printing methods. Raw materials used in the research were defined by particle size distribution, specific surface area, morphology by scanning electron microscopy, X-ray diffraction, thermal analysis, radioactivity tests, X-ray fluorescence, Fourier transform infrared spectroscopy and leaching. The geopolymers, concrete, and hybrid samples were described according to compressive strength, flexural strength, and abrasion resistance. The study also evaluates the influence of the liquid-to-solid ratio on the properties of geopolymers, based on fly ash (FA) and metakaolin (MK). Printing tests of the analyzed mixtures were also carried out and their suitability for various applications related to 3D printing technology was assessed. Geopolymers and hybrids based on a geopolymer matrix with the addition of 5% cement resulted in the final materials behaving similarly to a non-Newtonian fluid. Without additional treatments, this type of material can be successfully used to fill the molds. The hybrid materials based on cement with a 5% addition of geopolymer, based on both FA and MK, enabled precise detail printing.     

Use of Fluidized Bed Combustion Fly Ash as a Partial Substitute for Cement in Underwater Concrete Mixes

Despite limitations to coal combustion energy production, many countries face the still-unresolved problem of utilising the wastes from fluidised bed coal combustion. One direction of rational utilisation can be using these wastes in the building materials industry. The study aimed to analyse the possibility of using fluidised bed combustion fly ashes as a partial substitute for cement in the underwater concrete (UWC). Two groups of concrete mixes were tested, containing 20 to 50% of fluidised bed combustion fly ashes. Investigations of the rheological properties of the concrete mixes and the mechanical performance of the hardened concrete confirmed the possibility of replacing cement in UWC with fluidised bed combustion fly ash up to 30% of the cement mass. The higher content of the fly ashes significantly worsens the UWC strength as well as the consistency and wash-out loss of the concrete mixes, excluding its use in underwater concreting.     

The Influence of Cement Substitution by Biomass Fly Ash on the Polymer–Cement Composites Properties

The generation of energy for the needs of the population is currently a problem. In consideration of that, the biomass combustion process has started to be implemented as a new source of energy. The dynamic increase in the use of biomass for energy generation also resulted in the formation of waste in the form of fly ash. This paper presents an efficient way to manage this troublesome material in the polymer–cement composites (PCC), which have investigated to a lesser extent. The research outlined in this article consists of the characterization of biomass fly ash (BFA) as well as PCC containing this waste. The characteristics of PCC with BFA after 3, 7, 14, and 28 days of curing were analyzed. Our main findings are that biomass fly ash is suitable as a mineral additive in polymer–cement composites. The most interesting result is that the addition of biomass fly ash did not affect the rheological properties of the polymer–cement mortars, but it especially influenced its compressive strength. Most importantly, our findings can help prevent this byproduct from being placed in landfills, prevent the mining of new raw materials, and promote the manufacture of durable building materials.     

Influence of the Fly Ash Content on the Fresh and Hardened Properties of Alkali-Activated Slag Pastes with Admixtures

A study on the influence of the inclusion of slag or fly ash and five types of superplasticizers on the fresh and hardened properties of alkali-activated cements is presented. Three alkali-activated slag formulations with different fly ash content (0, 15, and 30%) in the presence of five admixtures (vinyl copolymer, melamine, and three polycarboxylates with different chain lengths) were assessed for fluidity control and setting adjustment without loss of mechanical properties. Solid sodium metasilicate was used as an alkaline activator. Their fresh and hardened properties were studied through slump, setting time, isothermal calorimetry, mechanical strengths, and porosity tests. The results showed that the increase of fly ash content delayed the reaction and improved workability but reduced compressive strengths. Concerning the admixtures, these maintained fluidity especially for the one based on polycarboxylate with very long chains. The melamine and polycarboxylate with very long chain admixtures did not have a drastic impact on mechanical properties at early ages; even a gain of flexural and compressive strength was noted.     

Influence of Mechanical and Mineralogical Activation of Biomass Fly Ash on the Compressive Strength Development of Cement Mortars

Biomass combustion is a significant new source of green energy in the European Union. The adequate utilization of byproducts created during that process is a growing challenge for the energy industry. Biomass fly ash could be used in cement composite production after appropriate activation of that material. This study had been conducted to assess the usefulness of mechanical and physical activation methods (grinding and sieving), as well as activation through the addition of active silica in the form of silica fume, as potential methods with which to activate biomass fly ash. Setting time, compressive strength, water absorption and bulk density tests were performed on fresh and hardened mortar. While all activation methods influenced the compressive strength development of cement mortar with fly ash, sieving of the biomass fly ash enhanced the early compressive strength of cement mortar. The use of active silica in the form of silica fume ensured higher compressive strength results than those of control specimens throughout the entire measurement period.     

Hydration Characteristics of Low-Heat Cement Substituted by Fly Ash and Limestone Powder

This study proposed a new binder as an alternative to conventional cement to reduce the heat of hydration in mass concrete elements. As a main cementitious material, low-heat cement (LHC) was considered, and then fly ash (FA), modified FA (MFA) by vibrator mill, and limestone powder (LP) were used as a partial replacement of LHC. The addition of FA delayed the induction period at the hydration heat curve and the maximum heat flow value (q_max) increased compared with the LHC based binder. As the proportion and fineness of the FA increased, the induction period of the hydration heat curve was extended, and the q_max increased. The hydration production of Ca(OH)₂ was independent of the addition of FA or MFA up to an age of 7 days, beyond which the amount of Ca(OH)₂ gradually decreased owing to their pozzolanic reaction. In the case of LP being used as a supplementary cementitious material, the induction period of the hydration heat curve was reduced by comparison with the case of LHC based binder, and monocarboaluminate was observed as a hydration product. The average pore size measured at an age of 28 days was smaller for LHC with FA or MFA than for 100% LHC.     

Effect of Cathodic Protection on Reinforced Concrete with Fly Ash Using Electrochemical Noise

Corrosion of steel reinforcement is the major factor that limits the durability and serviceability performance of reinforced concrete structures. Impressed current cathodic protection (ICCP) is a widely used method to protect steel reinforcements against corrosion. This research aimed to study the effect of cathodic protection on reinforced concrete with fly ash using electrochemical noise (EN). Two types of reinforced concrete mixtures were manufactured; 100% Ordinary Portland Cement (OCP) and replacing 15% of cement using fly ash (OCPFA). The specimens were under-designed protected conditions (−1000 ≤ E ≤ −850 mV vs. Ag/AgCl) and cathodic overprotection (E < −1000 mV vs. Ag/AgCl) by impressed current, and specimens concrete were immersed in a 3.5 wt.% sodium chloride (NaCl) Solution. The analysis of electrochemical noise-time series showed that the mixtures microstructure influenced the corrosion process. Transients of uniform corrosion were observed in the specimens elaborated with (OPC), unlike those elaborated with (OPCFA). This phenomenon marked the difference in the concrete matrix’s hydration products, preventing Cl⁻ ions flow and showing passive current and potential transients in most specimens.     

Evaluation of Strength Properties of Sand Stabilized with Wood Fly Ash (WFA) and Cement

The article describes the laboratory evaluation of mixtures of sand modified with wood fly ash (WFA) and additionally stabilized with different amounts of cement. Laboratory research includes determining the California Bearing Ratio (CBR), compressive and indirect tensile strengths of the mixtures, and the resistance of mixtures to freezing/thawing cycles. The aim of the research is to determine if WFA, an alternative material, can improve sand bearing capacity and contribute to strength development while reducing necessary cement amounts and satisfying the technical regulation for use in pavement base courses. The test results obtained show that WFA has a considerable stabilization effect on the sand mixture and improves its load bearing capacity. By adding a small quantity of the cement, the hydraulic reaction in the stabilized mixture is more intense and results in greater strengths and an improved resistance to freezing. The test results show that, by replacement of part of the sand with WFA (in the quantity of 30%), greater strengths can be achieved in relation to the mixture of only sand and cement. Additionally, the content of cement necessary for the stabilization of sand (usually 8–12%) is considerably reduced, which enables cost savings in the construction of pavement structures.     

Influence of Particle Morphology of Ground Fly Ash on the Fluidity and Strength of Cement Paste

The grinding process has become widely used to improve the fineness and performance of fly ash. However, most studies focus on the particle size distribution of ground fly ash, while the particle morphology is also an important factor to affect the performance of cement paste. This article aims at three different kinds of ground fly ash from the ball mill and vertical mill, and the particle morphology is observed by scanning electron microscopy (SEM) to calculate the spherical destruction (the ratio of spherical particles broken into irregular particles in the grinding process of fly ash), which provides a quantification of the morphology change in the grinding process. The fluidity of cement paste and the strength of cement mortar are tested to study the relation of spherical destruction and fluidity and strength. The results show that the spherical destruction of ground fly ash in a ball mill is more than 80% and that in a vertical mill with a separation system is only 11.9%. Spherical destruction shows a significant relation with the fluidity. To different addition of ground fly ash, the fluidity of cement paste decreases with the increase of spherical destruction. To the strength of cement paste, particle size distribution and spherical destruction are both the key factors. Therefore, spherical destruction is an important measurement index to evaluate the grinding effect of the fly ash mill.     

Assessment of the Possibility of Using Fly Ash from Biomass Combustion for Concrete

This article analyses the possibility of using fly ash from the combustion of wood–sunflower biomass in a fluidized bed boiler as an additive to concrete. The research shows that fly ash applied in an amount of 10–30% can be added as a sand substitute for the production of concrete, without reducing quality (compression strength and low-temperature resistance) compared to control concrete. The 28-day compressive strength of concrete with fly ash increases with the amount of ash added (up to 30%), giving a strength 28% higher than the control concrete sample. The addition of fly ash reduces the extent to which the compression strength of concrete is lowered after low-temperature resistance tests by 22–82%. The addition of fly ash in the range of 10–30% causes a slight increase in the water absorption of concrete. Concretes containing the addition of fly ash from biomass combustion do not have a negative environmental impact with respect to the leaching of heavy metal ions into the environment.     

Experimental Study of Chloride Resistance of Polypropylene Fiber Reinforced Concrete with Fly Ash and Modeling

Herein, the paper reports an experimental investigation lasting one year on the chloride resistance of polypropylene fiber (PF) reinforced concrete with fly ash (FA). Four influential factors at four levels were studied, viz. water to binder ratio (w/b) (0.53, 0.34, 0.29, and 0.25), PF dosage (0%, 0.06%, 0.08%, and 0.1% in volume basis of the total volume of concrete), FA content (0%, 15%, 25%, and 35% in mass substitution ratio of cement) and concentration of NaCl solution (0%, 3%, 5%, and 7%). Dry–wet cyclic immersion and long-term soaking were taken into consideration in addition to the aforementioned factors. A L16(4⁴) orthogonal table was used to sequence influencing factors and to determine the optimal combination. Results showed that 7% NaCl solution caused the highest chloride content in 0–5 mm depth, whilst the w/b ratio of 0.25 curbed the chloride penetration within 10 mm even for concrete subjected to dry–wet cyclic immersion for 360 d. Subsequently, a respond surface model (RSM) basing on polynomials was constructed to visually evaluate the effect of PF dosage and FA content. Results clarified that a cubic model was more precise and PF dosage and FA content turned out to have the positive facilitation to chloride resistance. The positive effect of PF however is not consistent and commensurate for concrete with varied fly ash content. Finally, a fuzzy logic based nonlinear model accommodating all seven influencing factors was verified to be proper and adaptive in predicting chloride content.     

Prediction of the Chloride Resistance of Concrete Modified with High Calcium Fly Ash Using Machine Learning

The aim of the study was to generate rules for the prediction of the chloride resistance of concrete modified with high calcium fly ash using machine learning methods. The rapid chloride permeability test, according to the Nordtest Method Build 492, was used for determining the chloride ions’ penetration in concrete containing high calcium fly ash (HCFA) for partial replacement of Portland cement. The results of the performed tests were used as the training set to generate rules describing the relation between material composition and the chloride resistance. Multiple methods for rule generation were applied and compared. The rules generated by algorithm J48 from the Weka workbench provided the means for adequate classification of plain concretes and concretes modified with high calcium fly ash as materials of good, acceptable or unacceptable resistance to chloride penetration.     

Influence of Cement Replacement with Fly Ash and Ground Sand with Different Fineness on Alkali-Silica Reaction of Mortar

The alkali-silica reaction (ASR) is an important consideration in ensuring the long-term durability of concrete materials, especially for those containing reactive aggregates. Although fly ash (FA) has proven to be useful in preventing ASR expansion, the filler effect and the effect of FA fineness on ASR expansion are not well defined in the present literature. Hence, this study aimed to examine the effects of the filler and fineness of FA on ASR mortar expansion. FAs with two different finenesses were used to substitute ordinary Portland cement (OPC) at 20% by weight of binder. River sand (RS) with the same fineness as the FA was also used to replace OPC at the same rate as FA. The replacement of OPC with RS (an inert material) was carried out to observe the filler effect of FA on ASR. The results showed that FA and RS provided lower ASR expansions compared with the control mortar. Fine and coarse fly ashes in this study had almost the same effectiveness in mitigating the ASR expansion of the mortars. For the filler effect, smaller particles of RS had more influence on the ASR reduction than RS with coarser particles. A significant mitigation of the ASR expansion was obtained by decreasing the OPC content in the mortar mixture through its partial substitution with FA and RS.     

Use of Isothermal and Isoperibolic Calorimetry to Study the Effect of Zinc on Hydration of Cement Blended with Fly Ash

Increasing utilization of secondary raw materials and alternative fuels results in increasing contents of metals in cements. Zinc is one of these elements. It comes to cement with secondary raw materials such as slag or fly ash or by the utilization of used tires as an alternative fuel. Zinc ions significantly prolong the hydration process in cement. This work deals with the influence of zinc ions in the form of very poorly soluble ZnO salt and easily soluble ZnCl₂ and Zn(NO₃)₂ on the hydration of cement blended with fly ash. Zinc was dosed in the range of 0.05%, 0.1%, 0.5% and 1% of cement weight. The effect of zinc on hydration was monitored by isothermal and isoperibolic calorimetry. A 15% addition of fly ash to cement mainly causes further retardation of hydration reactions due to the reactions of fly ash particles with Ca²⁺ ions from cement. The strongest effect on the hydration retardation from all investigated compounds showed in ZnO as it dissolves very slowly. On the contrary, for the dosage of 1% of zinc in the form of ZnCl₂ significant acceleration of hydration occurred. In this work, a synergistic effect on the prolongation of hydration with a combination of cement, zinc and fly ash was demonstrated. The lengths of induction periods were assessed from detected calorimetric curves and from these lengths the curves were gained by fitting with the exponential function. Final products were next analyzed using X-ray diffraction.     

Investigation of the Effect of Mixing Time on the Mechanical Properties of Alkali-Activated Cement Mixed with Fly Ash and Slag

This is an experiment on the effect of mixing time for alkali-activated cement (AAC) using a binder mixed with ground granulated blast furnace slag (slag) and fly ash (FA) in a ratio of 1:1 on the mechanical properties. The mixing method of ASTM C305 was used as the basic mixing method, and the following mixing method was changed. Simply adding the same mixing time and procedure, the difference in the order of mixing slag and FA, and controlling the amount of activator and mixed water were considered. As a result of the experiment, the addition of the same mixing time and procedure, pre-injection of slag, and high-alkali mixed water in which half of the activator and mixing water were mixed showed the highest mechanical properties and a dense pore structure. As a result, the design of a blending method that can promote the activation action of slag rather than FA at room temperature was effective in improving the mechanical properties of AAC. In addition, these blending factors showed a clearer effect as the concentration of the activator increased. Through the results of this experiment, it was shown that high-temperature curing, high fineness of the binder, or even changing the setting of the mixing method without the use of excessive activators can lead to an improvement of mechanical properties.     

Effect of High Calcium Fly Ash,Ladle Furnace Slag,and Limestone Filler on Packing Density,Consistency, and Strength of Cement Pastes

Environmental considerations and technical benefits have directed research towards reducing cement clinker content in concrete, and one of the best ways to do this is to replace cement with supplementary cementitious materials. High calcium fly ash, ladle furnace slag, and limestone filler were investigated as supplementary cementitious materials in cement pastes, and binary mixtures were produced at 10%, 20%, and 30% cement replacement rates for each material. The water requirement for maximum packing and for normal consistency were obtained for each paste, and strength development was determined at 3, 7, 28, and 90 days for the 20% replacement rate. Furthermore, two ternary mixtures at 30% cement replacement were also prepared for maximum packing density and tested for compressive strength development. The results showed that high calcium fly ash decreased cement paste packing and increased water demand but contributed to strength development through reactivity. Ladle furnace slag and limestone filler, on the other hand, were less reactive and seemed to contribute to strength development through the filler effect. The ternary paste with 70% cement, 20% high calcium fly ash, and 10% limestone filler showed equivalent strength development to that of the reference cement paste.     

Recyclability of Concrete Pavement Incorporating High Volume of Fly Ash

Recyclable concrete pavement was made from fly ash and crushed limestone sand and gravel as aggregates so that the concrete pavement could be recycled to raw materials for cement production. With the aim to use as much fly ash as possible for the sustainable development of society, while achieving adequate strength development, pavement concrete having a cement-replacement ratio of 40% by mass was experimentally investigated, focusing on the strength development at an early age. Limestone powder was added to improve the early strength; flexural strength at two days reached 3.5 MPa, the minimum strength for traffic service in Japan. The matured fly ash concrete made with a cement content of 200 kg/m³ achieved a flexural strength almost equal to that of the control concrete without fly ash. Additionally, Portland cement made from the tested fly ash concrete was tested to confirm recyclability, with the cement quality meeting the Japanese classification of ordinary Portland cement. Limestone-based recyclable fly ash concrete pavement is, thus, a preferred material in terms of sustainability.     

Impact of Fly Ashes from Combustion in Fluidized Bed Boilers and Siliceous Fly Ashes on Durability of Mortars Exposed to Seawater and Carbonation Process

This article presents test results of aggressive environment impact, i.e., seawater, acid solutions and carbonation, on the durability of cement–ash mortars. Tests were conducted on CEM I 42.5R-based mortars containing 35 to 70% by mass of FBC fly ash from brown and black coal combustion in a homogeneous form and mixtures of 35% by mass of siliceous fly ashes (CFA) and 35% by mass of FBC fly ash. It was demonstrated that in normal conditions (20 °C), FBC ashes showed higher pozzolanic activity than CFA, except when their curing temperature was increased to 50 °C. FBC ashes increased mortars’ water demands, which led to an accelerated carbonation process. In an environment of Cl^- ions, cement–ash mortars showed more Ca²⁺ ions leached and no expansive linear and mass changes, which, with their increased strength, might be an argument in favour for their future use in construction of coastal structures resistant to seawater. FBC ash content may be increased to 35% by mass, maintaining mortars’ resistance to seawater, acid rain and carbonation. A favourable solution turned out to be a FBC and CFA mixed addition to cement of 35% by mass each, in contrast to mortars containing 70% of FBC fly ash in homogeneous form.