The Properties of Lightweight Aggregates Pre-Coated with Cement Pastes and Their Suitability for Concrete

One of the biggest technological problems connected with the production of lightweight concretes made of porous aggregates is their much higher water absorption, which may cause on the one hand workability loss, and on the other hand excess water content in concrete. The aim of this research was to assess the effect of impregnation of lightweight aggregates (LWAs) with cement paste on their properties and to verify its effectiveness in concretes. Three types of lightweight aggregates differing in porosity and pore structure (sintered fly ash Lytag, expanded clay: Leca and Liapor) were selected for the tests. The following parameters were taken into consideration in the research program: LWA type and size, LWA initial moisture content, strength, and rheology of cement pastes. The tests of 22 different aggregates, plain and coated with cement paste, included density, crushing strength, and development of water absorption in time. The research program proved that porous aggregates, due to their impregnation with cement pastes, may be effectively sealed and strengthened. All tested LWAs showed a considerable decrease in water absorption by up to 71%. However, only Lytag aggregate showed a visibly enhanced crushing strength. Verification of effectiveness of aggregate sealing on the enhancement of concrete properties showed both a considerable reduction in water absorption of composites (by up to 52%) and a very high increase in their strength (by up to 107%).     

Effect of Thermal Properties of Aggregates on the Mechanical Properties of High Strength Concrete under Loading and High Temperature Conditions

The effect of the thermal properties of aggregates on the mechanical properties of high-strength concrete was evaluated under loading and high-temperature conditions. For the concrete, granite was selected as a natural aggregate, and ash-clay and clay as lightweight aggregates. The mechanical properties of the concrete (stress–strain, compressive strength, elastic modulus, thermal strain, and transient creep) were evaluated experimentally under uniform heating from 20 to 700 °C while maintaining the load at 0, 20, and 40% of the compressive strength at room temperature. Experimental results showed that the concrete containing lightweight aggregates had better mechanical properties, such as compressive strength and elastic modulus, than that of the concrete with a granite aggregate at high temperature. In particular, the concrete containing lightweight aggregates exhibited high compressive strength (60–80% of that at room temperature) even at 700 °C. Moreover, the concrete containing granite exhibited a higher thermal strain than that containing lightweight aggregates. The influence of the binding force under loaded conditions, however, was found to be larger for the latter type. The transient creep caused by the loading was constant regardless of the aggregate type below 500 °C but increased more rapidly when the coefficient of the thermal expansion of the aggregate was above 500 °C.     

Effect of Lightweight Aggregate Impregnation on Selected Concrete Properties

The impregnation of lightweight aggregate (LWA) is an alternative method to its pre-moistening, which is used to limit the loss of fresh concrete workability due to the aggregate’s ability to absorb a great amount of mixing water. The aim of this study was to access the effectiveness, by pre-coating LWAs with cement paste, in modifying the properties of concrete composites. Two types of lightweight aggregates (Lytag and Leca) characterized with a relatively open-structure shell were selected. The other changeable parameters taken into consideration in this research were: LWA size, initial moisture of aggregate before the impregnation process and type of cement paste applied as an impregnant. Sixteen concretes prepared with pre-moistened and pre-coated lightweight aggregates were subject to a density test in different moisture conditions, a water absorption test and a compressive strength test. On the one hand, the pre-coating of LWAs with cement paste resulted in a relatively slight increase in concrete density (by up to 19%) compared to the pre-moistening of LWAs. On the other hand, it caused a very significant reduction (by up to 52%) in the composite’s water absorption and an incomparably greater growth (by up to 107%) in compressive strength. The most crucial factors determining the effectiveness of impregnation of LWAs with cement pastes in improvement of composite properties were the aggregate type and its size. The composition of impregnating slurry and the initial moisture content of LWA before pre-coating also mattered.     

Sustainable Green Lightweight Concrete Containing Plastic-Based Green Lightweight Aggregate

Nowadays the environment and its natural resources face many issues, related to the depletion of natural resources beside the increase in environmental pollution resulted from uncontrolled plastic waste disposal. Therefore, it is important to find effective and feasible solutions to utilize these wastes, such as using them to produce environmentally friendly green concrete. In this study, plastic-based green lightweight aggregates (PGLAs) containing PET plastic waste and by product additives were developed, and their subsequent physical and mechanical properties were compared with those of reference aggregates. Then, green lightweight aggregate concrete mixes (GLACs) were produced at 100% replacement of normal weight and lightweight coarse aggregate with developed PGLAs; and their fresh, hardened, microscopic and durability-related properties were compared to those of control mixes. Study results revealed that the unit weight of PGLAs were 21% to 29% less than that of normal coarse aggregate. Additionally, PGLAs had low water absorption that varied between 1.2% and 1.6%. The developed aggregates had 45% higher strength compared to that of lightweight coarse aggregate. Study results confirmed that structural green lightweight aggregate concretes (GLACs), that satisfied the dry density, compressive and splitting tensile strength requirements specified in ASTM C330, were feasibly produced. Finally, GLACs had low-to-moderate chloride penetration in accordance with ASTM C1202, thus it can be used in those areas exposed to the risk of chloride attack.     

Incorporation of Cement Bypass Dust in Hydraulic Road Binder

This article describes utilization of a cement kiln bypass dust utilization as an added component in a hydraulic road binder. Three experimental binder mixes (BM1–BM3) with variation in the composition of the main constituents (cement clinker, ground limestone and ground granulated blast furnace slag) and constant content of bypass dust (10%) were prepared under laboratory conditions. The properties of binder constituents, fresh experimental binder mixes and hardened specimens were tested according to STN EN 13282-2 for a normal hardening hydraulic road binder. The physical and chemical properties of all binder mixes (fineness: +90 µm ≤ 15 wt.%; SO₃ content: <4 wt.%) met the standard requirements. The bypass dust addition led to an increase in the water content for standard consistency of cement mixes (w/c = 0.23) and to a shortening of the initial setting time for two experimental blended cement pastes (BM1 and BM3) compared with the value required by the standard. Only BM2 with the lowest SO₃ content (0.363 wt.%) and the highest percentage of granulated blast furnace slag (9.5 wt.%) and alkalis (Na₂O and K₂O content of 5.9 wt.%) in the binder mix met the standard value for the initial setting time (≥150 min). The results of compressive strength testing of experimental specimens after 56 days of hardening (59.2–63.9 MPa) indicate higher values than the upper limit of the standard requirement for the N4 class (≥32.5; ≤52.5 MPa).     

Zeolite Lightweight Repair Renders: Effect of Binder Type on Properties and Salt Crystallization Resistance

Rendering mortars with lightweight zeolite aggregates were designed and tested. The effect of the type of binder used was also researched. For the hardened mortars, macrostructural parameters, mechanical characteristics, hygric and thermal properties were assessed. Specific attention was paid to the analysis of the salt crystallization resistance of the developed rendering mortars. Quartz sand was fully replaced in the composition of mortars with zeolite gave materials with low density, high porosity, sufficient mechanical strength, high water vapor permeability and high water absorption coefficient, which are technical parameters required for repair rendering mortars as prescribed in the WTA directive 2-9-04/D and EN 998-1. Moreover, the zeolite enhanced mortars exhibit good thermal insulation performance and high sorption capacity. The examined rendering mortars were found to be well durable against salt crystallization, which supports their applicability in salt-laden masonry. Based on the compatibility of the repair materials with those originally used, the lime and natural hydraulic lime zeolite mortars can be used as rendering mortars for the repair of historical and heritage buildings. The cement-lime zeolite render is applicable for repair purposes only in the case of the renewal of masonry in which Portland cement-based materials were originally used.     

Zeolite-Supported Aggregate as Potential Antimicrobial Agents in Gypsum Composites

Relatively easy treatment of glass aggregates can lead to the formation of a highly porous zeolite aggregate. This study focuses on the possibility of using such an aggregate as an active additive to a gypsum binder. The physical properties of hardened gypsum composites with zeolite fillers doped with various metal ions (Ni²⁺, Cu²⁺, and Zn²⁺) have been compared. In addition to studies of the basic physical properties of the composites, structural and microstructural studies as well as antimicrobial tests were performed. It was found that the parameters of the composites with the addition of various ions do not differ significantly from the reference but modifies the microstructure. Among other things, the ions analyzed reduce the microporosity of gypsum composites. Using all aggregates, a product with adequate strength (above 2 MPa) and thermal conductivity (about 0.35 W/m·K) appropriate for typical lightweight gypsum composites can be obtained. The bacteriostatic effect of formulations with copper and zinc against Escherichia coli and with copper against Staphylococcus aureus was found.     

Preparation and Characterization of the Functional Properties of Synthetic Aggregates from Silico-Manganese Slag

A large number of natural aggregates are used in the field of construction materials, resulting in the exhaustion of natural aggregates. Therefore, looking for an alternative will slow down the consumption of natural aggregates. The sintering method not only consumes a lot of energy to prepare aggregates but also produces a lot of pollutants. In this study, silico-manganese (SM) slag was dried, ground into powder, and used as raw material. Solid and liquid alkaline activator methods were used to prepare SM slag non-burning aggregate (SMNA) by the cold bonding method. The effects of grinding time, amounts of solid and liquid alkaline activators, curing temperature, and the amount of added fly ash on aggregate properties were investigated. The aggregate microstructure was characterized by XRD, SEM, and FTIR methods, and the toxic leaching analysis of aggregate was performed. The results showed that with a fixed amount of liquid activator (16.2% wt.) and solid activator (15% wt.) and fly ash (20% wt.), respectively, and curing was performed at room temperature, the aggregate properties were optimal: the bulk density of 1236.6–1476.9 kg/m³ and the water absorption lower than 4.9–5.5%. The apparent density was 1973.1–2281.6 kg/m³, and the bulk crushing strength was 24.7–27.9 MPa. The XRD, SEM, and FTIR results indicated that amorphous gel could be formed from SM under an alkaline activator, improving the aggregate strength. The results of toxic leaching showed that the aggregate prepared from SM exhibited environmentally friendly characteristics. The SMNA was obtained via the simple and low-energy consumption production process, paving the new way toward large-scale utilization of SM.     

Preparation and Physico-Chemical Performance Optimization of Sintering-Free Lightweight Aggregates with High Proportions of Red Mud

Sintering-free lightweight aggregates were prepared with high proportions of red mud and a binder material derived from whole solid wastes through rolling granulation at room temperature. The preparation process was optimized by changing the material matching and size parameters of the SFLAs. The physico-chemical performance, including the density, mechanical strength, water absorption, hydration products, heavy metal leaching, and microstructure were evaluated by jointly employing X-ray Fluorescence, X-ray Diffraction, and Inductively Coupled Plasma Optical Emission Spectrometry, Shadow Electron Microscope, etc. The results indicated that the red mud and waste-based binders were highly compatible in the granulation process, with up to 80% red mud being successfully added. The sintering-free lightweight aggregates products at the binder content of 30% and the size coverage of 10–16 mm exhibited a bulk density of 900–1000 kg·m⁻³, a 28 d cylinder compressive strength of 9.2–11.3 MPa, and water absorption of less than 10%. Owing to the formation of important hydration products, ettringite, the heavy metal leaching of the sintering-free lightweight aggregates was also proven to be environmentally acceptable. This work provides a promising pathway to prepare low-cost, high-strength, and green lightweight aggregates through the large-scale utilization of solid waste red mud.     

Effect of Ornamental Stone Waste Incorporation on the Rheology,Hydration, Microstructure,and CO2 Emissions of Ordinary Portland Cement

The ornamental stone industry generates large amounts of waste thus creating environmental and human health hazards. Thus, pastes with 0–30 wt.% ornamental stone waste (OSW) incorporated into ordinary Portland cement (OPC) were produced and their rheological properties, hydration kinetics, and mechanical properties were evaluated. The CO₂ equivalent emissions related to the pastes production were estimated for each composition. The results showed that the paste with 10 wt.% of OSW exhibited similar yield stress compared to the plain OPC paste, while pastes with 20 and 30 wt.% displayed reduced yield stresses up to 15%. OSW slightly enhanced the hydration kinetics compared to plain OPC, increasing the main heat flow peak and 90-h cumulative heat values. The incorporation of OSW reduced the 1-, 3-, and 28-days compressive strength of the pastes. Water absorption results agreed with the 28 days compressive strength results, indicating that OSW increased the volume of permeable voids. Finally, OSW incorporation progressively reduced the CO₂ emission per m³ of OPC paste, reaching a 31% reduction for the highest 30 wt.% OSW content. Overall, incorporating up to 10 wt.% with OSW led to pastes with comparable fresh and hardened properties as comported to plain OPC paste.     

Mechanical Properties and Microstructure of Epoxy Mortars Made with Polyethylene and Poly(Ethylene Terephthalate) Waste

The article describes the results of a study to determine the simultaneous effect of polyethylene terephthalate waste (PET) and polyethylene (PE) on the strength characteristics and bulk density of epoxy mortars. In these mortars, 9 wt.% of the polymer binder was replaced by glycolysate which was made from PET waste and propylene glycol. Additionally, 0–10 vol.% of the aggregate was substituted with PE agglomerate made from plastic bags waste, respectively. The modification of the composition of epoxy mortar has a special environmental and economic aspect. It also allows to protect natural sources of the aggregate, while reducing the amount of waste and reducing problems arising from the need to store them. The resulting composite has very good strength properties. With the substitution of 9 wt.% of resin and 5 vol.% of sand, a flexural strength of 35.7 MPa and a compressive strength of 101.1 MPa was obtained. The results of the microstructure study of the obtained mortars constitute a significant part of the paper.     

Waste-Based One-Part Alkali Activated Materials

Ordinary Portland Cement is the most widely used binder in the construction sector; however, a very high carbon footprint is associated with its production process. Consequently, more sustainable alternative construction materials are being investigated, namely, one-part alkali activated materials (AAMs). In this work, waste-based one-part AAMs binders were developed using only a blast furnace slag, as the solid precursor, and sodium metasilicate, as the solid activator. For the first time, mortars in which the commercial sand was replaced by two exhausted sands from biomass boilers (CA and CT) were developed. Firstly, the characterization of the slag and sands (aggregates) was performed. After, the AAMs fresh and hardened state properties were evaluated, being the characterization complemented by FTIR and microstructural analysis. The binder and the mortars prepared with commercial sand presented high compressive strength values after 28 days of curing-56 MPa and 79 MPa, respectively. The mortars developed with exhausted sands exhibit outstanding compressive strength values, 86 and 70 MPa for CT and CA, respectively, and the other material’s properties were not affected. Consequently, this work proved that high compressive strength waste-based one-part AAMs mortars can be produced and that it is feasible to use another waste as aggregate in the mortar’s formulations: the exhausted sands from biomass boilers.     

On Developing a Hydrophobic Rubberized Cement Paste

It is well known that most cement matrix materials are hydrophilic. For structural materials, hydrophilicity is harmful because the absorption of water will induce serious damage to these materials. In this study, crumb rubber was pretreated by partial oxidation and used as an additive to develop a hydrophobic rubberized cement paste. The pretreated crumb rubber was investigated using Fourier-transform infrared spectrometry (FT-IR) to understand the function groups on its surface. The pyrolysis oil adsorbed on the surface of the crumb rubber was observed by FT-IR and nuclear magnetic resonance (NMR) spectroscopy. A colloid probe with calcium silicate hydrate (C–S–H) at the apex was prepared to measure the intermolecular interaction forces between the crumb rubber and the C-S-H using an atomic force microscope (AFM). Pure cement paste, cement paste with the as-received crumb rubber, and cement paste with pretreated crumb rubber were prepared for comparison. FT-IR, X-ray diffraction (XRD), and scanning electron microscopy (SEM) were used to understand the microstructure of the pastes. The static contact angle was used as the index of the hydrophobicity of the pastes. Experimental results showed that the hardened cement paste containing partially oxidized crumb rubber had excellent hydrophobic properties with an insignificant reduction in the compressive strength.     

Bond–Slip Relationship between Sand-Coated Polypropylene Coarse Aggregate Concrete and Plain Rebar

Recycled plastic waste as an aggregate in concrete mixtures is one of the important issues in the construction industry since it allows the reduction of building weight and has beneficial effects on the environment. In addition, the bonding ability of this kind of lightweight concrete to reinforcement is also a prerequisite as a composite material in forming reinforced concrete structures. Therefore, in this study, the bond of plain rebar embedded in artificial lightweight aggregate concrete made from polypropylene plastic waste coated with sand was investigated. A pull-out test of nine group specimens was conducted to study the bond strength of 10 mm, 12 mm, and 16 mm diameter plain rebar embedded in polypropylene plastic waste coarse aggregates lightweight concrete (PWCAC), failure mode, and bond stress–slip relationship. The test results show that the bond–slip relationship and bond strength depend mainly on the bar diameter for PWCAC. Meanwhile, for all PWCAC specimens tested, the pull-out failure modes were observed. A bond equation for PWCAC was formulated by performing a regression analysis on the experimental results and afterward was combined with an existing bond–slip equation for normal concrete to have the bond–slip formulation for the lightweight concrete studied. The comparison between the model and experimental results indicates a close agreement.     

Thermophysical and Mechanical Properties of Hardened Cement Paste with Microencapsulated Phase Change Materials for Energy Storage

In this research, structural-functional integrated cement-based materials were prepared by employing cement paste and a microencapsulated phase change material (MPCM) manufactured using urea-formaldehyde resin as the shell and paraffin as the core material. The encapsulation ratio of the MPCM could reach up to 91.21 wt%. Thermal energy storage cement pastes (TESCPs) incorporated with different MPCM contents (5%, 10%, 15%, 20% and 25% by weight of cement) were developed, and their thermal and mechanical properties were studied. The results showed that the total energy storage capacity of the hardened cement specimens with MPCM increased by up to 3.9-times compared with that of the control cement paste. The thermal conductivity at different temperature levels (35–36 °C, 55–56 °C and 72–74 °C) decreased with the increase of MPCM content, and the decrease was the highest when the temperature level was 55–56 °C. Moreover, the compressive strength, flexural strength and density of hardened cement paste decreased with the increase in MPCM content linearly. Among the evaluated properties, the compressive strength of TESCPs had a larger and faster degradation with the increase of MPCM content.     

Mechanical and Thermal Properties of Synthetic Polypropylene Fiber–Reinforced Renewable Oil Palm Shell Lightweight Concrete

Oil palm shell (OPS) is an agricultural solid waste from the extraction process of palm oil. All these wastes from industry pose serious disposal issues for the environment. This research aims to promote the replacement of conventional coarse aggregates with eco-friendly OPS aggregate which offers several advantages, such as being lightweight, renewable, and domestically available. This paper evaluates the mechanical and thermal performances of renewable OPS lightweight concrete (LWC) reinforced with various type of synthetic polypropylene (SPP) fibers. Monofilament polypropylene (MPS) and barchip polypropylene straight (BPS) were added to concrete at different volume fractions (singly and hybrid) of 0%, 0.1%, 0.3% and 0.4%. All specimens were mixed by using a new mixing method with a time saving of up to 14.3% compared to conventional mixing methods. The effects of SPP fibers on the mechanical properties were investigated by compressive strength, splitting tensile strength and residual strength. The strength of the oil palm shell lightweight concrete hybrid 0.4% (OPSLWC–HYB–0.4%) mixture achieved the highest compressive strength of 29 MPa at 28 days. The inclusion of 0.3% of BPS showed a positive outcome with the lowest thermal conductivity value at 0.55 W/m °C. Therefore, the results revealed that incorporation of BPS fiber enhanced the performance of thermal conductivity tests as compared to inclusion of MPS fiber. Hence, renewable OPS LWC was proven to be a highly recommended environmentally friendly aggregate as an alternative solution to replace natural aggregates used in the concrete industry.     

The Effect of Crystalline Waterproofing Admixtures on the Self-Healing and Permeability of Concrete

This paper investigates the effectiveness of a specific crystalline waterproofing admixture (CWA) in concrete as a function of a water–binder ratio. Four concrete mixes with and without CWA were prepared; two of them with a water–binder ratio of 0.45 and two of them with a water–binder ratio of 0.55. Water permeability and compressive strength were tested on hardened concrete specimens and self-healing of cracks over time was observed. Cement paste and CWA paste were prepared to clarify the results obtained on the concrete specimens. SEM and EDS and XRD and FTIR were performed on the hardened pastes to explain the mechanism of CWA working. The results show that the addition of CWA had no significant effect on the compressive strength of the concrete, but reduced the water penetration depth in the concrete, and the reduction was more effective for mixes with lower water–binder ratio. Regarding the self-healing effect, it can be concluded that the addition of CWA improves the crack healing in concrete, but the efficiency of self-healing is highly dependent on the initial crack width. The mechanisms involved in the reduction of water penetration depth and crack healing in concrete can be explained by different mechanisms; one is creation of the CSH gel from unreacted clinker grains, then formation carbonate, and additional mechanism is gel formation (highly expansive Mg-rich hydro-carbonate) from magnesium based additives. The presence of sodium silicate, which would transform into carbonate/bicarbonate, also cannot be excluded.     

Adverse Effects of Using Metallurgical Slags as Supplementary Cementitious Materials and Aggregate: A Review

This paper discusses a sustainable way to prepare construction materials from metallurgical slags. Steel slag, copper slag, lead-zinc slag, and electric furnace ferronickel slag are the most common metallurgical slags that could be used as supplementary cementitious materials (SCMs) and aggregates. However, they have some adverse effects that could significantly limit their applications when used in cement-based materials. The setting time is significantly delayed when steel slag is utilized as an SCM. With the addition of 30% steel slag, the initial setting time and final setting time are delayed by approximately 60% and 40%, respectively. Because the specific gravity of metallurgical slags is 10–40% higher than that of natural aggregates, metallurgical slags tend to promote segregation when utilized as aggregates. Furthermore, some metallurgical slags deteriorate the microstructure of hardened pastes, resulting in higher porosity, lower mechanical properties, and decreased durability. In terms of safety, there are issues with the soundness of steel slag, the alkali-silica reaction involving cement and electric furnace ferronickel slag, and the environmental safety concerns, due to the leaching of heavy metals from copper slag and lead-zinc slag.     

Mechanical and Electrical Characteristics of Lightweight Aggregate Concrete Reinforced with Steel Fibers

There is increased interest in applying electromagnetic (EM) shielding to prevent EM interference, which destroys electronic circuits. The EM shielding’s performance is closely related to the electrical conductivity and can be improved by incorporating conductive materials. The weight of a structure can be reduced by incorporating lightweight aggregates and replacing the steel rebars with CFRP rebars. In this study, the effects of lightweight coarse aggregate and CFRP rebars on the mechanical and electrical characteristics of concrete were investigated, considering the steel fibers’ incorporation. The lightweight coarse aggregates decreased the density and strength of concrete and increased the electrical conductivity of the concrete, owing to its metallic contents. The steel fibers further increased the electrical conductivity of the lightweight aggregate concrete. These components improved the EM shielding performance, and the steel fibers showed the best performance by increasing shielding effectiveness by at least 23 dB. The CFRP rebars behaved similarly to steel rebars because of their carbon fiber content. When no steel fiber was mixed, the shielding effectiveness increased by approximately 2.8 times with reduced spacing of CFRP rebars. This study demonstrates that lightweight aggregate concrete reinforced with steel fibers exhibits superior mechanical and electrical characteristics for concrete and construction industries.     

An Experimental Study on Structural Concrete Containing Recycled Aggregates and Powder from Construction and Demolition Waste

For complete utilization of construction and demolition (C&D) waste, an investigation of all size fractions of C&D waste generated during the recycling process should be conducted. In this work, the effects of three recycled concrete materials with different sizes (recycled coarse aggregate (RCA) with a size of 4.75–25 mm, recycled fine aggregate (RFA) of 0.15–4.75 mm, and recycled powder (RP) smaller than 0.15 mm) produced from concrete waste on the fresh and hardened mechanical properties of concrete were evaluated. The replacement ratios of natural coarse and fine aggregates by RCA and RFA were 30, 60, and 100%, and those of ordinary Portland cement for RP were 10, 20, and 30%. The results showed that the concrete properties deteriorated with increasing replacement ratio regardless of the type of recycled materials. The properties were reduced in the order of the use of RFA, RCA, and the simultaneous use of RCA and RFA. In addition, concrete with 30% RP showed lower mechanical strength than concrete with 100% RCA and 100% RFA. However, all concretes could be applicable for structural purposes under different environmental exposure conditions. In particular, concretes with 10% RP and 20% RP showed better cost-benefits compared to natural aggregate concrete with 100% ordinary Portland cement. These promising findings provide valuable initiatives for the effective and complete recycling of C&D waste.