Permeation Properties and Pore Structure of Surface Layer of Fly Ash Concrete

This paper presents an experimental study on the nature of permeation properties and pore structure of concrete surface layers containing fly ash. Concretes containing different dosages of fly ash as a replacement for cement (15% and 30% by weight of total cement materials, respectively) were investigated. Concrete without any fly ash added was also employed as the reference specimen. Laboratory tests were conducted to determine the surface layer properties of concrete including chloride transport, apparent water permeability and pore structure. The results demonstrate that incorporation of fly ash, for the early test period, promotes the chloride ingress at the surface layer of concrete but substituting proportions of fly ash may have little impact on it. With the process of chloride immersion, the chloride concentration at the surface layer of concrete with or without fly ash was found to be nearly the same. In addition, it is suggested that the water permeability at the concrete surface area is closely related to the fly ash contents as well as the chloride exposure time. Pore structure was characterized by means of mercury intrusion porosimetry (MIP) test and the scanning electron microscopy (SEM) images. The modification of pore structure of concrete submersed in distilled water is determined by the pozzolanic reaction of fly ash and the calcium leaching effect. The pozzolanic reaction was more dominant at the immersion time of 180 days while the calcium leaching effect became more evident after 270 days.     

Effect of Fly Ash on Leaching Characteristics of Cement-Stabilized Macadam Base

To study the leaching characteristics of a cement-stabilized macadam base with fly ash, a calcium leaching test, using varying cement and fly ash dosages in an ammonium chloride solution, was designed to obtain the rate of calcium ion leaching, porosity, and permeability coefficient of cement-stabilized macadam with leaching time. The results showed that the number of leached calcium ions increased with the cement dosage in the leaching of cement-stabilized macadam. With an increase in the cement dosage, the leaching rate of calcium ions decreased, and the leaching process of the material was delayed. The incorporation of fly ash could effectively slow down the degree of calcium ion leaching. The permeability coefficient increased gradually with the extension of leaching time, and the increase in fly ash content had a more significant effect on the improvement of the permeability coefficient than the increase in cement dosage did.     

Study on the Physical and Chemical Properties of Cement-Based Grout Containing Coal–Fly Ash

To study the physical and chemical properties of grout containing fly ash, Class II fly ash was used as a mineral admixture and mixed with silicate cement to produce grout, and the rheological properties, strength properties, hydration properties, and microscopic mechanism were studied. The results of the study showed the following. The incorporation of fly ash reduced the thixotropic area of the composite cement slurry, which facilitated pumping in the pipeline conveying process. The inclusion of fly ash reduced the yield stress and plastic viscosity of the cement paste, but the rheological index increased and then decreased with the increase in fly ash, and the composite paste had the lowest degree of shear thinning at 30% fly ash inclusion. The incorporation of fly ash reduced the hydration exothermic rate and total hydration exothermic amount of the composite slurry and prolonged the hydration induction period, but the promotion effect of fly ash on the hydration rate of cement was obvious at 10% fly ash admixture. The admixture of fly ash increased the empty volume of the composite slurry, but the effect on the most probable aperture was not significant, and the porosity of the system increased, resulting in a decrease in compressive strength. The effect of adding fly ash on the hydration products was reflected mainly by the C-S-H gel produced by cement hydration and the change in calcium alumina and Ca(OH)₂. Fly ash does not directly participate in the hydration reaction of cement, but it can promote cement hydration and increase the reaction rate of cement. By analyzing the rheological properties, mechanical properties, and hydration properties of fly ash composite cement paste, the comprehensive analysis found that the rheological properties are excellent when the fly ash admixture is 20–30%, and the water–cement ratio can be reduced to improve the strength without affecting the pumping demand.     

Effects of Leaching Behavior of Calcium Ions on Compression and Durability of Cement-Based Materials with Mineral Admixtures

Leaching of calcium ions increases the porosity of cement-based materials, consequently resulting in a negative effect on durability since it provides an entry for aggressive harmful ions, causing reinforcing steel corrosion. This study investigates the effects of leaching behavior of calcium ions on the compression and durability of cement-based materials. Since the parameters influencing the leaching behavior of cement-based materials are unclear and diverse, this paper focuses on the influence of added mineral admixtures (fly ash, slag and silica fume) on the leaching behavior of calcium ions regarding compression and durability of cemented-based materials. Ammonium nitrate solution was used to accelerate the leaching process in this study. Scanning electron microscopy, X-ray diffraction analysis, and thermogravimetric analysis were employed to analyze and compare the cement-based material compositions prior to and after calcium ion leaching. The experimental results show that the mineral admixtures reduce calcium hydroxide quantity and refine pore structure through pozzolanic reaction, thus enhancing the compressive strength and durability of cement-based materials.     

Performance of Cement Paste with Denitrified Fly Ash Containing NH4HSO4

The denitrification process was completed in coal-fired power plants, resulting in the fly ash containing NH₄HSO₄. When this kind of fly ash with ammonia was applied to cement and concrete, there could be phenomena such as a retarded setting time, decreased compressive strength, and volume expansion. This paper mainly investigated the influence of fly ash containing NH₄HSO₄ on the properties of fly ash cement paste, and pastes with NaHSO₄ were set as the control samples. The research on Na⁺ in cement hydration was studied. The influence of NH₄HSO₄ content in fly ash on the properties of fly ash cement paste was also investigated. It was found that NH₄⁺ could greatly affect the properties of fly ash cement paste, such as significantly reducing the fluidity, prolonging the setting time, decreasing the compressive strength, increasing the drying shrinkage, decreasing the total heat released during the hydration, and affecting the content of calcium hydroxide hydrate. Increasing the ammonia content of the denitrified fly ash would reduce fluidity, retard its setting time, increase the porosity of the cement stone, and increase the number of pores with large sizes in the fly ash cement paste. The increase of porosity and pores with large sizes in cement decreases the compressive strength and increases the drying shrinkage of the fly ash cement paste.     

Preparation and Properties of Foam Concrete Incorporating Fly Ash

Foam concrete is fire resistant and durable and has broad applicability as a building insulation material. However, cement has high energy consumption and causes pollution, necessitating an environment-friendly cementitious material to replace the cement used to prepare foam concrete. In this study, foam concrete was prepared through chemical foaming. The influence of the foaming agent material, foam stabiliser, and fly ash on the basic properties of the foam concrete, including the dry bulk density, compressive strength, and thermal conductivity, was studied, and the pore structure was characterised. The results show that with an increase in the hydrogen peroxide (H₂O₂) content, the dry bulk density, compressive strength, and thermal conductivity of foam concrete decreases, whereas the pore diameter increases (0.495 to 0.746 mm). When the calcium stearate content is within 1.8%, the pore size tends to increase (0.547 to 0.631 mm). With increase in the fly ash content, the strength of foam concrete gradually decreases, and the dry bulk density first decreases and then increases. When the blending ratio of fly ash is 10–40%, the thermal conductivity gradually decreases; an extreme thermal conductivity of 0.0824 W/(m·K) appears at the blending ratio of 40%, and the dry bulk density is 336 kg/m³.     

A Comprehensive Study on the Hardening Features and Performance of Self-Compacting Concrete with High-Volume Fly Ash and Slag

The main concern of this work is to evaluate the influences of supplementary cementitious materials (fly ash, slag) and a new type of polycarboxylate superplasticizer containing viscosity modifying agents (PCE-VMA) on the performance of self-compacting concrete (SCC). The workability, hydration process, mechanical property, chloride permeability, degree of hydration and pore structure of SCC were investigated. Results indicate that the addition of fly ash and slag slows down early hydration and decreases the hydration degree of SCC, and thus leads to a decline in compressive strengths, especially within the first 7 days. The addition of slag refines pore structure and contributes to lower porosity, and thus the chloride permeability of SCC is decreased during the late hydration stage. Additionally, a new factor of calculated water–binder ratio is put forward, which can directly reflect the free water content of concrete mixture after mixing, and guide the mix proportion design of SCC.     

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.     

Influence of Potassium-Based Alkaline Electrolyzed Water on Hydration Process and the Properties of Cement-Based Materials with Fly Ash

Alkaline electrolyzed water, a kind of clean green water with excellent characteristics such as high activity, strong alkalinity, high ion penetrating ability, electrical charge, and good molecule adsorption, was significant to the resource utilization of industrial fly ash waste. This paper studies highly active potassium-based alkaline electrolyzed water’s impact, compared with ordinary water, on the cement hydration process using microstructural methods such as a hydration heat test, differential thermal analysis, X-ray diffraction (XRD) pattern, and Scanning electron microscope (SEM) image analysis. Fly ash cement-based materials were first prepared with alkaline electrolyzed water as the mixing water. The alkaline electrolyzed water’s influence on fly ash paste workability and the mechanical properties of fly ash mortar for varying fly ash proportions were ratified. Then alkaline electrolyzed water with the best pH value was selected to prepare fly ash concrete, and its durability was studied. The test results showed that it is feasible to increase the utilization rate of fly ash by using alkaline electrolyzed water. Furthermore, it promoted the process of cement hydration, increased the rate of the hydration reaction, and the promotion effect increased with the increase in pH value of the alkaline electrolyzed water, and also promoted the effective decomposition of the vitreous shell of fly ash to stimulate its early activity. Concurrent tests with ordinary water paste showed that the water requirement for normal consistency and setting time with alkaline electrolyzed water paste were significantly less. Alkaline electrolyzed water also solved the problem related to the low early strength of fly ash mortar. Furthermore, using alkaline electrolyzed water with an optimum pH value of 11.5 to prepare fly ash concrete effectively reduced concrete’s carbonation depth and carbonation rate and lessened the chloride ion migration coefficient.     

Effects of Different Factors on the Performance of Recycled Aggregate Permeable Pavement Concrete

Urban construction has produced a large amount of construction waste which has caused huge environmental problems. The sponge city is the development direction of urban construction, and permeable pavement concrete is an important material for sponge city construction. To see the law influencing different factors on the performance of recycled aggregate permeable pavement concrete, different water binder ratios, recycled aggregate particle gradations, ordinary aggregate substitution rates, and fly ash and admixture contents are designed to prepare permeable concrete. The compressive strength, permeability coefficient, frost resistance, and pore structure of permeable concrete are tested. The results show that when the replacement rate of recycled aggregate is 50%, the 28-d strength of concrete with a 0.25 water binder ratio can reach 28.9 MPa, and the permeability coefficient is 13.26 mm/s. The addition of fly ash will reduce the compressive strength, and the permeability coefficient increases first and then decreases with the increase of the fly ash content. When the mass fraction of fly ash instead of cement is 12%, the 28-d strength is 94.8% of that of the cement group, and the permeability coefficient can reach 14.03 mm/s. A water-reducing agent can obviously improve the workability of permeable concrete; the best content of the water-reducing agent is 0.2% of the cement mass. A reasonable amount of fly ash and water-reducing agent can optimize the number of harmless holes and less harmful holes in the concrete to improve the frost resistance and strength after the freeze–thaw, and the frost resistance is F150. This study provides a theoretical basis and technical guarantee for the resource utilization of recycled aggregate in permeable pavement concrete.     

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.     

Using Fly Ash Wastes for the Development of New Building Materials with Improved Compressive Strength

Fly ash wastes (silica, aluminum and iron-rich materials) could be smartly valorized by their incorporation in concrete formulation, partly replacing the cement. The necessary binding properties can be accomplished by a simple procedure: an alkali activation process, involving partial hydrolysis, followed by gel formation and polycondensation. The correlations between the experimental fly ash processing conditions, particle characteristics (size and morphology) and the compressive strength values of the concrete prepared using this material were investigated by performing a parametric optimization study to deduce the optimal processing set of conditions. The alkali activation procedure included the variation of the NaOH solutions concentration (8–12 M), temperature values (25–65 °C) and the liquid/solid ratio (1–3). The activation led to important modifications of the crystallography of the samples (shown by powder XRD analysis), their morphologies (seen by SEM), particle size distribution and Blaine surface values. The values of the compressive strength of concrete prepared using fly ash derivatives were between 16.8–22.6 MPa. Thus, the processed fly ash qualifies as a proper potential building material, solving disposal-associated problems, as well as saving significant amounts of cement consumed in concrete formulation.     

Nano Calcium Carbonate (CaCO3) as a Reliable,Durable, and Environment-Friendly Alternative to Diminishing Fly Ash

Fly ash is widely used in the cement industry to improve the performance and durability of concrete. The future availability of fly ash, however, is a concern, as most countries are inclining towards renewable energy sources as opposed to fossil fuels. Additional concerns have been raised regarding the impact of strict environmental regulations on fly ash quality and variability. This paper, therefore, evaluates if nano calcium carbonate (nano CaCO₃) can be used as an alternative to fly ash. This paper presents comprehensive testing results (fresh, hardened, and durability) for OPC (Ordinary Portland Cement) and PLC (Portland Limestone Cement) concretes with 1% nano CaCO₃ and compares them to those for concretes with fly ash (both Class F and C). Compared to concretes with fly ash, OPC and PLC with nano CaCO₃ presented improved testing results in most cases, including later age strength, permeability, and scaling resistance. As nanotechnology in concrete is a relatively new topic, more research on the efficient use of nanotechnology, such as for proper dispersion of nano CaCO₃ in the concrete, has potential to offer increased benefits. Further, nano CaCO₃ is environmentally and economically viable, as it has the potential to be produced within the cement plant while utilizing waste CO₂ and generating economic revenue to the industry. Thus, nano CaCO₃ has the potential to serve as an alternative to fly ash in all beneficial aspects—economic, environmental, and technical.     

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%).     

Durability Performance of Self-Compacting Concrete Containing Crumb Rubber,Fly Ash and Calcium Carbide Waste

Waste tire disposal continues to pose a threat to the environment due to its non-biodegradable nature. Therefore, some means of managing waste tires include grinding them to crumb rubber (CR) sizes and using them as a partial replacement to fine aggregate in concrete. However, the use of CR has a series of advantages, but its major disadvantage is strength reduction. This leads to the utilization of calcium carbide waste (CCW) to mitigate the negative effect of CR in self-compacting concrete (SCC). This study investigates the durability properties of SCC containing CR modified using fly ash and CCW. The durability properties considered are water absorption, acid attack, salt resistance, and elevated temperature of the mixes. The experiment was conducted for mixes with no-fly ash content and their replica mixes containing fly ash to replace 40% of the cement. In the mixes, CR was used to partially replace fine aggregate in proportions of 0%, 10%, and 20% by volume, and CCW was used as a partial replacement to cement at 0%, 5%, and 10% by volume. The results indicate that the mixes containing fly ash had higher resistance to acid (H₂SO₄) and salt (MgSO₄), with up to 23% resistance observed when compared to the mix containing no fly ash. In addition, resistance to acid attack decreased with the increase in the replacement of fine aggregate with CR. The same principle applied to the salt attack scenario, although the rate was more rapid with the acid than the salt. The results obtained from heating indicate that the weight loss was reduced slightly with the increase in CCW, and was increased with the increase in CR and temperature. Similarly, the compressive strength was observed to slightly increase at room temperature (27 °C) and the greatest loss in compressive strength was observed between the temperature of 300 and 400 °C. However, highest water absorption, of 2.83%, was observed in the mix containing 20% CR, and 0% CCW, while the lowest water absorption, of 1.68%, was found in the mix with 0% CR, 40% fly ash, and 10% CCW. In conclusion, fly ash is recommended for concrete structures immersed in water, acid, or salt in sulphate- and magnesium-prone areas; conversely, fly ash and CR reduce the resistance of SCC to heat beyond 200 °C.     

Inhibition of Alkali-Carbonate Reaction by Fly Ash and Metakaolin on Dolomitic Limestones

In this paper, the dolomitic limestone determined as alkali–carbonate-reactive by various methods is used as an aggregate. Inhibition experiments were carried out on the basis of the concrete microbar method (RILEM AAR-5 standard), in which 10%, 30%, and 50% fly ash and metakaolin were used to replace cement. Thermogravimetric–differential scanning calorimetry (TG-DSC), X-ray diffractometry (XRD), mercury intrusion porosimetry (MIP), and scanning electron microscopy–energy dispersive X-ray spectrometry (SEM-EDS) were used to analyze the inhibition mechanism of fly ash and metakaolin on ACR. The results show that the expansion of samples at the age of 28 days are less than 0.10% when the fly ash contents exceed 30% and the metakaolin contents exceed 10%, which proves that the ACR is inhibited effectively. Meanwhile, the Ca(OH)₂ content of the samples was reduced and the pore structure of the samples was optimized after adding fly ash and metakaolin. The dolomite crystals in the samples containing 50% fly ash and metakaolin are relatively complete.     

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.     

Influence of Hydrated Lime on the Chloride-Induced Reinforcement Corrosion in Eco-Efficient Concretes Made with High-Volume Fly Ash

The main objective of this study was to analyze the influence that the addition of finely ground hydrated lime has on chloride-induced reinforcement corrosion in eco-efficient concrete made with 50% cement replacement by fly ash. Six tests were carried out: mercury intrusion porosimetry, chloride migration, accelerated chloride penetration, electrical resistivity, and corrosion rate. The results show that the addition of 10–20% of lime to fly ash concrete did not affect its resistance to chloride penetration. However, the cementitious matrix density is increased by the pozzolanic reaction between the fly ash and added lime. As a result, the porosity and the electrical resistivity improved (of the order of 10% and 40%, respectively), giving rise to a lower corrosion rate (i_CORR) of the rebars and, therefore, an increase in durability. In fact, after subjecting specimens to wetting–drying cycles in a 0.5 M sodium chloride solution for 630 days, corrosion is considered negligible in fly ash concrete with 10% or 20% lime (i_CORR less than 0.2 µA/cm²), while in fly ash concrete without lime, corrosion was low (i_CORR of the order of 0.3 µA/cm²) and in the reference concrete made with Portland cement, only the corrosion was high (i_CORR between 2 and 3 µA/cm²).     

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.     

Sustainable Use of Waste Oyster Shell Powders in a Ternary Supplementary Cementitious Material System for Green Concrete

The increasing concern for decarbonization and sustainability in construction materials is calling for green binders to partially replace cement since its production is responsible for approximately 8% of global anthropogenic greenhouse gas emissions. Supplementary cementitious materials (SCMs), including fly ash, slag, silica fume, etc., can be used as a partial replacement for ordinary Portland cement (OPC) owing to reduced carbon dioxide emissions associated with OPC production. This study aims to investigate the sustainable use of waste oyster shell powder (OSP)-lithium slag (LS)-ground granulated blast furnace slag (GGBFS) ternary SCM system in green concrete. The effect of ternary SCMs to OPC ratio (0%, 10%, 20%, and 30%) on compressive strength and permeability of the green concrete were studied. The reaction products of the concrete containing OSP-LS-GGBFS SCM system were characterized by SEM and thermogravimetric analyses. The results obtained from this study revealed that the compressive strength of concrete mixed with ternary SCMs are improved compared with the reference specimens. The OSP-LS-GGBFS ternary SCMs-based mortars exhibited a lower porosity and permeability compared to the control specimens. However, when the substitution rate was 30%, the two parameters showed a decline. In addition, the samples incorporating ternary SCMs had a more refined pore structure and lower permeability than that of specimens adding OSP alone. This work expands the possibility of valorization of OSP for sustainable construction materials.