Mechanical Properties and Microstructure of Class C Fly Ash-Based Geopolymer Paste and Mortar

This paper presents workability, compressive strength and microstructure for geopolymer pastes and mortars made of class C fly ash at mass ratios of water-to-fly ash from 0.30 to 0.35. Fluidity was in the range of 145–173 mm for pastes and 131–136 mm for mortars. The highest strengths of paste and mortar were 58 MPa and 85 MPa when they were cured at 70 °C for 24 h. In XRD patterns, unreacted quartz and some reacted product were observed. SEM examination indicated that reacted product has formed and covered the unreacted particles in the paste and mortar that were consistent with their high strength.     

The Durability of Mortar Containing Alkali Activated Fly Ash-Based Lightweight Aggregate

Beneficiating fly ash as valuable construction material such as artificial lightweight aggregate (LWA) could be an alternative solution to increase the utilization of the industrial by-product. However, generally, LWA is characterized by high porosity and a related high water absorption, which on the one hand allows production of lightweight mortar, but on the other hand can affect its performance. Thus, in this research, the durability performance of mortar composed with alkali-activated fly ash-based LWA, and commercial expanded clay (EC) LWA was investigated. The fly ash LWA was prepared in a pan granulator, with a 6-molar solution of NaOH mixed with Na₂SiO₃ in a Na₂SiO₃/NaOH weight ratio of 1.5 being used as activator (FA 6M LWA). The results revealed that mortar containing FA 6M LWA had equivalent mechanical strength with mortar containing EC LWA. The mortar containing FA 6M LWA had comparable capillary water uptake and chloride migration resistance with the reference and EC LWA mortar. Furthermore, the addition of FA 6M LWA was proven to enhance the carbonation resistance in the resulting mortar, due to the denser interfacial transition zone (ITZ) of mortar with LWA.     

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.     

Effect of Nano-SiO2/PVA on Corrosion Behavior of Steel Rebar Embedded in High-Volume Fly Ash Mortar under Accelerated Chloride Attack

In this paper, the influence of Nano-silica (NS) and Polyvinyl alcohol (PVA) fibers on the corrosion behavior of steel rebar embedded in high-volume fly ash cement mortars under accelerated chloride attack was studied by using an impressed voltage technique. The PVA fibers used were 1.0 vol.%, and two mass fractions of cement (50 and 60 wt.%) were replaced by fly ash. Four NS mass fractions (0, 0.5, 1.0, and 1.5 wt.%) were utilized in this paper. In addition, the mono and hybrid effects of NS and PVA on the mechanical properties and water absorption of mortar were also studied. The results showed that the incorporation of PVA and nano-SiO₂ can improve the flexural and compressive strengths of high-volume fly ash mortar. Generally, the flexural and compressive strengths increased with the increase of nano-SiO₂ content. Moreover, the incorporation NS can also reduce the capillary water–absorption rate of cement mortar. The impressed voltage corrosion test indicated that the composite incorporation of nano-SiO₂ and PVA can significantly delay the deterioration process of steel bars in mortar, effectively reducing the steel rebar’s corrosion level and increasing the exposure time of the surface crack. With hybrid-incorporation 1.0 vol.% PVA and 1.0 wt.% nano-SiO₂, the steel rebar had the lowest corrosion degree, which exhibited a mass loss of 49% and increased the broken time by 71% as compared to the control mortar.     

The Effect of Basalt Aggregates and Mineral Admixtures on the Mechanical Properties of Concrete Exposed to Sulphate Attacks

In this study, basalt, which is common around Diyarbakır province (Turkey), is used as concrete aggregate, waste materials as mineral additives and Portland cement as binding material to prepare concrete mixes. This paper aims to determine the proper admixture levels and usability of Diyarbakır basalt in concrete mixtures based on mechanical, physical and chemical tests. Thus, in order to determine the strength and durability performance of concrete mixtures with Diyarbakır basalt as aggregate, 72 sample cubes of 150 mm were prepared in three groups: mineral-free admixture (MFA), 10% of cement amount substituted for silica fume (SFS) and 20% for fly ash (FAS) as waste material. The samples were exposed to water curing and 100g/L sulphate solution to determine the loss in weight of the concrete cubes and compressive strength was examined at the end of 7, 28 and 360 days of the specimens. Analysis of the microstructure and cracks that influence durability, were also performed to determine effects of sulphate attacks alkali-silica reactions on the specimens using scanning electron microscopy (SEM). A loss in weight of the concrete cubes and compressive strength was distinctly evident at the end of 56 and 90 days in both acids.     

The Correlation of Temperature-Mineral Phase Transformation as a Controlling Factor of Thermal and Mechanical Performance of Fly Ash-Based Alkali-Activated Binders

This research focuses on an evaluation of mineral phase and structure transformations in Class F fly ash-based geopolymer systems. The research also studies the strength response of geopolymers when exposed to temperatures between 25 and 800 °C. The purpose of this research is to understand the processes that occur in alkali-activated systems within a wide range of high-working temperatures. The XRD, SEM, and DTA/TG analyses performed for the alkali-activated compositions after exposure to different temperatures confirmed a direct correlation of structural transformations with strength performance. The detrimental effect of sodium hydrocarbonate Na₃(HCO₃)(CO₃) 2H₂O or trona contained in one of the fly ash products was observed for the corresponding alkali-activated composite under high-temperature exposure between 600 and 800 °C. It was also detected that a high-temperature interval of 400–800 °C created favorable conditions that helped to form nanosized nepheline crystals and an additional vitreous substance that also contributed to a denser alkali-activated matrix.     

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.     

Strength and Microstructure of Geopolymer Based on Fly Ash and Metakaolin

The production of Portland cement is widely regarded as a major source of greenhouse gas emissions. This contributes to 6–7% of total CO₂ emissions, according to the International Energy Agency. As a result, several efforts have been made in recent decades to limit or eliminate the usage of Portland cement in concrete. Geopolymer has garnered a lot of attention among the numerous alternatives due to its early compressive strength, low permeability, high chemical resistance, and great fire-resistant behaviour. This study looks at the strength and microstructure of geopolymer based on fly ash and a combination of metakaolin and fly ash. Compressive strengths were measured at 7, 14, and 28 days, and microstructure was examined using SEM and XRD.     

Chloride Diffusion in Concrete Made with Coal Fly Ash Ternary and Ground Granulated Blast-Furnace Slag Portland Cements

Ternary Portland cement usage with a high amount of cement constituents different from clinker can afford great climate change advantages by lowering the Portland cement clinker content in the final product. This will contribute to cutting greenhouse gas emissions to close to zero by 2050. Such ternary Portland cements can be composed of different amounts of ground granulated blast-furnace slag (GBFS), coal fly ash (CFA), and clinker (K). Cements made with GGBFS, or CFA boast pozzolanic characteristics. Therefore, they would improve both the concrete compressive strength at later ages and durability. The 28- and 90-days mechanical strength test, non-steady state chloride migration test, described in NT BUILD 492, and natural chloride diffusion test (NT BUILD 443) were performed in concrete. Ternary cements made with GBFS and/or CFA presented better chloride diffusion resistance than concrete made with plain Portland cements. Furthermore, the development of compressive strength was delayed. The service life study was developed for concretes made with ternary cements with regard to the chloride penetration case.     

Morphology and Chemical Composition of Magnetic Particles Separated from Coal Fly Ash

Iron and other metal compounds are the materials that often appear in coal seams, because they also appear as a component of former organic matter in coal rocks. Although iron is the dominant element in coal rocks, other metals such as titanium, lead, cobalt, nickel, and copper are also present. In this study, the properties of magnetic particles of a size between 1 and 20 µm of globular structure and iron containing, were separated from coal fly ash, and studied using a scanning electron microscopy, energy disperse spectroscopy, and X-ray diffraction spectroscopy. The investigations were comprised of micrographs of the structure of these particles, their elemental composition, and phase analysis.     

The Performance Evaluation of Asphalt Mortar and Asphalt Mixture Containing Municipal Solid Waste Incineration Fly Ash

The aim of the research is to quantify the property of asphalt mortar and asphalt mixture containing municipal solid waste incineration (MSWI) fly ash. The potential of partially replacing mineral fillers with MSWI fly ash in asphalt mixture production was investigated. Five different MSWI fly ash replacement ratios, which include 0%, 25%, 50%, 75%, and 100%, were adopted to assess the influence of fly ash dosage, and the optimum fly ash replacement ratio was proposed. The rheological characteristics of asphalt mortar with MSWI fly ash were assessed with the dynamic shear rheometer (DSR) and bending beam rheometer (BBR). The high temperature properties of the mixture with MSWI fly ash were assessed with the Marshall stability test and the rutting test. The low temperature cracking property was determined with the indirect tensile strength test at low temperatures. The moisture stability property was identified with the immersed Marshall test and the freeze-thaw cycles conditioned indirect tensile strength test. Based on the test results, the addition of fly ash and mineral filler remarkably increased the ǀG*ǀ of the asphalt mortar. The δ of asphalt decreased as the dosage of fly ash and mineral filler increased. The addition of fly ash and mineral filler degraded the low temperature characteristics of the mortar. Fly ash improved the high temperature characteristics of the asphalt mixture. The asphalt mixture with MSWI fly ash was more susceptible to thermal cracking than the control sample. The addition of fly ash weakened the moisture stability of the asphalt mixture. In order to guarantee the low temperature characteristics and the moisture susceptibility of the asphalt mixture, the fly ash replacement ratio was recommended to be set around 25%. With proper mixture design and fly ash dosage, the asphalt mixture would have adequate performance, as well as reduced environmental impact.     

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.     

Influence of Asphalt Emulsion Inclusion on Fly Ash/Hydrated Lime Alkali-Activated Material

Supplementary cementitious materials have been widely used to reduce the greenhouse gas emissions caused by ordinary Portland cement (OPC), including in the construction of road bases. In addition, the use of OPC in road base stabilization is inefficient due to its moisture sensitivity and lack of flexibility. Therefore, this study investigates the effect of hybrid alkali-activated materials (H-AAM) on flexibility and water prevention when used as binders while proposing a new and sustainable material. A cationic asphalt emulsion (CAE) was applied to increase this cementless material’s resistance to moisture damage and flexibility. The physical properties and structural formation of this H-AAM, consisting of fly ash, hydrated lime, and sodium hydroxide, were examined. The results revealed that the addition of CAE decreased the material’s mechanical strength due to its hindrance of pozzolanic reactions and alkali activations. This study revealed decreases in the cementitious product’s peak in the x-ray diffraction analysis (XRD) tests and the number of tetrahedrons detected in the Fourier transform infrared spectroscopy analysis (FTIR) tests. The scanning electron microscope (SEM) images showed some signs of asphalt films surrounding hybrid alkali-activated particles and even some unreacted FA particles, indicating incomplete chemical reactions in the study material’s matrix. However, the H-AAM was still able to meet the minimum road base strength requirement of 1.72 MPa. Furthermore, the toughness and flexibility of the H-AAM were enhanced by CAE. Notably, adding 10% and 20% CAE by weight to the hybrid alkali-activated binder produced a significant advantage in terms of water absorption, which can be explained by its influence on the material’s consolidation of its matrices, resulting in significant void reductions. Hence, the outcomes of this study might reveal an opportunity for developing a new stabilizing agent for road bases with water-prevention properties and flexibility that remains faithful to the green construction material concept.     

Resistance of Soda Residue–Fly Ash Based Geopolymer Mortar to Acid and Sulfate Environments

The early mechanical performances of low-calcium fly ash (FFA)-based geopolymer (FFA–GEO) mortar can be enhanced by soda residue (SR). However, the resistance of SR–FFA–GEO mortar to acid or sulfate environments is unclear, owing to the various inorganic calcium salts in SR. The aim of this study was to investigate the long-term mechanical strengths of up to 360 d and evaluate the resistance of SR–FFA–GEO mortar to 5% HCl and 5% Na₂SO₄ environments through the losses in compressive strength and mass. Scanning Electron Microscopy (SEM), Energy-Dispersive Spectroscopy (EDS) and Fourier Transform Infrared Spectrometer (FTIR) experiments were conducted for the SR–FFA–GEO mortars, both before and after chemical attack, to clarify the attack mechanism. The results show that the resistances of the SR–FFA–GEO mortar with 20% SR (namely M10) to 5% HCl and 5% Na₂SO₄ environments are superior to those of cement mortar. The environmental HCl reacts with the calcites in SR to produce CaCl₂, CO₂ and H₂O to form more pores under HCl attack, and the environmental Na⁺ cations from Na₂SO₄ go into Si-O-Al network structure, to further enhance the strength of mortar under Na₂SO₄ attack. These results provide the experimental basis for the durability optimization of SR–FFA–GEO mortars.     

Setting Time,Microstructure, and Durability Properties of Low Calcium Fly Ash/Slag Geopolymer: A Review

Ordinary Portland cement (OPC) is known for its significant contribution to carbon dioxide emissions. Geopolymer has a lower footprint in terms of CO₂ emissions and has been considered as an alternative for OPC. A well-developed understanding of the use of fly-ash-based and slag-based geopolymers as separate systems has been reached in the literature, specifically regarding their mechanical properties. However, the microstructural and durability of the combined system after slag addition introduces more interactive gels and complex microstructural formations. The microstructural changes of complex blended systems contribute to significant advances in the durability of fly ash/slag geopolymers. In the present review, the setting time, microstructural properties (gel phase development, permeability properties, shrinkage behavior), and durability (chloride resistance, sulfate attack, and carbonatation), as discussed literature, are studied and summarized to simplify and draw conclusions.     

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).     

Experimental Investigation on Ambient-Cured One-Part Alkali-Activated Binders Using Combined High-Calcium Fly Ash (HCFA) and Ground Granulated Blast Furnace Slag (GGBS)

The challenges of handling user-hostile alkaline solutions in the conventional alkali-activated binders (AAB) have initiated the development of “just add water” or one-part solid-based AAB systems. This paper aims to present a preliminary investigation on the development of one-part ambient-cured alkali-activated binders produced by synthesising high-calcium fly ash (HCFA) and ground granulated blast furnace slag (GGBS) using sodium metasilicate anhydrous. Three test series were conducted in this study to investigate the effects of GGBS/binder, activator/binder and water/binder ratios on the fresh and hardened properties of the one-part synthesis AAB system. It was found that the SiO₂/Al₂O₃ molar ratio plays an important role in the attainment of compressive strength and limits the amounts of solid activators effective in contributing to the alkali-activation reaction process. The optimum SiO₂/Al₂O₃ molar ratio was found between 3.20 and 3.30. The test results revealed that the optimum proportion between HCFA and GGBS was discovered at a GGBS/binder ratio of 0.50. The optimum activator/binder ratio was between 0.08 and 0.12, and it is recommended that the water/binder ratio should not exceed 0.50. This study demonstrated the potential of the one-part synthesis method in the production of alkali-activated binder for practical structural applications.     

Mixture Design and Mechanical Properties of Recycled Mortar and Fully Recycled Aggregate Concrete Incorporated with Fly Ash

Recycled aggregate concrete (RAC) is a sort of green, low carbon, environmental protection building material, its application is of great significance to the low carbonization of the construction industry. The performance and strength of RAC are much lower than natural aggregate concrete (NAC), which are the key factors restricting its application. Class F fly ash is a cementitious material that is considered environmentally hazardous. In this paper, appropriate water-binder (w/b) ratios were found through a mortar expansion test at first. The compressive strength of recycled mortar incorporated with class F fly ash was further studied. On this basis, the mechanical properties of nine groups of fully recycled aggregate concrete (FRAC) with a w/b ratio of 0.3, 0.35, and 0.4, and fly ash replacement ratios of 0, 20%, and 40%, were studied. The influence of the w/b ratio and fly ash replacement ratio on mechanical properties was analyzed and compared with previous research results. In addition, the conversion formulas between the splitting tensile strength, flexural strength, and compressive strength of FRAC were fitted and established. The research results have a certain guiding significance for the mixture design of FRAC and further application of class F fly ash.     

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.