Effect of Structural Build-Up on Interlayer Bond Strength of 3D Printed Cement Mortars

Understanding the relationship between the intrinsic characteristics of materials (such as rheological properties and structural build-up) and printability and controlling intrinsic characteristics of materials through additives to achieve excellent printability is vital in digital concrete additive manufacturing. This paper aims at studying the effects of material’s structural build-up on the interlayer bond strength of 3DPC with different time gaps. Structural build-up can indirectly affect the interlayer bond strength by affecting the surface moisture of concrete. Based on the structural build-up of 3DPC, a new parameter, maximum operational time (MOT), is proposed, which can be considered as the limit of time gap to ensure high interlayer bond strength. Slump-retaining polycarboxylate superplasticizer (TS) slightly slows down the physical flocculation rate, but increases the maximum operational time of the cement paste. Nano clay significantly increases the sort-term structural build-up rate and has the function of internal curing and water retaining. Composite with nano-clay and TS can reduce the loss of surface moisture of 3D printed layers, prevent the formation of interface weak layer, and increase the interlayer bond strength between printed layers. This contribution can provide new insight into the design of 3D-printed ink with good extrudability, outstanding buildability, and excellent interlayer bond strength.     

Effect of Paraffin and Silica Matrix Phase Change Materials on Properties of Portland Cement Mortars

In the search for methods to incorporate Phase Change Materials (PCM) into Portland cement mortar mixtures, PCM based on paraffins adhered to a silica-based matrix appear as a suitable option. However, paraffin particles have been observed to escape from the silica matrix when water is added. There are only limited data on how the use of such PCM affects the behaviour of mortars. To evaluate the effect of this PCM addition, Portland mortar mixtures were elaborated with 5%, 10% and 15% of PCM content, and using CEM 42.5 I R and CEM I 52.5 R cement types. Physical properties such as density, open porosity, air content and water absorption were analysed for fresh and dry samples. The results obtained show that the PCM-added mixtures require greater water and cement amounts than the standard mortar mixtures to achieve similar compressive strengths. Compared to non-PCM mixtures the PCM-added mortars present a density lowering of 37% for fresh mixtures and near 45% for dry state forms. A maximum compressive strength of 15.9 MPa was reached for 15% PCM mixtures, while values beyond 40 MPa were achieved for 5% PCM mixtures. Thus, the proposed study contributes to broad the available knowledge of PCM cement mortar mixtures behaviour and their mix design.     

Effects of Elevated Temperatures on the Properties of Cement Mortars with the Iron Oxides Concentrate

Using the waste materials in the production of the building materials limits the storage of the wastes, burdensome for the environment and landscape, and makes possible to manufacture the materials and products with the use of the less volume of the raw materials. Cement concretes and mortars as the basic building materials offer the broad prospects of utilization of the recyclable or waste materials. The wastes from the iron ore processing are the solid wastes resulting from the process of enrichment of the ore concentrate. The paper presents the results of testing three mortars, in which a part of fine aggregate was replaced with the iron oxide concentrate (IOC) resulting from such a process. IOC has been used as a substitute of 10%, 20% and 30% (by mass) of the fine aggregate. The effect of the concentrate on the mechanical performance of the mortars at the high temperature (up to 600 °C) was also investigated. The IOC is a neutral material, not affecting chemically the process of cement hydration. The addition of IOC slightly improves the strength of the cement mortars (by 5% to 10%). In the case of the larger amount (20–30%) of the addition, the use of superplasticizer is necessary. The IOC significantly improves the high temperature resistance of the cement mortars (300 °C). The cement mortars containing 30% of the IOC addition keep 80% of the initial flexural and compressive strength when exposed to the temperature 450 °C.     

Improving the Durability of Lime Finishing Mortars by Modifying Them with Silicic Acid Sol

Lime materials are in great demand for the restoration of the walls of historical buildings. However, lime coatings have insufficient resistance during operation. The purpose of this work was the modification of lime mortars with silicic acid sol in order to obtain more durable crystalline materials for construction purposes. A technology has been developed for obtaining a silica-containing additive, which consists in passing a liquid glass solution with a density of 1.053 kg/m³ through a cationic column and obtaining a silicic acid sol with a pH of 3–4 and a charge of (−) 0.053 V. The regeneration time and the amount of sol have been determined. Regularities of change in the radius of particles of silicic acid sol depending on age are determined. It is established that at an early age (up to 5 days), the radius of sol particles can be determined in accordance with the Rayleigh equation, and at a later age, in accordance with the Heller equation. The results of the calculation show that at the age of 1–5 days, the radius of the sol particles is 17.1–17.9 nm, and then the particles become coarser and the particle radius is 131.2–143 nm at the age of 19 days. The work of adhesion of silicic acid sol to lime and the heat of wetting are estimated. It is shown that the work of adhesion of water to lime is 28.9 erg/cm², and that of the sol is 32.8 erg/cm². The amount of heat Q released when lime is wetted with SiO₂ sol is 15.0 kJ/kg, and when lime is wetted with water, it is 10.6 kJ/kg.     

Innovative Calcium Carbonate-Based Products to Repair Cracked Cement Mortars

The durability of Portland cement mortars is often affected by environmental factors, which can cause physicochemical and mechanical degradation processes. In this study, the performance of three products, calcium acetoacetate and calcium tetrahydrofurfuryloxide dissolved in two different solvents developed and tested as stone consolidants, was evaluated in terms of crack filling or sealing and consolidation. Realistic cracks were induced in quasibrittle cement mortar prisms using a custom-designed test rig. The effectiveness and the performance of the considered treatments, investigated on specimens, were evaluated by optical and scanning electron microscopy, colourimetry, water absorption rate, ultrasonic pulse velocity, and surface hardness measurements. Results revealed that, in the examined conditions, the products were more suitable as surface consolidants than as crack fillers.     

Mechanical and Durability Performance Improvement of Natural Hydraulic Lime-Based Mortars by Lithium Silicate Solution

Natural hydraulic lime (NHL) as a building material has been widely used to restore the historic structure. However, the slow growth rate of strength and durability limits its engineering application. In this work, the NHL-based mortars were pretreated by lithium silicate (LS) solution impregnation and surface spraying. The results show that the compressive strength, surface hardness, and freeze-thaw cycle (FTC) resistance of NHL-based mortar were greatly improved after LS pretreatment. Specifically, the compressive strengths of the sample increased by about 32.7–52.0%. LS was sprayed on the sample’s surface (about 0.2 kg/m²) and the surface hardness increased by up to 10 grades. Compared with the control samples, the weight loss of treated samples decreased by about 31.6–43.8%. A rehydration process to generate the hydrated calcium silicate gel (C-S-H) was observed between calcium hydroxide (CH) and LS, which can decrease the sample’s porosity and form a silicate coating on the surface. With an increase in the concentration of LS, the macropores (50–10,000 nm) content decreased, while the mesopores (10–50 nm) and nanopores (less than 10 nm) increased. This work reveals that the LS pretreatment provides a potential route to improve NHL-based mortar’s mechanical properties and durability.     

Effect of Polycarboxylate-Silane Modified Graphene Oxide Composite on the Properties of Cement Pastes

As a nano-carbon material with excellent properties, Graphene oxide (GO) has been widely used in cement-based materials, and the negative effect of paste workability caused by GO agglomeration has also been widely concerning. In this study, a polycarboxylate-silane modified graphene oxide composite (PSG) was prepared by coupling polycarboxylate molecules to the surface of graphene oxide (GO) via a reaction with vinyl triethoxysilane. The effects of GO and PSG on the cement paste and the mechanisms underpinning these effects were investigated using fluidity and rheological parameter measurements, and ion concentration and zeta potential analyses. It was found that, in the aqueous phase of the paste, the polycarboxylate molecular chains on the surface of the PSG complexed with calcium ions (Ca²⁺), thereby preventing Ca²⁺ from bridging the GO sheets, and thus stabilizing the surface potential and the electrostatic repulsion. This prevented the PSG from forming an agglomerate structure such as that formed by GO under the same conditions, thereby substantially enhancing workability of paste with nano-carbon material. This study provides some new foundations and ideas for the further application of graphene oxide materials in cement-based materials.     

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

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

Effect of Ground Waste Glass Addition on the Strength and Durability of Low Strength Concrete Mixes

By recycling used glass containers, we are able to recover and reuse their valuable properties, which is a way to preserve the relevant natural resources and lessen environmental burdens. For example, recycled waste glass (in the form of powder) can be used in the production of concrete. This article analyses the effect of waste glass addition on the properties of C12/15, which is used, for example, as concrete bedding material to support road drainage gutters and kerbs. Ground waste glass was used as a filler in the mix, i.e., without decreasing the amount of cement. Brown glass collected as municipal solid waste was used in this research. The research comprised an experiment prepared on the basis of the central composite design. The independent variables included water/cement ratio and the amount of glass powder, expressed as the glass to cement ratio by weight. The adopted research program mainly included the definition of the concrete compressive strength, water absorption and freeze–thaw resistance after 25 and 100 cycles of freezing and thawing. For selected systems, the characteristics of air voids in hardened concrete were also defined. The beneficial effect of ground waste glass added as a filler to the concrete mixture on the strength and durability of concrete was confirmed by the obtained test results.     

Mechanical Properties and Durability of CNT Cement Composites

In the present paper, changes in mechanical properties of Portland cement-based mortars due to the addition of carbon nanotubes (CNT) and corrosion of embedded steel rebars in CNT cement pastes are reported. Bending strength, compression strength, porosity and density of mortars were determined and related to the CNT dosages. CNT cement paste specimens were exposed to carbonation and chloride attacks, and results on steel corrosion rate tests were related to CNT dosages. The increase in CNT content implies no significant variations of mechanical properties but higher steel corrosion intensities were observed.     

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

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

Effect of Hydrogen Nanobubbles on the Mechanical Strength and Watertightness of Cement Mixtures

This study analyzed the effects of applying highly concentrated hydrogen nanobubble water (HNBW) on the workability, durability, watertightness, and microstructure of cement mixtures. The number of hydrogen nanobubbles was concentrated twofold to a more stable state using osmosis. The compressive strength of the cement mortar for each curing day was improved by about 3.7–15.79%, compared to the specimen that used general water, when two concentrations of HNBW were used as the mixing water. The results of mercury intrusion porosimetry and a scanning electron microscope analysis of the cement paste showed that the pore volume of the specimen decreased by about 4.38–10.26%, thereby improving the watertightness when high-concentration HNBW was used. The improvement in strength and watertightness is a result of the reduction of the microbubbles’ particle size, and the increase in the zeta potential and surface tension, which activated the hydration reaction of the cement and accelerated the pozzolanic reaction.     

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

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

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.     

Study on the Strength and Hydration Behavior of Sulfate-Resistant Cement in High Geothermal Environment

The hydration process and compressive strength and flexural strength development of sulphate-resistant Portland cement (SRPC) curing at 20 °C, 40 °C, 50 °C, and 60 °C were studied. In addition, MIP, XRD, SEM, and a thermodynamic simulation (using Gibbs Energy Minimization Software (GEMS)) were used to study the pore structure, the types, contents, and transformations of hydration products, and the changes in the internal micro-morphology. The results indicate that, compared with normal-temperature curing (20 °C), the early compressive strength (1, 3, and 7 d) of SRPC cured at 40~60 °C increased by 10.1~57.4%, and the flexural strength increased by 1.8~21.3%. However, high-temperature curing was unfavorable for the development of compressive strength and flexural strength in the later period (28~90 d), as they were reduced by 1.5~14.6% and 1.1~25.5%, respectively. With the increase in the curing temperature and curing age, the internal pores of the SRPC changed from small pores to large pores, and the number of harmful pores (>50 nm) increased significantly. In addition, the pore structure was further coarsened after curing at 60 °C for 90 d, and the number of multiple harmful pores (>200 nm) increased by 17.9%. High-temperature curing had no effect on the types of hydration products of the SRPC but accelerated the formation rate of hydration products. The production of the hydration products C-S-H increased by 13.5%, 18.6%, and 22.8% after curing at 40, 50, and 60 °C for 3 d, respectively. The stability of ettringite (AFt) reduced under high-temperature curing, and its diffraction peak was not observed in the XRD patterns. When the curing temperature was higher than 50 °C, AFt began to transform into monosulfate, which consumed more tricalcium aluminate hydrate and inhibited the formation of “delayed ettringite”. Under high-temperature curing, the compactness of the internal microstructure of the SRPC decreased, and the distribution of hydration products was not uniform, which affected the growth in its strength during the later period.     

Durability of Construction and Demolition Waste-Bearing Ternary Eco-Cements

In recent years, the development of ternary cements has become a priority research line for obtaining cements with a lower carbon footprint, with the goal to contribute to achieve climate neutrality by 2050. This study compared ordinary Portland cement (OPC) durability to the performance of ternary cements bearing OPC plus 7% of a 2:1 binary blend of either calcareous (Hc) or siliceous (Hs) concrete waste fines and shatterproof glass. Durability was measured further to the existing legislation for testing concrete water absorption, effective porosity, pressurized water absorption and resistance to chlorides and CO₂. The experimental findings showed that the 7% blended mortars performed better than the reference cement in terms of total and effective porosity, but they absorbed more pressurized water. They also exhibited lower CO₂ resistance, particularly in the calcareous blend, likely due to its higher porosity. Including the binary blend of CDW enhanced chloride resistance with diffusion coefficients of 2.9 × 10⁻¹¹ m² s⁻¹ (calcareous fines-glass, 7%Hc-G) and 1.5 × 10⁻¹¹ m² s⁻¹ (siliceous fines-glass, 7%Hs-G) compared to the reference cement’s 4.3 × 10⁻¹¹ m² s⁻¹. The siliceous fines-glass blend out-performed the calcareous blend in all the durability tests. As the mortars with and without CDW (construction and demolition waste) performed to similar standards overall, the former were deemed viable for the manufacture of future eco-efficient cements.     

Strength Characteristics and Microstructure of Cement Stabilized Soft Soil Admixed with Silica Fume

Soft soil improvement is an important subject in civil engineering, and searching for an effective admixture is an important research. Silica fume (SF) is a kind of recycled material, it can be used in engineering as a pozzolanic material. The main objective of this study is to assess the effectiveness of industrial waste silica fume (SF) as an admixture to improve the cement stabilized soft soil. The unconfined compressive test (UCT) and scanning electron microscopy (SEM) test of cement stabilized soil with different SF contents and different curing times have been carried out. UCT after 28 days revealed that the addition of SF can effectively increase the strength of cement stabilized soil and reduce the amount of cement, and 1.5% SF content is considered optimum, excessive SF will not further increase the strength. SF helped to accelerate the cement hydration reaction and significantly improve the early-age strength of stabilized soil even at 3 days, which can improve construction efficiency in actual projects. SEM analyses shows that the proper SF content could make the hydration product calcium silicate hydrate gel (CSH) fill the pores and increase the strength of the material, but excessive SF will increase the large pores content of the material and reduce the strength. This provided a basis for application of SF in improving soft soil.     

Effect of the Moisture Content of Recycled Aggregate on the Mechanical Performance and Durability of Concrete

Wasted concrete was often used as a recycled aggregate instead natural stone in fresh concrete to reduce the environmental impact in a decade. However, because of the residual mortar interface, the performance of recycled aggregate was weaker. In this paper, the recycled aggregate was prewetted, and the effects of prewetted degree on the workability, strength, and durability of concrete were studied. The properties of the interfacial transition zone (ITZ), including microhardness, pore structure, and width, were also investigated. The results show that the workability intensity increased with the increase in prewetted degree from 0% to 100%, while the strength was first increased and then decreased with the optimal value of 43.3 MPa when the prewetted degree was 50–65%. The water absorption and chloride ion diffusion coefficient were also decreased by approximately 10% at minimum with the prewetted degree around 55% because of the declined fraction of pores larger than 50 μm and smaller porosity. The width of ITZ was first sharply decreased with a prewetted degree of 50–65%, then increased again with higher moisture, while microhardness of the ITZ showed the opposite trend and reached 82.7 MPa at maximum, at 50%. The appropriate moisture (50–65%) improved the pore structure and hydration products with an internal curing effect. When the moisture content was too high, the excess water was released from aggregate to the matrix, causing a higher water–cement ratio at ITZ; the porosity and the number of macrospores were increased to weaken the performance of concrete.     

The Effect of Municipal Solid Waste Incineration Ash on the Properties and Durability of Cement Concrete

The aim of this study is to investigate the effect of municipal solid waste incineration bottom ash from a cogeneration plant on the physical and mechanical properties and durability of cement concrete. Part of the cement in concrete mixtures tested was replaced with 0%, 3%, 6%, 9%, and 12% by weight of municipal solid waste incineration bottom ash. Concrete modified with 6% of bottom ash had a higher density (2323 kg/m³), compressive strength at 28 days (36.1 MPa), ultrasonic pulse velocity (3980 m/s), and lower water absorption rate (3.93%). The tests revealed that frost resistance, determined in all-sided testing directions, of concrete modified with 6%, 9%, and 12% of bottom ash added by weight of cement corresponds to strength grade F100. Such concrete can be used in construction works.     

Physical and Mechanical Performance of Coir Fiber-Reinforced Rendering Mortars

Coir fiber is a by-product waste generated in large scale. Considering that most of these wastes do not have a proper disposal, several applications to coir fibers in engineering have been investigated in order to provide a suitable use, since coir fibers have interesting properties, namely high tensile strength, high elongation at break, low modulus of elasticity, and high abrasion resistance. Currently, coir fiber is widely used in concrete, roofing, boards and panels. Nonetheless, only a few studies are focused on the incorporation of coir fibers in rendering mortars. This work investigates the feasibility to incorporate coir fibers in rendering mortars with two different binders. A cement CEM II/B-L 32.5 N was used at 1:4 volumetric cement to aggregate ratio. Cement and air-lime CL80-S were used at a volumetric ratio of 1:1:6, with coir fibers were produced with 1.5 cm and 3.0 cm long fibers and added at 10% and 20% by total mortar volume. Physical and mechanical properties of the coir fiber-reinforced mortars were discussed. The addition of coir fibers reduced the workability of the mortars, requiring more water that affected the hardened properties of the mortars. The modulus of elasticity and the compressive strength of the mortars with coir fibers decreased with increase in fiber volume fraction and length. Coir fiber’s incorporation improved the flexural strength and the fracture toughness of the mortars. The results emphasize that the cement-air-lime based mortars presented a better post-peak behavior than that of the cementitious mortars. These results indicate that the use of coir fibers in rendering mortars presents a potential technical and sustainable feasibility for reinforcement of cement and cement-air-lime mortars.