Properties and Strength Prediction Modeling of Green Mortar with Brick Powder Subjected to a Short-Term Thermal Shock at Elevated Temperatures

The cement industry is responsible for 8% of global CO₂ production. Therefore, a clear trend has been observed recently to replace to some extent the main binder of cement composites with environmentally friendly or recycled materials with a lower carbon footprint. This paper presents the effect of brick powder (BP) on the physico-chemical and mechanical properties of cement mortars. The effect of a short-term thermal shock on morphology and strength properties of green mortars was investigated. BP addition caused increase in porosity and decrease in compressive and flexural strength of mortars. The best results were obtained for samples with 5% wt. BP addition. Above this addition the strength decreased. The mechanical performance of the samples subjected to thermal loading increased compared to the reference samples, which is the result of a process called as the “internal autoclaving”. The BP addition positively affects the linear shrinkage, leading to its reduction. The lowest linear shrinkage value was achieved by the mortar with the highest BP addition. An intelligent modeling approach for the prediction of strength characteristics, depending on the ultrasonic pulse velocity (UPV) is also presented. To solve the model problem, a supervised machine-learning algorithm in the form of an SVM (support vector machines) regression approach was implemented in this paper. The results indicate that BP can be used as a cement replacement in cement mortars in limited amounts. The amount of the additive should be moderate and tuned to the features that mortars should have.     

Comparative Study of Effects of Air-Entraining Plasticizing Admixture and Lime on Physical and Mechanical Properties of Masonry Mortars and Plasters

This article presents research on selected physical and mechanical properties of cement-based plasters and masonry mortars with consistency-improving additives, namely, traditional hydrated lime and a plasticizing and aerating mixture (APA), which, in practice, is often considered to be a lime substitute. Comparative analysis of the properties of mortars with alternative additives—lime or APA—was carried out, taking into consideration possible effects of cement, as two types of Portland cement were used for the research. For fresh mortar, mixture consistency, air content, resistance to segregation, and water retention were determined. Tests on hardened mortars included tests of porosity and impermeability, depth of penetration of water under pressure, drying shrinkage, as well as compressive and bending strength, modulus of elasticity, and adhesion of mortars to the base. In addition, research has shown that cement–lime mortars and cement mortars with APA admixture of similar consistency in the fresh state are characterized by significantly different properties. The results show, in most of the features analyzed, more favorable properties of mortars with the use of traditional lime. For shrinkage only, the use of admixture turned out to be more advantageous.     

Fresh,Mechanical, and Durability Properties of Self-Compacting Mortar Incorporating Alumina Nanoparticles and Rice Husk Ash

This paper presents a comprehensive evaluation on self-compacting (SC) mortars incorporating 0, 1, 3, and 5% alumina nanoparticles (NA) as well as 0% and 30% rice husk ash (RHA) used as Portland cement replacement. To evaluate the workability, mechanical, and durability performance of SC mortars incorporating NA and RHA, the fresh properties (slump flow diameter and V-funnel flow time), hardened properties (compressive strength, flexural strength, and ultrasonic pulse velocity), and durability properties (water absorption, rapid chloride permeability, and electrical resistivity) were determined. The results indicated that the addition of NA and RHA has negligible effect on the workability and water absorption rate of the SC mortars. However, significant compressive and flexural strength development was observed in the SC mortars treated with NA or the combination of NA and RHA. The introduction of RHA and NA also reduced the rapid chloride permeability and enhanced the electrical resistivity of the SC mortars significantly. It is concluded that the coexistence of 30% RHA and 3% NA as cement replacement in SC mortars can provide the best mechanical and durability performance.     

Enhanced Mechanical and Durability Properties of Cement Mortar by Using Alumina Nanocoating on Carbon Nanofibers

This study evaluated the effect of carbon nanofibers (CNFs) coated by aluminum oxide Al₂O₃ as a reinforcement on compressive strength, frost resistance, and drying shrinkage of cement mortars. Three weight ratios of 0.125%, 0.25%, and 0.5% of Al₂O₃/CNFs and bare CNF cement mortars were compared with reference cement mortar samples. The reactive porous and high surface area layer of alumina induced the hydration reaction and promoted the production of well-distributed hydration gel. Derivative thermal analysis–differential thermogravimetric (TGA-DTG) and X-ray powder diffraction (XRD) characterization showed that Al₂O₃/CNFs reinforcement led to greater hydration gel production than bare CNFs. Transmission electron microscopy (TEM) and scanning electron microscopy (SEM) were performed to study the coating and microstructure of the cement mortars evaluated in this paper. The results show that the optimum enhancement of the cement mortar properties was obtained at ratios of 0.125% for Al₂O₃/CNFs and 0.25% for CNFs. This enhancement was greater with Al₂O₃/CNFs-reinforced specimens in terms of high compressive strength, less compressive strength degradation after 150 cycles, and less drying shrinkage. The low use of the CNFs in Al₂O₃/CNFs samples indicates the coating is an economical and promising approach for improving the performance of cement mortars.     

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.     

Influence of the Type of Cement on the Action of the Admixture Containing Aluminum Powder

The study of the effect of cement type on the action of an admixture increasing the volume of concrete (containing aluminum powder), used in amounts of 0.5–1.5% of cement mass, was presented. The tests were carried out on cement mortars with Portland (CEM I) and ground granulated blast-furnace slag cement (CEM III). The following tests were carried out for the tested mortars: the air content in fresh mortars, compressive strength, flexural strength, increase in mortar volume, bulk density, pore structure evaluation (by the computer image analysis method) and changes in the concentration of OH⁻ ions during the hydration of used cements. Differences in the action of the tested admixture depending on the cement used were found. To induce the expansion of CEM III mortars, a smaller amount of admixture is required than in the case of CEM I cement. Using the admixture in amounts above 1% of the cement mass causes cracks of mortars with CEM III cement due to slow hydrogen evolution, which occurs after mortar plasticity is lost. The use of an aluminum-containing admixture reduces the strength properties of the cement mortars, the effect being stronger in the case of CEM III cement. The influence of the sample molding time on the admixture action was also found.     

The Influence of Cement Type on the Properties of Plastering Mortars Modified with Cellulose Ether Admixture

In this article, the effect of cement type on selected properties of plastering mortars containing a cellulose ether admixture was studied. In the research, commercial CEM I Portland cement, CEM II and CEM III, differing in the type and amount of mineral additives, and cement class, were used as binders. Tests of consistency, bulk density, water retention value (WRV), mechanical properties and calorimetric tests were performed. It was proved that the type of cement had no effect on water retention, which is regulated by the cellulose ether. All mortars modified with the admixture were characterized by WRV of about 99%. High water retention is closely related to the action of the cellulose ether admixture. As a result of the research, the possibility of using cement with additives as components of plasters was confirmed. However, attention should be paid to the consistency, mechanical properties of the tested mortars and changes in the pastes during the hydration process. Different effects of additives resulted from increasing or decreasing the consistency of mortars; the flow was in the range from 155 mm to 169 mm. Considering the compressive strength, all plasters can be classified as category III or IV, because the mortars attained the strength required by the standard, of at least 3.5 MPa. The processes of hydration of pastes were carried out with different intensity. In conclusion, the obtained results indicate the possibility of using CEM II and CEM III cements to produce plastering mortars, without changing the effect of water retention.     

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.     

Experimental Investigation on Environmentally Sustainable Cement Composites Based on Wheat Straw and Perlite

Environmentally sustainable cement mortars containing wheat straw (Southern Italy, Apulia region) of different length and dosage and perlite beads as aggregates were prepared and characterised by rheological, thermal, acoustic, mechanical, optical and microstructural tests. A complete replacement of the conventional sand was carried out. Composites with bare straw (S), perlite (P), and with a mixture of inorganic and organic aggregates (P/S), were characterised and compared with the properties of conventional sand mortar. It was observed that the straw fresh composites showed a decrease in workability with fibre length decrease and with increase in straw volume, while the conglomerates with bare perlite, and with the aggregate mixture, showed similar consistency to the control. The thermal insulation of the straw mortars was extremely high compared to the sand reference (85–90%), as was the acoustic absorption, especially in the 500–1000 Hz range. These results were attributed to the high porosity of these composites and showed enhancement of these properties with decrease in straw length and increase in straw volume. The bare perlite sample showed the lowest thermal insulation and acoustic absorption, being less porous than the former composites, while intermediate values were obtained with the P/S samples. The mechanical performance of the straw composites increased with length of the fibres and decreased with fibre dosage. The addition of expanded perlite to the mixture produced mortars with an improvement in mechanical strength and negligible modification of thermal properties. Straw mortars showed discrete cracks after failure, without separation of the two parts of the specimens, due to the aggregate tensile strength which influenced the impact compression tests. Preliminary observations of the stability of the mortars showed that, more than one year from preparation, the conglomerates did not show detectable signs of degradation.     

Fresh and Rheological Performances of Air-Entrained 3D Printable Mortars

The effect of air-entraining admixture (AEA) on the fresh and rheological behavior of mortars designed to be used in 3D printers was investigated. Blast furnace slag, calcined kaolin clay, polypropylene fiber, and various chemical additives were used in the mortar mixtures produced with Super White Cement (CEM I 52.5 R) and quartz sand. In addition to unit weight, air content, and compressive strength tests, in order to determine the stability of 3D printable mortar elements created by extruding layer by layer without any deformation, extrudability, buildability, and open time tests were applied. Fresh and rheological properties of 3D printable mortars were also determined. It was concluded that the addition of AEA to the mortars decreased the unit weight, viscosity, yield, and compressive strength, but increased the air content, spread diameter, initial setting time, and thixotropy of 3D printable mortar. It is recommended to develop a unique chemical admixture for 3D printable mortars, considering the active ingredients of the chemical additives that affect fresh and rheological performance of mortar such as superplasticizer, viscosity modifying, and cement hydration control.     

Influence of Linseed Oil Varnish Admixture on Glauconite Clay Mortar Properties

Raw clay is used nowadays in construction as a component of mortars and plasters and as a binder in composites based on straw or shives. It is a material with good sorption properties and vapor permeability, but it is susceptible to shrinkage, is not resistant to water, and also is characterized by low mechanical strength, which makes it impossible to be used, for example, in external plasters. Various additives and admixtures are used to improve selected properties of clay mortars. The article presents the research results and assessment of the effect of glauconite clay mortar modification with an admixture of linseed oil varnish on selected properties. Admixtures in the amounts of 1%, 2%, and 3% in relation to clay weight were used. Flexural and compressive strength, water resistance, shrinkage, drying capacity, density, and porosity of mortar, were tested. The admixture of linseed oil varnish in the amounts used in the investigation had a positive effect on some of the tested properties; regardless of the quantity of the admixture, the modified mortars had better parameters concerning flexural strength, shrinkage reduction, and water resistance than the reference mortar, without admixture.     

Recycled Cellulose Fiber Reinforced Plaster

This paper aims to develop recycled fiber reinforced cement plaster mortar with a good workability of fresh mixture, and insulation, mechanical and adhesive properties of the final hardened product for indoor application. The effect of the incorporation of different portions of three types of cellulose fibers from waste paper recycling into cement mortar (cement/sand ratio of 1:3) on its properties of workability, as well as other physical and mechanical parameters, was studied. The waste paper fiber (WPF) samples were characterized by their different cellulose contents, degree of polymerization, and residues from paper-making. The cement to waste paper fiber mass ratios (C/WPF) ranged from 500:1 to 3:1, and significantly influenced the consistency, bulk density, thermal conductivity, water absorption behavior, and compressive and flexural strength of the fiber-cement mortars. The workability tests of the fiber-cement mortars containing less than 2% WPF achieved optimal properties corresponding to plastic mortars (140–200 mm). The development of dry bulk density and thermal conductivity values of 28-day hardened fiber-cement mortars was favorable with a declining C/WPF ratio, while increasing the fiber content in cement mortars led to a worsening of the water absorption behavior and a lower mechanical performance of the mortars. These key findings were related to a higher porosity and weaker adhesion of fibers and cement particles at the matrix-fiber interface. The adhesion ability of fiber-cement plastering mortar based on WPF samples with the highest cellulose content as a fine filler and two types of mixed hydraulic binder (cement with finely ground granulated blast furnace slag and natural limestone) on commonly used substrates, such as brick and aerated concrete blocks, was also investigated. The adhesive strength testing of these hardened fiber-cement plaster mortars on both substrates revealed lime-cement mortar to be more suitable for fine plaster. The different behavior of fiber-cement containing finely ground slag manifested in a greater depth of the plaster layer failure, crack formation, and in greater damage to the cohesion between the substrate and mortar for the observed time.     

Mechanical and Electrical Properties of Rapid-Strength Reactive Powder Concrete with Assembly Unit of Sulphoaluminate Cement and Ordinary Portland Cement

Fast-hardening cement can be used to quickly repair concrete constructions. Characterizing mechanical properties by electrical properties is a promising method to evaluate the mechanical performance nondestructively. However, little attention has been paid to this area. In this paper, copper-coated fine-steel-fibers-reinforced reactive powder concrete (RPC) with compound cement was manufactured. The mass ratio of sulphoaluminate and ordinary Portland cement in the compound cement was 1:1. The influence of copper-coated fine steel fibers with the volume increasing from 0 to 3.0% by the total volume of RPC on the working performances (fluidity and setting time), mechanical properties (flexural strength and toughness, drying shrinkage rate and compressive strength) and electrical parameters (AC electrical resistance and AC impedance spectroscopy curves) was investigated. The electron microscope energy spectrum experiment was applied in analyzing the macro properties of RPC. The results exhibited that the increasing volume of steel fibers led to decreasing the fluidity and retarding the setting of RPC. The electrical resistance of RPC decreased in the form of a quartic function with the volume of steel fibers. The steel fibers volume of 1.5% was the percolation threshold value. The specimens cured for 28 days showed higher electrical resistance than the specimens cured for 1 day. The flexural or compressive strength of the specimens satisfied a specific functional relationship with the volume of steel fibers and electrical resistance. The addition of steel fibers led to improving the flexural toughness and decreasing the shrinkage rate. Furthermore, 3.0% steel fibers could improve the flexural toughness by 3.9 times and decrease the shrinkage to 88.3% of the specimens without steel fibers.     

Lightweight Cement Conglomerates Based on End-of-Life Tire Rubber: Effect of the Grain Size,Dosage and Addition of Perlite on the Physical and Mechanical Properties

Lightweight cement mortars containing end-of-life tire rubber (TR) as aggregate were prepared and characterized by rheological, thermal, mechanical, microstructural, and wetting tests. The mixtures were obtained after total replacement of the conventional sand aggregate with untreated TR with different grain sizes (0–2 mm and 2–4 mm) and distributions (25%, 32%, and 40% by weight). The mortars showed lower thermal conductivities (≈90%) with respect to the sand reference due to the differences in the conductivities of the two phases associated with the low density of the aggregates and, to a minor extent, to the lack of adhesion of tire to the cement paste (evidenced by microstructural detection). In this respect, a decrease of the thermal conductivities was observed with the increase of the TR weight percentage together with a decrease of fluidity of the fresh mixture and a decrease of the mechanical strengths. The addition of expanded perlite (P, 0–1 mm grain size) to the mixture allowed us to obtain mortars with an improvement of the mechanical strengths and negligible modification of the thermal properties. Moreover, in this case, a decrease of the thermal conductivities was observed with the increase of the P/TR dosage together with a decrease of fluidity and of the mechanical strengths. TR mortars showed discrete cracks after failure without separation of the two parts of the specimens, and similar results were observed in the case of the perlite/TR samples thanks to the rubber particles bridging the crack faces. The super-elastic properties of the specimens were also observed in the impact compression tests in which the best performances of the tire and P/TR composites were evidenced by a deep groove before complete failure. Moreover, these mortars showed very low water penetration through the surface and also through the bulk of the samples thanks to the hydrophobic nature of the end-of-life aggregate, which makes these environmentally sustainable materials suitable for indoor and outdoor elements.     

Recycling Blast Furnace Ferronickel Slag as a Replacement for Paste in Mortar: Formation of Carboaluminate,Reduction of White Portland Cement,and Increase in Strength

Blast furnace ferronickel slag (BFFS) is generated in the production of ferronickel alloys and is used as cement replacement in concrete or mortar. The effectivity in reducing cement consumption and improving performance are limited. By referring to the paste replacement method, this work used BFFS to replace an equal volume of the white Portland cement paste to obtain greater performance enhancement. BFFS was used with five levels of replacement (0%, 5%, 10%, 15%, 20%) and four water-to-cement ratios (0.40, 0.45, 0.50, 0.55) were designed. Fluidity, mechanical strength, hydration products, and pore structure of every mixture were measured. The results showed that the workability of the mortars decreased due to the reduced volume of water, but the 28-day compressive strength of the mortars increased, and the cement content of the mortars was also reduced by 33 wt %. The X-ray diffraction (XRD) patterns revealed that there existed a carboaluminate phase, and the presence of the ettringite was stabilized, indicating that the accumulating amount of the hydration products of the mortar increased. Furthermore, the BFFS could consume the portlandite and free water to form a higher amount of chemically bound water due to its pozzolanic activity. A high degree of hydration and a large volume of the hydration products refined the porosity of the hardened mortars, which explained the enhancement of the strength of the mortars. Compared to the cement replacement method, the paste replacement method was more effective in preparing eco-friendly mortar or concrete by recycling BFFS for reducing the cement content of the mortar while improving its strength.     

Mechanical Performance of Single-Graded Copolymer-Modified Pervious Concrete in a Corrosive Environment

Polymer-modified cement has found numerous applications due to its excellent tensile strength. When cement was modified with a single polymer, its tensile strength and performance marginally increased. However, when a small amount of the flexible polymer latex was added to cement, the mechanical performance of cement considerably improved. In this study, single-graded copolymer-modified pervious concrete was prepared by mixing styrene-butadiene rubber (SBR) with different acrylate polymers, and its mechanical performance and durability were systematically studied through mechanical tests and theoretical analyses. The main findings are as follows: (1) When a waterborne emulsion was added, the freeze resistance of cement concrete increased, and its mass loss rate decreased. Cement concrete with two latexes had higher sulphate corrosion resistance and substantially lower dry shrinkage strain than ordinary cement concrete. (2) Through scanning electron microscopy, the microstructural changes in the cement binder, ordinary polymer-modified concrete, and the copolymer-modified cement concrete used in this study were observed, and the findings were compared with those reported in the literature. (3) Single-graded copolymer-modified pervious concrete exhibited excellent shrinkage performance. This study showed that single-graded copolymer-modified pervious concrete satisfied the performance requirements for use as a paving material for special cases.     

Physicomechanical and Antimicrobial Characteristics of Cement Composites with Selected Nano-Sized Oxides and Binary Oxide Systems

In recent years, increasing attention has been paid to the durability of building materials, including those based on cementitious binders. Important aspects of durability include the increase of the strength of the cement matrix and enhancement of material resistance to external factors. The use of nanoadditives may be a way to meet these expectations. In the present study, zinc, titanium and copper oxides, used in single and binary systems (to better the effect of their performance), were applied as additives in cement mortars. In the first part of this work, an extensive physicochemical analysis of oxides was carried out, and in the second, their application ranges in cement mortars were determined. The subsequent analyses were employed in determining the physicochemical properties of pristine oxides: Fourier transform infrared spectroscopy (FTIR), energy dispersive X-ray fluorescence (EDXRF), scanning electron microscopy (SEM), measurement of the particle size distribution, as well as zeta potential measurement depending on the pH values. Influence on selected physicomechanical parameters of the cement matrix and resistance to the action of selected Gram-positive and Gram-negative bacteria and fungi were also examined. Our work indicated that all nanoadditives worsened the mechanical parameters of mortars during the first 3 days of hardening, while after 28 days, an improvement was achieved for zinc and titanium(IV) oxides. Binary systems and copper(II) oxide deteriorated in strength parameters throughout the test period. In contrast, copper(II) oxide showed the best antibacterial activity among all the tested oxide systems. Based on the inhibitory effect of the studied compounds, the following order of microbial susceptibility to inhibition of growth on cement mortars was established (from the most susceptible, to the most resistant): E. coli < S. aureus < C. albicans < B. cereus = P. aeruginosa < P. putida.     

Creep and Shrinkage Behaviour of Disintegrated and Non-Disintegrated Cement Mortar

One way to prevent cement from ending up in landfills after its shelf life is to regain its activity and reuse it as a binder. As has been discovered, milling by planetary ball mill is not effective. Grinding by collision is considered a more efficient way to refine brittle material and, in the case of cement, to regain its activity. There has been considerable research regarding the partial replacement of cement using disintegrated cement in mortar or concrete in the past few decades. This article determines and compares the creep and shrinkage properties of cement mortar specimens made from old disintegrated, old non-disintegrated, and new non-disintegrated Portland cement. The tests show that the creep strains for old disintegrated and old non-disintegrated cement mortars are close, within a 2% margin of each other. However, the creep strains for new non-disintegrated cement mortar are 30% lower. Shrinkage for old disintegrated and non-disintegrated cement mortar is 20% lower than for new non-disintegrated cement mortar. The research shows that disintegration is a viable procedure to make old cement suitable for structural application from a long-term property standpoint. Additionally, it increases cement mortar compressive strength by 49% if the cement is disintegrated together with sand.     

Effect of High-Dispersible Graphene on the Strength and Durability of Cement Mortars

Graphene’s outstanding properties make it a potential material for reinforced cementitious composites. However, its shortcomings, such as easy agglomeration and poor dispersion, severely restrict its application in cementitious materials. In this paper, a highly dispersible graphene (TiO₂-RGO) with better dispersibility compared with graphene oxide (GO) is obtained through improvement of the graphene preparation method. In this study, both GO and TiO₂-RGO can improve the pore size distribution of cement mortars. According to the results of the mercury intrusion porosity (MIP) test, the porosity of cement mortar mixed with GO and TiO₂-RGO was reduced by 26% and 40%, respectively, relative to ordinary cement mortar specimens. However, the TiO₂-RGO cement mortars showed better pore size distribution and porosity than GO cement mortars. Comparative tests on the strength and durability of ordinary cement mortars, GO cement mortars, and TiO₂-RGO cement mortars were conducted, and it was found that with the same amount of TiO₂-RGO and GO, the TiO₂-RGO cement mortars have nearly twice the strength of GO cement mortars. In addition, it has far higher durability, such as impermeability and chloride ion penetration resistance, than GO cement mortars. These results indicate that TiO₂-RGO prepared by titanium dioxide (TiO₂) intercalation can better improve the strength and durability performance of cement mortars compared to GO.