Metakaolin is a well-studied supplementary cementitious material (SCM) and precursor in alkali-activation. The utilisation of limited kaolinite content clays generated from large-scale industrial activity, denoted as waste clays, in alkali-activation is still largely unexplored. This paper investigates the use of five samples of calcined waste clays from different locations in a kaolinite extraction site as precursors in alkali-activated cements (AACs). Calcined waste clay precursors are blended with ground granulated blast furnace slag (GGBFS) and activated with sodium silicate. The physical and chemical properties of the calcined waste clays are characterised. Both Chapelle and R3 tests for pozzolanic reactivity are examined based on calcined waste clay properties. The R3 test data obtained for sieved particle fractions < 63 µm show marked improvement in the case of C4, elucidating potential calcined waste clay behaviour with prior processing in alkali activated systems. Clay particle size distribution and morphology are identified as key factors to be considered for initial calcination and in mix designs, strongly affecting both the fresh properties and workability of blended pastes. Good workability is highlighted as being crucial for achieving well-behaving calcined waste clay blended binders with resulting dense microstructures and high strength values, comparable with other reported GGBFS systems. Quartz, muscovite, and alkali-feldspar present in the calcined waste clays remain stable throughout alkali-activation. Reaction of the amorphous phase fraction present in the calcined waste clays results in the formation of additional cross-linked gel. A replacement level of up to 20 wt% calcined waste clay is found to exhibit similar compressive strengths to pure GGBFS binders, whilst achieving lower porosity within the bulk. This study provides a methodology for characterising the behaviour of calcined waste clays in alkali-activated systems and a proof of concept in the formulation of novel binders that incorporate waste clays.

In recent years data acquisition from remote sensing has become readily available to the quarry sector. This study demonstrates how such data may be used to evaluate and back analyse rockfall potential of a legacy slope in a blocky rock mass. Use of data obtained from several aerial LiDAR (Light Detection and Ranging) and photogrammetric campaigns taken over a number of years (2011 to date) provides evidence for potential rockfall evolution from a slope within an active quarry operation in Cornwall, UK. Further investigation, through analysis of point cloud data obtained from terrestrial laser scanning, was undertaken to characterise the orientation of discontinuities present within the rock slope. Aerial and terrestrial LiDAR data were subsequently used for kinematic analysis, production of surface topography models and rockfall trajectory analyses using both 2D and 3D numerical simulations. The results of an Unmanned Aerial Vehicle (UAV)-based 3D photogrammetric analysis enabled the reconstruction of high resolution topography, allowing one to not only determine geometrical properties of the slope surface and geo-mechanical characterisation but provide data for validation of numerical simulations. The analysis undertaken shows the effectiveness of the existing rockfall barrier, while demonstrating how photogrammetric data can be used to inform back analyses of the underlying failure mechanism and investigate potential runout.

In the face of strong competition, the kaolin calcination industry is aiming at higher profitability through increased productivity and reduction of costs. Specifically, the industry is facing market demands to maintain product quality with the depletion of high-quality ore. Therefore, considerable research is being conducted to enhance existing processes and their operation and control. In this paper, the concept of a mineralogy-driven control strategy for multiple hearth furnaces for kaolin production is presented and discussed. The aim of the advanced control concept is to increase capacity and to reduce energy consumption while maintaining the desired product quality. The control is based on two main soft sensors: the spinel phase reaction rate indicator for energy use reduction and the mullite content indicator for capacity improvement. In this simulation study, the control strategy is tested and compared with an industrial controller based on a proportional–integral scheme as a benchmark. The results show that the capacity of the process is considerably improved and energy use is remarkably reduced.

Analysis of bacterial populations in situ provides insights into pathogen population dynamics and potential reservoirs for disease. Here we report a culture-independent study of ovine footrot (FR); a debilitating bacterial disease that has significant economic impact on sheep farming worldwide. Disease begins as an interdigital dermatitis (ID), which may then progress to separation of the hoof horn from the underlying epidermis causing severe footrot (SFR). Dichelobacter nodosus is the causative agent of ovine FR, however, the role of Fusobacterium necrophorum and other bacteria present in the environment and on the feet of sheep is less clear. The objective of this study was to use fluorescence in situ hybridisation (FISH) to detect, localise and quantify D. nodosus, F. necrophorum and the domain Bacteria from interdigital skin biopsies of healthy, ID- and SFR-affected feet. D. nodosus and F. necrophorum populations were restricted primarily to the epidermis, but both were detected more frequently in feet with ID or SFR than in healthy feet. D. nodosus cell counts were significantly higher in feet with ID and SFR (p<0.05) than healthy feet, whereas F. necrophorum cell counts were significantly higher only in feet with SFR (p<0.05) than healthy feet. These results, together with other published data, indicate that D. nodosus likely drives pathogenesis of footrot from initiation of ID to SFR; with D. nodosus cell counts increasing prior to onset of ID and SFR. In contrast, F. necrophorum cell counts increase after SFR onset, which may suggest an accessory role in disease pathogenesis, possibly contributing to the severity and duration of SFR.

A multilayer coated paper substrate, combining barrier and printability properties was manufactured utilizing a pilot-scale slide curtain coating technique. The coating structure consists of a thin mineral pigment layer coated on top of a barrier layer. The surface properties, i.e. smoothness and surface porosity, were adjusted by the choice of calendering parameters. The influence of surface properties on the fine line printability and conductivity of inkjet-printed silver lines was studied. Surface roughness played a significant role when printing narrow lines, increasing the risk of defects and discontinuities, whereas for wider lines the influence of surface roughness was less critical. A smooth, calendered surface resulted in finer line definition, i.e. less edge raggedness. Dimensional stability and its influence on substrate surface properties as well as on the functionality of conductive tracks and transistors were studied by exposure to high/low humidity cycles. The barrier layer of the multilayer coated paper reduced the dimensional changes and surface roughness increase caused by humidity and helped maintain the conductivity of the printed tracks. Functionality of a printed transistor during a short, one hour humidity cycle was maintained, but a longer exposure to humidity destroyed the non-encapsulated transistor.

The optical properties of pigmented coatings containing titanium dioxide, calcined and hydrous kaolin, and ethylene–vinyl acetate latex at various pigment volume concentrations were measured during drying using the technique of polarized light reflectometry. Gloss (at two acceptance angles), effective refractive index (RI), microroughness, and backscattered intensity were obtained simultaneously as a function of time. It is shown that the gloss response depends on measurement geometry and the combined effects of several sample physical properties and therefore requires caution in interpretation. The combination of RI, microroughness and backscatter provides more direct information on physical transitions during drying and fits with a three-stage description of drying. Differences in drying due to pigment aspect ratio are relatively small, but the platy kaolin appears to extend the period required for solids immobilization and also prolongs measurable development of surface microstructure during film formation.

Printability of functional inks on multilayer curtain coated substrates was investigated. The inks represent those commonly used to produce solution processable electronic devices, such as organic transistors. The substrate, which combines sufficient barrier and printability properties for printed functional devices, was manufactured utilizing high speed curtain coating technique. The coating structure consists of a mineral pigment layer coated on top of a barrier layer. The combination of the two layers allows for controlling the absorption of ink solvents. By adjusting the thickness, porosity and surface energy of the top-coating the printability can be tuned for various functional inks. Focus was set on printing conducting silver and carbon inks, both with nano- and micrometer sized particles, as well as printing of an organic semiconductor, poly(3-hexylthiophene). The pore volume in the top-coating determined the spreading of the micrometer sized silver ink as well as the amount semiconductor per area required, whereas the pore size was the determining factor regarding penetration of the nano-sized silver ink. As a proof of concept hygroscopic insulator field effect transistors were printed on the multi-layer curtain coated paper using a custom-built roll to roll hybrid printer.

Detailed information about the external and internal structure of microparticles plays an important role in the development of new materials. Scanning electron microscopy (SEM) can be used for studying the external structure of particles and transmission electron microscopy (TEM) can be used to identify some aspects of the internal structure of particles. However, neither technique really characterises the internal structure of kaolin particles. Thermal treatment or calcination of kaolin alters the internal structure and being able to characterise these changes has always been a challenge. In recent years, the ability of a focused ion beam (FIB) to cross-section single particles thus exposing their internal structure has raised increasing interest. This paper describes how a FIB is successfully used to (i) analyse the effect of soak and flash calcining on the internal structure of kaolin and (ii) to characterise the internal structure of some other industrial mineral microparticles.