Granular Skeleton Research Articles

Granular packaging analysis for UHPC production

ABSTRACT The optimisation of the UHPC granular skeleton shows resistance, durability and environmental gains. However, for the manufacture of UHPC, it is not feasible to sieve the aggregates in order to obtain an optimum curve of granular skeleton. An existing alternative is to mix the aggregates in order to obtain a curve close to the optimal curve. In this sense, the present research presents a methodology to perform mixtures of aggregates by means of matrix analysis combining the packaging models of Andreasen and Andersen modified and of Toufar while analysing the best packaging coefficient to be used with the objective to reduce cement consumption. The results indicate that matrix analysis can be used, leading to a low void rate in the granular mixture.

Recovery and Restructuring of Fine and Coarse Soil Fractions as Earthen Construction Materials

Excessive consumption of natural resources to meet the growing demands of building and infrastructure projects has put enormous stress on these resources. On the other hand, a significant quantity of soil is excavated for development activities across the globe and is usually treated as waste material. This study explores the potential of excavated soils in the Brittany region of France for its reuse as earthen construction materials. Characterization of soil recovered from building sites was carried out to classify the soils and observe their suitability for earthen construction materials. These characteristics include mainly Atterberg limits, granulometry, organic matter and optimum moisture content. Soil samples were separated into fine and coarse particles through wet sieving. The percentage of fines (particles smaller than 0.063 mm) in studied soil samples range from 28% to 65%. The methylene blue value (MBV) for Lorient, Bruz and Polama soils is 1, 1.2 and 1.2 g/100 g, and French classification (Guide de terrassements des remblais et des couches de forme; GTR) of soil samples is A1, B5 and A1, respectively. The washing of soils with lower fine content helps to recover excellent-quality sand and gravel, which are a useful and precious resource. However, residual fine particles are a waste material. In this study, three soil formulations were used for manufacturing earth blocks. These formulations include raw soil, fines and restructured soil. In restructured soil, a fine fraction of soil smaller than 0.063 mm was mixed with 15% recycled sand. Restructuring of soil fine particles helps to improve soil matrix composition and suitability for earth bricks. Compressed-earth blocks of 4 × 4 × 16 cm were manufactured at a laboratory scale for flexural strength testing by using optimum molding moisture content and compaction through Proctor normal energy. Compressive strength tests were performed on cubic blocks of size 4 × 4 × 4 cm. Mechanical testing of bricks showed that bricks with raw soil had higher resistance with a maximum of 3.4 MPa for Lorient soil. Removal of coarse particles from soil decreased the strength of bricks considerably. Restructuring of fines with recycled sand improves their granular skeleton and increases the compressive strength and durability of bricks.

Design of Alkali-Activated Materials and Geopolymer for Deep Soilmixing: Interactions with Model Soils.

This study focuses on the use of alkali-activated materials and geopolymer grouts in deep soilmixing. Three types of grouts, incorporating metakaolin and/or slag and activated with sodium silicate solution, were characterized at different scales to understand the development of their local structure and macroscopic properties. The performance of the soilmix was assessed by using combinations of the grouts and model soils with different clay contents. Feret's approach was used to understand the development of compressive strength at different water-to-solid ratios ranging from 0.65 to 1. The results suggested that incorporating calcium reduced the water sensitivity of the materials, which is crucial in soilmixing. Adding soils to grouts resulted in improved mechanical properties, due to the influence of the granular skeleton. Based on strength results, binary soilmix mixtures containing 75% of metakaolin and 25% of slag, with H2O/Na2O ratios ranging from 28 to 42 demonstrated potential use for soilmixing due to the synergistic reactivity of metakaolin and slag. The optimization of compositions is necessary for achieving the desired properties of soil mixtures with higher H2O/Na2O ratios.

Small-strain shear modulus and liquefaction resistance of calcareous sand with non-plastic fines

Incorporation of non-plastic fines can dramatically affect the liquefaction resistance and stiffness of sands. In this study, the aim is to evaluate the influence of non-plastic fines on the liquefaction resistance and small-strain shear modulus of calcareous sand under cyclic loading. Forty-seven sets of undrained cyclic triaxial tests and companion bender element tests are conducted on reconstituted specimens. The cyclic behaviour of clean sand and silty sand with varying fines content is examined with respect to the global void ratio, relative density and granular skeleton void ratio. The findings demonstrate that the microscopic contacts between coarse and fine grains have a significant impact on the macroscopic behaviour of sand–fines mixtures. The experimental findings are evaluated using the equivalent granular skeleton void ratio, which has been recognised as a suitable parameter to describe the overall effect of fines. The findings on calcareous sand with fines are supplemented and compared with published data in accordance with the semiempirical simplified approach for liquefaction triggering based on shear wave velocity.

Towards Sustainable Material: Optimizing Geopolymer Mortar Formulations for 3D Printing: A Life Cycle Assessment Approach

Geopolymer-based concretes have been elaborated among others for their potential to lower the environmental impact of the construction sector. The rheology and workability of fresh geopolymers make them suitable for new applications such as 3D printing. In this paper, we aim to develop a potassium silicate- and metakaolin-based geopolymer mortar with sand and local earth additions suited for 3D printing and an environmental assessment framework for this material. The methodology aims at the optimization of both the granular skeleton and the geopolymer matrix for the development of a low-environmental-impact material suited for 3D printing. Using this approach, various metakaolin/earth geopolymer mortars are explored from a mechanical and environmental point of view. The environmental assessment of the lab-scale process shows an improvement for the climate change category but a degradation of other indicators, compared to Portland-cement-based concrete. Several promising options exist to further optimize the process and decrease its environmental impacts. This constitutes the main research perspective of this work.

Granular Skeleton Optimisation and the Influence of the Cement Paste Content in Bio-Based Oyster Shell Mortar with 100% Aggregate Replacement

The purpose of this paper is to propose a methodology to optimise the granular skeleton assembly of cementitious materials containing non-spherical aggregates. The method is general and can be applied to any granular skeleton whatever the aggregate shape, size, or composition because it is simply based on the direct minimisation of the intergranular porosity to consequently increase the skeleton’s compactness. Based on an experimental design approach, this method was applied to and validated for bio-based oyster shell (OS) mortar with 100% aggregate replacement. First, the best combination of seven crushed oyster shell particle classes was determined and compared with a standardised sand skeleton (0/4 mm) and three other non-optimised OS gradings in terms of intergranular porosity. In particular, it is shown that simply mimicking a reference grading curve initially designed for spherical particles with non-spherical particles led to poor performances. Then, different mortars were cast with the standardised sand skeleton, the optimised OS grading, and the three other non-optimised OS gradings by keeping the water-to-cement ratio (0.5), the aggregate bulk volume, and the cement paste content constant. Mechanical tests in compression confirmed the higher performance of the optimised OS mortar, validating the global optimisation approach. However, the high elongation of the oyster shell aggregates led to high skeleton intergranular porosities—even after optimisation—and the cement paste content needed to be adapted. For a given granular skeleton and for a constant aggregate bulk volume, the increase of the cement paste content led to an increase of both the filling ratio and the mechanical properties (compressive and flexural strengths). Finally, it is shown that the proposed skeleton optimisation and a cement paste content adjustment allowed recovering good mechanical properties for an oyster shell mortar with 100% aggregate replacement, especially in flexural tension.

Cementor: A toolbox to generate bio-cemented soils with specific microstructures

Bio-cemented soils can exhibit various types of microstructure depending on the relative position of the carbonate crystals with respect to the host granular skeleton. Different microstructures can have different effects on the mechanical and hydraulic responses of the material, hence it is important to develop the capacity to model these microstructures. The discrete element method (DEM) is a powerful numerical method for studying the mechanical behaviour of granular materials considering grain-scale features. This paper presents a toolbox that can be used to generate 3D DEM samples of bio-cemented soils with specific microstructures. It provides the flexibility of modelling bio-cemented soils with precipitates in the form of contact cementing, grain bridging and coating, and combinations of these distribution patterns. The algorithm is described in detail in this paper, and the impact of the precipitated carbonates on the soil microstructure is evaluated. The results indicate that carbonates precipitated in different distribution patterns affect the soil microstructure differently, suggesting the importance of modelling the microstructure of bio-cemented soils.

Mesoscale FEM approach on cemented sands: Generating and testing the digital twin

The mechanics of Cemented Granular Material (CGM) have been studied by means of geotechnical experimental testing, whose output consists the basis of mathematical models which approach the material response in various loading states. The information derived from standard experimental response curves is the basis of understanding and handling the material. Still, it is intuitive to analyse the CGM down to the mesoscale and dray conclusions over the interaction of the constituent material phases. Diverging from the practice of equivalent continuum, the alternative description of a three phase composite of sand particles, cement binder and void pores has been realised in this study. In order to implement the specific morphology of this multiphase, geomaterial, X-ray Computed Tomography is used to capture the internal structure and quantify it into a three dimensional greyvalue map (or a three dimensional image). The distinction of the material phases is made possible by the application of a developed filter, which corrects the artefacts caused by beam hardening phenomena and allows for the generation of a phase segmented equivalent image. An image adapted meshing algorithm has been utilized to transform the labelled image into a tetrahedral mesh, grouped into sets that correspond to the different materials. The tetrahedral domain was assigned boundary conditions and was numerically tested under uniaxial compression using the finite element method. The kinematics of the simulation proved that the mesoscale approach, which carries internal structure information of the granular fabric and the cement paste distribution, provides a output which captures the kinematics of the granular skeleton.

Effects of cementing matrix characteristics and particle size on the adhesion rule and mechanical properties of cemented granular materials

The process of filling self-compacting cement grout (SCCG) into granular packing without disturbing the granular skeleton culminates in the formation of a well-defined cemented granular materials (CGMs). The inherent attributes of both the cementing matrix and granular packing critically dictate the adhesion behavior and mechanical performance of CGMs. A succession of cement grout flow tests was conducted to elucidate the influence of particle size and the SCCG flowability on SCCG adhesion mechanism within granular packing. Furthermore, the influence of particle size and the cementing matrix volume on the mechanical characteristics of CGMs was scrutinized via uniaxial compressive testing. The results illuminate that the adhesion behavior of SCCG within granular packing is predominantly dependent on the yield stress of SCCG and the average particle size. Additionally, it is established that the peak strength of CGMs is intimately intertwined with the cementing matrix volume and the average particle size, as corroborated by a substantial aggregate of 135 uniaxial compression tests.

Effect of Particle Size Distributions (PSDs) on ground responses induced by tunnelling in dense coarse-grained soils: A DEM investigation

Tunnelling-induced ground responses in coarse-grained soils often exhibit complex behaviours such as soil arching and progressive ground instability. However, the effect of particle size distributions (PSDs) on ground responses in tunnelling remains largely unexplored. This study provides new insights into PSD’s effect on tunnelling ground response and the underlying mechanism based on granular skeleton quantification. The coarse-grained soils with 9 typical PSDs were modelled by the discrete element method (DEM) with varied granular skeleton structures. A representative volume element (RVE) assembly method, with a novel iteration-based specimen generation method, is developed to build ground models incorporating millions of soil grains, where an eccentric displacement boundary was embedded for reproducing the tunnel volume losses. The results demonstrated that the change in skeleton structures from fine-grains to coarse-grains dominated leads to the acceleration of soil arch emergence and the deceleration of soil arch collapse-rebuilding. With an increase in ded, the strengthened soil arch leads to a more evident deformation localization in ground, and results in more significant hysteresis of ground instability from the tunnel to the surface. The effect of PSDs on ground responses becomes prominent as the overburden thickness decreases and the tunnel volume loss increases, and a decrease in ded would increase the risk of overall failure in tunnelling.

Investigation of the load sustaining micro mechanisms of cemented sand using the mesoscale FEM approach

While the mechanics of cemented granular material have already been approached by means of constitutive modeling, the capacity of introducing the precise internal structure of multiphase media in numerical simulations offers an alternative perspective of investigation. In specific, means of X-ray computed tomography are able to quantify the internal irregular geometry of the composite material in the form of three-dimensional images. Image analysis can be applied in order to distinguish the topology of each material phase and advanced meshing techniques are able to form a twin meshed domain. The current paper deals with the quantitative description of the morphology of small cemented sand samples, the application of developed image analysis algorithms to treat imaging artefacts (mainly due to beam hardening), the equivalent mesh generation via the image adapted meshing technique and the numerical testing using the Finite Element Method. Four samples are imaged, meshed and numerically tested in uniaxial compression; the mesoscale finite element simulations are able to display the intergranular stress transmission chains. A statistical analysis of the load carried by the granular skeleton provides evidence of the influence of the cementation degree and the compaction of the aggregates on the uniformity of the stress distribution.

Effect of the sands close to the mascara region in the manufacture of self-compacting mortars

Sand plays a very important role during the manufacture of concrete and mortar for the need of civil engineering and building. It influences both the properties of cementary materials in the fresh state and in the hardened state. The objective of this work is the development of self-compacting mortars with the various sands existing in the region of the city of Mascara for the main study of mechanical performance. Six sands were used for this purpose: three natural sands and three crushed sands. The tests carried out during this research are: physical tests, tests in the fresh state and tests on hardened mortars. The results to which our research has led is that self-compacting mortars made with crushed sands give a granular skeleton with high compactness and superior mechanical performance compared to self-compacting mortars made with natural sands.

Effect of Excessive Bleeding on the Properties of Cement Mortar

The bleeding of cementitious materials corresponds to the settlement of the granular skeleton accompanied by the accumulation of water at the surface (bleed water). Part of this water (internal bleeding) remains trapped under the aggregates (sand or gravel) or the reinforcements. The excess of this trapped water can weaken the bond between the cementitious matrix and the aggregates (or the reinforcements), which affects the mechanical performance and durability of the material. This study aims to investigate the effect of excessive bleeding induced by superplasticizer on the properties of mortars. For this, a study of cement paste bleeding in the presence of superplasticizer was carried out. The effects of the water-to-cement ratio (w/c) and the superplasticizer (SP) dosage on this bleeding have been characterized. Then, the influence of the proportion of sand on the bleeding was examined by varying the sand/cement (s/c) ratio. The water trapped by sand (internal bleeding) was determined by the difference between the external bleeding on the cement paste and the external bleeding on the corresponding mortar. The results show that the internal bleeding increases with the s/c ratio and the SP dosage, until it reaches a plateau. The effect of the internal bleeding on the mechanical properties and the porosity of the mortar were then examined. Microscopic observations were made to assess the quality of the paste/sand bond. The results showed that the internal bleeding causes a degradation of the paste/sand bond (a more porous bond), resulting in a decrease in the mechanical strength (by 30% for compressive strength and 25% for flexural strength) of the hardened mortar.

New insight on rheology of self-consolidating earth concrete (SCEC)

Self-consolidating earth concrete (SCEC) is a novel alternative to facilitate the earth-based construction. A new concrete-equivalent mortar (CEM) approach with constant excess-paste (EP) thickness was proposed to evaluate the rheological and thixotropic properties of various SCEC mixtures proportioned with different clay and superplasticizer types. The use of non-esterified polycarboxylate (NE-PC) and sodium polynaphtalene superplasticizer types in combination with a finer clay type led to a thixotropic behavior. Mixtures made with sodium hexametaphosphate resulted in significantly high yield stress and plastic viscosity values. The rheological properties were mainly controlled by the admixture type, followed by the type and content of clay and water-to-powder ratio (W/P). Empirical models were proposed to predict the rheology of earth-based paste, CEM, and SCEC mixtures using the governing key mixture parameters, including the fineness of the powder constituents (i.e., clay, silt, and cement), water content, EP thickness, paste volume, and packing of the granular skeleton.

Effect of Aggregates Packing with the Maximum Density Methodology in Pervious Concrete

The granulometric distribution of the aggregates used in pervious concrete can significantly impact its mechanical and hydraulic properties by modifying granular skeleton and pore distribution. The unit weight increases when single-sized aggregates are combined, which results in improved mechanical properties. In this study, the maximum density methodology was applied to enhance pervious concrete’s mechanical strength by using three narrow-sized basaltic aggregates and their combination. The experimental results showed that the mechanical performance of the samples created with packed aggregates improved compressive strength by up to 81.2% and the energy support impact was higher than 225 J (50% higher than the reference sample) after curing for 28 days. Although the densification of packing aggregates increased, the greatest reduction in porosity was 24.3%. The lowest infiltration rate was 0.43 cm/s, a satisfactory value according to the literature. These findings suggest that the aggregates packing methodology is effective in producing optimized and sustainable pervious concretes.

Multiscale investigation of self-consolidating earthen materials using a novel concrete-equivalent mortar approach

Earth-based materials have been used since ancient times due to their low environmental impact and superior thermal performance. The rammed earth (RE) method, as a common earthen construction, consists in casting the material layer-by-layer, which is time-consuming, labor-intensive, and energy consuming. Designing self-consolidating earth concrete (SCEC) can speed up the construction process and overcome the disadvantages of conventional RE and enhance its performance. Achieving high fluidity and adequate compressive strength for early demolding is challenging because of the presence of clay and low cement content, respectively. Moreover, diversity of existing soil types does not allow to propose a universal mixture proportioning approach. In this study, workability, drying shrinkage, and compressive strength of SCEC mixtures were evaluated using a new concrete-equivalent mortar (CEM) approach to facilitate the optimization process and reduce the number of experiments and materials. The approach is mainly based on optimizing the excess paste (EP) thickness to consider the variation of packing density of the granular skeleton. The mixture parameters included the water-to-powder ratio (W/P), volumetric sand-to-total aggregate ratio (S/A), and the excess paste thickness. Good correlations between the investigated CEMs and their corresponding concrete mixtures were established. According to the carried-out ANOVA analysis, the main influencing parameters on workability, drying shrinkage, and compressive strength of SCEC include the specific surface area and Atterberg limits of the ternary binder system, W/P, paste volume, and EP thickness.

Effects of Particle Size Distribution of Standard Sands on the Physical-Mechanical Properties of Mortars.

Obtained natural sands can present different particle size distributions (PSD), although they have the same mineralogical origin. These differences directly influence the physical and mechanical behavior of mortars and, therefore, the performance of mortar and ceramic renderings. Standardizing the particle size of sands based on pre-established requirements in normative standards (NBR 7214 or ASTM C778) is one way to minimize these effects. However, these standards do not consider the optimization of the granular skeleton through the analysis of bulk density and PSD, which may be insufficient to obtain satisfactory results. Therefore, this paper analyzes the effects of using different particle size ranges on the physical and mechanical behavior of cement and hydrated lime mortars. The properties of consistency index, bulk density, air content, capillary water absorption, water absorption by immersion, flexural strength, compressive strength, and dynamic modulus of elasticity were evaluated. For this purpose, standardized sands of the same mineralogical origin were made with different particle size ranges, being: (i) standardized sand constituted by 25% of coarse and fine fractions (S25-control), (ii) standardized sand constituted by 30% of coarse fraction and 20% of fine fraction (S30-20), and (iii) standardized sand composed by 40% of coarse fraction, and 10% of fine fraction (S40-10), respectively. The results indicated that variations in the particle size composition of the standardized sands are necessary to obtain mixtures with higher compactness and, therefore, mortars with better physical and mechanical performance. Thus, the dosage of the particle size fractions of standardized sand should consider the optimization of the granular skeleton, being the unit mass and the granulometric composition as important parameters to meet this premise.

Improving mechanical stability of anammox granules with organic stress by limited filamentous bulking

Under organic stress, the limited filamentous bulking (FB) was demonstrated to improve anammox capability by inhibiting granule disintegration and washout. The accumulation of internal stress played a more important role than the adverse physicochemical properties (low viscoelasticity and hydrophobicity) of granules in limiting granular strength by consuming the granular elastic energy. Different from the floc-forming heterotrophic bacteria (HB) that stored its growth stress as internal stress by pushing the surrounded anammox micro-colonies outwards under the spatial constraint of elastic anammox “shell”, the filamentous HB grew into a uniform network structure within granules, endowed granules low internal stress and acted as the granular skeleton due to its rich amyloid substance, which was benefited from the elimination of inhomogeneous growth and the consequent expansion competition for living space. Combined with the mechanical instability and sticking-spring models, controlling FB at limited level was effective for improving granular strength without affecting sludge-water separation.

Effects of morphological gene decay and mutation on the micro–macro mechanical behaviours of granular soils

Particle morphology is multi-scale in nature. To investigate the effects of particle morphology at a specific length scale on the macro–micro mechanical behaviours of granular soils, morphological gene decay and mutation was incorporated into discrete-element method (DEM) simulations through spherical harmonic-based principal component analysis. All DEM samples were subjected to axial compression and constant confining stress. The macro-scale and grain-scale behaviours of the granular assembly were investigated. It was found that particle morphology shows significant effects on macro-scale behaviours including initial stiffness, peak stress ratio, volumetric contraction and dilation, and shear band formation, as well as grain-scale behaviours including coordination number, particle rotation and granular skeleton sustaining the major contact force chains. Among the different length scales, local roundness contributes the most to stress ratio, volumetric strain and particle coordination number, while general form contributes the most to shear strain, particle rotation and fabric structure. Another interesting finding was that the particle morphological effects are well reflected in the granular skeleton sustaining the major contact force chains, which is featured with a strong variation of the degree of particle shape irregularity among different kinds of gene-mutated samples.

Evaluation of three non-linear packing density models on micropowder mixtures

The formulation of powders often requires an optimized packing density of the granular skeleton which takes into account the desired properties. More accurate than the conventional linear models, three non-linear packing density models are evaluated from published data on binary or ternary mixtures of alumina powders, glass microbeads, siliceous microaggregates: the Compressible Packing Model (CPM), the 3-parameter Particle Packing Model (3PPM), the Theoretical Packing Density Model (TPDM). Depending on the models, they involve a compaction index K and certain particle interactions: the loosening effect a and possibly the critical cavity size ratio x0 from which it appears, the wall effect b and the wedging effect c. The CPM (with a, b, K), by incorporating only 2 interaction functions for a and b, reduces its versatility but is efficient for siliceous. The 3PPM (with a, b, c), by incorporating 9 interaction functions, adapts well to the various micropowders with however a lower performance for the siliceous for which the packing densities predicted in “compacted” conditions are lower than in “uncompacted” conditions. The TPDM (with a, b, K, x0) is effective for all types of micropowders and generates the best statistical indicators.