Lightweight Aggregate Research Articles

Study on the effect of lightweight aggregate types and steel fibers on the mechanical properties of lightweight engineered geopolymer composites (LW-EGC)

In this paper, the effects of the content of steel fiber and lightweight aggregate types on the mechanical properties of lightweight engineered geopolymer composites (LW-EGC) were investigated by uniaxial compression tests. The effect on compressive strength, stress-strain curves, elasticity modulus, peak strain, and energy absorption were discussed. The results showed that the type of lightweight aggregate had a significant effect on the mechanical properties of LW-EGC. LW-EGC-C had higher compressive strength, elasticity modulus, and energy absorption capacity. LW-EGC-S had a higher peak strain. Adding steel fibers could greatly increase the compressive strength, peak strain, and energy absorption. Meanwhile, there was an optimal range for the volume content of steel fiber, so the best improvement effect was achieved when the content of steel fiber was 1.0 %. Compared with LW-EGC-M, the above mechanical properties were improved by 39.28 %, 15.32 %, and 26.17 %, respectively. In addition, based on the existing constitutive models and test results, a stress-strain model for LW-EGC suitable for incorporating steel fibers is proposed. The constitutive model was divided into a rising phase and a falling phase, which could describe the falling curve more accurately than the existing constitutive models, indicating that it could reliably describe the compressive stress-strain response of LW-EGC.

The Detailed Axial Compression Behavior of CFST Columns Infilled by Lightweight Concrete

The utilization of lightweight aggregate concrete (LWC) plays a major role in reducing the self-weight of CFST (concrete-filled steel tube) columns, which is reflected in the behavior of the structural system. This paper aims to investigate the characteristics of lightweight concrete-filled steel tubular (LWCFST) columns under an axial compressive load, using a total of (48) LWCFST column models. The simulated models were divided into four groups with different concrete compressive strength, length-to-diameter ratios (L/D), and diameter-to-thickness ratios (D/t). Four concrete compressive values were examined (30, 40, 50, and 60) MPa, three length-to-diameter ratios short (L/D = 3), medium (L/D = 6), and long (L/D = 9), and four diameter-to-thickness ratios (36, 31, 26, and 21). The method of nonlinear finite element analysis (NLFEA) was used to fulfill the objective of this study where results were presented as graphical plots between the compressive loading versus the axial and lateral strains along with the failure modes. In addition, the results were compared with the AISC360-16 and EC4 codes predictions to examine their applicability on the LWCFST columns where the AISC was overpredicted in most cases with higher percentages under lower (L/D) values, whereas the EC2 was underestimated in most cases with high percentages up to 28%, which become closer to the NLFEA predictions at higher (L/D) values. It has been revealed that the utilization of steel tubes significantly improves the LWCFST column’s mechanical performance, ductility, compressive strength, and toughness. Moreover, the structural behavior of the LWCFST columns and their associated failure modes was found to be highly affected by the geometrical properties of the CFST column (i.e., L/D ratio and D/t ratio) where specimens with small tube thickness show bad behavior. Finally, the utilization of high-strength concrete has a favorable performance compared to the utilization of thick steel tubes.

Lifecycle Assessment and Multi-Parameter Optimization of Lightweight Cement Mortar with Nano Additives.

With the growing global concerns regarding sustainable development in the building and construction industries, concentration only on the engineering properties of building materials can no longer meet the requirements. Although some studies have been implemented based on the lifecycle assessment of lightweight cement-based materials, very few attempts have been made pertaining to multi-criteria optimization, especially when fly ash cenospheres are used as lightweight aggregates and nano additives are incorporated as modifying admixtures. This investigation utilized cenospheres as fine aggregates to produce green, sustainable, lightweight cement mortar. Multi-walled carbon nanotubes at 0.05, 0.15, and 0.45% were binarily added, together with 0.2, 0.6, and 1.0% of nano silica to improve the mechanical performance. Strength tests were conducted to measure the flexural and compressive behaviors, combined with a cradle-to-gate lifecycle assessment and direct cost analysis to assess the environmental and economic viability. Integrated indexes and the TOPSIS method were adopted to systematically evaluate the mortar mixes and determine the optimal mix. The outcomes show that nano additives worked synergically to enhance the mechanical properties of the mortars. The utilization of cenospheres effectively reduced environmental impacts and improved economic feasibility. Nano additives significantly affected the sustainability and economic viability; in particular, the utilization of multi-walled carbon nanotubes increased the material costs. To minimize the impact of the price of multi-walled carbon nanotubes, it is proposed to binarily use less expensive nano silica. In the multi-parameter optimization, the mix with 0.05% multi-walled carbon nanotubes and 0.02% nano silica was recommended to be the optimal mix.

Experimental investigation of the after fire mechanical properties of both fibre and lightweight concrete

ABSTRACT Concrete stands as a fundamental material in the construction industry. However, it encounters challenges such as cracking, crumbling, or disintegration at elevated temperatures, attributed to high thermal stresses and low tensile strength. This study addresses these issues by reinforcing concrete samples with steel and polypropylene fibres, exposing them to temperatures ranging from 25 to 800°C, and conducting mechanical tests. In order to provide a comprehensive examination, a concrete mixture containing lightweight aggregate was also prepared and tested along with other mixtures. The test results showed that adding steel and polypropylene fibres enhanced or maintained compressive strength up to 200°C compared to the control sample. Furthermore, samples containing steel fibres exhibited the highest tensile strength across all temperatures. Notably, at 600°C and above, the lightweight concrete sample demonstrated comparable or superior compressive strength as well as tensile strength compared to the control sample. In addition, it was observed that polypropylene fibres began to melt at 400°C, leading to a decline in compressive and tensile strength in samples containing this fibre type at temperatures exceeding 400°C.

Experimental Research of Bond Strength of Lightweight Aggregate Concrete to 15.7 mm Non-Pretensioned Steel Strands.

This paper deals with the issue of the bond of concrete with the new artificial aggregate Certyd to prestressing steel strands. The solution of the problem is of great importance in the development of the use of lightweight aggregate concrete for prestressed concrete elements. Experimental research on the bond stress-slip relationship of concrete to 15.7 mm non-pretensioned steel strand was carried out. The results of bond stress-slip tests for various embedment lengths (40, 80, 120, 240, 330 and 460 mm) for test specimens made of the same lightweight aggregate concrete mixture, in which the transfer of prestressing force took place at different levels of concrete maturity (after 3, 7 and 28 days of concrete maturing), are presented. Based on the obtained results, an analytical model of the bond stress-slip relationship of lightweight aggregate Certyd concrete to 15.7 mm non-pretensioned steel strand was proposed. The tests presented demonstrated that the lightweight aggregate (Certyd) concrete is suitable for the production of pretensioned concrete elements.

Geopolymer-based insulated wall incorporating construction and demolition waste: Experimental assessment of thermo-physical behavior

The benefit of the application of geopolymers in the building sector is nowadays undisputed. In addition to good structural characteristics, these are characterized by interesting thermophysical properties, obtained through a production process, that reduces CO2 emissions and could incorporate recycled material, thus responding to environmental sustainability. However, it is noted the lack of studies regarding the in-field thermal performance. Thus, the aim of the present study is to investigate the thermal performance, under real conditions, of an innovative geopolymer-based insulated wall. It incorporates over 70% of net weight of Construction and Demolition Waste materials. The wall is conceived within the European project called “Green INSTRUCT” aimed to realize modular prefabricated building elements, for retrofitting and new construction of buildings. Two wall prototypes are analysed, which differ for the type of lightweight aggregate of geopolymer matrix, 3% by weight: expanded polystyrene or extruded polystyrene. The study refers to almost one year of continuous monitoring within a full-scale test room located in southern Italy. The method developed consists of 5 different phases and it involves also a normative-insulated reference wall. The results show higher insulation level of the proposed wall package, with a reduction of the heat flux of about 66% and more stable indoor thermal conditions, compared to the reference wall. Also the inertial properties are satisfactory, showing an experimental decrement factor equal to 0.05 and a time-shift of decrement factor higher than 6 h. All told, the experimental results can provide valuable insights into the real impact of innovative technology on energy efficiency and indoor thermal comfort.

Employment Employment of Brick Residue in the Production of a Lightweight Concrete

The important way to obtain lightweight concrete with compressive strength, density, and thermal insulation properties that differ from normal concrete was by adding materials with cementitious properties to the concrete mix instead of cement or using lightweight aggregate. In most cases, the compressive strength of the lightweight concrete produced was less than that of normal concrete. The aim of this research was to conduct three main objectives. The first objective is to produce lightweight concrete with good compressive strength compared to the same type of concrete by adding chemical additives (Super-Plasticizer S.P and Carbon Powder C.P) to the lightweight concrete mix. The second objective is to recycle the residues of the local brick and use them as coarse aggregates in the production of lightweight concrete. The third objective is to increase the thermal insulation rate of concrete by adding the same r additive. The results were good, concrete was produced from this work with the lowest density of up to (1810 kg/m3) and the highest compressive strength of up to (31.240 MPa) when only carbon powder was added in certain proportions and the density of up to (1944 kg/m3) and compressive strength of up to (31.946 MPa) when adding (Super-Plasticizer) to the same percentages of carbon powder. Compared to ordinary lightweight concrete without chemical additives, its density reaches (1894 kg/m3) and compressive strength (24.848 MPa) at the age of 28 days. In addition, the thermal conductivity values reached about (0.507 W/m.oC), compared to ordinary lightweight concrete (2.242 W/m.oC).

Development of Fly Ash-Based Geopolymer Lightweight Aggregates

This research delves into the utilization of microwave hybrid heating as a curing technique for producing fine aggregates from fly ash. Various concentrations of alkali activator solutions were employed as binders to pelletize the fly ash (ranging from 0% to 10%). The resultant green fly ash-based geopolymer (FAG) aggregates were subjected to a 15-minute microwave kiln treatment. The microwave-sintered FAG fine aggregates, varying in sizes from 0.60 to 2.36 mm, were then utilized to fabricate 50 mm cubic cement mortar samples. Findings indicated that the density of FAG aggregates was approximately 36% lower than that of natural sand, while the water absorption capacity of FAG aggregates exhibited a fivefold increase compared to natural sand. Notably, cement mortar samples made with FAG aggregate of 4% alkali activator exhibited maximum compressive strengths of 31, 37, and 42 MPa at 7, 14, and 28 days of curing, respectively. These compressive strengths were only 12% lower than those of cement mortars made with natural sand across all curing periods. The use of microwave hybrid heating to transform fly ash into aggregates with sufficient strength appears viable, suggesting that these manufactured FAG aggregates could serve as substitutes for natural aggregates in concrete production

Oil-based drilling cutting pyrolysis residues-recycled fine powder sintered ceramsite: Basic properties, microsintering mechanism, lightweight concrete application and heavy metals solidification

Oil-based Drilling Cutting Pyrolysis Residue (ODPR) is a waste produced during oilfield drilling using oil-based mud. Recycled Fine Powder (RFP) consists of particles less than 0.16 mm, crushed and sieved from waste concrete. China's solid waste is characterized by high production, low utilization rates, and high pollution levels. This study explores the feasibility of preparing ceramsite from ODPR and RFP. By examining the effects of varying temperatures and proportions on the macroscopic and microscopic properties of ODPR-RFP ceramsite (ORC), the optimal process was determined: ODPR: RFP = 7:3, 2 % borax flux, 10 minutes ball milling, 1200℃ sintering temperature, and 30 minutes insulation. The resulting ORC, with a bulk density of 1120 kg/m³, cylinder compression strength of 10.50 MPa, and water absorption rate of 7.8 %, meets the "Lightweight aggregates and its test methods (GT/B17431.2)" standard. Batch production of ORC products of various sizes was conducted to evaluate their practical application in LC30 lightweight aggregate concrete. Replacing the aggregate in lightweight concrete with ORC yielded a concrete with excellent mixing performance, reaching a maximum strength of 31.2 MPa after 7d and 44.8 MPa after 28d. The damage pattern of ORC lightweight concrete is characterized by longitudinal splitting, with varied crack initiation and expansion paths. In the interfacial transition zone of ORC concrete, the ORC form a strong bond with the cement mortar, enhancing the strength of the lightweight concrete. Additionally, the leaching of heavy metals (HMs) from the ORC was examined to assess potential environmental pollution. The results indicated that preparing ORC from these two types of solid waste can effectively immobilize HMs, with a solidification rate of up to 92.10 %. Pb with high content is mainly solidified in the form of solid solution to form (Ba, Pb) SO4. The ecological risk assessment method for HMs shows that using this solid waste and process to prepare ORC does not pose HMs risks and is an environmentally friendly building material.

Hydrothermal Manufacture of Zeolitic Lightweight Aggregates from Clay and Marine Plastic Litter

Hydrothermal Manufacture of Zeolitic Lightweight Aggregates from Clay and Marine Plastic Litter

Comparative life cycle assessment (LCA) of the composite prefabricated ultra-shallow slabs (PUSS) and hollow core slabs in the UK

Life cycle assessment studies of precast construction methods highlight their superiority over traditional cast-in-situ construction in reducing buildings’ environmental impacts. Among the extensively used precast structural elements, hollow core precast slabs have proven benefits with their practical implementation in flooring systems across various flooring spans and live loads. This paper presents a case study comparing the global warming potential and embodied energy impacts of a recently developed lightweight prefabricated composite flooring system (PUSS) with zinghollow core precast slabs in the UK. The analysis is based on 16 live load/flooring span scenarios, between 6 and 12m. The study examines the benefits and drawbacks of utilising different concrete types in PUSS flooring, namely normal weight concrete, lightweight aggregates concrete and geopolymer concrete. PUSS with GPC demonstrates potential savings of up to 50 % in GWP compared with hollow core slabs, while PUSS with LWC exhibits potential savings of up to 35 % in total EE compared with hollow core slabs.

Understanding and predicting micro-characteristics of ultra-high performance concrete (UHPC) with green porous lightweight aggregates: Insights from machine learning techniques

Ultra-high performance concrete (UHPC) is an advanced material in construction. Porous lightweight aggregates (PLWA) could reduce the self-shrinkage risk of UHPC by maintaining internal relative humidity. However, understanding and predicting the water migration processes influenced by PLWA are still challenging. Given that machine learning (ML) has shown promise in modeling complex relationships, this study aims to create a reliable ML model to predict and analyze the micro-properties of UHPC with different green PLWAs (pumice and phosphogypsum aggregates). Furthermore, it aims to enhance our understanding of how PLWA influences the microstructure development within the UHPC. The research results demonstrated that convolutional neural network (CNN) algorithm with an R2 value exceeding 0.95 in both the test and training data. Meanwhile, the CNN was employed to predict time-dependent water content and hydration degree of UHPC containing various types of PLWA and multiple-aggregates, aiding in the exploration of how different PLWA impact the water migration of UHPC. Based on the ML analysis results, pumice aggregates and multiple-aggregates both contributed to reducing the rate of water migration, subsequently reducing UHPC shrinkage. Finally, some insights on the use of ML techniques for predicting and understanding the micro properties of UHPC were discussed. ML was employed for micro-performance prediction and in-depth analysis, thereby advancing the intelligent evolution of green UHPC products.

Optimization and Evaluation of Alkali Activated Fly Ash for Lightweight Aggregate Production

This study investigates the utilization of solid waste, specifically fly ash, and other materials to produce aggregates through geopolymerisation. The research aims to explore the properties of fly ash aggregates and assess their viability in concrete production. The objectives of the study encompass the preparation of aggregates using different proportions of fly ash and alkali activator such as sodium hydroxide and sodium silicate, alongside the casting of concrete cubes utilizing the artificial aggregate. The methodology employed involves the preparation of alkali activator, mix proportioning, and the subsequent processes of mixing, casting, crushing, and curing. Various ratios of fly ash to activator (2.5:1, 3:1, and 3.5:1) were investigated, with corresponding results obtained for properties such as abrasion value, impact value, bulk specific gravity, and water absorption. The findings reveal that the properties of the fly ash aggregates vary with different ratios, with notable differences observed in abrasion value, impact value, bulk specific gravity, and water absorption. For 2.5:1 abrasion value is 26.02%, impact value is 19.32%, bulk specific gravity 1.821 and water absorption 9.61%.For 3:1 abrasion value is 37.14%, impact value is 25.15%, bulk specific gravity 1.78 and water absorption 10.58%.For 3.5:1 abrasion value is 46.5%, imapct value is 32.87%, bulk specific gravity 1.648 and water absorption 12.83%. Casting cude using ratio 2.5:1, 28 day strength is 20.46 N/mm2.. This research project offers an eco-friendly solution for utilizing fly ash in the production of high-performance aggregates, contributing to sustainable construction practices. The implications of the findings include reduced environmental impact, enhanced resource efficiency, and the potential for resilient and environmentally conscious built environments. Further research and development in this area could lead to broader adoption of geopolymerized fly ash aggregates in the construction industry, paving the way for a more sustainable and Greener future.

Effect and mechanism of phase change lightweight aggregate on temperature control and crack resistance in high-strength mass concrete

Under temperature stress, high-strength mass concrete is brittle due to its high total heat of hydration. In this study, a control mixture of C55 high-strength mass concrete meeting the performance requirements was prepared. The effects of different functional aggregates on the thermal properties, such as setting and hardening rate, peak temperature, and temperature rise and fall rate in the early stage of cement hydration, as well as the effects of functional lightweight aggregates on the workability, mechanical properties, and deformation properties of concrete, were investigated in this paper using two types of aggregates with thermal insulation and phase change energy storage functions. The study shows that, in addition to having some early strength impacts and temperature management capabilities, thermal storage coarse lightweight aggregate (PCCLA) and thermal insulation fine lightweight aggregate (TIFLA) can both increase the workability and crack resistance of concrete. When it comes to temperature regulation, thermal storage coarse aggregate outperforms thermal insulation functional aggregate significantly. Thermal insulation fine aggregate can improve the rate of setting and hardening, while coarse thermal storage aggregate may work as in-situ self-heating curing in the early stages due to its phase change energy storage. This quickens the rate of setting and hardening and increases the resistivity of the set period, which in turn increases the rate of drying shrinkage.

Development and Characterization of Basalt Fiber-Reinforced Green Concrete Utilizing Coconut Shell Aggregates

Lightweight aggregate concrete (LWAC) is gaining interest due to its reduced weight, high strength, and durability while being cost-effective. This research proposes a method to design an LWAC by integrating coconut shell (CS) as coarse lightweight aggregate and a high volume of wet-grinded ultrafine ground granulated blast furnace slag (UGGBS). To optimize the mix design of LWAC, a particle packing model was employed. A comparative analysis was conducted between normal-weight concrete (M40) and the optimized LWAC reinforced with basalt fibers (BF). The parameters analyzed include CO2 emissions, density, surface crack conditions, water absorption and porosity, sorptivity, and compressive and flexural strength. The optimal design was determined using the packing density method. Also, the impact of BF was investigated at varying levels (0%, 0.15%, and 1%). The results revealed that the incorporation of UGGBS had a substantial enhancement to the mechanical properties of LWAC when BF and CS were incorporated. As a significant finding of this research, a grade 30 LWAC with demolded density of 1864 kg/m3 containing only 284 kg/m3 cement was developed. The LWAC with high-volume UGGBS and BF had the minimum CO2 emissions at 390.9 kg/t, marking a reduction of about 31.6% compared to conventional M40-grade concrete. This research presents an introductory approach to sustainable, environmentally friendly, high-strength, and low-density concrete production by using packing density optimization, thereby contributing to both environmental conservation and structural outcomes.

Effect of triethanolamine on the synthetic process of porous magnesia lightweight aggregates

Effect of triethanolamine on the synthetic process of porous magnesia lightweight aggregates

From Mg(OH)2 to lightweight closed-pore MgO refractory aggregates: The role of NiO additive

MgO refractory aggregates with high closed porosity were prepared using light-burned MgO and Mg(OH)2 with adding NiO additive. The evolutions of microstructure and pores and their effects on the properties were investigated. The introduction of NiO effectively enhanced growth of MgO grains and transformation of large open pores into small closed ones, attributing to the lattice distortion caused by MgxNi1-xO solid solution formation. Due to the occurrence of more closed pores and lattice distortion, thermal insulation performance was improved significantly. Moreover, the formed circular closed pores and MgxNi1-xO could absorb thermal stress, lower thermal expansion coefficient and induce crack deflection, thus effectively enhancing thermal shock resistance. The specimen with 4.0 wt% NiO showed the best performance, with a median pore diameter of 5.69 μm, closed/apparent porosity of 9.4 %/3.6 %, thermal conductivity of 9.9 W/(m·K) (500 °C), flexural strength of 68.5 MPa, and residual flexural strength of 10.8 MPa after thermal shock.

Fiber Lightweight Aggregate Pipe Segment Fire Performance Study

Fiber Lightweight Aggregate Pipe Segment Fire Performance Study

Properties, Treatment and Resource Utilization of Bauxite Tailings: A Review

A substantial amount of bauxite tailings (BTs) at abandoned mine sites have been stored in waste reservoirs for long periods, leading to significant land occupation and environmental degradation. Although many studies of the resource utilization of BTs were conducted to address this challenge, there is still a lack of efforts to systematically review the state of the art in BTs. In the present paper, a systematic literature review was carried out to summarize and analyze the properties, treatment, and resource utilization of BTs. Physical characteristics and the mineral and chemical composition of BTs are introduced. The efficacy of physical, chemical, and microbial treatment methods for BTs in terms of dehydration are outlined, and their respective benefits and limitations are discussed. Moreover, the extraction process of valuable elements (e.g., Si, Al, Fe, Li, Na, Nd, etc.) from BTs is examined, and the diverse applications of BTs in adsorption materials, ceramic materials, cementitious materials, lightweight aggregates, foamed mixture lightweight soil, among others, are studied. Finally, an efficient and smart treatment strategy for BTs was proposed. The findings of the present review provide a scientific basis and reference for future research focusing on the treatment and resource utilization of BTs.

Experimental investigation on the microstructure and physical properties of natural, recycled fire brick and lightweight aggregates after exposure to high temperature

Experimental investigation on the microstructure and physical properties of natural, recycled fire brick and lightweight aggregates after exposure to high temperature