Mortar Mixes Research Articles

Research on the influence of curing strategies on the compressive strength and hardening behaviour of concrete prepared with Ordinary Portland Cement

Modernizations in the chemical and construction industries have made it possible to create novel curing techniques. Many studies have been conducted to determine the effectiveness of curing and how it impacts the properties of concrete. In this paper, a class of Ordinary Portland Cement (OPC) type-I Iranian Qayen is utilized to prepare for the Compound Curing Agent (CCA) and the Water Base Curing (WBC) concrete specimens. This paraffin-based water emulsion is adopted to protect fresh concrete against the rapid evaporation of mixing water. The findings from an experimental investigation conducted according to the ASTM standards to determine the compressive strength of mortar cylinders are summarized. After mixing, the slump test is used to determine the mixing efficiency. Then, the concrete specimens are prepared with an altering water/binder ratio of 0.47, utilizing ASTM-graded sand and OPC, and cured with WBC and CCA for 7 days, 14 days, 21 days, and 28 days for compressive strength testing. The influence of structural grade mortar mixing with cement on the concrete strength is investigated, the compressive strengths of different curing procedures are compared, and the technical effectiveness of concrete protection using the curing compounds in Kabul is examined. The experiment results show that the compressive strength of the concrete specimens is determined to be slightly larger in concrete specimens cured with water than in specimens cured with a curing compound. In contrast, the reliability of compressive strength data of the compound-cured concrete specimens is better than that of the water-cured ones. Finally, various hardening models are used to fit the compressive strength test results of the concrete specimens. The estimated findings show that the asymptotic model can more precisely reflect the hardening behaviour of concrete during the curing process when compared to the bilinear and broken line models.

Performance assessment of sustainable mortar mixes using recycled fine aggregate obtained from different processing techniques

Performance assessment of sustainable mortar mixes using recycled fine aggregate obtained from different processing techniques

Performance of high workability plaster mortar for water tanks

Cement sand mortar is frequently used as water proofing plaster layer for water retaining structures. However, the current practice of using standard mortar for plastering has shown to be infective due to observed leakages and low durability of some water retaining structures. In the effort of solving these problems, materials engineers have used artificial chemicals like Zypex to control leakages and improve durability with some success. This paper reports on a study done to address the use of high workability plaster mortar as a solution to meet serviceability requirements for water retaining structures. The study involved the development of mix ratios 1:2, 1:3 and 1:4 for standard mortar mixes and using the same mix ratios with different doses of super-plasticizer from 0.00% to 0.50%, testing all mortar mixes for physical properties then determining their performances. The performance of mortar mixes was investigated in terms of workability, unit weight, strength development, tensile strength and water absorption. The test results have indicated high performance and suitability of high workability mortar mixes forplastering water retaining structures.

Determination of properties and environmental impact due to the inclusion of cigarette fibers in mortar: a new solution to mitigate the CB pollution.

Cigarette butts generated are one of the major sources of total solid waste production and lead to environmental issues. This article has the objective of evaluating the effects of cellulose acetate microfibers (CAFs) sourced from discarded cigarette filters (CFs) as fiber reinforcement on the physico-mechanical properties and thermal conductivity of cementitious materials. To do so, mortar samples were prepared using different incorporated quantities of fibers (0.5, 1, 1.5, 2, 2.5, and 5% compared to the quantity of sand added to the mixture) and subjected to different tests to characterize the influence of CAFs on the microstructure of elaborated materials, considering the changes in workability time, compressive strength, flexural strength, density, water absorption, and microstructural analysis. Furthermore, the life cycle assessment (LCA) of mortar mixes in terms of CO2 emissions is made. The results revealed that the increasing percentages of CAFs reduced the dry density and compressive strength, by approximately 1.62-51% and 37-69.64%, respectively, and a notable enhancement of insulation characteristics by about 5-47.5% was achieved. Microstructure analysis confirmed the experimental investigation and revealed that adding more than 1% of fibers resulted in a significantly low unit weight with greater entrapped air content. The studies prove the possibility of recycling cigarette butts for insulating cementitious matrix. In addition, applying mortar containing acetate cellulose fibers is recognized as a more environmentally friendly mixture in terms of reducing CO2 emissions and could participate significantly in the achievement of SDGs.

Properties of blended mortars produced with recycled by-products from different waste streams

The construction industry encounters significant challenges in effectively managing solid waste produced during the extraction and production of building materials. In different countries, slurry waste generated from granite and marble processing industries, such as glass industry waste, constitutes a considerable portion of the total solid waste. Its undesirable disposal is causing unprecedented environmental damage. Using these non-biodegradable wastes to produce building materials would reduce the environmental burden and contribute to sustainable construction. This study, in detail, investigates the feasibility of utilizing Granite Powder (GP), Ground Granite Powder (GGP), and Ground Glass Waste (GGW) as partial replacements of components in blended mortar mixes. The mix modifications consist of partial replacement of cement with GGW, GP, and GGP in the range of 5–15% and fine aggregate replacement with Marble powder (MP) in 10–30% by mass. The mechanical, physical, and microstructure properties of blended and control mortar mixes were studied on the 3rd, 7th, 28th, and 91st curing days. The results demonstrate that the partial substitution of 10% GGW and 5% GP with cement and 10% MP with fine aggregates in blended mortars enhance the compressive strength at the later curing age (28 and 91 days) compared to that of a control mortar, which is associated to the development of higher pozzolanic reactivity. The XRD results showed the formation of the lowest content of calcium hydroxide (CH) and the highest content of calcium silicate gel in the blended mortars compared to the control mortar. The results enrich the data available in the literature not always univocal, as in the case of using marble and glass waste, providing also interesting information about the influence of granite powder on the hydration process in a mortar mix actually missing.

Feasibility of Using Sugar Cane Bagasse Ash in Partial Replacement of Portland Cement Clinker

This work presents a technical and economic study using sugar cane bagasse ash (SCBA) to partially replace Portland cement clinker. To evaluate the technical viability, the replacement rates of 10, 20, and 30% of Portland cement were used in the experiments. The ashes used were in the following conditions: (i) as collected (AC), (ii) ground (G), and (iii) re-burnt and ground (RG). Three composition parameters were used in the mortar mix procedures: (i) mix with water factor/fixed binder in volume, (ii) mix with water factor/fixed binder in weight, and (iii) mix with the fixed flow. After the technical feasibility analysis, the benefit of the substitutions and an analysis of the relationship between cement consumption and the acquired compressive strength, correlating with possible economic costs, were discussed. SCBA AC was not suitable for the partial replacement of Portland cement clinker. SCBA G presented a satisfactory performance and SCBA RG was the ash that presented the best performance in the partial replacement of Portland cement clinker. For the same levels of compressive strength, the consumption of Portland cement per cubic meter of concrete reduced; from this, the cost of concrete and mortar could be reduced by 8%, with the ash having the same value as cement. Furthermore, the use of SCBA RG at 30% inhibited the alkali–silica reaction (ASR) in concretes with a reactive basalt and quartzite aggregate. SCBA G (20 and 30%) and SCBA RG (10 and 20%) inhibited the ASR in concretes with a reactive basalt aggregate and reduced the expandability in concretes with a reactive quartzite aggregate. Another point to highlight was the durability shown by the cements with SCBA, which, 900 days after the accelerated test of expansion by the alkali–aggregate reaction, maintained high levels of flexural strength when compared to the results obtained before the accelerated test of expansion. The present work concluded that using sugar cane bagasse ash to replace Portland cement is feasible from a technical, environmental, and economic perspective.

Exploring the untapped potentials of oily sludge ash blended with fly ash for geopolymer binder via waste valorisation approach

Globally, large quantities of oily sludge are produced in petroleum refineries as wastes from petroleum refining processes. Petroleum refinery oily sludge (PROS) is a major by-product of the processes and a major contributor to pollution in the oil and gas industry. In this study, Response Surface Methodology (RSM) was used for optimising and modelling experimental work. Thermally treated PROS replaced fly ash (FA) at 5–20 % in geopolymer mortar mixes at a fixed combination of sodium silicate (Na2SiO3) and sodium hydroxide (NaOH). The visual observations and effects of PROS on the density and compressive strength of PROS geopolymer mortar (PGM) were studied. PGM with 10 % replacement of PROS had the maximum compressive strength of 38.17 MPa after 28 days. P-values obtained from the quadratic models developed for the synergistic effect of FA-PROS on density and compressive strength were less than 0.005. Optimisation of the synergistic effect of FA-PROS binder produced an optimal combination of both materials for maximum compressive strength and density of 2200 kg/m3 with desirability factor of 0.981. This investigation shows that replacing PROS with FA in geopolymer mortar can result in a new supply chain for greener binder materials in geopolymer mortar.

Investigation of the Mechanical and Microstructural Properties of Masonry Mortar Made with Seashell Particles.

In order to study the mechanical and microstructural properties of masonry mortar, combined particles of cockle and scallop seashell wastes were incorporated and analysed through destructive and non-destructive tests. River sand was replaced with the combined seashell particles (SPs) at seven mixes, viz., 0, 5, 10, 15, 20, 25, and 30% with a 0.5 constant water-to-cement ratio (W/C). A mortar mix design of M4-type of BS EN 1996-1-1 was adopted with a target compressive strength of 5.17 MPa at 28 days. The physical, chemical and mineralogy properties of the SPs were analysed through BS standard sieving, X-ray fluorescence (XRF), scanning electron microscopy (SEM), and X-ray diffraction (XRD) methods. The hardened SP-based mortars were subjected to direct compressive strength, rebound hammer, ultrasonic pulse velocity tests, and nonevaporable degree of hydration analysis. The XRF, SEM, and XRD analysis results of the SPs showed over 86% calcium oxide content, irregular and needle-like particles, and hydroxyapatite/calcium silicates, respectively. The direct compressive strength and the non-destructive test results revealed that up to 30% sand replacement with SP in masonry mortar, an improvement of 45% compressive strength could be attained over the control sample. The nonevaporable water method of the degree of hydration analysis showed that after 28 days, hydration increased considerably for the SP-blended mortars over the control, especially the SPM-30 with 30% sand replacement. Therefore, the study concludes that the investigated SPs in blended masonry mortar could benefit an eco-friendly environment and conservation of natural resources.

Influence of Mixing Water Content and Curing Time on Bond Strength of Clinker Masonry: The Wrench Test Method

In the present study, experimental investigations on the influence of mixing water content used for the preparation of mortar mix using factory-made dry-mix mortar dedicated to bricklaying with clinker masonry units are presented, as well as the curing time on flexural bond strength of masonry made of these two materials. The flexural bond strength was tested using the "wrench test" method. The masonry tests specimens were prepared using three volumes of mixing water as follows: 4.0 L (the value recommended by the mortar manufacturer); 4.5 L; and 5 L of tap water per one 25 kg bag of dry pre-mixed mortar. The influence of the mixing water content was analyzed in relation to curing time. All masonry specimens were tested in four series after 9, 14, 21, and 28 days of sample curing. The results showed that the use of 6 and 18% more mixing water than recommended by the manufacturer (4.5 and 5 L per bag) adversely affected flexural bond strength. Moreover, for all three mixing water amounts, it was found that the maximum values of bonding strength were reached after 9 days of curing, which decreased over time. The largest decreases (30-40%) were recorded after 14 days. After 21 days, these values continued to decrease, but more slowly. The final value of the ratio of bond strength to flexural strength of the mortar was similar for all amounts of mixing water and for the 28-day curing time, it oscillated around 0.2.

Development of sustainable high performance geopolymer concrete and mortar using agricultural biomass—A strength performance and sustainability analysis

Geopolymer concrete is a sustainable substitute for traditional Portland cement concrete. In addition, rising carbon taxes on carbon emissions and energy-intensive materials like cement and lime, impacts the cost of industrial by-products due to their pozzolanic nature. This research evaluates the compressive strength and flexural strength of geopolymer concrete, and the compressive strength of geopolymer mortar. Geopolymer mortar data were used for the strength assessment employing an analytical approach, and geopolymer concrete data were utilized for the strength and sustainability performances. Using artificial neural networks (ANNs), multi-linear regression (MPR) analysis, and swarm-assisted linear regression, compressive strength models were created based on experimental datasets of geopolymer mortar mixes with variable precursors, alkali-activator percentages, Si/Al, and Na/Al ratios. The strength and sustainability performances of geopolymer concrete blends with various precursors were assessed by considering cost-efficiency, energy efficiency, and eco-efficiency. The work’s originality comes from enhancing sustainable high-performance concrete without overestimating or underestimating precursors. Extensive experimental work was done in the current study to determine the best mix of geopolymer concrete by varying silica fume, ground granulated blast furnace slag (GGBS), and rice husk ash (RHA). A scanning electron microscopic study was conducted to understand the geopolymer matrix’s microstructure further. A comprehensive discussion section is presented to explain the potential role of RHA. The replacement of conventional concrete in all its current uses may be made possible by this sustainable high-performance concrete utilizing RHA.

Effect of enzyme Induced carbonate precipitate on mechanical properties of PPC Mortar

Current study presents the utilization of plant urease for calcium carbonate precipitation, which is also known as Enzyme Induced Calcium Carbonate Precipitation (EICCP). Urease containing watermelon seeds (powdered) were directly added in mortar mix in addition to calcium hydroxide and urea in fixed amounts. The optimum dose watermelon seeds powder, calcium hydroxide and urea; was identified for effective biocementation in Portland Pozzolana Cement (PPC) mortar. Large amount of watermelon seeds which are not consumed by humans and are wasted or used as cattle food. Thus, utilizing a waste product makes the process environment friendly. Mechanical properties of these biocemented mortar samples were studied, and compared to control (untreated) mortar samples. Results signified a critical improvement in the properties of experimental samples when contrasted with control samples.

Microstructural and Macroperformance of Recycled Mortar with High-Quality Recycled Aggregate and Powder from High-Performance Concrete Waste

The amount of high-performance concrete (HPC) in construction engineering is growing at a predictable high rate following rapid urban development. However, the utilization of HPC waste as secondary building materials has received little attention until now because previous investigations have focused on the reclamation of ordinary concrete waste. Therefore, this work studied the characterization of mortar containing high-quality recycled aggregate (HRA) and high-quality recycled powder (HRP), both sourced from HPC waste. HRP contains some active components, and the pore structure of paste incorporated with HRP is finer than that of paste containing ordinary recycled powder. Incorporating HRP in paste shortens the setting time and improves the fluidity, and mixing HRA with coarse surface benefits the performance of interfacial transition zone. Incorporating HRA and HRP can both reduce the drying shrinkage, and the maximum shrinkage value of HRA mixed mortar is obviously lower than that of ordinary recycled-aggregate mixed mortar. The mechanical strength first increases and then drops with the HRA incorporation. The incorporated HRP reduces the mechanical strength, but decreasing HRP particle size enhances the mechanical strength of mortar. The water absorption of mortar increases as HRA or HRP is incorporated, but decreasing HRP particle size reduces the water absorption of HRP-incorporated mortar. The mortar with both HRA and HRP has a distinct lower water absorption than the mortar with both ordinary recycled aggregate and powder. High-quality recycled mortar owning good performance can be made by intermixing a suitable amount of HRA and HRP.

Effect of sand types and mixing procedures on the flexural behaviour of the high ductile mortar in monotonic and cyclic loadings

The use of fibre in concrete enhances its flexural behaviour and ductility. Different types of synthetic fibres are developed and replaced steel fibre to solve the corrosion of steel. Polyvinyl alcohol (PVA) is one of the synthetic fibres used in cementitious fibre composites. The High Ductile Mortar (HDM) was developed using PVA fibres. This paper assesses the effect of sand types and mixing procedures on the (PVA) fibre-reinforced high ductile mortar (HDM) in monotonic and cyclic loadings. Two different types of sands (crushed and river) and mixing methods were used for the comparison of the properties of HDM. The Pre-mixed mortar method refers to the mixing of PVA fibres in the pre-mixed mortar. And, pre-mixed paste method refers to the mixing of PVA fibres in a pre-mixed paste and the mixing of PVA mortar with the addition of sand. The pre-mixed mortar method gave a better flexural performance of the HDM than the pre-mixed paste method. The pre-mixed mortar method with crusher sand enhanced the flexural strength in the cyclic loading (11.8 MPa) than in the monotonic loading (10.3 MPa). It was the same for the case of river sand (11.4 MPa). Overall, the pre-mixed mortar method using river (finer) sand is better to enhance the strength, deflection, strain hardening, fracture energy, and toughness. The coarser sand is better for rigidity and fatigue flexural strength.

Effect of a New Multi-Walled CNT (MWCNT) Type on the Strength and Elastic Properties of Cement-Based Mortar

Creating new construction materials with improved strength, elasticity, and durability properties represent the focus of many research works. Significant research effort has been invested in investigating the use of carbon nanotubes (CNTs) in cementitious materials, especially multi-walled carbon nanotubes (MWCNTs) which consist of a series of concentric graphite tubes. The use of MWCNTs is closely related to the use of surfactants and ultra-sonication procedures which may alter their properties and the properties of cement-based materials. The paper presents the preliminary results of an experimental investigation on the suitability of using a new, modified, MWCNT type aimed at eliminating the need of using surfactants and ultrasonication. The modified MWCNTs have a much lower surface energy compared to “classical” ones which would result in a decreased tendency of self-aggregation. A comparison was carried out from the point of view of density, flexural and compressive strength as well as dynamic modulus of elasticity of the obtained mortars. The mortar mix incorporating the modified MWCNTs showed improved mechanical properties even for a low percentage of CNT addition (0.025% by mass of cement). The results are discussed based on the material structure determined from a series of scanning electron microscopy (SEM) and X-ray diffraction (XRD) analyses.

Elucidation of Microstructural and Mechanical Properties of Coconut Husk Mortar as a Sustainable Building Material for Ferrocement

The main objective of this study is to use coconut husk to produce mortar for ferrocement. Mortar mix proportions are selected per ACI codes’ recommendation and the WRD Handbook. Four types of mortars: Cement and River Sand mortar (CSM), Cement, River Sand and Steel fibre mortar (CSSFM), Cement and Coconut Husk mortar (CCHM), and Cement, River Sand (60%), Coconut Husk (40%), and Steel fibre mortar (CSCHSFM) are used for this study Microstructural studies like SEM, EDX, XRD, and FTIR analysis on cement mortar constituents and mortar mixes are studied and reported. At 3, 7, and 28 days tests of hardened mortar, such as compressive, split tensile, flexural strength, and impact strength resistance, were studied. Test results revealed that the coconut husk is innovative and sustainable and could be an alternative fine aggregate that can be utilized in place of river sand, which in turn can be used for mortar production. Since it has a lesser density which proves to be an advantage for developing lightweight mortar, it can be used for ferrocement applications.

Optimal design of ferronickel slag alkali-activated mortar for repair exposed to high thermal load

In this work, the optimal design of a mortar based on alkali-activated material technology is presented. Ferronickel slag, a byproduct of the ferronickel alloy industry, was used both as a binder component (in a finely ground form) and as fine aggregate in alignment with a circular economy approach. The proportions of binder, fine aggregate, and water were optimized using Design of Experiment Design of Mixtures. The performance indicators evaluated were flow, flexural and compressive strength both before and after high-temperature exposure, mass loss, and thermal shrinkage. Life cycle assessment was used to calculate the relative environmental cost of the studied mixes in comparison to a counterpart traditional Ordinary Portland Cement mortar. The optimal mix design exhibited high flexural strength (8.5 and 10.5 MPa, before and after high-temperature exposure, respectively), an unheated compressive strength equal to 69.5 MPa, and a post-heating residual one of 33.9 MPa, 7.7% mass loss and 3.4% thermal shrinkage. Mercury Intrusion Porosimetry along with Scanning Electron Microscopy with Energy Dispersive X-Ray Analysis were also performed on optimal mortar samples in order to link micro-structural heat-induced changes to residual (post-heating) macro-mechanical performances. Finally, when compared to OPC-based products, the optimized mortar mix resulted in 70% lower CO2 emissions indicating great potential for the construction sector where concern about environmental impact keeps growing.

Development of Insulating Masonry Bricks from Wood Fiber and Varying Milled Glass Proportion

Thermal efficient sandcrete bricks are masonry units with good thermal insulating properties. Wood fiber (WF) possesses low thermal conductivity, hence, its incorporation in mortar mix results in thermal efficient masonry units. Milled glass (MG) could be added for strength enhancement. This study incorporated WF into mortar mix at a constant dosage of 5 wt.%, with varying MG proportions of 0, 5, 10, 15 and 20 wt.% and cured for 7, 14 and 28 days. The results obtained showed minimization of porosity and water absorption at increasing MG content. Density and compressive strength were enhanced as MG content increased. Flexural and splitting tensile strengths appreciated and peaked at 15 wt.% MG. Thermal performance measured demonstrated progressive appreciation in thermal conductivity while specific heat capacity followed a downtrend as MG dosage increased. The study revealed that the collage of 5 wt. % wood fiber and 15 wt. % MG yielded optimum result. The study, therefore, concludes that the addition of milled glass and wood fiber positively and significantly affected the properties of sandcrete bricks. 15 wt.% of milled glass and 5% wood fiber inclusion in sandcrete bricks are recommended for use by construction practitioners.

Effect of sillimanite sand on the mechanical property and thermal resistance of alkali-activated slag mortar

The change in the properties of fine aggregate has significant potential in altering the efficacy of alkali-activated slag. Therefore, this study investigated the influence of sillimanite sand on the mechanical and microstructural properties of alkali-activated slag (AAS) mortar at ambient temperature, and after exposure to elevated temperatures (250, 500, 750, and 1050 °C). In addition, the effect of the concentration of sodium hydroxide solution (6, 8, 10, and 12 M) was evaluated. The silicious normal sand was replaced with sillimanite sand at 25, 50, 75, and 100 % by volume. The results show that the superior physical properties of sillimanite sand improved the strength of the AAS mortar, compared with silicious normal sand. After heating at 250 °C, all AAS mortar mixes showed a significantly higher increase in compressive strength compared to unheated samples. Utilization of the largest concentration of sodium hydroxide solution (12 M) as well as sillimanite sand resulted in a residual compressive strength equivalent to the control sample after 500 °C temperature exposure. A significant drop in residual compressive strength was observed for all mixes at 750 °C. Visual observation of the heated samples revealed that casting the mortar samples with sillimanite sand limited the number, width and extent of thermal cracks. XRD analysis revealed the decomposition of C-S-H and the formation of silica oxide at 750 °C. The results of this study suggest that replacing silicious normal sand with sillimanite sand can help the modification of the engineering properties of AAS mortar at ambient temperature, and after exposure to elevated temperatures.

Influence of the mix parameters on shrinkage properties of environment-friendly mortar

ABSTRACT Cracks in concrete structures are generally initiated due to the shrinkage i.e. the volume change characteristics of the concrete structures. In this experimental study, effects of the mix parameters related to alkaline liquid (AL) and recycled fine aggregate (RFA) on the shrinkage behaviour of environment-friendly mortar mixes produced with fly ash (FA)-based geopolymer binder and RFA were investigated and reported. To find out the effects of AL, concentration of liquid sodium hydroxide (LSH) was varied from 6M to 16M, ratio of liquid sodium silicate (LSS) to LSH in AL was varied from 1.0 to 2.5 and AL/FA ratio was considered as 0.4 and 0.6. Different fly ash-based geopolymer mortar mix were produced depending on above-said combinations of mix parameters along with the RFA content (by weight) of 10%, 20%, 30%, 40% and 50% in lieu of natural fine aggregate. Prismatic specimens (25 mm × 25 mm × 285 mm) were cast and cured at ambient air temperature to determine the shrinkage behaviour. Higher RFA content in mix, higher LSS/LSH ratio in AL and higher AL/FA ratio resulted in higher shrinkage value. But, lesser shrinkage value was noticed for those specimens of mortar mix with the consideration of higher concentration of LSH in AL with varying RFA content.

Proportioning, Carbonation, Performance Assessment, and Application of Reactive Magnesium Oxide Cement–Based Composites with Superplasticizers

Formulation of highly workable reactive magnesium oxide (MgO) cement (RMC)–based composites is critical to their wider adoption in the construction industry. Yet, the performance of the binder with the presence of chemical admixtures is not well understood. This study assessed the influence of polycarboxylate ether (PCE)–based superplasticizers on the hydration and carbonation kinetics of RMC. Its application was also demonstrated. RMC-based composites were prepared with conventional aggregates, superplasticizers to aid workability, and fibers to control cracking induced by volume changes under both hydration and carbonation. Two carbonation methods were utilized: 20% CO2 in a carbonation chamber and CO2 in an enclosed plastic bag to emulate a low-technology carbonation process. Highly workable RMC-based mortar mixes were achieved with a superplasticizer content of 2% by weight, despite the presence of 0.2% by volume polyethylene microfibers. The admixtures slowed down the hydration rate and altered the morphology of the hydration product. Compressive strength of 32.7 MPa was attained after 7 days under 20% CO2 in a carbonation chamber compared with 15.6 MPa under carbonation inside the plastic bag condition. The crystalline carbonation products within the exterior regions were dominated by nesquehonite. A significantly reduced carbonation level was observed within the interior regions due to the formation of the carbonation products and the resulting pore refinement within the exterior regions. Also, the PE fibers provided a crack control mechanism, and their failure mode was characterized by pullout. The finalized mix was successfully applied for the construction of a large-scale architectural structure.