This paper presents the experimental results of an on-going research project on geopolymer lightweight concrete using two locally available waste materials--low calcium fly ash (FA) and oil palm shell (OPS)--as the binder and lightweight coarse aggregate, respectively. OPS was pretreated with three different alkaline solutions of sodium hydroxide (NaOH), potassium hydroxide, and sodium silicate as well as polyvinyl alcohol (PVA) for 30 days; afterwards, oil palm shell geopolymer lightweight concrete (OPSGPC) was cast by using both pretreated and untreated OPSs. The effect of these solutions on the water absorption of OPS, and the development of compressive strength in different curing conditions of OPSGPC produced by pretreated OPS were investigated; subsequently the influence of NaOH concentration, alkaline solution to FA ratio (A/FA), and different curing regimes on the compressive strength and density of OPSGPC produced by untreated OPS was inspected. The 24-hour water absorption value for OPS pretreated with 20% and 50% PVA solution was about 4% compared to 23% for untreated OPS. OPSGPC produced from OPS treated with 50% PVA solution produced the highest compressive strength of about 30 MPa in ambient cured condition. The pretreatment with alkaline solution did not have a significant positive effect on the water absorption of OPS aggregate and the compressive strength of OPSGPC. The result revealed that a maximum compressive strength of 32 MPa could be obtained at a temperature of 65°C and curing period of 4 days. This investigation also found that an A/FA ratio of 0.45 has the optimum amount of alkaline liquid and it resulted in the highest level of compressive strength.
The binary effect of pulverized fuel ash (PFA) and palm oil fuel ash (POFA) on heat of hydration of aerated concrete was studied. Three aerated concrete mixes were prepared, namely, concrete containing 100% ordinary Portland cement (control sample or Type I), binary concrete made from 50% POFA (Type II), and ternary concrete containing 30% POFA and 20% PFA (Type III). It is found that the temperature increases due to heat of hydration through all the concrete specimens especially in the control sample. However, the total temperature rises caused by the heat of hydration through both of the new binary and ternary concrete were significantly lower than the control sample. The obtained results reveal that the replacement of Portland cement with binary and ternary materials is beneficial, particularly for mass concrete where thermal cracking due to extreme heat rise is of great concern.
Coal combustion and the disposal of combustion wastes emit enormous quantities of nano-sized particles that pose significant health concerns on exposure, particularly in unindustrialized countries. Samples of fresh and weathered class F fly ash were analysed through various techniques including X-ray fluorescence (XRF), X-ray diffraction (XRD), focused ion beam scanning electron microscopy (FIB-SEM), field-emission gun scanning electron microscopy (FE-SEM), high-resolution transmission electron microscopy (HR-TEM) coupled with energy dispersive x-ray spectroscopy (EDS), and Raman Spectroscopy. The imaging techniques showed that the fresh and weathered coal fly ash nanoparticles (CFA-NPs) are mostly spherical shaped. The crystalline phases detected were quartz, mullite, ettringite, calcite, maghemite, hematite, gypsum, magnetite, clay residues, and sulphides. The most abundant crystalline phases were quartz mixed with Al-Fe-Si-K-Ti-O-amorphous phases whereas mullite was detected in several amorphous phases of Al, Fe, Ca, Si, O, K, Mg, Mn, and P. The analyses revealed that CFA-NPs are 5-500 nm in diameter and encapsulate several potentially hazardous elements (PHEs). The carbon species were detected as 5-50 nm carbon nanoballs of graphitic layers and massive fullerenes. Lastly, the aspects of health risks related to exposure to some detected ambient nanoparticles are also discussed.
This paper presents a comparative study of the characteristic of unfoamed and foamed geopolymers after exposure to elevated temperatures (200-800 °C). Unfoamed geopolymers were produced with Class F fly ash and sodium hydroxide and liquid sodium silicate. Porous geopolymers were prepared by foaming with hydrogen peroxide. Unfoamed geopolymers possessed excellent strength of 44.2 MPa and degraded 34% to 15 MPa in foamed geopolymers. The strength of unfoamed geopolymers decreased to 5 MPa with increasing temperature up to 800 °C. Foamed geopolymers behaved differently whereby they deteriorated to 3 MPa at 400 °C and increased up to 11 MPa at 800 °C. Even so, the geopolymers could withstand high temperature without any disintegration and spalling up to 800 °C. The formation of crystalline phases at higher temperature was observed deteriorating the strength of unfoamed geopolymers but enhance the strength of foamed geopolymers. In comparison, foamed geopolymer had better thermal resistance than unfoamed geopolymers as pores provide rooms to counteract the internal damage.
An incredible amount of joss fly ash is produced from the burning of Chinese holy joss paper; thus, an excellent method of recycling joss fly ash waste to extract aluminosilicate nanocomposites is explored. The present research aims to introduce a novel method to recycle joss fly ash through a simple and straightforward experimental procedure involving acidic and alkaline treatments. The synthesized aluminosilicate nanocomposite was characterized to justify its structural and physiochemical characteristics. A morphological analysis was performed with field-emission transmission electron microscopy, and scanning electron microscopy revealed the size of the aluminosilicate nanocomposite to be ~25 nm, while also confirming a uniformly spherical-shaped nanostructure. The elemental composition was measured by energy dispersive spectroscopy and revealed the Si to Al ratio to be 13.24 to 7.96, showing the high purity of the extracted nanocomposite. The roughness and particle distribution were analyzed using atomic force microscopy and a zeta analysis. X-ray diffraction patterns showed a synthesis of faceted and cubic aluminosilicate crystals in the nanocomposites. The presence of silica and aluminum was further proven by X-ray photoelectron spectroscopy, and the functional groups were recognized through Fourier transform infrared spectroscopy. The thermal capacity of the nanocomposite was examined by a thermogravimetric analysis. In addition, the research suggested the promising application of aluminosilicate nanocomposites as drug carriers. The above was justified by an enzyme-linked apta-sorbent assay, which claimed that the limit of the aptasensing aluminosilicate-conjugated ampicillin was two-fold higher than that in the absence of the nanocomposite. The drug delivery property was further justified through an antibacterial analysis against Escherichia coli (gram-negative) and Bacillus subtilis (gram-positive).
Lightweight cementitious composite (LCC) produced by incorporating lightweight silica aerogel was explored in this study. Silica aerogel was incorporated as 60% replacement of fine aggregate (sand/crushed glass) in producing the LCC. The effect of aerogel on the drying shrinkage and alkali-silica expansion of LCC was evaluated and compared with those of lightweight expanded perlite aggregate. At the density of 1600 ± 100 kg/m3, the aerogel/ expanded perlite LCC had attained compressive strength of about 17/24 MPa and 22/26 MPa in mixtures with sand and crushed glass as a fine aggregate, respectively. The inclusion of aerogel and expanded perlite increased the drying shrinkage. The drying shrinkage of aerogel LCC was up to about 3 times of the control mixtures. Although the presence of aerogel and expanded perlite could reduce the alkali-silica expansion when partially replacing crushed glass, the aerogel-glass LCC still recorded expansion exceeding the maximum limit of 0.10% at 14 days. However, when 15% cement was replaced with fly ash and granulated blast furnace slag, the alkali-silica expansion was reduced to 0.03% and 0.10%, respectively. Microstructural observations also revealed that the aerogel with fly ash can help in reducing the alkali-silica expansion in mixes containing the reactive crushed glass aggregate.
Characterisation of the leaching behaviour of coal fly ash from Tenaga Nasional Berhad (TNB) by using tank leaching test method has been reported. The leachability of the constituents such as major elements and toxic metals in the coal fly ash was studied. Eight renewed leachant solutions after 6 hours, 1, 2, 5, 8, 21, 36 and 64 days were investigated after filtration. The parameters namely pH, cumulative release regarding the major elements and toxic metals to duration were presented. The results showed that the pH solutions increased from pH 4 to neutral and remained stable during the test. It might have resulted from the large buffering capacity of the coal fly ashes. Five major elements namely Al, Ca, K, Mg and Na were detected with Ca concentration in the leachant solutions was the highest for all samples. Toxic metals such as As, Ba, Co, Cr, Mn, Ni, Pb, Se and Zn were found and the test showed consistent results on the As, Ba, Mn, Se and Zn in leachant solutions. The findings also showed that some of the toxic metal concentrations namely As, Ba, Cr, Pb and Se exceeded the maximum allowance of the guideline of drinking water quality in Malaysia and WHO. Obviously, proper waste management has to be applied in this scenario.
Cement industries globally produced about 2.282 billion ton/year and 25 billion tons of concrete are produced yearly
all over the world, necessary measures are to be taken to reduce energy use along with the prevention of environmental
degradation, depletion of the limited resources and contribute 7% to global warming effects due to the release of carbon
dioxide to the atmosphere. Cement additives quality improver polymer (CAQIP) was developed from synthesized polymer,
waste materials derived from petro-chemical and palm oil waste for production of sustainable cement. Industrial scale
trial in a local cement plants by dosing 0.009%-0.690% CAQIP significant improved productivity, 8.3-27.5% efficiency in
saving, 24.73-86.36% clinkering energy and 7.7-21.57% grinding energy in the production of Ordinary Portland Cement
and sustainable cement. Strength quality improved 7.31-34.8% (2 day) and 3.85-57.58% (28 day). Carbon dioxide and
others toxic gases emission was reduced 21.90-90.0% by replacing clinker with waste material such as fly ash (25-
35%), out-spec clinker (50-100%) and limestone waste (5-25%). The developed CAQIP significant improved productivity,
quality strength, reduced CO2
emission, grinding & clinkering energy and enhanced production of sustainable cement
and concrete in Malaysia.
A chemical method to synthesize amorphous silica nanoparticles from the incinerated paddy straw has been introduced. The synthesis was conducted through the hydrolysis by alkaline-acidic treatments. As a result, silica particles produced with the sizes were ranging at 60-90 nm, determined by high-resolution microscopy. The crystallinity was confirmed by surface area electron diffraction. Apart from that, chemical and diffraction analyses for both rice straw ash and synthesized silica nanoparticles were conducted by X-ray diffraction and Fourier-transform infrared spectroscopy. The percentage of silica from the incinerated straw was calculated to be 28.3. The prominent surface chemical bonding on the generated silica nanoparticles was with Si-O-Si, stretch of Si-O and symmetric Si-O bonds at peaks of 1090, 471, and 780 cm-1, respectively. To confirm the impurities of the elements in the produced silica, were analyzed using X-ray photoelectron spectroscopy and energy dispersive X-ray spectroscopy. The stability of silica nanoparticles was investigated using thermogravimetric analysis and zeta potential. The measured size from zeta potential analysis was 411.3-493 nm and the stability of mass reduction was located at 200 °C with final amount of mass reduced ∼88% and an average polydispersity Index was 0.195-0.224.
As a cementitious material, geopolymers show a high quasi-brittle behavior and a relatively low fracture energy. To overcome such a weakness, incorporation of fibers to a brittle matrix is a well-known technique to enhance the flexural properties. This study comprehensively evaluates the short and long term impacts of different volume percentages of polypropylene fiber (PPF) reinforcement on fly ash based geopolymer composites. Different characteristics of the composite were compared at fresh state by flow measurement and hardened state by variation of shrinkage over time to assess the response of composites under flexural and compressive load conditions. The fiber-matrix interface, fiber surface and toughening mechanisms were assessed using field emission scan electron microscopy (FESEM) and atomic force microscopy (AFM). The results show that incorporation of PPF up to 3 wt % into the geopolymer paste reduces the shrinkage and enhances the energy absorption of the composites. While, it might reduce the ultimate flexural and compressive strength of the material depending on fiber content.
The concentrations of primordial radionuclides (226Ra, 232Th and 40K) in commonly used building materials (brick, cement and sand), the raw materials of cement and the by-products of coal-fired power plants (fly ash) collected from various manufacturers and suppliers in Bangladesh were determined via gamma-ray spectrometry using an HPGe detector. The results showed that the mean concentrations of 226Ra, 232Th and 40K in all studied samples slightly exceeded the typical world average values of 50 Bq kg(-1), 50 Bq kg(-1) and 500 Bq kg(-1), respectively. The activity concentrations (especially 226Ra) of fly-ash-containing cement in this study were found to be higher than those of fly-ash-free cement. To evaluate the potential radiological risk to individuals associated with these building materials, various radiological hazard indicators were calculated. The radium equivalent activity values for all samples were found to be lower than the recommended limit for building materials of 370 Bq kg(-1), with the exception of the fly ash. For most samples, the values of the alpha index and the radiological hazard (external and internal) indices were found to be within the safe limit of 1. The mean indoor absorbed dose rate was observed to be higher than the population-weighted world average of 84 nGy h(-1), and the corresponding annual effective dose for most samples fell below the recommended upper dose limit of 1 mSv y(-1). For all investigated materials, the values of the gamma index were found to be greater than 0.5 but less than 1, indicating that the gamma dose contribution from the studied building materials exceeds the exemption dose criterion of 0.3 mSv y(-1) but complies with the upper dose principle of 1 mSv y(-1).
The recycling of millions of tons of glass bottle waste produced each year is far from optimal. In the present work, ground blast furnace slag (GBFS) was substituted in fly ash-based alkali-activated mortars (AAMs) for the purpose of preparing glass bottle waste nano-powder (BGWNP). The AAMs mixed with BGWNP were subsequently subjected to assessment in terms of their energy consumption, economic viability, and mechanical and chemical qualities. Besides affording AAMs better mechanical qualities and making them more durable, waste recycling was also observed to diminish the emissions of carbon dioxide. A more than 6% decrease in carbon dioxide emissions, an over 16% increase in compressive strength, better durability and lower water absorption were demonstrated by AAM consisting of 5% BGWNP as a GBFS substitute. By contrast, lower strength was exhibited by AAM comprising 10% BGWNP. The conclusion reached was that the AAMs produced with BGWNP attenuated the effects of global warming and thus were environmentally advantageous. This could mean that glass waste, inadequate for reuse in glass manufacturing, could be given a second life rather than being disposed of in landfills, which is significant as concrete remains the most commonplace synthetic material throughout the world.
In this study, the use of nano-silica (nano-SiO2) and bentonite as mortar additives for combating reinforcement corrosion is reported. More specifically, these materials were used as additives in ordinary Portland cement (OPC)/fly ash blended mortars in different amounts. The effects of nano-silica and bentonite addition on compressive strength of mortars at different ages was tested. Accelerated corrosion testing was used to assess the corrosion resistance of reinforced mortar specimens containing different amounts of nano-silica and bentonite. It was found that the specimens containing nano-SiO2 not only had higher compressive strength, but also showed lower steel mass loss due to corrosion compared to reference specimens. However, this was accompanied by a small reduction in workability (for a constant water to binder ratio). Mortar mixtures with 4% of nano-silica were found to have optimal performance in terms of compressive strength and corrosion resistance. Control specimens (OPC/fly ash mortars without any additives) showed low early age strength and low corrosion resistance compared to specimens containing nano-SiO2 and bentonite. In addition, samples from selected mixtures were analyzed using scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDX). Finally, the influence of Ca/Si ratio of the calcium silicate hydrate (C-S-H) in different specimens on the compressive strength is discussed. In general, the study showed that the addition of nano-silica (and to a lesser extent bentonite) can result in higher strength and corrosion resistance compared to control specimens. Furthermore, the addition of nano-SiO2 can be used to offset the negative effect of fly ash on early age strength development.
This paper details analytical research results into a novel geopolymer concrete embedded with glass bubble as its thermal insulating material, fly ash as its precursor material, and a combination of sodium hydroxide (NaOH) and sodium silicate (Na2SiO3) as its alkaline activator to form a geopolymer system. The workability, density, compressive strength (per curing days), and water absorption of the sample loaded at 10% glass bubble (loading level determined to satisfy the minimum strength requirement of a load-bearing structure) were 70 mm, 2165 kg/m3, 52.58 MPa (28 days), 54.92 MPa (60 days), and 65.25 MPa (90 days), and 3.73 %, respectively. The thermal conductivity for geopolymer concrete decreased from 1.47 to 1.19 W/mK, while the thermal diffusivity decreased from 1.88 to 1.02 mm2/s due to increased specific heat from 0.96 to 1.73 MJ/m3K. The improved physicomechanical and thermal (insulating) properties resulting from embedding a glass bubble as an insulating material into geopolymer concrete resulted in a viable composite for use in the construction industry.
Aggregates can be categorized into natural and artificial aggregates. Preserving natural resources is crucial to ensuring the constant supply of natural aggregates. In order to preserve these natural resources, the production of artificial aggregates is beginning to gain the attention of researchers worldwide. One of the methods involves using geopolymer technology. On this basis, this current research focuses on the inter-particle effect on the properties of fly ash geopolymer aggregates with different molarities of sodium hydroxide (NaOH). The effects of synthesis parameters (6, 8, 10, 12, and 14 M) on the mechanical and microstructural properties of the fly ash geopolymer aggregate were studied. The fly ash geopolymer aggregate was palletized manually by using a hand to form a sphere-shaped aggregate where the ratio of NaOH/Na2SiO3 used was constant at 2.5. The results indicated that the NaOH molarity has a significant effect on the impact strength of a fly ash geopolymer aggregate. The highest aggregate impact value (AIV) was obtained for samples with 6 M NaOH molarity (26.95%), indicating the lowest strength among other molarities studied and the lowest density of 2150 kg/m3. The low concentration of sodium hydroxide in the alkali activator solution resulted in the dissolution of fly ash being limited; thus, the inter-particle volume cannot be fully filled by the precipitated gels.
The alkali-silica reaction (ASR) is an important consideration in ensuring the long-term durability of concrete materials, especially for those containing reactive aggregates. Although fly ash (FA) has proven to be useful in preventing ASR expansion, the filler effect and the effect of FA fineness on ASR expansion are not well defined in the present literature. Hence, this study aimed to examine the effects of the filler and fineness of FA on ASR mortar expansion. FAs with two different finenesses were used to substitute ordinary Portland cement (OPC) at 20% by weight of binder. River sand (RS) with the same fineness as the FA was also used to replace OPC at the same rate as FA. The replacement of OPC with RS (an inert material) was carried out to observe the filler effect of FA on ASR. The results showed that FA and RS provided lower ASR expansions compared with the control mortar. Fine and coarse fly ashes in this study had almost the same effectiveness in mitigating the ASR expansion of the mortars. For the filler effect, smaller particles of RS had more influence on the ASR reduction than RS with coarser particles. A significant mitigation of the ASR expansion was obtained by decreasing the OPC content in the mortar mixture through its partial substitution with FA and RS.
Geopolymer concrete has the potential to replace ordinary Portland cement which can reduce carbon dioxide emission to the environment. The addition of different amounts of steel fibers, as well as different types of end-shape fibers, could alter the performance of geopolymer concrete. The source of aluminosilicate (fly ash) used in the production of geopolymer concrete may lead to a different result. This study focuses on the comparison between Malaysian fly ash geopolymer concrete with the addition of hooked steel fibers and geopolymer concrete with the addition of straight-end steel fibers to the physical and mechanical properties. Malaysian fly ash was first characterized by X-ray fluorescence (XRF) to identify the chemical composition. The sample of steel fiber reinforced geopolymer concrete was produced by mixing fly ash, alkali activators, aggregates, and specific amounts of hook or straight steel fibers. The steel fibers addition for both types of fibers are 0%, 0.5%, 1.0%, 1.5%, and 2.0% by volume percentage. The samples were cured at room temperature. The physical properties (slump, density, and water absorption) of reinforced geopolymer concrete were studied. Meanwhile, a mechanical performance which is compressive, as well as the flexural strength was studied. The results show that the pattern in physical properties of geopolymer concrete for both types of fibers addition is almost similar where the slump is decreased with density and water absorption is increased with the increasing amount of fibers addition. However, the addition of hook steel fiber to the geopolymer concrete produced a lower slump than the addition of straight steel fibers. Meanwhile, the addition of hook steel fiber to the geopolymer concrete shows a higher density and water absorption compared to the sample with the addition of straight steel fibers. However, the difference is not significant. Besides, samples with the addition of hook steel fibers give better performance for compressive and flexural strength compared to the samples with the addition of straight steel fibers where the highest is at 1.0% of fibers addition.
Alkali activated concretes have emerged as a prospective alternative to conventional concrete wherein diverse waste materials have been converted as valuable spin-offs. This paper presents a wide experimental study on the sustainability of employing waste sawdust as a fine/coarse aggregate replacement incorporating fly ash (FA) and granulated blast furnace slag (GBFS) to make high-performance cement-free lightweight concretes. Waste sawdust was replaced with aggregate at 0, 25, 50, 75, and 100 vol% incorporating alkali binder, including 70% FA and 30% GBFS. The blend was activated using a low sodium hydroxide concentration (2 M). The acoustic, thermal, and predicted engineering properties of concretes were evaluated, and the life cycle of various mixtures were calculated to investigate the sustainability of concrete. Besides this, by using the available experimental test database, an optimized Artificial Neural Network (ANN) was developed to estimate the mechanical properties of the designed alkali-activated mortar mixes depending on each sawdust volume percentage. Based on the findings, it was found that the sound absorption and reduction in thermal conductivity were enhanced with increasing sawdust contents. The compressive strengths of the specimens were found to be influenced by the sawdust content and the strength dropped from 65 to 48 MPa with the corresponding increase in the sawdust levels from 0% up to 100%. The results also showed that the emissions of carbon dioxide, energy utilization, and outlay tended to drop with an increase in the amount of sawdust and show more the lightweight concrete to be more sustainable for construction applications.
Thermal performance, combustibility, and fire propagation of fly ash-metakaolin (FA-MK) blended geopolymer with the addition of aluminum triphosphate, ATP (Al(H2PO4)3), and monoaluminium phosphate, MAP (AlPO4) were evaluated in this paper. To prepare the geopolymer mix, fly ash and metakaolin with a ratio of 1:1 were added with ATP and MAP in a range of 0-3% by weight. The fire/heat resistance was evaluated by comparing the residual compressive strengths after the elevated temperature exposure. Besides, combustibility and fire propagation tests were conducted to examine the thermal performance and the applicability of the geopolymers as passive fire protection. Experimental results revealed that the blended geopolymers with 1 wt.% of ATP and MAP exhibited higher compressive strength and denser geopolymer matrix than control geopolymers. The effect of ATP and MAP addition was more obvious in unheated geopolymer and little improvement was observed for geopolymer subjected to elevated temperature. ATP and MAP at 3 wt.% did not help in enhancing the elevated-temperature performance of blended geopolymers. Even so, all blended geopolymers, regardless of the addition of ATP and MAP, were regarded as the noncombustible materials with negligible (0-0.1) fire propagation index.
Grog is an additive material that plays important roles in ceramic making. It improves the fabrication process of green bodies as well as the physical properties of fired bodies. Few low-cost materials and wastes have found their application as grog in recent years, thus encouraging the replacement of commercial grogs with cost-saving materials. Coal fly ash, a combustion waste produced by coal-fired power plant, has the potential to be converted into grog owing to its small particle sizes and high content of silica and alumina. In this study, grog was derived from coal fly ash and mixed with kaolin clay to produce ceramics. Effects of the grog addition on the resultant ceramics were investigated. It was found that, to a certain extent, the grog addition reduced the firing shrinkage and increased the total porosity of the ceramics. The dimensional stability of the ceramics at a firing temperature of 1200 °C was also not noticeably affected by the grog. However, the grog addition in general had negative effects on the biaxial flexural strength and refractoriness of the ceramics.