Study on the durability of concrete with FNS fine aggregate

Recycle of steel slag as cementitious material and fine aggregate in concrete: mechanical, durability property and environmental impact

Using steel slag (SS) as cementitious material and fine aggregate in concrete is an effective and environmental method for SS consumption and cost reduction. In this paper, SS was recycled in large volumes in concrete as partial cementitious material and fine aggregate. The compressive strength and reaction mechanism of cementitious material with different SS powder contents including 20%, 25%, 30%, and 35% were presented. The results indicated that 20% of SS powder improved the compressive strength by 34.57% and the hydration products were ettringite (AFt) and calcium silica hydrate(C-(A)-S-H). Furthermore, the mechanical and durability performance of concrete with SS as fine aggregate were investigated. When the SS substitution rate was 75%, the compressive strength was increased by 37.83%. The volume shrinkage rate and 28d-carbonation depth were reduced nearly by 64% for 90 days and 2.33 mm, respectively. The chloride ion penetration resistance reached the optimal grade Q-V and abrasion resistance was improved by nearly 24%. Along with the reduced CO2 by 210-294 kg/m3 and the decreased cost by 12.61 USD/m3, it is regarded as an effective method to consume steel slag. As such, this research provided a scientific and systematic basis for the large-scale disposal and utilization of industrial waste residues as well as recycled materials preparation.

Activation Mechanism of Ammonium Fluoride in Facile Synthesis of Hydrated Silica Derived from Ferronickel Slag-Leaching Residue

A novel process for the synthesis of hydrated silica derived from ferronickel slag (FNS)-leaching residue was proposed in this study. The products of the purification of hydrated silica with 99.68% grade and 95.11% recovery can be obtained through ammonium fluoride (NH4F) roasting, followed by the process of water leaching, ammonia precipitating, and acid cleaning under the optimized conditions. The effects of NH4F mass ratio, roasting temperature, and roasting time on the water-leaching efficiency were investigated in detail. The thermodynamic and X-ray diffraction analyses indicated that the amorphous silica in FNS-leaching residue was converted to water-soluble fluoride salts ((NH4)2SiF6) during the roasting process, which are also supported by the scanning electron microscopy and thermogravimetry analyses. The Si-O bonds in amorphous silica could be effectively broken through the ammonium fluoride activation during a low-temperature roasting process. This work provides a meaningful reference for further studies on the facile synthesis of hydrated silica with similar mineral compositions.

Recycling of ferronickel slag tailing in cementitious materials: Activation and performance

As an industrial by-product containing pozzolanic components, recycled ferronickel slag (FNS) has the potential to be supplementary cementitious materials (SCMs) to reduce the massive carbon footprint of the cement industry, however, the main limitation of ferronickel slag as SCMs is the low hydration rate at an early age. In this study, the pozzolanic activity property results indicate that if the proportion is more than 10 %, FSN can hardly participate in the cement hydration reaction during the early stage, even the mechanical strength of FNS-mortar decreases obviously with the higher proportion of ferronickel slag. Therefore, mechanical grinding and steam curing at an early age are applied to promote the reaction activity of the recycled ferronickel slag tailing in this study. Compared with standard curing, the compressive strength of hardened FNS-cement paste with steam curing at 60 °C or 80 °C increased by 8.2 % or 33.8 %, and the connected porosity decreased by 18.9 % or 17.3 %. And MgO in the ferronickel slag exists as Mg₂SiO₄ in raw materials and enters the C-S-H gel with the formation of M-S-H gel during the secondary hydration stage. This study provides a theoretical basis for solid waste-based concrete and promotes the recycling, conservation, and resources of solid waste in building materials.

Durability and life prediction of fly ash geopolymer concrete in corrosion environments caused by dry and wet circulation

The use of tailings, waste rock, fly ash, and slag to prepare geopolymer concrete can effectively solve the problems of land resources occupied by tailings and waste rock, low utilization rate, and environmental pollution. Using a dry-wet circulation method, fly ash for a different corrosion solution to geopolymer concrete (referred to as TWGPC) was analyzed. Through an appearance change, the corrosion resistance coefficient of the compressive strength, relative dynamic elastic modulus, tensile splitting strength, relative mass, and durability were investigated, using scanning electron microscopy (SEM) analysis of the microstructure, The life of TWGPC was predicted based on the GM(1,1) prediction model of grey system theory. The test results show that with an increase in the number of dry-wet cycles, the surface of the specimen crystallizes, cracks, spalls, and exhibits other phenomena. The compressive strength corrosion coefficient, relative dynamic elastic modulus, crack tensile strength, and relative mass show a trend of increasing first and then decreasing, finally reaching the peak value after 40 cycles. The erosion products generated by the early reaction fill the slurry aggregate pores and improve the strength of TWGPC. In a later stage, a large number of erosion products absorb water and expand; the internal pores of TWGPC are connected, leading to a decrease in strength. Cl^- inhibits the corrosion of SO₄^2- in concrete and improves the durability of concrete.

The Effect of Low-Modulus Plastic Fiber on the Physical and Technical Characteristics of Modified Heavy Concretes Based on Polycarboxylates and Microsilica

Manufacturers of building materials strive to optimize the three basic concrete properties—strength, durability, and shrinkage deformation, of which the focus is generally on the durability in the structure when designing and monitoring the poured concrete. Studying concretes’ structural performance and the change in their characteristics over time enables the solution of many important issues associated with the design of reliable, durable, and cost-effective buildings and structures. This article presents studies aimed at improving the physical, technical, and operational characteristics of cement concrete and reducing cement consumption in heavy concretes through the use of complex modifiers and volumetric fiber reinforcement. Four concrete compositions of widely recognized grades were developed, of which samples were molded and tested for compressive and flexural strength, frost resistance, volumetric water absorption, and density. Test results confirmed the possibility of binder (cement) economy up to 18% and increasing frost resistance up to W300 when using microsilica, reduction in volumetric water absorption of up to 40% when using both microsilica and hyperplasticizer, and increasing flexural strength by over 30% when using polymer fiber. The developed compositions passed the industrial tests, and were successfully introduced in the production process of the operating reinforced concrete products’ manufacturer.

Engineering Characteristics of Cement Composites Containing a Chitosan-Based Polymer and Steel Slag Aggregates

Recently, sustainable development has attracted significant global attention. Toward this, several studies have been performed on the development of alternative aggregates for mortar or concrete to prevent environmental damage and rapid depletion of natural aggregates. In this study, we investigated the applicability of a chitosan-based polymer (CBP), a biomimetic polymer, to cement mortar using steel slag as a fine aggregate. The CBP was synthesized via an amide coupling reaction among chitosan, 1-ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride, and 3-(3,4-dihydroxyphenyl)propionic acid. Upon addition to cement mortar using natural sand or a blast furnace slag aggregate, the CBP contributed toward increasing the compressive strength and tensile strength. However, in mortar mixes using a ferronickel slag aggregate, the tensile strength decreased by ~5.7%–25.4% upon CBP addition. Moreover, the CBP reduced the total charge passed through the mixes. In particular, in the mortar mix using the steel slag aggregate, the CBP showed improved chloride-ion penetration resistance. The results showed that the as-prepared CBP was a suitable improving agent and exhibited promising compatibility with cement composites containing steel slag aggregates.

Hazardous characteristics and variation in internal structure by hydrodynamic damage of BOF slag-based thin asphalt overlay

For the sustainable development of society, recycling of solid waste has received considerable attention worldwide. In this research, steel slag was used to replace natural aggregate in the thin asphalt overlay, and the hazardous characteristics and internal microstructure of this overlay were explored. The resistance to hydrodynamic damage of the overlay containing steel slag was also evaluated and compared with that of the traditional overlay. The results indicate that steel slag has potential leaching risk, which can lead to environmental hazards in long-term leaching processes. However, the recycling of steel slag in thin asphalt overlay inhibits the release of toxic heavy metals due to the encapsulation effect, thereby reducing the leaching concerns. Steel slag can significantly reinforce the skeleton structure and enhance the ability of the asphalt overlay to bear the load. The superior skeleton stability and moisture resistance of the steel slag asphalt overlay were observed after hydrodynamic treatment compared with overlays made of natural aggregate. The variations in the volumetric parameters and connectivity in the steel slag asphalt overlay are significantly less than those in conventional overlay after hydrodynamic treatment. This indicates that the volumetric characteristics of steel slag asphalt overlays are less affected by hydrodynamic pressure.

Granite Powder vs. Fly Ash for the Sustainable Production of Air-Cured Cementitious Mortars

The partial replacement of cement in concrete with the addition of granite powder and fly ash can help to reduce the carbon dioxide (CO₂) emissions into the atmosphere associated with cement production. The aim of the article is to compare the performance of granite powder and fly ash for the sustainable production of air-cured cementitious mortars. The morphological, chemical, and granulometric properties of these additives were first compared with the properties of cement. Afterward, a series of mortars modified with the addition of granite powder and fly ash was made. The properties of the fresh mixes and the mechanical properties of the hardened composites were then tested. Finally, based on the obtained results, a cost analysis of the profitability of modifying cementitious composites with granite powder or fly ash was investigated. The obtained results allow similarities and differences between granite powder and fly ash in relation to cement to be shown. To conclude, it should be stated that both of these materials can successfully be used for the sustainable production of air-cured cementitious composites. This conclusion has a significant impact on the possibility of improving the natural environment by reducing the amount of cement production. More sustainable production of cement-based materials could enable CO₂ emissions to be decreased. The use of granite powder for the production of cementitious mortars can significantly reduce the amount of this material deposited in landfills.