Influence of Composition and Technological Factors on Variatropic Efficiency and Constructive Quality Coefficients of Lightweight Vibro-Centrifuged Concrete with Alkalized Mixing Water

Analytical Review of the Current State of Technology, Structure Formation, and Properties of Variatropic Centrifugally Compacted Concrete

Current regulatory documents and the scientific literature lack a theoretical framework and practical guidance for calculating centrifugally compacted reinforced concrete structures, taking into account the variatropy of their structure and the material's characteristics across the section. A problem related to this research lies in the need to form a systematized, theoretical, and practical knowledge base about variatropic concretes, the importance of which has been proven by various scientists without, to date, the creation of a unified scientific methodological base. The importance of this study is linked to the need for the world's construction projects and processes to transition to the most economically, materially, and resource-efficient types of building structures, which, of course, include structures made of variable-type concrete. This study's objective is to fill these scientific and engineering gaps. The purpose of this study was to systematize the existing knowledge base about the technology, structure formation, and properties of variatropic concrete, using an analytical review of previously conducted studies by ourselves and others, both in Russia and abroad. A theoretical justification for the formation of the structure of variatropic materials is presented. An analysis of the basic physical and mechanical properties of variatropic concretes is carried out and the features of their microstructures are considered. The main structures created using centrifugation technology are considered. Variatropic concrete has an increased amount of mechanical characteristics compared to traditional concrete, on average by up to 45%. The durability of variatropic concrete is improved, on average, by up to 30% compared to conventional concrete.

Influence of Polymer Fibers on the Structure and Properties of Modified Variatropic Vibrocentrifuged Concrete

The application of polymer materials in concrete structures is widespread and effectively used. However, there is a lack of a systematic knowledge base about the structure formation and properties of variatropic vibrocentrifuged modified fiber-reinforced concrete. The purpose of this work is the investigation of the influence of polypropylene (PF) and basalt fiber (BF) and modification with microsilica (MS) on the properties of variatropic concretes obtained using the synthesized vibration centrifugation technology. Test samples were made using vibration centrifugation technology, followed by sawing. Various types of fiber reinforcement were studied, both individually and in combination. To determine the degree of effectiveness of each recipe solution, the following main characteristics were monitored: the density and workability of concrete mixtures; the density of hardened composites; compressive strength (CS); bending strength (BS); water absorption (WA). In variatropic vibrocentrifuged concrete, the greatest efficiency is achieved with dispersed BF reinforcement in an amount of 1.5%. Compared to the control composition, the increase in CS was 8.50%, the increase in BS was 79.17%, and WA decreased by 27.54%. With PF reinforcement, the greatest effect was recorded at a dosage of 1.0%. The increase in CS was 3.16%, the increase in BS was 10.42%, and WA decreased by 17.39%. The MS modification showed the best effect with 8% replacement of part of the Portland cement. The increase in CS was 17.43%, the increase in BS was 14.58%, and WA decreased by 33.30%. The most effective and economically rational formulation solution for vibrocentrifuged concrete is combined fiber reinforcement in combination with the MS modification in the following quantities: BF-1.0%; PF-0.5%; MS-8%. The increase in CS was 22.82%, the increase in BS was 85.42%, and WA decreased by 37.68%.

Eco-Friendly Sustainable Concrete and Mortar Using Coal Dust Waste

Finding the solution to the problem of the accumulating waste from the mining and processing industries, as well as reducing their carbon footprint, is among the most important tasks today. Within the construction industry, in the field of the production of building materials such as concrete, these problems may be solved through the use of waste and by saving the binder component. The purpose of this study is to substantiate the feasibility of using waste coal dust (CD) in concrete and cement-sand mortars as a partial replacement for cement. Test samples were made by partially replacing cement with CD in an amount from 0% to 10% in increments of 2% by weight. The following main characteristics were studied: mobility and density of mixtures, as well as density, compressive strength, bending strength and water absorption of concrete and mortars. X-ray diffraction and microscopic analysis methods were used in this work. The introduction of CD to replace part of the cement, up to 10%, did not have a significant effect on the density of concrete and mortar mixtures but reduced their workability. The best values of physical and mechanical characteristics were recorded for concrete and mortar with 4% CD. The increases in the compressive strength of concrete and mortars were 6.6% and 5.7%, and in flexural strength 6.1% and 5.6%, respectively. Water absorption decreased by 9.7% for concrete and by 9.3% for mortar.

Prediction of Mechanical Properties of Highly Functional Lightweight Fiber-Reinforced Concrete Based on Deep Neural Network and Ensemble Regression Trees Methods

Currently, one of the topical areas of application of artificial intelligence methods in industrial production is neural networks, which allow for predicting the performance properties of products and structures that depend on the characteristics of the initial components and process parameters. The purpose of the study was to develop and train a neural network and an ensemble model to predict the mechanical properties of lightweight fiber-reinforced concrete using the accumulated empirical database and data from construction industry enterprises, and to improve production processes in the construction industry. The study applied deep learning and an ensemble of regression trees. The empirical base is the result of testing a series of experimental compositions of fiber-reinforced concrete. The predicted properties are cubic compressive strength, prismatic compressive strength, flexural tensile strength, and axial tensile strength. The quantitative picture of the accuracy of the applied methods for strength characteristics varies for the deep neural network method from 0.15 to 0.73 (MAE), from 0.17 to 0.89 (RMSE), and from 0.98% to 6.62% (MAPE), and for the ensemble of regression trees, from 0.11 to 0.62 (MAE), from 0.15 to 0.80 (RMSE), and from 1.30% to 3.4% (MAPE). Both methods have shown high efficiency in relation to such a hard-to-predict material as concrete, which is so heterogeneous in structure and depends on many factors. The value of the developed models lies in the possibility of obtaining additional useful information in the process of preparing highly functional lightweight fiber-reinforced concrete without additional experiments.

The Investigation of Compacting Cement Systems for Studying the Fundamental Process of Cement Gel Formation

Fundamental knowledge of the processes of cement gel formation for new generation concretes is a scientific deficit. Studies aimed at the formation of a cement gel for standard vibrated concrete research, and especially for centrifugally compacted concrete, are of interest because the structure of this concrete differs significantly from the structure of standard vibrated concrete. This article aims to study the fundamental dependencies of the theoretical and practical values that occur during compaction using vibration, as well as the centrifugal force of new emerging concrete structures. New theoretical findings about the processes of cement gel formation for three technologies were developed: vibrating, centrifuging, and vibrocentrifuging of concrete; the fundamental difference in gel formation has been determined, the main physical and chemical processes were described, and a significant effect of technology on the gel formation process was established. The influence of indirect characteristics based on the processes of cement gel formation, rheological properties of concrete mixtures, water squeezing processes, and the ratio between the liquid and solid phases in the mixture was evaluated. The process of formation of cement gel for centrifugally compacted cement systems was studied and graphical dependences were constructed, giving answers to the mechanism of interaction according to the principle “composition-rheological characteristics-structure-properties of concrete”. The quantitative aspect of the achieved result is expressed in the increase in the indicators demonstrated by centrifuged and especially vibrocentrifuged samples compared to vibrated ones. Additionally, in terms of strength indicators, vibrocentrifuged samples demonstrated an increase from 22% to 32%, depending on the type of strength, and the rheological characteristics of concrete mixes differed by 80% and 300% in terms of delamination.

Numerical Simulation of the Bearing Capacity of Variotropic Short Concrete Beams Reinforced with Polymer Composite Reinforcing Bars

One of the disadvantages of reinforced concrete is the large weight of structures due to the steel reinforcement. A way to overcome this issue and develop new types of reinforcing elements is by using polymer composite reinforcement, which can successfully compensate for the shortcomings of steel reinforcement. Additionally, a promising direction is the creation of variotropic (transversely isotropic) building elements. The purpose of this work was to numerically analyze improved short bending concrete elements with a variotropic structure reinforced with polymer composite rods and to determine the prospects for the further extension of the results obtained for long-span structures. Numerical models of beams of a transversally isotropic structure with various types of reinforcement have been developed in a spatially and physically nonlinear formulation in ANSYS software considering cracking and crashing. It is shown that, in combination with a stronger layer of the compressed zone of the beam, carbon composite reinforcement has advantages and provides a greater bearing capacity than glass or basalt composite. It has been proven that the use of the integral characteristics of concrete and the deflections of the elements are greater than those when using the differential characteristics of concrete along the height of the section (up to 5%). The zones of the initiation and propagation of cracks for different polymer composite reinforcements are determined. An assessment of the bearing capacity of the beam is given. A significant (up to 146%) increase in the forces in the reinforcing bars and a decrease in tensile stresses (up to 210–230%) were established during the physically non-linear operation of the concrete material. The effect of a clear redistribution of stresses is in favor of elements with a variotropic cross section in height.

Nano-Modified Vibrocentrifuged Concrete with Granulated Blast Slag: The Relationship between Mechanical Properties and Micro-Structural Analysis

Currently, in civil engineering, the relevant direction is to minimize the cost of the manufacture of the hollow structures of annular sections, as well as their construction and installation efficiency. To optimize the costs associated with building products and structures, it is proposed to apply the technology of vibrocentrifugation, to reconsider and comprehensively approach the raw materials for the manufacture of such products and structures. The purpose of this study is a theoretical substantiation and experimental verification with analytical numerical confirmation of the possibility of creating improved variotropic structures of vibrocentrifuged concrete nano-modified with ground granulated blast-furnace slag. The study used the methods of electron microscopy, laser granulometry, and X-ray diffraction. Slag activation was carried out in a planetary ball mill; samples were prepared on a special installation developed by the authors—a vibrocentrifuge. The optimal and effective prescription–technological factors were experimentally derived and confirmed at the microlevel using structural analysis. The mathematical dependencies among the composition, macrostructure, microstructure, and final properties of vibrocentrifuged concrete nano-modified by slag are determined. Empirical relationships were identified to express the variation of some mechanical parameters and identify the relationship between them and the composition of the mixture. The optimal dosage of slag was determined, which is 40%. Increases in strength indicators ranged from 16% to 27, density—3%.

High-Performance Concrete Nanomodified with Recycled Rice Straw Biochar

The development of new and improvement of existing technologies based on the use of waste products from various industries or recyclable materials is a current trend in the construction industry. Including in the composition of binders and concrete by-products of industry, reducing the proportion of Portland cement, it is crucial to maintain and improve the resulting products’ mechanical characteristics and life cycle. The main aim of the study was to investigate the influence of biochar additive on the microstructure and properties of the concrete and obtain the composition with improved characteristics due to nanomodification of rice straw recycled biochar. An environmentally friendly technology for concrete manufacture was obtained, using agricultural waste, rice straw, as its components, developing a composition of concrete nanomodified with processed rice straw biochar, identifying the dependences of concrete properties on their nanomodification with processed rice straw coal. It has been established that the most effective dosage is the addition of rice straw biochar in the amount of 6% by weight of cement. The improvement in the properties of concrete was expressed in the increase in its physical and mechanical characteristics and changes in deformability according to the results of the analysis of the stress-strain diagrams. The increase in strength characteristics ranged from 17% to 25%. The modulus of elasticity increased to 14%. The deformation characteristics decreased from 12% to 24%. Introducing a finely dispersed additive of rice straw biochar modified by the electromagnetic method leads to a decrease in cement consumption by up to 10%.

Development of High-Tech Self-Compacting Concrete Mixtures Based on Nano-Modifiers of Various Types

Promising areas of concrete material science are maximum greening, reducing the carbon footprint, and, at the same time, solving the problems of increasing the cost of raw materials using industrial waste as modifiers for self-compacting concrete mixtures. This study aimed to review, investigate and test from the point of view of theory and practice the possibility of using various industrial types as a nano-modifier in self-compacting concrete with improved performance. The possibility of nano-modification of self-compacting concrete with a complex modifier based on industrial waste has been proved and substantiated theoretically and experimentally. The possibility of improving the technological properties of concrete mixtures using such nanomodifiers was confirmed. The recipe and technological parameters of the process were revealed and their influence on the characteristics of concrete mixes and concretes were expressed and determined. Experimental technological and mathematical dependencies between the characteristics of the technological process and raw materials and the characteristics of concrete mixtures and concretes were determined. The optimization of these parameters was carried out, a theoretical substantiation of the obtained results was proposed, and a quantitative picture was presented, expressed in the increment of the properties of self-compacting concrete mixtures using nano-modifiers from industrial waste concretes based on them. The mobility of the concrete mixture increased by 12%, and the fluidity of the mixture increased by 83%. In relation to the control composition, the concrete strength increased by 19%, and the water resistance of concrete increased by 22%. The ultimate strains decreased by 14%, and elastic modulus increased by 11%.

Mathematical Modeling and Experimental Substantiation of the Gas Release Process in the Production of Non-Autoclaved Aerated Concrete

The widespread use of aerated concrete in construction has led to the emergence of many types and compositions. However, additional research should fill theoretical gaps in the phenomenon of gas release during the formation of the structure of aerated concrete. Based on theoretical analysis and experimental studies, the article proposes a mathematical model of the swelling process based on the physicochemical laws of convection and molecular diffusion of hydrogen from a mixture and the conditions of swelling, precipitation, and stabilization of the mixture. An improved method for the manufacture of aerated concrete is proposed, which consists of introducing cement pre-hydrated for 20–30 min into the composition of the aerated concrete mixture and providing improved gas-holding capacity and increased swelling of the mixture, reducing the average density of aerated concrete up to 29% and improving heat-shielding properties up to 31%. At the same time, the small dynamics of a decrease in the strength properties of aerated concrete were observed, which is confirmed by an increased structural quality factor (CSQ) of up to 13%. As a result, aerated concrete has been obtained that meets the requirements of environmental friendliness and has improved mechanical and physical characteristics. Economic efficiency is to reduce the cost of production of aerated concrete and construction in general by about 15%.

Quantitative and Qualitative Aspects of Composite Action of Concrete and Dispersion-Reinforcing Fiber

The interest in using polymer-dispersed reinforcement in the construction industry in the context of sustainability has led to significant research on this scientific problem. The article is devoted to studying the processes of fiber interaction depending on its dispersion and the concrete matrix, and their combined contact work during the formation of a concrete structure, work under stresses arising in a concrete body, and during a collapse. The physical and mechanical processes of deformation and destruction of the “matrix–fiber” system were studied using high-precision microscopic equipment, and the nature of the work and deformation of fibers in concrete were revealed. The work aimed to establish and characterize the quantitative and qualitative aspects of the concrete matrix and dispersion-reinforcing fiber combined work. It was established that the best values of the adhesion index were observed at a volume content of fiber in the amount of 2% by weight of cement, regardless of the type of dispersion-reinforcing fiber. It was shown that the microstructure of polydispersion-reinforced fiber-cement specimens was denser, and microcracks formed during fracture in polydispersion-reinforced specimens had a smaller opening width. It was established that polydispersion-reinforced concrete had higher values of strength (up to 126%) and deformation (up to 296%) characteristics compared to monodispersion fiber-reinforced concrete.

The Influence of Composition and Recipe Dosage on the Strength Characteristics of New Geopolymer Concrete with the Use of Stone Flour

Currently, considering global trends and challenges, as well as the UN sustainable development goals and the ESG plan, the development of geopolymer binders for the production of geopolymer concrete has become an urgent area of construction science. This study aimed to reveal the influence of the component composition and recipe dosage on the characteristics of fine-grained geopolymer concrete with the use of stone flour. Eleven compositions of geopolymer fine-grained concrete were made from which samples of the mixture were obtained for testing at the beginning and end of setting and models in the form of beams and cubes for testing the compressive strength tensile strength in bending. It was found that the considered types of stone flour can be successfully used as an additive in the manufacture of geopolymer concrete. An analysis of the setting time measurements showed that stone flour could accelerate the hardening of the geopolymer composite. It was found that the addition of stone waste significantly improves the compressive strength of geopolymers in comparison with a geopolymer composite containing only quartz sand. The maximum compressive strength of 52.2 MPa and the tensile strength in bending of 6.7 MPa provide the introduction of potassium feldspar in an amount of 15% of the binder mass. Microstructural analysis of the geopolymer composite was carried out, confirming the effectiveness of the recipe techniques implemented in this study.

Developing Environmentally Sustainable and Cost-Effective Geopolymer Concrete with Improved Characteristics

Improving the efficiency and quality of construction mainly depends on the cost of building materials, which is about 55–65% of total capital-construction costs. The study aimed to obtain geopolymer fine-grained concrete with improved quality characteristics that meet the construction field’s sustainable development criteria and that have environmental friendliness, economic efficiency, and advantages over competing analogues. The dependences of strength characteristics on various compositions of geopolymer concrete were obtained. It was found that the most effective activator is a composition of NaOH and Na2SiO3 with a ratio of 1:2. The increase in the indicators of the obtained geopolymer concrete from the developed composition (4A) in relation to the base control (1X) was 17% in terms of compressive strength and 24% in tensile strength in bending. Polynomial equations were obtained showing the dependence of the change in the strength characteristics of geopolymer concrete on the individual influence of each of the activators. A significant effect of the composition of the alkaline activator on the strength characteristics of geopolymer fine-grained concrete was noted. The optimal temperature range of heat treatment of geopolymer concrete samples, contributing to the positive kinetics of compressive strength gain at the age of 28 days, was determined. The main technological and recipe parameters for obtaining geopolymers with the desired properties, which meet the ecology requirements and are efficient from the point of view of economics, were determined.

Nanomodification of Lightweight Fiber Reinforced Concrete with Micro Silica and Its Influence on the Constructive Quality Coefficient

A hypothesis was put forward that a nano-modifying additive of micro silica, which had a beneficial effect on achieving a perfect structure of heavy concrete, can also be effectively used in lightweight fiber-reinforced concrete. The nano-modifying additives of micro silica application in manufacturing lightweight fiber reinforced concrete products and structures can significantly enchain their strength characteristics without increasing their mass and consequently improve their design characteristics. The purpose of the work was to increase the structural quality coefficients for all types of strengths of lightweight fiber-reinforced concrete due to its modification with micro silica. The effect of nano-modifying additives of micro silica on the strength characteristics of lightweight fiber reinforced concrete was studied. The optimal amount of micro silica addition was experimentally confirmed and established of 10% of the cement mass. The coefficients of constructive quality for all experimentally determined strength characteristics of lightweight fiber-reinforced concrete modified with micro silica additives were calculated. The coefficient of constructive quality for tensile strength in bending of lightweight fiber reinforced concrete with additives was two and a half times higher than that of heavy concrete without additives and up to 37% higher than that of lightweight fiber-reinforced concrete without additives.