Lightweight Sorel's cement composites doped with coal fly ash were produced and tested. Commercially available foam granulate was used as lightening aggregate. For comparison, reference composites made of magnesium oxychloride cement (MOC) and quartz sand were tested as well. The performed experiments included X-ray diffraction, X-ray fluorescence, scanning electron microscopy, light microscopy, and energy dispersive spectroscopy analyses. The macro- and microstructural parameters, mechanical resistance, stiffness, hygric, and thermal parameters of the 28-days matured composites were also researched. The combined use of foam glass and fly ash enabled to get a material of low weight, high porosity, sufficient strength and stiffness, low water imbibition, and greatly improved thermal insulation performance. The developed lightweight composites can be considered as further step in the design and production of alternative and sustainable materials for construction industry.

• Keywords
• Sorel’s cement, coal fly ash, construction composites, foamed glass, hygrothermal performance, structural parameters,
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• Journal Article MeSH

In this contribution, composite materials based on magnesium oxychloride cement (MOC) with multi-walled carbon nanotubes (MWCNTs) used as an additive were prepared and characterized. The prepared composites contained 0.5 and 1 wt.% of MWCNTs, and these samples were compared with the pure MOC Phase 5 reference. The composites were characterized using a broad spectrum of analytical methods to determine the phase and chemical composition, morphology, and thermal behavior. In addition, the basic structural parameters, pore size distribution, mechanical strength, stiffness, and hygrothermal performance of the composites, aged 14 days, were also the subject of investigation. The MWCNT-doped composites showed high compactness, increased mechanical resistance, stiffness, and water resistance, which is crucial for their application in the construction industry and their future use in the design and development of alternative building products.

• Keywords
• composites, magnesium oxychloride cement, multi-walled carbon nanotube (MWCNT),
• Publication type
• Journal Article MeSH

A high-performance magnesium oxychloride cement (MOC) composite composed of silica sand, diatomite powder, and doped with graphene nanoplatelets was prepared and characterized. Diatomite was used as a 10 vol.% replacement for silica sand. The dosage of graphene was 0.5 wt.% of the sum of the MgO and MgCl2·6H2O masses. The broad product characterization included high-resolution transmission electron microscopy, X-ray diffraction, X-ray fluorescence, scanning electron microscopy and energy dispersive spectroscopy analyses. The macrostructural parameters, pore size distribution, mechanical resistance, stiffness, hygric and thermal parameters of the composites matured for 28-days were also the subject of investigation. The combination of diatomite and graphene nanoplatelets greatly reduced the porosity and average pore size in comparison with the reference material composed of MOC and silica sand. In the developed composites, well stable and mechanically resistant phase 5 was the only precipitated compound. Therefore, the developed composite shows high compactness, strength, and low water imbibition which ensure high application potential of this novel type of material in the construction industry.

• Keywords
• composites, diatomite, graphene, magnesium oxychloride, sorel cement,
• Publication type
• Journal Article MeSH

Self-compaction concrete (SCC) is ranked among the main technological innovations of the last decades. Hence, it introduces a suitable possibility for further utilization of supplementary cementitious materials (SCM) in terms of sustainable development. The aim of the work is the assessment of a new approach to binder design, which takes into consideration the activity of the used mineral additive. The proposed approach, which allows a systematic design of a binding system with varied properties of the used mineral additive, was studied on ternary blends consisting of Portland cement (PC), limestone powder and fly ash (FA). The verification was conducted on SCC mixtures in terms of their workability, mechanical properties and the most attention was paid to long-term durability. The long-term durability was assessed on the basis of shrinkage measurement, freeze-thaw resistance and permeability tests including initial surface absorption, chloride migration, water penetration and an accelerated carbonation test, which was compared with the evolution of carbonation front in normal conditions. The durability of studied mixtures was evaluated by using durability loss index, which allow general assessment on the basis of multiple parameters. The carbonation resistance had a dominant importance on the final durability performance of studied mixtures. The experimental program revealed that the proposed design method is reliable only in terms of properties in fresh state and mechanical performance, which were similar with control mixture. Despite suitable results of freeze-thaw resistance and shrinkage, an increasing amount of fly ash in terms of the new design concept led to a fundamental increase of permeability and thus to decay of long-term durability. Acceptable properties were achieved for the lowest dosage of fly ash.

• Keywords
• carbonation, durability, fly ash addition, limestone powder, self-compacting concrete,
• Publication type
• Journal Article MeSH

In this paper, magnesium oxychloride cement with stoichiometry 3Mg(OH)2∙MgCl2∙8H2O (MOC 3-1-8) was prepared and characterized. The phase composition and kinetics of formation were studied by X-ray diffraction (XRD) and Rietveld analysis of obtained diffractograms. The chemical composition was analyzed using X-ray fluorescence (XRF) and energy dispersive spectroscopy (EDS). Furthermore, scanning electron microscopy (SEM) was used to study morphology, and Fourier Transform Infrared (FT-IR) spectroscopy was also used for the analysis of the prepared sample. In addition, thermal stability was tested using simultaneous thermal analysis (STA) combined with mass spectroscopy (MS). The obtained data gave evidence of the fast formation of MOC 3-1-8, which started to precipitate rapidly. As the length of the time of ripening increased, the amount of MgO decreased, while the amount of MOC 3-1-8 increased. The fast formation of the MOC 3-1-8 phase at an ambient temperature is important for its application in the production of low-energy construction materials, which corresponds with the challenges of a sustainable building industry.

• Keywords
• MOC phases, kinetics of formation, magnesium oxychloride cement, non-hydraulic binder, thermal stability,
• Publication type
• Journal Article MeSH

In this paper, crushed lava granulate was used as full silica sand replacement in composition of repair mortars based on hydrated lime, natural hydraulic lime, or cement-lime binder. Lava granules were analyzed by X-ray fluorescence analysis (XRF), X-ray diffraction (XRD), and scanning electron microscopy (SEM). Particle size distribution of both silica and lava aggregates was assessed using standard sieve analysis. Hygrothermal function of the developed lightweight materials was characterized by the measurement of complete set of hygric, thermal, and structural parameters of the hardened mortar samples that were tested for both 28 days and 90 days cured specimens. As the repair mortars must also meet requirements on mechanical performance, their compressive strength, flexural strength, and dynamic Young's modulus were tested. The newly developed mortars composed of lava aggregate and hydrated lime or natural hydraulic lime met technical, functional, compatibility, and performance criteria on masonry and rendering materials, and were found well applicable for repair of historically valuable buildings.

• Keywords
• compatibility, functional properties, hygrothermal performance, lava granulate, repair mortars,
• Publication type
• Journal Article MeSH

Mechanically-activated wood-based biomass ash (WBA) was studied as a potential active admixture for design of a novel lime-pozzolan-based mortar for renovation purposes. The replacement ratio of lime hydrate in a mortar mix composition was 5%, 10%, and 15% by mass. The water/binder ratio and the sand/binder ratio were kept constant for all examined mortar mixes. Both binder constituents were characterized by their powder density, specific density, BET (Brunauer-Emmett-Teller), and Blaine specific surfaces. Their chemical composition was measured by X-ray fluorescence analysis (XRF) and mineralogical analysis was performed using X-ray diffraction (XRD). Morphology of WBA was investigated by scanning electron microscopy (SEM) and element mapping was performed using an energy dispersive spectroscopy (EDS) analyzer. The pozzolanic activity of WBA was tested by the Chapelle test and assessment of the Portlandite content used simultaneous thermal analysis (STA). For the hardened mortar samples, a complete set of structural, mechanical, hygric, and thermal parameters was experimentally determined. The mortars with WBA admixing yielded similar or better functional properties than those obtained for traditional pure lime-based plaster, pointing to their presumed application as rendering and walling renovation mortars. As the Chapelle test, STA, and mechanical test proved high pozzolanity of WBA, it was classified as an alternative eco-efficient low-cost pozzolan for use in lime blend-based building materials. The savings in CO2 emissions and energy by the use of WBA as a partial lime hydrate substitute in mortar composition were also highly appreciated with respect to the sustainability of the construction industry.

• Keywords
• binder physical and chemical analyses, environmental assessment, functional properties, industrial waste, lime-pozzolan renovation mortars, pozzolanic activity, wood-based biomass ash,
• Publication type
• Journal Article MeSH

Two waste fired brick powders coming from brick factories located in Argentine and Czech Republic were examined as alternative mineral admixtures for the production of blended cements. In pastes composition, local Portland cements (Argentine and Czech) were substituted with 8-40%, by mass, with powdered ceramic waste. For the ceramic waste-Portland cement system, workability, the heat released, pozzolanity, specific density, compressive strength, hydrated phases, porosity, and pore size distribution were tested. The relevance of the dilution effect, filler effect, and pozzolanic activity was analyzed to describe the general behavior of the pozzolan/cement system. The properties and performance of cement blends made with finely ground brick powder depended on the composition of ceramic waste and its reactivity, the plain cement used, and the replacement level. Results showed that the initial mini-slump was not affected by a low ceramic waste replacement (8% and 16%), and then it was decreased with an increase in the ceramic waste content. Brick powder behaved as a filler at early ages, but when the hydration proceeded, its pozzolanic activity consumed partially the calcium hydroxide and promoted the formation of hydrated calcium aluminates depending on the age and present carbonates. Finally, blended cements with fired brick powder had low compressive strength at early ages but comparable strength-class at later age.

• Keywords
• analysis of hydrated products, heat of hydration, physical and chemical parameters, pozzolan, red ceramic waste,
• Publication type
• Journal Article MeSH

The goal of the paper was development and testing of a novel type of ternary blended binder based on lime hydrate, metakaolin, and biomass ash that was studied as a binding material for production of lightweight mortar for renovation purposes. The biomass ash used as one of binder components was coming from wood chips ash combustion in a biomass heating plant. The raw ash was mechanically activated by grinding. In mortar composition, wood chips ash and metakaolin were used as partial substitutes of lime hydrate. Silica sand of particle size fraction 0⁻2 mm was mixed from three normalized sand fractions. For the evaluation of the effect of biomass ash and metakaolin incorporation in mortar mix on material properties, reference lime mortar was tested as well. Among the basic physical characterization of biomass ash, metakaolin and lime hydrate, specific density, specific surface, and particle size distribution were assessed. Their chemical composition was measured by X-Ray fluorescence analysis (XRF), morphology was examined using scanning electron microscopy (SEM), elements mapping was performed using energy dispersive spectroscopy (EDS) analyser, and mineralogical composition was tested using X-Ray diffraction (XRD). For the developed mortars, set of structural, mechanical, hygric, and thermal properties was assessed. The mortars with ternary blended binder exhibited improved mechanical resistance, lower thermal conductivity, and increased water vapor permeability compared to the reference lime mortar. Based on good functional performance of the produced mortar, the tested biomass ash could potentially represent a novel sustainable alternative to other pozzolans commonly used in construction industry. Moreover, reuse of biomass ash in production of building materials is highly beneficial both from the environmental and economic reasons especially taking into account circular economy principles. The ternary blended binder examined in this paper can find use in both rendering and walling repair mortars meeting the requirements of culture heritage authorities and technical standards.

• Keywords
• biomass combustion, functional properties, lightweight mortar, pozzolanic activity, ternary blended binder,
• Publication type
• Journal Article MeSH