Influence of aggregate pre-wetting and fly ash on mechanical properties of lightweight concrete

This study has examined the mechanical properties of lightweight aggregate concrete with a density of 1800 kg/m3. The effects of the following parameters on the concrete properties have been analyzed: the pre-wetting time of the lightweight aggregate and the percentage of pulverized fly ash used as cementitious replacement material. The strength of the lightweight aggregate was found to be the primary factor controlling the strength of high-strength lightweight concrete. An increase in the cementitious content from 420 to 450 kg/m3 does not significantly increase the strength of lightweight aggregate concrete. The relationship between the flexural and compressive strength at 28 days can be represented by the equation fr=0.69/fck. The elastic modulus was found to be much lower than that of normal weight concrete, ranging from 15.0 to 20.3 GPa. The addition of PFA increases the slump and density of lightweight aggregate concrete.     

Recycling and recovery routes for incinerated sewage sludge ash (ISSA): A review

The drivers for increasing incineration of sewage sludge and the characteristics of the resulting incinerated sewage sludge ash (ISSA) are reviewed. It is estimated that approximately 1.7 million tonnes of ISSA are produced annually world-wide and is likely to increase in the future. Although most ISSA is currently landfilled, various options have been investigated that allow recycling and beneficial resource recovery. These include the use of ISSA as a substitute for clay in sintered bricks, tiles and pavers, and as a raw material for the manufacture of lightweight aggregate. ISSA has also been used to form high density glass–ceramics. Significant research has investigated the potential use of ISSA in blended cements for use in mortars and concrete, and as a raw material for the production of Portland cement. However, all these applications represent a loss of the valuable phosphate content in ISSA, which is typically comparable to that of a low grade phosphate ore. ISSA has significant potential to be used as a secondary source of phosphate for the production of fertilisers and phosphoric acid. Resource efficient approaches to recycling will increasingly require phosphate recovery from ISSA, with the remaining residual fraction also considered a useful material, and therefore further research is required in this area.     

双掺粉煤灰再生骨料对混凝土强度影响研究

通过试验研究再生骨料混凝土中粉煤灰和再生骨料对混凝土强度的影响。采用粉煤灰替代部分水泥、再生骨料替代部分天然粗骨料的方法,通过正交试验测定混凝土立方体抗压强度的方法,来研究粉煤灰对再生骨料混凝土强度的影响。试验得出:当再生骨料掺量为20%~30%时,粉煤灰的最佳掺量为20%左右;当再生骨料掺量高于40%、粉煤灰掺量高于20%时,其混凝土拌合物搅拌时间不小于240 s,且当粉煤灰在20%~30%时,可获得较理想的混凝土抗压强度;当粉煤灰的掺入量分布在20%~30%、再生骨料的最佳掺量为50%时,可获得较理想的混凝土抗压强度。由此得出,合理的再生骨料、粉煤灰掺量对混凝土的抗压强度影响并不明显且有提高的趋势,对降低混凝土成本,提高建筑垃圾的再生利用,有一定的经济效益和社会效益。     

国内城市生活垃圾焚烧飞灰研究现状及进展

随着我国经济快速发展及城市化水平提升,城市生活垃圾产量越来越大,焚烧逐渐成为城市生活垃圾处理的主要方式.但焚烧会产生大量的垃圾焚烧飞灰(以下简称飞灰),飞灰属于危险废物.论述了飞灰的来源、成分、特性及危害,介绍了飞灰的处理处置技术:水泥固化技术、化学药剂稳定化技术、熔融固化技术、水热稳定化技术和水泥窑协同处理技术,并分...     

Fabrication and characterization of lightweight aggregate prepared from steel mill sludge in one step

Journal of Material Cycles and Waste Management - The qualified green lightweight aggregate (LWA) was successfully prepared from steel mill sludge (SMS) and fly ash (FAS) in one step using the...     

Reuse of thermosetting plastic waste for lightweight concrete

This paper presents the utilization of thermosetting plastic as an admixture in the mix proportion of lightweight concrete. Since this type of plastic cannot be melted in the recycling process, its waste is expected to be more valuable by using as an admixture for the production of non-structural lightweight concrete. Experimental tests for the variation of mix proportion were carried out to determine the suitable proportion to achieve the required properties of lightweight concrete, which are: low dry density and acceptable compressive strength. The mix design in this research is the proportion of plastic, sand, water-cement ratio, aluminum powder, and lignite fly ash. The experimental results show that the plastic not only leads to a low dry density concrete, but also a low strength. It was found that the ratio of cement, sand, fly ash, and plastic equal to 1.0:0.8:0.3:0.9 is an appropriate mix proportion. The results of compressive strength and dry density are 4.14N/mm(2) and 1395kg/m(3), respectively. This type of concrete meets most of the requirements for non-load-bearing lightweight concrete according to ASTM C129 Type II standard.     

Fly ash of mineral coal as ceramic tiles raw material

The aim of this work was to evaluate the use of mineral coal fly ash as a raw material in the production of ceramic tiles. The samples of fly ash came from Capivari de Baixo, a city situated in the Brazilian Federal State of Santa Catarina. The fly ash and the raw materials were characterized regarding their physical chemical properties, and, based on these results; batches containing fly ash and typical raw materials for ceramic tiles were prepared. The fly ash content in the batches varied between 20 and 80 wt%. Specimens were molded using a uniaxial hydraulic press and were fired. All batches containing ash up to 60 wt% present adequate properties to be classified as several kinds of products in the ISO 13006 standard () regarding its different absorption groups (pressed). The results obtained indicate that fly ash, when mixed with traditional raw materials, has the necessary requirements to be used as a raw material for production of ceramic tiles.     

Manufacture of artificial aggregate using MSWI bottom ash

This paper reports the results of an investigation on material recovery by stabilization/solidification of bottom ash coming from a municipal solid waste incineration plant. Stabilization/solidification was carried out to produce artificial aggregate in a rotary plate granulator by adding hydraulic binders based on cement, lime and coal fly ash. Different mixes were tested in which the bottom ash content ranged between 60% and 90%. To avoid undesirable swelling in hardened products, the ash was previously milled and then granulated at room temperature. The granules were tested to assess their suitability to be used as artificial aggregate through the measurement of the following properties: density, water absorption capacity, compressive strength and heavy metals release upon leaching. It was demonstrated that the granules can be classified as lightweight aggregate with mechanical strength strongly dependent on the type of binder. Concrete mixes were prepared with the granulated artificial aggregate and tested for in-service performance, proving to be suitable for the manufacture of standard concrete blocks in all the cases investigated.     

Compressive strength and resistance to chloride ion penetration and carbonation of recycled aggregate concrete with varying amount of fly ash and fine recycled aggregate

Construction and demolition waste has been dramatically increased in the last decade, and social and environmental concerns on the recycling have consequently been increased. Recent technology has greatly improved the recycling process for waste concrete. This study investigates the fundamental characteristics of concrete using recycled concrete aggregate (RCA) for its application to structural concrete members. The specimens used 100% coarse RCA, various replacement levels of natural aggregate with fine RCA, and several levels of fly ash addition. Compressive strength of mortar and concrete which used RCA gradually decreased as the amount of the recycled materials increased. Regardless of curing conditions and fly ash addition, the 28 days strength of the recycled aggregate concrete was greater than the design strength, 40 MPa, with a complete replacement of coarse aggregate and a replacement level of natural fine aggregate by fine RCA up to 60%. The recycled aggregate concrete achieved sufficient resistance to the chloride ion penetration. The measured carbonation depth did not indicate a clear relationship to the fine RCA replacement ratio but the recycled aggregate concrete could also attain adequate carbonation resistance. Based on the results from the experimental investigations, it is believed that the recycled aggregate concrete can be successfully applied to structural concrete members.     

全废砖再生轻骨料混凝土试验研究

将废粘土砖加工成粗细骨料,用于配制全废砖再生轻骨料混凝土.检测结果表明：所用废砖粗细骨料属轻骨料范畴,但其吸水率较大,且细骨料级配不良.试验表明：本试验配合比体系中,净水灰比为0.42,体积砂率为50％时最佳;以全废砖配制的再生砖轻骨料混凝土的强度发展规律与普通轻骨料混凝土类似,均有随水泥用量提高而强度提高的趋势,但随着所配制的混凝土强度等级的提高,再生轻骨料混凝土的强度提高趋势下降.以全废砖为骨料适合配制强度等级LC30及以下的再生轻骨料混凝土.     

Evaluation on the applicability of dry processed bottom ash as lightweight aggregate for construction fields

Currently, wet bottom ash is not sufficiently utilized due to its content of unburned coal, chloride and moisture. In contrast, bottom ash discharged from the recently introduced dry process spends a longer time on the clinker conveyer in the lower part of the boiler and consequently contains a significantly smaller amount of unburned coal. Consequently, it has high potential for use as a lightweight aggregate for construction material because of properties such as high porosity, low unburned coal content, non-chloride, and non-moisture. However, it is not frequently used for construction because the ash particle has a flat and thin shape, coarse surface and unfavorable structural strength. Against this backdrop, this study has conducted a range of experiments to identify the shapes, structure, density, absorption, percentage of floating particles, unit volume weight, solid volume, characteristics of air bubbles and micro pores, crushing strength of bottom ash, and the following results were observed. Though the dry bottom ash has sharp and angular edges, its flat and thin shapes lead to vulnerable structures. Dry bottom ash of the size of 0.6 mm or larger has 50–60 % of the total pore rate and 30–50 % of the closed pore rate. Considering these qualities, by removing the relatively fragile surface parts and making the particles more globular, dry bottom ash can be used as a lightweight aggregate for construction field having outstanding performance in terms of light weight and insulation.     

Classification and categorization of treatment methods for ash generated by municipal solid waste incineration: A case for the 2 greater metropolitan regions of greece

The primary goal of managing MSW incineration residues is to avoid any impact on human health or the environment. Incineration residues consist of bottom ash, which is generally considered as rather harmless and fly ash which usually contains compounds which are potentially harmful for public health. Small quantities of ash (both bottom and fly) are produced currently in Greece, mainly from the healthcare waste incineration facility in Attica region. Once incineration plants for MSW (currently under planning) are constructed in Greece, the produced ash quantities will increase highly. Thus, it is necessary to organize, already at this stage, a roadmap towards disposal/recovery methods of these ash quantities expected.Certain methods, related to the treatment of the future generated ash which are more appropriate to be implemented in Greece are highlighted in the present paper. The performed analysis offers a waste management approach, having 2016 as a reference year for two different incineration rates; 30% and 100% of the remaining MSW after recycling process. The results focus on the two greater regions of Greece: Attica and Central Macedonia. The quantity of potential future ash generation ranges from 137 to 459 kt for Attica region and from 62 to 207 kt for central Macedonia region depending on the incineration rate applied. Three alternative scenarios for the treatment of each kind of ash are compiled and analysed. Metal recovery and reuse as an aggregate in concrete construction proved to be the most advantageous -in terms of economy-bottom ash management scenario. Concerning management of the fly ash, chemical treatment with phosphoric solution addition results to be the lowest total treatment cost and is considered as the most profitable solution. The proposed methodology constitutes a safe calculation model for operators of MSW incineration plants regardless of the region or country they are located in.     

Evaluating the strength development of mortar using clinker fine aggregate with a combination of fly ash and its inhibitory effects on alkali–silica reaction and delayed ettringite formation

The aggregate composed of cement clinker, an intermediate cement product, improves strength development and mass transfer resistance of concrete. Fly ash (FA) is a supplementary cementitious material that can be substituted by cement. This study investigated the strength development of highly FA-substituted mortar mixed with cement clinker fine aggregate (CL) and tested its inhibitory effect against the alkali–silica reaction (ASR). In addition to these, this study provides the testing results of evaluating the effects of using cement clinker fine aggregate on delayed ettringite formation (DEF), which can be problematic for precast concrete products. The study results revealed that at 91 days of age, in the case of 80% replacement ratio of fly ash to cement, using CL exhibited similar strength development as mortar with limestone fine aggregate and no FA substitution. Furthermore, mortars with 70% and 80% FA substitution did not exhibit clear ASR-induced expansion even at 182 days of age. Lastly, mortar using clinker fine aggregate could suppress DEF-induced expansion at 182 days of age, which was similar to the effect obtained using FA. These results can promote the utilization of CL resources for concrete and using clinker as fine aggregate in precast concrete products.

     

New technology and application of brick making with coal fly ash

China has ranked first in the coal fly ash emission in the world. The multipurpose use of the fly ash from power plant waste is always an important topic for the Chinese environmental protection, which has drawn the concern of the government, scientific research departments, manufacturing enterprises and industry experts. This paper introduces an experimental research on how to recycle fly ash effectively, a kind of new technology of making bricks by which fly ash content could be amounted to 50–80 %. The article introduces raw materials of fly ash brick, production process and key control points. It introduces how to change the technical parameters of the existing brick-making mechanical device, optimize the parameters combination and improve the device performance. High-content fly ash bricks are manufactured, which selects wet fly ash from power plants, adding aggregate with reasonable ratio and additives with reasonable dosage, and do the experimental research on manufactured products for properties, production technology and selection about technology parameters of production equipment. All indexes of strength grade, freezing-thawing resisting, and other standards of the studied bricks reached the national standards for building materials industry.     

Lightweight aggregate made from sewage sludge and incinerated ash

In this study, sewage sludge ash (SSA), with similar characteristics to expansive clay, was used as the principal material and sewage sludge (SS) as the admixture to sinter lightweight aggregate and to study the influences of raw material composition on pelletising, sintering effect and aggregate properties. Results showed that both SS and SSA could be sintered to produce synthetic aggregates individually or mixed. Increasing the amount of SS would decrease the pelletising ratio. Under the consideration of energy saving, the mixture of SSA was better for sintering normal weight aggregate. On the contrary, the mixture that added 20-30% of SS was more adequate to make lightweight aggregates. Adding SS would enhance the oxidation-reduction reaction and lower the bulk density and sintering temperature of aggregates to save energy. Sintering temperature affected the properties of sewage sludge ash lightweight aggregate (SSALA) more than retention period did. Prolonging the retention period could improve bloating effect.     

Preparation of activated carbons from heavy-oil fly ashes

The use of heavy oil fly ash with high ash content (45 wt.%) as a precursor for the preparation of activated carbons has been investigated. The raw fly ash and the fly ash with lower ash content, obtained by a HCl/HF washing treatment, have been pyrolyzed at 900 degrees C and then activated with CO(2) in the temperature range of 800-900 degrees C for different times. The activated carbons have been characterised as regards the surface area and the pore volume. The evolution of the porosity has been related to the burn-off degree.     

Influence of pelletization process on the properties of fly ash aggregates

A pelletization process is used to manufacture artificial lightweight coarse aggregate using fly ash. Pelletization depends on the size of particles and their distribution, the wettability of particles and moisture content, along with the process related parameters. A review indicates that only limited studies have been reported on the pelletization of fly ash aggregates. The influence of the following parameters has been studied: (i) speed of revolution of pelletizer disc, (ii) angle of pelletizer disc, (iii) moisture content, and (iv) duration of pelletization. Fractional factorial experiments using the concept of Taguchi's orthogonal array is used in this study, which uses an orthogonal array table to arrange multifactor experiments and uses statistical methods to analyze the experimental results. The relative influence of the factors above and their interaction effects on the strength, water absorption and size growth of fly ash aggregates are discussed.     

Production of lightweight aggregate from industrial waste and carbon dioxide

The concomitant recycling of waste and carbon dioxide emissions is the subject of developing technology designed to close the industrial process loop and facilitate the bulk-re-use of waste in, for example, construction. The present work discusses a treatment step that employs accelerated carbonation to convert gaseous carbon dioxide into solid calcium carbonate through a reaction with industrial thermal residues. Treatment by accelerated carbonation enabled a synthetic aggregate to be made from thermal residues and waste quarry fines. The aggregates produced had a bulk density below 1000 kg/m³ and a high water absorption capacity. Aggregate crushing strengths were between 30% and 90% stronger than the proprietary lightweight expanded clay aggregate available in the UK. Cast concrete blocks containing the carbonated aggregate achieve compressive strengths of 24 MPa, making them suitable for use with concrete exposed to non-aggressive service environments. The energy intensive firing and sintering processes traditionally required to produce lightweight aggregates can now be augmented by a cold-bonding, low energy method that contributes to the reduction of green house gases to the atmosphere.     

Investigating mechanical properties and durability of concrete containing recycled rubber ash and fibers

This article investigates the suitability of utilizing end of life rubber tyre particles in concrete as fine aggregate. Rubber ash and rubber fibers were used to develop two series of rubber ash concrete (series I) and hybrid concrete (series II) mixes. The natural fine aggregate was replaced by rubber ash (by volume of 5%, 10%, 15% and 20%) in series I; whereas in series II, the amount of rubber ash was kept constant at 10% and rubber fiber was introduced as replacement of fine aggregate (by volume of 5%, 10%, 15%, 20% and 25%). The concrete mixes were evaluated for compressive strength, flexural strength, resistance to impact loading, fatigue loading, water penetration and shrinkage strain was evaluated. It was observed that inclusion of rubber ash resulted in the improvement of impact resistance of concrete. The results also show that up to 10% rubber ash and rubber fibers can be utilized as fine aggregate to develop feasible and durable rubberized concrete pavements, crash barriers and paver blocks.

     

A Grey-Based Taguchi Approach for Characterization of Erosive Wear Phenomenon of Glass–Polyester Fly Ash Filled Composites

Fly ash is a solid waste generated in huge quantities from coal fired thermal power stations during the combustion of coal. In India, less than half of this is used as a raw material for concrete manufacturing and construction; the remaining is directly dumped on land side as land fill or simply piled up. Only a small fraction of it is used in development of high valued product. Due to environmental regulations, new ways of utilizing fly ash are being explored in order to safeguard the environment and provide useful ways for its utilization and disposal. With its richness in various metal oxides, it has tremendous potential to be utilized as a filler material in polymer composites. These days glass reinforced polyester composites find widespread application in erosive environment due to several advantages like high wear resistance, strength-to-weight ratio, and low cost. The cost of the composites can be further brought down using cheaper filler materials. To this end, this work uses fly ash in composite making and thereby suggests a new way of better utility of this industrial waste. It includes the processing, characterization and study of the erosion behavior of a class of such fly ash filled polyester-glass fiber composites. The engineering application of composites demands that it should have high wear resistance, low density and high tensile strength. In order to assess the behavior of composites satisfying multiple performance measures, a grey-based Taguchi approach has been adopted. After thorough analysis of factors, optimal factor settings have been suggested to improve multiple responses viz., erosive wear rate, density, flexural strength and tensile strength. This technique eliminates the need for repeated experiments; thus saves time and material. The systematic experimentation leads to determination of significant process parameters and material variables that predominantly influence the multiple responses.